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widos 6113 mobile Working Instructions Translation

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 6113 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 6113 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 2 of 81...
  • Page 3 Due to this structure, the searched information can be easily found.  12/10/2013 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. 10.12.13 Working Instructions WIDOS 6113 mobile Page 3 of 81...
  • Page 4 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 4 of 81...

  • Page 5: Table Of Contents

    Safety measures ........................7 1.3. Conformity ..........................7 1.4. Machine overview .........................8 1.5. Designation of the product ....................8 1.5.1. Technical data ........................8 1.5.1.1. WIDOS 6113 mobile General data ................9 1.5.1.2. Basic frame ........................9 1.5.1.3. Hydraulic pump ......................9 1.5.1.4. Heating element.......................10 1.5.1.5. Planer........................10 1.6.
  • Page 6 How to lubricate the joints for heating element, planer, carriage and pipe lifter ..45 8.11. Transport..........................45 8.12. Protect machine parts against corrosion ................ 46 8.13. Disposal..........................46 ELECTRIC AND HYDRAULIC DIAGRAMS ..............47 10. DECLARATION OF CONFORMITY................81 10.12.13 Working Instructions WIDOS 6113 mobile Page 6 of 81...

  • 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 6113 mobile has been designed for the heating element butt welding of pipes and fittings with a diameter of OD 315 up to OD 630 mm / 12” – 22” IPS.

  • Page 8: 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. 10.12.13 Working Instructions WIDOS 6113 mobile Page 8 of 81...

  • Page 9: Widos 6113 Mobile General Data

    Description of the product Chapter 1 Kunststoffschweißtechnik 1.5.1.1. WIDOS 6113 mobile General data Pipe diameter range: OD = 315 mm up to 630 mm / 12” – 22” IPS Material which can be welded: PP, PE80, PE 100 Weight: appr. ?? kg Emission - There will be noise exceeding 80 dB (A);...

  • Page 10: Heating Element

    Drive pinion for planer (1/2“x5/16“ / Z= 12) 081412 Drive chain without lock (1/2 x 5/16““, 158 chain links) K1216 Chain lock (1/2“) KSCH12 Wheel Ø 540 x 170 (R6.00-9/6-K100RK) on request Hydraulic oil HLDP35 10.12.13 Working Instructions WIDOS 6113 mobile Page 10 of 81...

  • Page 11: Accessories

    WI-FIX® clamping insert 22“ IPS 0808558 Pan-head screw M 10x40 DIN 7984 7984J40X (for OD 12“ IPS – 20“ IPS) Pan-head screw M 10x35 DIN 7984 (for OD 22“ IPS) 7984J35X 10.12.13 Working Instructions WIDOS 6113 mobile Page 11 of 81...
  • Page 12 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 12 of 81...

  • Page 13: Safety Rules

    This symbol indicates a possible risk of injuring to persons or damage to the machine.  Do not enter areas which are marked by this symbol. The regulations for the prevention of accidents are valid (UVV). 10.12.13 Working Instructions WIDOS 6113 mobile Page 13 of 81...

  • Page 14: Obligations Of The Owner

     A person who is being trained may only work at the machine under supervision of an experienced person. 10.12.13 Working Instructions WIDOS 6113 mobile Page 14 of 81...

  • Page 15: Maintenance And Inspection, Repair

    2.8. Dangers while handling the machine The machine WIDOS 6113 mobile is 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 16: Dangers Caused By The Hydraulics

     Never park the machine in unsecured condition; block the wheels by chocks and the mechanical brakes.  Secure the machine e.g. by a vehicle before you remove the chocks and release the brakes. 10.12.13 Working Instructions WIDOS 6113 mobile Page 16 of 81...

  • Page 17: Danger Of Crushing By Clamping Devices And Guideways

     Make sure that the machine cannot tilt, during swiveling the tools in and out or during opening and closing of the clamping rings.  Secure the welded pipe before lifting the pipe lifters, so that the pipe cannot slip uncontrollably. 10.12.13 Working Instructions WIDOS 6113 mobile Page 17 of 81...

