widos 4400 Working Instructions
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widos 4400 Working Instructions

Heating element butt welding machine
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WIDOS
WIDOS
WIDOS
WIDOS
Wilhelm Dommer Söhne
GmbH
Working Instructions
Working Instructions
Working Instructions
Working Instructions
Heating Element Butt Welding Machine
Heating Element Butt Welding Machine
Heating Element Butt Welding Machine
Heating Element Butt Welding Machine
Headquarters: D-71254 Ditzingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer, Dr. Kai Dombrowski
Einsteinstraße 5
D-71254 Ditzingen
info@widos.de
Translation
Translation
Translation
Translation
WIDOS 4400
WIDOS 4400
WIDOS 4400
WIDOS 4400
Keep for further use!
Phone
+49 7152 9939 0
Fax
+49 7152 9939 40
Internet: www.widos.de

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  • Page 1 Translation Heating Element Butt Welding Machine Heating Element Butt Welding Machine Heating Element Butt Welding Machine Heating Element Butt Welding Machine WIDOS 4400 WIDOS 4400 WIDOS 4400 WIDOS 4400 Keep for further use! Headquarters: D-71254 Ditzingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer, Dr. Kai Dombrowski...
  • Page 2 Address of Address of anufacturer anufacturer anufacturer WIDOS WIDOS WIDOS WIDOS Wilhelm Dommer Söhne GmbH Einsteinstrasse 5 D-71254 Ditzingen Phone: ++49 7152 99 39 0 Telefax: ++49 7152 99 39 40 15.11.18 Working Instructions WIDOS 4400 Page 2 of 44...
  • Page 3  WIDOS WIDOS 15.11.2018 WIDOS WIDOS Wilhelm Dommer Söhne GmbH Einsteinstraße 5 D-71254 Ditzingen All rights reserved. Reprinting only allowed with permission of the corporation. Any changes prior to technical innovations. 15.11.18 Working Instructions WIDOS 4600 Page 3 of 44...

  • Page 4: Table Of Contents

    ........................7 7 7 7 1.5.1. Technical data ............................... 7 1.5.1.1. WIDOS 4400 4400 4400 General data ........................7 4400 1.5.1.2. Heating element ............................8 1.5.1.3. Planer ................................8 1.5.1.4. Hydraulic aggregate ..........................9 1.5.1.5. Basic frame ..............................9 1.5.1.6.
  • Page 5 ..42 42 42 42 ..DECLARATION OF CONFO DECLARATION OF CONFO DECLARATION OF CONFO DECLARATION OF CONFORMITY RMITY RMITY RMITY ....................................................................44 44 44 44 ......15.11.18 Working Instructions WIDOS 4400 Page 5 of 44...

  • Page 6: Conformity Conformity

    Usage and urpose oriented urpose oriented The WIDOS WIDOS 4400 4400 has been designed only for heating element butt welding of pipes and fittings with a WIDOS WIDOS 4400 4400 diameter range of Ø = 50 - 160 mm (standard diameters: 50 / 63 / 75 / 90 / 110 / 125 / 140 / 160 mm).

  • Page 7: Machine Overview

    - Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear protection! - When using the named pipe materials and when welding below 260 °C / 500 °F no toxicant damp arises. 15.11.18 Working Instructions WIDOS 4400 Page 7 of 44...

  • Page 8: Heating Element

    4,1 A Frequency: 50 Hz (± 10 %) RPM n of planer: 100 rpm Attached elements: - Switch on/off with fixing device - Connecting cable and plug Weight: appr. 7,5 kg 15.11.18 Working Instructions WIDOS 4400 Page 8 of 44...

  • Page 9: Hydraulic Aggregate

    Allen key angulate size 3 / 5 / 6 1 each Allen key with T grip size 3 / 4 option Reduction inserts (large, extra large), roller brackets for the pipes, transformer 15.11.18 Working Instructions WIDOS 4400 Page 9 of 44...
  • Page 10 T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) . 15.11.18 Working Instructions WIDOS 4400 Page 10 of 44...

