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widos 25000 mobile Working Instructions Translation

Heating element butt welding machine
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WIDOS
W. Dommer Söhne GmbH
Working Instructions
Heating element butt welding machine
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
website: www.widos.de
Translation
WIDOS 25000 mobile
Keep for further use!
Phone
++49 7152 9939 - 0
Fax
++49 7152 9939 - 40
email: info@widos.de
Kunststoffschweißtechnik

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  • Page 1 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen ++49 7152 9939 - 40 website: www.widos.de email: info@widos.de Kunststoffschweißtechnik Working Instructions Translation Heating element butt welding machine WIDOS 25000 mobile Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer...
  • Page 2 D-09224 Grüna / Sachsen CH – 9201 Gossau Phone: ++49 371 / 8 15 73 - 0 Phone: +41 (0) 79 432 5737 Fax: ++49 371 / 8 15 73 - 20 07.02.13 Working Instructions WIDOS 25000 mobile Page 2 of 116...
  • Page 3 Due to this structure, the searched information can be easily found.  2/7/2013 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. 07.02.13 Working Instructions WIDOS 25000 mobile Page 3 of 116...

  • Page 4: Table Of Contents

    Machine overview .........................8   1.5.   Designation of the product ....................9   1.5.1.   Technical data ........................9   1.5.1.1.   WIDOS 25000 mobile General data ................9   1.5.1.2.   Basic frame ........................9   1.5.1.3.   Hydraulic aggregate....................10   1.5.1.4.  ...
  • Page 5 Aligning..........................50   6.6.   Heating ..........................50   6.7.   Change-over ........................50   6.8.   Cooling / Joining.........................51   6.9.   End of welding ........................51   7.  DIAGNOSIS PROGRAM ....................52  07.02.13 Working Instructions WIDOS 25000 mobile Page 5 of 116...
  • Page 6 How to swing in the front leveling legs ................62   9.6.   How to swing in the rear leveling leg ................63   10.  ELECTRIC DIAGRAMS....................64  11.  DECLARATION OF CONFORMITY ................120  07.02.13 Working Instructions WIDOS 25000 mobile Page 6 of 116...

  • Page 7: 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 25000 mobile has been designed for the heating element butt welding of pipes and fittings with a diameter range from OD 1600 mm (optional) up to OD 2500 mm.

  • Page 8: Machine Overview

    Front leveling leg, flat Front leveling leg Main cylinder for welding Heating element Pipe cutter Right clamping tools Switch cabinet Hydraulic pump Left clamping tools Pipe clampers Remote control Abdominal belt 07.02.13 Working Instructions WIDOS 25000 mobile Page 8 of 116...

  • Page 9: Designation Of The Product

    All important technical data of each single component are displayed. They allow rapid information about the working capacity and the structure. 1.5.1.1. WIDOS 25000 mobile General data Pipe diameter range: OD 1600 mm (optional) – OD 2500 mm Material which can be welded:...

  • Page 10: Hydraulic Aggregate

    OMR 80 Speed: appr. 21 rpm Inlet pressure: 175 bar (factory-set) 1.5.1.6. Vacuum device AF 14 (optional) Power: 2,2 kW Voltage: 400V (+-10%) Current: 5 A (+-10%) Frequency: 50 Hz 07.02.13 Working Instructions WIDOS 25000 mobile Page 10 of 116...

  • Page 11: Equipment (Optional)

    Socket wrench size 36 Torx-Screw driver T15 Cordless impact wrench 180 AFT-W 1,5 Nut for cordless impact wrench size 30 Wire rope with hook (J9994) Manual for vacuum device AF14 (Company Felder, optional) 07.02.13 Working Instructions WIDOS 25000 mobile Page 11 of 116...

  • Page 12: 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). 07.02.13 Working Instructions WIDOS 25000 mobil Page 12 of 116...

  • Page 13: Obligations Of The Owner

     A person who is being trained may only work at the machine under supervision of an experienced person. 07.02.13 Working Instructions WIDOS 25000 mobile Page 13 of 116...

  • Page 14: Maintenance And Inspection, Repair

    2.8. Dangers while handling the machine The machine WIDOS 25000 mobile has been constructed according to the latest technical standard and the acknowledged technical safety rules. However, dangers for the operator or other persons standing nearby may occur. Also material damages are possible.

  • Page 15: Specific Dangers

    For this reason, please take care that the inflammation point is above the actual temperature of the heating element.  Do not bring any fire sources (e.g. cigarettes) close thereto. 07.02.13 Working Instructions WIDOS 25000 mobile Page 15 of 116...