  • Page 18: Structural Modifications On The Machine

     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 19: 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 19 of 81...
  • Page 20 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 20 of 81...

  • Page 21: Operating And Indicating Elements

    Switch cabinet with main switch, connecting cable, sockets for planer and heating element and fuses etc. Movable clamping rings, for inserting pipes, the surfaces open and shut hydraulically Four pieces clamping cylinder for clamping the inserted pipes 10.12.13 Working Instructions WIDOS 6113 mobile Page 21 of 81...

  • Page 22: Portable Operator Panel

     to swing planer to the rear into initial position  to swing planer into the machine into heating position Manometer Displays the current hydraulic pressure digital 10.12.13 Working Instructions WIDOS 6113 mobile Page 22 of 81...

  • Page 23: Hydraulic Control Elements

     Activate the planer in order to work with the machine (1). Start planing using the joystick inclusive button for planning: < > located on the operator panel.  You may re-tension the chain using the chain tensioner (chapter: 8.9) 10.12.13 Working Instructions WIDOS 6113 mobile Page 23 of 81...

  • Page 24: Heating Element

    Lock for switch cabinet * Socket for heating element, 16A Fuses etc. inside Socket for planer, 16A Connecting cable with plug CEE -63A * Attention! Hand over the key to authorized personnel only. 10.12.13 Working Instructions WIDOS 6113 mobile Page 24 of 81...
  • Page 25 Fault-current circuit breaker 25A Motor protective 4,5-6,3A, hydraulic pump 3 pieces circuit breaker B16A, heating element Motor protective 2,8-4A, planer Soft starter hydraulic pump Contactor planer 24V – switch supply unit 10.12.13 Working Instructions WIDOS 6113 mobile Page 25 of 81...
  • Page 26 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 26 of 81...

  • Page 27: Starting And Operating

    Check the heating element surfaces shortly before each welding. They must be clean and especially non greasy. In case of dirtiness clean them by means of a fiber-free paper and a cleaning agent (e.g. PE cleaner) or WIDOS-pipe cleaning tissues.

  • Page 28: Secure Carriage

    Terminal box with control Display Temperature adjusting knob  Therefore swivel in the heating element with Joystick < > on: .  Set the temperature with screwdriver and adjusting knob. 10.12.13 Working Instructions WIDOS 6113 mobile Page 28 of 81...

  • Page 29: How To Remove The Outer Fix Clamping Ring

    Spacer shaft in the front Detach the countersunk screws at both clamping rings and remove the spacer shafts out of the machine. Detach both countersunk screws and lift the clamping tool down. 10.12.13 Working Instructions WIDOS 6113 mobile Page 29 of 81...

  • Page 30: How To Disconnect Basic Machine, Planer And Heating Element From The Carriage

     Take up the machine e.g. with a crane, lift the machine vertically upwards until the base frame is above the stud bolts.  Put down the machine directly next to the carriage.  Coonect the couplings of machine and carriage with the optional extension hoses. 10.12.13 Working Instructions WIDOS 6113 mobile Page 30 of 81...

  • Page 31: Remove The Outer Fix Clamping Ring From The Basic Machine

    Detach the countersunk screws for the spacer shaft at the front and rear of the inner fix clamping ring. Detach the two pan-head screws and washers, afterwards you can remove the short base frame outwards. 10.12.13 Working Instructions WIDOS 6113 mobile Page 31 of 81...

  • Page 32: Remove Planer And Heating Element From The Carriage

    Suspend the planer with the ring bolt e.g. from a crane. Now detach the three hexagon socket screws and washers by which the planer is mounted to the planer holder. 10.12.13 Working Instructions WIDOS 6113 mobile Page 32 of 81...

