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widos 10000 mobile Working Instruction

Heating element butt welding machine
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WIDOS
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen
Working Instructions
Heating element butt welding machine
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Einsteinstr. 5
website: www.widos.de
Translation
WIDOS 10000 mobile
Keep for further use!
Phone ++49 7152 9939 - 0
Fax
++49 7152 9939 - 40
email: info@widos.de
Ku nst sto ffschweißtec hni k

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  • Page 1 ++49 7152 9939 - 40 website: www.widos.de email: info@widos.de Ku nst sto ffschweißtec hni k Working Instructions Translation Heating element butt welding machine WIDOS 10000 mobile Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer...
  • Page 2 ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79 Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73 30.07.12 Working Instructions WIDOS 10000 mobile Page 2 of 52...
  • Page 3 Due to this structure, the searched information can be easily found.  7/30/2012 WIDOS W. Dommer Söhne GmbH Einsteinstraße 5 D-71254 Ditzingen-Heimerdingen All rights reserved. Reprinting only allowed with permission of the corporation. Any changes are subject to technical innovations. 30.07.12 Working Instructions WIDOS 10000 mobile Page 3 of 52...

  • Page 4: Table Of Contents

    1.2. Safety measures ......................6 1.3. Conformity........................6 1.4. Machine overview ......................7 1.5. Designation of the product....................7 1.5.1. Technical data........................7 1.5.1.1. WIDOS 10000 mobile General data..............8 1.5.1.2. Basic frame ......................8 1.5.1.3. Hydraulic pump ......................8 1.5.1.4. Heating element .....................9 1.5.1.5. Planer........................9 1.6. Tools and accessories ....................9 Verschleißteile ..............Fehler! Textmarke nicht definiert.
  • Page 5 How to check and refill the hydraulic oil ...............31 7.8. Used hydraulic oil......................31 7.9. Planer..........................31 7.10. Protect machine parts against corrosion..............32 7.11. Transport........................32 7.12. Disposal..........................32 ELECTRIC AND HYDRAULIC DIAGRAMS..............33 DECLARATION OF CONFORMITY .................. 52 30.07.12 Working Instructions WIDOS 10000 mobile Page 5 of 52...

  • Page 6: Description Of The Product

    All technical details of the machine are put together as a general arrangement. 1.1. Usage and purpose-oriented use The WIDOS 10000 mobile has been designed for the heating element butt welding of pipes and fittings with a diameter of OD 1000 (optional OD 500 mm up to 900 mm).

  • Page 7: Machine Overview

    It contains the type, the serial number and the year of construction of the machine. 1.5.1. Technical data All important technical data of each machine part is listed. This allows quick information on performance and installation. 30.07.12 Working Instructions WIDOS 10000 mobile Page 7 of 52...

  • Page 8: Widos 10000 Mobile General Data

    Description of the product Chapter 1 Ku nst sto ffschweißtec hni k 1.5.1.1. WIDOS 10000 mobile General data Pipe diameter range: OD = 1000 mm (optional 500 mm up to 900 mm) Material which can be welded: PP, PE80, PE 100 Weight: appr.

  • Page 9: Heating Element

    Drive chain without lock (1“, 143 chain links) K100143 Half a chain link (1“) K10001 Chain lock (1“) KSCH100 Wheel Ø 540 x 170 (R6.00-9/6-K100RK) on request Hydraulic oil HLDP35 30.07.12 Working Instructions WIDOS 10000 mobile Page 9 of 52...

  • Page 10: Safety Rules

    • It is a help for using all the functions on your machine in an optimal way and helps you to make the job easier. The regulations for the prevention of accidents are valid (UVV). 30.07.12 Working Instructions WIDOS 10000 mobile Page 10 of 52...

  • Page 11: Obligations Of The Owner

    • A person who is being trained may only work at the machine under supervision of an experienced person. 30.07.12 Working Instructions WIDOS 10000 mobile Page 11 of 52...

  • Page 12: Maintenance And Inspection, Repair

    The DVS gives the advice of inspection work after 1 year. For machines with a especially high usage percentage the testing cycle should be shortened. The work should be performed at the WIDOS GmbH company or by an authorized partner. 2.8. Dangers while handling the machine The machine WIDOS 10000 mobile is constructed according to the latest technical standard and the acknowledged technical safety rules.