  • Page 11: Safety Rules

    A person who is being trained may only work at the machine under supervision of an • experienced person. 15.11.18 Working Instructions WIDOS 4400 Page 11 of 44...
  • Page 12 The machine WIDOS 4400 WIDOS 4400 is constructed according to the latest technical standard and the WIDOS 4400 WIDOS 4400 acknowledged technical safety rules. However, dangers for the operator or other persons standing nearby may occur. Also damages to the machine itself or to other things are possible.

  • Page 13: Risk Of Injury By Noises

    Do not stand or put hands between clamped pipe ends. Do not stand or put hands between the inner clamping tools with not yet clamped pipes. • Do not block opening and closing of the machine slides. • 15.11.18 Working Instructions WIDOS 4400 Page 13 of 44...
  • Page 14 • No modifications, extensions or reconstructions may be made on the machine without permission of the manufacturer. • Machine parts which are not in a perfect condition are to be replaced immediately. • Only use original WIDOS WIDOS WIDOS WIDOS spare and wear parts.
  • Page 15 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 15.11.18 Working Instructions WIDOS 4400 Page 15 of 44...
  • Page 16 Hydraulic connection for - Non-dropping quick-acting coupling closing the slides Hydraulic connection for - Non-dropping quick-acting coupling opening the slides Screw with oil dipstick - checking the oil level - oil filler neck 15.11.18 Working Instructions WIDOS 4400 Page 16 of 44...