  • Page 33: Remove Heating Element

    The cables have been marked with adhesive tape in the areas where the cables are in the cable clips.  Put the cables with the markings back into the cable clips again ensuring the motions for the swinging of planer and heating element. 10.12.13 Working Instructions WIDOS 6113 mobile Page 33 of 81...
  • Page 34 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 10.12.13 Working Instructions WIDOS 6113 mobile Page 34 of 81...

  • Page 35: 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. 10.12.13 Working Instructions WIDOS 6113 mobile...
  • Page 36 1,5 mm for pipes with OD up to 1000 mm. You may compensate the mismatch by increase/decrease the clamping of each clamping cylinder by pushing levers to: <> or <>. 10.12.13 Working Instructions WIDOS 6113 mobile Page 36 of 81...
  • Page 37 In this case release the upper clamping ring manually with the lever. In case the machine is located in a hillside situation, secure the welded pipe against uncontrolled rolling-out. 10.12.13 Working Instructions WIDOS 6113 mobile Page 37 of 81...
  • Page 38 >. T h e w e l d i n g p r o c e s s i s c o m p l e t e d . 10.12.13 Working Instructions WIDOS 6113 mobile Page 38 of 81...

  • Page 39: Welding Log And Tables

    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 7. Welding log and tables 10.12.13 Working Instructions WIDOS 6113 mobile Page 39 of 81...
  • Page 40 Welding log and tables Chapter 7 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 40 of 81...
  • Page 41 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.
  • Page 42 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.
  • Page 43 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.
  • Page 44 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.
  • Page 45 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.
  • Page 46 Table for PE Kunststoffschweißtechnik Parameters based on: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N PE 80 The value for heating element temperature is between 200° C - 220° C / 392 °F - 428 °F.

  • Page 47: 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 48: 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: 8.7). 10.12.13 Working Instructions WIDOS 6113 mobile Page 43 of 81...

  • Page 49: 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). Cover Chain tightener 10.12.13 Working Instructions WIDOS 6113 mobile Page 44 of 81...

  • Page 50: How To Lubricate The Joints For Heating Element, Planer, Carriage And Pipe Lifter

     Afterward drive the planer carefully up to the inner fix clamping ring at appr. 3 mm, shift joystick for heating element to <>.  Swing the heating element into the machine with joystick to <>. 10.12.13 Working Instructions WIDOS 6113 mobile Page 45 of 81...

  • Page 51: Protect Machine Parts Against Corrosion

    (e.g. AVILUB NCI 9840). 8.13. 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. 10.12.13 Working Instructions WIDOS 6113 mobile Page 46 of 81...

  • Page 52: Electric And Hydraulic 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 9. Electric and hydraulic diagrams 10.12.13 Working instructions WIDOS 6113 mobile Page 47 of 81...
  • Page 53 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 48 of 81...
  • Page 54 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 49 of 81...
  • Page 55 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 50 of 81...
  • Page 56 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 51 of 81...
  • Page 57 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 52 of 81...
  • Page 58 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 53 of 81...
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  • Page 60 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 55 of 81...
  • Page 61 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 56 of 81...
  • Page 62 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 57 of 81...
  • Page 63 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 58 of 81...
  • Page 64 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 59 of 81...
  • Page 65 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 60 of 81...
  • Page 66 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 61 of 81...
  • Page 67 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 62 of 81...
  • Page 68 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 63 of 81...
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  • Page 70 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 65 of 81...
  • Page 71 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 66 of 81...
  • Page 72 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 67 of 81...
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  • Page 75 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 70 of 81...
  • Page 76 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 71 of 81...
  • Page 77 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 72 of 81...
  • Page 78 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 73 of 81...
  • Page 79 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 74 of 81...
  • Page 80 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 75 of 81...
  • Page 81 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 76 of 81...
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  • Page 85 Electric and hydraulic diagrams Chapter 9 Kunststoffschweißtechnik 10.12.13 Working Instructions WIDOS 6113 mobile Page 80 of 81...

  • Page 86: 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, 12/10/2013 Martin Dommer (Technical director) 10.12.13 Working instructions WIDOS 6113 mobile Page 81 of 81...

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