  • Page 13: Dangers Caused By The Hydraulics

    Persons may get injured or objects may get damaged by an unsecured carriage. • Never park the machine in unsecured condition; block the wheels by chocks. • Secure the machine e.g. by a vehicle before you remove the chocks. 30.07.12 Working Instructions WIDOS 10000 mobile Page 13 of 52...

  • Page 14: Danger Of Crushing By Clamping Devices And Guideways

    • Machine parts which are not in a perfect condition are to be replaced immediately. • Only use original WIDOS spare and wear parts. • In case of purchase orders please always state the machine number! 2.11.

  • Page 15: Functional Description

    The pipes are joined under prescribed welding pressure and then cool down under pressure (cooling time). The welded joint can be unclamped, the welding process is finished. Heating element heats the pipes up to welding temperature Finished welding with internal and external bead 30.07.12 Working Instructions WIDOS 10000 mobile Page 15 of 52...

  • Page 16: Operating And Indicating Elements

    Chock to fix the machine Portable operator panel, to switch the pump on and off, to move the heating element, the planer and welding motions 30.07.12 Working Instructions WIDOS 10000 mobile Page 16 of 52...

  • Page 17: Portable Operator Panel

    Belt To carry the operator panel, adjustable in the length 30.07.12 Working Instructions WIDOS 10000 mobile Page 17 of 52...

  • Page 18: Hydraulic Control Elements

    Lift / lower right pipe inner clamping ring 3 Open / shut flexible Open / shut flexible outer clamping ring 4 inner clamping ring 3 Clamp / release flexible outer clamping ring 4 30.07.12 Working Instructions WIDOS 10000 mobile Page 18 of 52...

  • Page 19: Switch Cabinet

    As soon as the oil temperature reaches ≥ 80°C, the pump switches off and the signal lamp illuminates in red. If the oil temperature has fallen to appr. 70°C, the pump switches on again automatically and the signal lamp extinguishes. 30.07.12 Working Instructions WIDOS 10000 mobile Page 19 of 52...

  • Page 20: Starting And Operating

    (e.g. PE cleaner or pipe cleaning tissues which are available at the WIDOS company). The anti-adhesive coating of the heating element must remain undamaged in the working area.

  • Page 21: How To Connect The Machine

    (or automatic change after 30s). During heating up to desired value, the control lamp K2 (4) is on. As soon as the desired temperature is reached, the control lamp K2 (4) is blinking. 30.07.12 Working Instructions WIDOS 10000 mobile Page 21 of 52...

  • Page 22: Welding Process

    • Shut all clamping rings one after the other; shift levers (1-4): to: < >. Align the pipes to each other. You may use WIDOS rollerstands in order to align longer pipes. • Swing manual all clamping cylinder into clamping ring upper parts, one after the other. Clamp the clamping cylinders;...
  • Page 23 • Having reached the prescribed revolving bead height, reduce pressure by pushing the joystick for slides to: < >. • The heating time begins. Press the stop watch and compare the current time with the nominal time taken from the table. 30.07.12 Working Instructions WIDOS 10000 mobile Page 23 of 52...
  • Page 24 • Drive the machine apart again by pushing the joystick for slides to: < >. T h e w e l d i n g p r o c e s s i s c o mp l e t e d . 30.07.12 Working Instructions WIDOS 10000 mobile Page 24 of 52...