  • Page 17: Elements On The Aggregate

    Denomination Denomination Function Function Socket 230V/50 Hz Possibility for connecting the planer / heating element Socket 230V/50 Hz Possibility for connecting the planer / heating element Mains cable 230V/50Hz Power supply 15.11.18 Working Instructions WIDOS 4400 Page 17 of 44...
  • Page 18 • maintained by a certain pulse-position ratio on on on on: signalizes that the heating element is heated • up at the moment. It has not yet reached the desired temperature 15.11.18 Working Instructions WIDOS 4400 Page 18 of 44...
  • Page 19 • If the surrounding temperature is under 5 °C / 41 °F, measures have to be taken: • Use a welding tent or preheat the pipe ends if necessary. • In addition, take measures against rain, wind and dust. 15.11.18 Working Instructions WIDOS 4400 Page 19 of 44...
  • Page 20 • When fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can also be used flush to the inside or to the outside. Small reduction insert, centered (for pipes) Shown here: Small reduction insert, flush to the inside (for bends, T-pieces) 15.11.18 Working Instructions WIDOS 4400 Page 20 of 44...
  • Page 21 • Lay the pipes to be welded into the clamping devices, tighten firmly the clamping nuts and align the pipes with respect to one another. In case of long pipe ends, use WIDOS rollerstands for alignment. • Close the slides, valve lever on: “FORWARDS”, thereby reading the movement pressure...
  • Page 22 • After expiration of the cooling time, release pressure, valve lever to position “Pressure release“. • Open the clamping devices and remove the welded part. • Open the slides, valve lever on: “BACKWARDS”. 15.11.18 Working Instructions WIDOS 4400 Page 22 of 44...
  • Page 23 Internet: www.widos.de 6. 6. 6. 6. Welding Welding l l l l og and og and t t t t ables ables Welding Welding og and og and ables ables 15.11.18 Working Instructions WIDOS 4400 Page 23 of 44...
  • Page 24 Welding Log and Tables Chapter 6 Chapter 6 Chapter 6 Chapter 6 15.11.18 Working Instructions WIDOS 4400 Page 24 of 44...
  • Page 25 05:00 06:30 03:30 17,6 00:36 04:00 05:00 06:30 03:30 00:38 04:00 05:00 06:30 03:30 13,6 00:47 04:10 05:12 06:44 03:37 00:58 05:02 06:18 08:04 04:17 01:11 06:04 07:35 09:37 05:04 01:26 07:07 08:56 11:25 05:58 15.11.2018 Working Instructions WIDOS 4400...
  • Page 26 03:30 17,6 00:51 04:29 05:36 07:13 03:52 00:54 04:43 05:54 07:35 04:02 13,6 01:07 05:46 07:12 09:08 04:49 01:22 06:50 08:35 10:56 05:43 10,1 01:41 08:10 10:17 13:13 06:52 12,3 02:03 09:42 12:15 15:52 08:10 15.11.2018 Working Instructions WIDOS 4400...
  • Page 27 17,6 01:11 06:04 07:35 09:37 05:04 01:14 06:17 07:52 09:59 05:14 13,6 01:32 07:32 09:29 12:08 06:19 11,4 01:54 09:05 11:28 14:47 07:38 14,0 02:20 10:47 13:43 17:56 09:09 17,1 02:51 12:47 16:22 21:42 10:55 15.11.2018 Working Instructions WIDOS 4400...
  • Page 28 01:31 07:28 09:23 12:01 06:16 01:35 07:45 09:45 12:30 06:30 11,8 13,6 01:58 09:22 11:49 15:16 07:53 14,6 02:26 11:10 14:14 18:39 09:29 17,9 02:59 13:18 17:03 22:40 11:22 21,9 03:39 16:04 20:29 27:19 13:39 15.11.2018 Working Instructions WIDOS 4400...
  • Page 29 05:00 06:30 03:30 00:45 04:00 05:00 06:30 03:30 01:08 05:02 06:18 08:04 04:17 01:22 06:04 07:35 09:37 05:04 01:38 07:07 08:56 11:25 05:58 10,5 01:59 08:27 10:39 13:42 07:06 12,7 02:22 09:57 12:36 16:21 08:24 15.11.2018 Working Instructions WIDOS 4400...
  • Page 30 03:52 01:03 04:43 05:54 07:35 04:02 01:34 06:50 08:35 10:56 05:43 10,1 01:54 08:10 10:17 13:13 06:52 12,3 02:18 09:42 12:15 15:52 08:10 15,0 02:45 11:26 14:34 19:09 09:43 18,1 03:17 13:25 17:14 22:54 11:29 15.11.2018 Working Instructions WIDOS 4400...
  • Page 31 01:25 06:17 07:52 09:59 05:14 11,4 02:09 09:05 11:28 14:47 07:38 14,0 02:35 10:47 13:43 17:56 09:09 17,1 03:07 12:47 16:22 21:42 10:55 20,8 03:43 15:17 19:33 26:03 13:02 25,1 04:23 18:21 23:14 30:58 15:29 15.11.2018 Working Instructions WIDOS 4400...
  • Page 32 01:48 07:45 09:45 12:30 06:30 14,6 02:41 11:10 14:14 18:39 09:29 17,9 03:15 13:18 17:03 22:40 11:22 21,9 03:53 16:04 20:29 27:19 13:39 26,6 04:36 19:26 24:33 32:43 16:23 32,1 05:21 23:26 29:33 39:13 19:53 15.11.2018 Working Instructions WIDOS 4400...
  • Page 33 The DVS gives the advice of inspection works after 1 year. For machines with a specially high usage percentage the testing cycle should be shortened. The works should be performed at the WIDOS GmbH company or by an authorized partner. 7.2.