  • Page 16: Danger Of Sqeezing At Clamping Tools And Guide Rails

     Always drive the leveling legs out thus far until the machine is aligned and fixed with or without carriage.  Never open the clamping tools unless the machine has been fixed by the leveling legs. 07.02.13 Working Instructions WIDOS 25000 mobile Page 16 of 116...

  • Page 17: Risk Of Injury By Noise

     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! 2.12.

  • Page 18: 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 07.02.13 Working Instructions WIDOS 25000 mobile page 18 of 116...

  • Page 19: Operating And Indicating Elements

    For transporting the machine, may be removed Front leveling leg, For aligning the machine with or without carriage flat version Front leveling leg For aligning the machine with or without carriage 07.02.13 Working Instructions WIDOS 25000 mobile page 19 of 116...

  • Page 20: Basic Machine

    - attached to each clamping ring, showing the current analogue clamping pressure Switch cabinet - with main switch, emergency stop and power sockets for illumination, power sockets for vacuum and SD card drive; different interfaces and fuses 07.02.13 Working Instructions WIDOS 25000 mobile Page 20 of 116...

  • Page 21: Reducer Inserts And Assembling Aid (Optional)

     Detach the knurled screw and shift the axis in arrow direction up to limit stop.  Fix the axis again by the knurled screw. Axis in position for right clamping rings Knurled screw 07.02.13 Working Instructions WIDOS 25000 mobile Page 21 of 116...
  • Page 22 Elastic pressure piece Bolt for reducer insert  Always insert the bolt for reducer insert into the drill hole up to limit stop; afterwards it is maintained by the elastic pressure piece. 07.02.13 Working Instructions WIDOS 25000 mobile Page 22 of 116...

  • Page 23: Hydraulic Aggregate And Hydraulic Blocks

    Fix clamping tool R2 Drive ejector R1 out of machine Drive ejector R1 into machine (optional) (optional) Drive ejector R2 out of machine Drive ejector R2 into machine (optional) (optional) 07.02.13 Working Instructions WIDOS 25000 mobile Page 23 of 116...
  • Page 24 Lift front left level Lower rear left level Lift rear left level M101 Left table locking, open M102 Left table locking, shut M105 Additional valve V3 inactive M106 Additional valve V3 active 07.02.13 Working Instructions WIDOS 25000 mobile Page 24 of 116...

  • Page 25: Heating Element

     Then mount the smaller heating plate and connect the plugs of this heating plate to the interfaces. 07.02.13 Working Instructions WIDOS 25000 mobile Page 25 of 116...

  • Page 26: How To Adjust The Travel Speed Of The Heating Element

    Heating zone 1 Heating zone 2 (front upper side) (rear upper side) Front heating plate Rear heating plate Heating zone 3 Heating zone 4 (front lower side) (rear lower side) 07.02.13 Working Instructions WIDOS 25000 mobile Page 26 of 116...

  • Page 27: Pipe Cutter

    Never exceed the red marking! Make sure that nobody can start the cutter by the remote control while you shift the blades back and forth by the portable screwdriver! 07.02.13 Working Instructions WIDOS 25000 mobile Page 27 of 116...
  • Page 28  You may only swing the cutter in or out if the color sensor detects the red color. This guarantees that the cutter does not collide with the base frame while swinging it. Make sure that the label is not removed! 07.02.13 Working Instructions WIDOS 25000 mobile Page 28 of 116...

  • Page 29: Front Leveling Leg

    You may swing the front leveling leg to the front side e.g. for the transport. Leveling leg Leveling leg flat Hexagon-head screw M24 Ring bolt Hydraulic connectors for left front leveling leg 07.02.13 Working Instructions WIDOS 25000 mobile Page 29 of 116...

  • Page 30: Rear Leveling Leg

     Remove the ring bolts on both sides.  Then pull out the claws on both sides.  Lift the machine by the leveling legs until there is enough air between machine and carriage. 07.02.13 Working Instructions WIDOS 25000 mobile Page 30 of 116...

  • Page 31: How To Fix Clamping Tools

     Put the fixing plate below the base frame and tighten the fixing plate from above by hexagon socket screws M 24.  Insert the spacer block between support angle and fixing plate and tighten the three parts by hexagon socket screws M 24. 07.02.13 Working Instructions WIDOS 25000 mobile Page 31 of 116...

  • Page 32: Stub End Holder (Optional)

     In order to adjust the limit stop, release the hexagon socket screw.  Shift the limit stop onto the requested dimension on the scale and fix the hexagon socket screw again. Read dimension here 07.02.13 Working Instructions WIDOS 25000 mobile Page 32 of 116...

  • Page 33: How To Put The Stub End Holder Onto The Transport Rack

     Then carefully lower the stub end holder onto the rack until the flange is located between the wooden limit stops.  Fix the stub end holder to the rack by clamping belts. 07.02.13 Working Instructions WIDOS 25000 mobile Page 33 of 116...