  • Page 25: Welding Log And Tables

    Phone ++49 7152 9939 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen ++49 7152 9939 - 40 website: www.widos.de email: info@widos.de Ku nst sto ffschweißtec hni k 6. Welding log and tables 30.07.12 Working Instructions WIDOS 10000 mobile Page 25 of 52...
  • Page 26 Welding log and tables Chapter 6 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 26 of 52...
  • Page 27 [mm] [mm] time pressure [min] 12,3 15,3 19,1 23,9 21,0 28,4 17,6 29,7 36,8 13,6 45,4 68,3 13,7 17,2 21,4 26,7 31,7 17,6 33,2 41,2 13,6 50,8 62,5 30.07.2012 Working instructions WIDOS 12000 mobile Page 27 / 1 of 52...
  • Page 28 15,4 19,3 24,1 30,0 35,7 17,6 37,4 46,3 13,6 57,2 62,5 17,4 21,8 27,2 33,9 40,2 17,6 42,1 52,2 13,6 64,5 19,6 24,5 30,6 38,1 45,3 17,6 47,4 30.07.2012 Working instructions WIDOS 12000 mobile Page 27 / 2 of 52...
  • Page 29 • no additional pressure during further cooling down • load onto the workpieces only after being completely cooled down • Join parts with wall thickness ≥15 mm 30.07.2012 Working instructions WIDOS 12000 mobile Page 27 / 3 of 52...
  • Page 30 28,4 17,6 13,7 17,2 21,4 31,7 17,6 15,4 19,3 24,1 35,7 17,6 17,4 21,8 27,2 40,2 17,6 19,6 24,5 30,6 45,3 17,6 22,0 27,6 34,4 51,0 17,6 30.07.2012 Working instructions WIDOS 10000 - 12000 mobile Page 28 / 1of 52...
  • Page 31 • no additional pressure during further cooling down • load onto the workpieces only after being completely cooled down • Join parts with wall thickness ≥15 mm 30.07.2012 Working instructions WIDOS 10000 - 12000 mobile Page 28 / 2of 52...

  • Page 32: Maintenance, Care And Repair

    For machines with a especially high usage percentage the testing cycle should be shortened. The work should be performed at the WIDOS GmbH company or by an authorized partner. • The operators are to be informed prior to the maintenance and repair work.

  • Page 33: Clamping Elements

    > until no more air is visible in the venting hoses. • Afterwards tighten the screws (A1) and (A2) again. Make sure that the tank always contains enough oil (chapter: 7.7.) 30.07.12 Working Instructions WIDOS 10000 mobile Page 30 of 52...

  • Page 34: How To Check And Refill The Hydraulic Oil

    • Afterwards screw cap again. • Check the blades of the planer for sharpness, turn them if necessary (grinded on both sides, max. thickness of the shavings: 0,2 mm). Chain tightener 30.07.12 Working Instructions WIDOS 10000 mobile Page 31 of 52...

  • Page 35: Protect Machine Parts Against Corrosion

    (chapter: 5.1) 7.12. Disposal At the end of the life time, the machine has to be disposed of properly, non- polluting and in accordance with the national laws of waste disposal. 30.07.12 Working Instructions WIDOS 10000 mobile Page 32 of 52...

  • Page 36: Electric And Hydraulic Diagrams

    Phone ++49 7152 9939 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen ++49 7152 9939 - 40 website: www.widos.de email: info@widos.de Ku nst sto ffschweißtec hni k 8. Electric and hydraulic diagrams 30.07.12 Working instructions WIDOS 10000 mobile Page 33 of 52...
  • Page 37 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 34 of 52...
  • Page 38 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 35 of 52...
  • Page 39 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 36 of 52...
  • Page 40 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 37 of 52...
  • Page 41 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 38 of 52...
  • Page 42 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 39 of 52...
  • Page 43 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 40 of 52...
  • Page 44 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 41 of 52...
  • Page 45 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 42 of 52...
  • Page 46 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 43 of 52...
  • Page 47 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 44 of 52...
  • Page 48 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 45 of 52...
  • Page 49 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 46 of 52...
  • Page 50 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 47 of 52...
  • Page 51 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 48 of 52...
  • Page 52 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 49 of 52...
  • Page 53 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 50 of 52...
  • Page 54 Electric and hydraulic diagrams Chapter 8 Ku nst sto ffschweißtec hni k 30.07.12 Working Instructions WIDOS 10000 mobile Page 51 of 52...

  • Page 55: Declaration Of Conformity

    The technical documentation is completely available. The following technical documentation can be examined at the corporation mentioned above: - testing documents - other technical documents Ditzingen-Heimerdingen, 7/30/2012 Martin Dommer (Technical director) 30.07.12 Working instructions WIDOS 10000 mobile Page 52 of 52...

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