  • Page 34 The lower vent screws always have to be vented at first because there is a direct connection between the upper and the lower cylinders. • If air remains in the lower cylinder, it will ascend in the upper cylinder when pressure is applied. 15.11.18 Working Instructions WIDOS 4400 Page 29 of 44...
  • Page 35 During the transport of the machine there may be cold weldings between the piston rod and the eyes of the planer housing. These spots on the piston rod may damage the sealing. Therefore the eyes must be lubricated with PTFE-spray before each transport! 15.11.18 Working Instructions WIDOS 4400 Page 30 of 44...
  • Page 36 9. 9. 9. 9. Hydraulic and Hydraulic and e e e e lectric lectric d d d d iagrams iagrams Hydraulic and Hydraulic and lectric lectric iagrams iagrams Working direction Hydraulic diagramm 15.11.18 Working Instructions WIDOS 4400 Page 31 of 44...
  • Page 37 Wiring Diagrams Chapter 9 Chapter 9 Chapter 9 Chapter 9 15.11.18 Working Instructions WIDOS 4400 Page 32 of 44...
  • Page 38 Basic achine achine achine 14 - 15 16 - 18 9 - 10 32 - 33 20 - 21 35 - 37 23 - 25 27 - 30 40 - 41 15.11.18 Working Instructions WIDOS 4400 Page 33 of 44...
  • Page 39 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 Basic Machine Basic Machine WIDOS 4400 Basic Machine Basic Machine Pos. Name Piece Order no. Clamping ring upper part 160105 Outer clamping ring lower part, movable 160104 Inner clamping ring lower part, movable...
  • Page 40 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 Basic Machine Basic Machine WIDOS 4400 Basic Machine Basic Machine Pos. Name Piece Order no. Washer M6 DIN 125 0125F Reducer inserts OD 50 - OD 140 mm 1 set 1608...*...
  • Page 41 Planer Planer Planer 1 / 2 31 - 35 5 - 7 36 - 39 8 - 13 16 / 17 18 - 20 21 / 22 23 - 25 41/42 15.11.18 Working Instructions WIDOS 4400 Page 35 of 44...
  • Page 42 Sheet metal screw M 4,8x8 DIN 7981 7981E080 Washer M 10 DIN 125 0125J Hexagon nut M 10 DIN 934 0934J Holder for planer 160401 Planer disc, left-hand 160403 Cover for planer switch 091420 15.11.2018 Working instructions WIDOS 4400 Page 36 of 44...
  • Page 43 Hydraulic Hydraulic Hydraulic a a a a ggregate ggregate ggregate ggregate 1 - 2 4- 6 22 - 23 9 - 16 12 - 18 31 - 32 28 - 29 15.11.18 Working Instructions WIDOS 4400 Page 37 of 44...
  • Page 44 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 44 - 48 36 - 40 54 - 55 56 - 59 51 - 52 15.11.18 Working Instructions WIDOS 4400 Page 38 of 44...
  • Page 45 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 Hydraulic Aggregate Hydraulic Aggregate Hydraulic Aggregate Hydraulic Aggregate WIDOS 4400 Pos. Name Piece Order no. Protective mounting 101042 Pan-head screw M6x16 DIN 912 0912F016 Cover 1010021 Control knob for pressure setting...
  • Page 46 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 Hydraulic Aggregate Hydraulic Aggregate Hydraulic Aggregate Hydraulic Aggregate WIDOS 4400 Pos. Name Piece Order no. Grub screw M 6x8 DIN 913 0913F008 Hexagon nut M6 DIN 934 0934F Set screw on request Plug-in element P83-1/2"x3/16"...
  • Page 47 10.4. 10.4. Heating Heating Heating Heating e e e e lement lement lement lement 17-19 4 / 5 21 - 23 7 / 8 10-12 13 - 16 25 - 28 15.11.18 Working Instructions WIDOS 4400 Page 40 of 44...
  • Page 48 Ersatzteilliste Kapitel 10 Kapitel 10 Kapitel 10 Kapitel 10 Heating Element Heating Element Heating Element Heating Element WIDOS 4400 Pos. Name Piece Order-no. Heating element H4400E Heating plate HG 205 E 230 V HP4400E Heating plate in exchange HPT4400 Tapped bushing...
  • Page 49 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 10.5. 10.5. 10.5. 10.5. Protection Protection Protection Protection b b b b ox ox ox ox 3 - 4 10 - 11 15.11.2018 Working Instructions WIDOS 4400 Page 42 of 44...
  • Page 50 Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 Protection Box Protection Box WIDOS 4400 man Protection Box Protection Box Pos. Name Piece Order-no. Strirrup 160537 Spacing bolt for planer 160534 Hexagon domed cap nut M8 DIN 1587...
  • Page 51 11. Declaration of conformity Issuing the declaration of conformity with regard to complying with the basic requirements and assembling the technical documentation is in the sole responsibility of: Manufacturer / Installation WIDOS Wilhelm Dommer Söhne GmbH company: Address: WIDOS GmbH Einsteinstr.

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