  • Page 34: Pipe Jack (Optional)

    The pressure is maintained by the corresponding back-pressure valves. Pipe jack illustrated horizontally: Quick-action couplings Spring plug Ring bolt Pipe jack outer part Pipe jack inner part Block cylinder 07.02.13 Working Instructions WIDOS 25000 mobile Page 34 of 116...

  • Page 35: Vacuum Device (Optional)

     Please learn handling and maintenance of the vacuum device AF14 from the separately enclosed working instructions of the Felder company. Empty the chip tank regularly, at the latest in case the vacuum performance decreases. 07.02.13 Working Instructions WIDOS 25000 mobile Page 35 of 116...

  • Page 36: Switch Cabinet

    Key may be removed in any position Light Switch stationary lamps and multiple socket outlet on / off Vacuum Power socket CEE-16A for vacuum device AF14 07.02.13 Working Instructions WIDOS 25000 mobile Page 36 of 116...

  • Page 37: Fuses In The Switch Cabinet

    Contactor emergency stop heating element zone 1 Contactor emergency stop heating element zone 2 Contactor emergency stop heating element zone 3 Contactor emergency stop heating element zone 4 24 V switch-mode power supply Service socket 07.02.13 Working Instructions WIDOS 25000 mobile Page 37 of 116...

  • Page 38: Additional Keyboard For Diagnosis Test

    Port in You may view the digital inlets using this key. Press <Port in>, the display shows: IN Ports: Display: line: In order to quit the program press <Enter> accordingly. 07.02.13 Working Instructions WIDOS 25000 mobile Page 38 of 116...

  • Page 39: Starting And Operating

    (e.g. PE cleaner or pipe cleaning tissues which are available at the WIDOS company). Never discard the heating element unprotected onto its coated surfaces.

  • Page 40: Remote Control

    - short pushing: to shorten the overtravel of the pump - longer pushing during welding: aborts welding Heater Position - not assigned P1 – P3 - Regulator, to adjust the different welding pressures min - max 07.02.13 Working Instructions WIDOS 25000 mobile Page 40 of 116...

  • Page 41: Meaning Of Control Levers 1 - 6 Within Mode Select 1 - 6

    Idle valve e.g. for pipe spreader, spread  / release  Lever 4 Idle valve e.g. for pipe spreader, spread  / release  Lever 5 Idle valve e.g. for pipe spreader, spread  / release  Lever 6 07.02.13 Working Instructions WIDOS 25000 mobile Page 41 of 116...

  • Page 42: Emergency Stop Switch

     Make sure that you have charged the accumulators in time and sufficiently.  While replacing the accumulators, always put in the second entirely charged accumulator first before you remove the dead one in order to recharge it. 07.02.13 Working Instructions WIDOS 25000 mobile Page 42 of 116...

  • Page 43: How To Switch On The Machine

    Display: LAB0 0000 00.0 line: Adjust wall thickness [mm] You may adjust the wall thickness by <+> and <-> Press <Start>: confirm and go to the next parameter 07.02.13 Working Instructions WIDOS 25000 mobile Page 43 of 116...
  • Page 44 Adjust cooling time You may adjust the cooling pressure by <+> and <-> Press <Start>: confirm and go to the next parameter WIDOS 25000 Display: Main menu 11:00 20.02.2012 line: 07.02.13 Working Instructions WIDOS 25000 mobile Page 44 of 116...

  • Page 45: Sd - Card And Drive

     The card can be read out with a WICON program.  The card may not be bent, opened, overheated and become wet! Please only use SD cards purchased from WIDOS. We will not be liable for any cards from other manufactures! 5.3.3.

  • Page 46: Data Format Of Wicon.txt On The Sd-Card

    Temperature 0x0040 Not assigned 0x0080 Not assigned 0x0100 Not assigned 0x0200 Not assigned 0x0400 Emergency stop 0x0800 Path measurement 0x1000 Not assigned 0x2000 Current interruption 0x4000 User break 0x8000 Tool 07.02.13 Working Instructions WIDOS 25000 mobile Page 46 of 116...

  • Page 47: Welding Process

    Clamping ring clamped with fish plate Clamping ring unclamped with fish plate Make sure while clamping the rings that the fish plate does not get jammed.  If necessary align the fish plate manually. 07.02.13 Working Instructions WIDOS 25000 mobile page 47 of 116...

  • Page 48: How To Plane The Pipe Ends

     Now drive the cutters back to initial position on both sides using the cordless impact wrench.  Drive the pipes apart by pushing <Joystick> to: Open  Remove the oddments and cutting wastes but do not touch the cutting surfaces. 07.02.13 Working Instructions WIDOS 25000 mobile Page 48 of 116...

  • Page 49: How To Check Pipe Mismatch

    <welding pressure> p2 slowly upwards until the clamping tools start moving with the clamped pipes.  Read the pressure and press <Start> assuming the accumulated pressure as motional pressure. 07.02.13 Working Instructions WIDOS 25000 mobile Page 49 of 116...

  • Page 50: Aligning

     Drive the heating element to the rear into initial position by pushing <Heater in> to:  thus driving the tear-off device back as well. 07.02.13 Working Instructions WIDOS 25000 mobile Page 50 of 116...

  • Page 51: Cooling / Joining

     Shift the welding piece out of the clamping tools by putting both levers <Pipe lift> to:  and remove the welding piece.  Drive the tables apart again, <Joystick> to: Open. Welding is completed. 07.02.13 Working Instructions WIDOS 25000 mobile Page 51 of 116...

  • Page 52: Diagnosis Program

    In case you change wrong values, this may cause malfunctions of the machine. The fourth value is for “slow” driving, the fifth value is for “fast” driving. 07.02.13 Working Instructions WIDOS 25000 mobile Page 52 of 116...
  • Page 53 Change the numerical value using <+ / - / Enter>. Then press <Start> several times until the basic menu appears. WIDOS 25000 CNC Display: Machine type is displayed, 20.02.2012 10:18 line: current date and time is displayed 07.02.13 Working Instructions WIDOS 25000 mobile Page 53 of 116...

  • Page 54: Maintenance, Care And Repair

    The DVS gives the advice of inspection work after 1 year. For machines with a specially high usage percentage the testing cycle should be shortened. The work should be performed at the WIDOS GmbH company or by an authorized partner. Take care that:...

  • Page 55: Storage

    8.6. Used hydraulic oil Only use HLPD 35. Features: protection against corrosion, resistance to ageing, abrasion-reducing additives, high carrying capacity and particularly water-repellent. The hydraulic oil has to be disposed of properly. 07.02.13 Working Instructions WIDOS 25000 mobile Page 55 of 116...

  • Page 56: How To Vent The Hydraulic Cylinders

    In case of air humidity of > 85 % and / or high temperatures you must treat the untreated steel parts of the machine with anti-corrosive protecting agent (e.g. AVILUB NCI 9840). 07.02.13 Working Instructions WIDOS 25000 mobile Page 56 of 116...

  • Page 57: Cutter

    8.10. How to lubricate the guidings for the leveling legs All four leveling legs feature lubricating nipples for lubricating the guiding axes.  Regularly (monthly) grease all guiding axes. Lubricating nipple 07.02.13 Working Instructions WIDOS 25000 mobile Page 57 of 116...

  • Page 58: Vacuum Device (Optional)

    „AF14“. 8.12. 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. 07.02.13 Working Instructions WIDOS 25000 mobile Page 58 of 116...

  • Page 59: Transport

    View from the inside: Flexible front clamping ring Hexagon socket screw Fix rear clamping ring  First detach the hexagon socket screws on the left and right side of the clamping rings. 07.02.13 Working Instructions WIDOS 25000 mobile Page 59 of 116...
  • Page 60 Pan-head screws  Detach the pan-head screws at each cylinder for the clamping rings and remove both angles from the cylinder.  Now you may remove the front clamping rings. 07.02.13 Working Instructions WIDOS 25000 mobile Page 60 of 116...

  • Page 61: How To Fix The Cutter In The Machine

     Also pull the ring bolt with plate and bolt out of the drill hole at the bottom.  Swing the heating element by 90° until it is parallel to the pipe axis. 07.02.13 Working Instructions WIDOS 25000 mobile Page 61 of 116...

  • Page 62: How To Remove The Carriage

     Detach the hexagon socket screws M 24 by which the locking bars have been fixed into the carriers.  Pull the locking bars to the front using the ring bolts (arrow). 07.02.13 Working Instructions WIDOS 25000 mobile Page 62 of 116...

  • Page 63: How To Swing In The Rear Leveling Leg

     Pull the ring bolts (8 units / leg) out and swing the leg to the front side by 90°.  Secure the requested position by the ring bolt again. Ring bolts 07.02.13 Working Instructions WIDOS 25000 mobile Page 63 of 116...

  • Page 64: Electric Diagrams

    WIDOS Einsteinstr. 5 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 Kunststoffschweißtechnik 10. Electric diagrams 07.02.13 Working Instructions WIDOS 25000 mobile Page 64 of 116...
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  • Page 120: 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, 2/7/2013 Martin Dommer (Technical director) 07.02.13 Working Instructions WIDOS 25000 mobile Page 120 of 116...

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