widos 6113 Working Instructions Translation
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widos 6113 Working Instructions Translation

Heating element butt welding machine
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WIDOS
Wilhelm Dommer Söhne
GmbH
Working Instructions
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing directors: Jürgen Dommer, Dr. Kai Dombrowski
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
website: http://www.widos.de
Translation
Heating element butt welding machine
WIDOS 6113
Keep for further use!
Phone
++49 7152 9939 0
Fax
++49 7152 9939 40
email:
info@widos.de

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  • Page 1 D-71254 Ditzingen-Heimerdingen ++49 7152 9939 40 GmbH website: http://www.widos.de email: info@widos.de Working Instructions Translation Heating element butt welding machine WIDOS 6113 Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing directors: Jürgen Dommer, Dr. Kai Dombrowski...
  • Page 2 Order of spare parts and after sales service: Address of manufacturer WIDOS W. Dommer Söhne GmbH Einsteinstrasse 5 D-71254 Ditzingen-Heimerdingen Phone: ++49 7152 99 39 0 Fax: ++49 7152 99 39 40 E-mail info@widos.de Internet www.widos.de 12.05.15 Working Instructions WIDOS 6113 Page 2 of 67...
  • Page 3 Due to this structure, the searched information can be easily found.  5/12/2015 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. 12.05.15 Working Instructions WIDOS 6113 Page 3 of 67...

  • Page 4: Table Of Contents

    Safety measures............................. 6 1.3. Conformity............................... 6 1.4. Designation of the product ..........................6 1.4.1. Technical data ................................7 1.4.1.1. WIDOS 6113 General data ..........................7 1.4.1.2. Heating element ..............................7 1.4.1.3. Planer ..................................7 1.4.1.4. Hydraulic aggregate open (optional) ....................... 8 1.4.1.5.
  • Page 5 Hydraulic aggregate open (optional) ......................55 10.3. Hydraulic aggregate enclosed (optional) ....................57 10.4. Planer ................................59 10.5. Heating element ............................61 10.6. Protection box ...............................63 10.7. Lift off device (optional)..........................65 DECLARATION OF CONFORMITY ......................67 12.05.15 Working Instructions WIDOS 6113 Page 5 of 67...

  • Page 6: Description Of The Product

    1.1. Usage and purpose-oriented use The WIDOS 6113 has been designed for the heating element butt welding of pipes and fittings with a diameter range of Ø = 315 - 630 mm. (standard diameters: 315 / 355 / 400 / 450 / 500 / 560 / 630 mm) It is a machine for construction sites and particularly designed for the usage on-site, as well as in the workshop.

  • Page 7: Technical Data

    Description of product Chapter 1 1.4.1. Technical data 1.4.1.1. WIDOS 6113 General data Material which can be welded: PP, PE Pipe diameter range: OD = 315 - 630 mm Weight: approx. 150 kg Weight (without accessories): 500 kg Feeding: CEE-32 A Wire cross section: 4,0 mm²...

  • Page 8: Hydraulic Aggregate Open (Optional)

    475 kg Velocity of piston rod: 3,4 cm/s 1.4.1.7. Lift-off device (optional) Lift capacity: appr. 100 kg Weight (complete) appr. 32 kg See spare parts list for order numbers and single parts 12.05.15 Working Instructions WIDOS 6113 Page 8 of 67...

  • Page 9: Machine Overview

    Combination spanner size 19 Open ended key, size 24  Different reduction inserts, Optional  roller stands for the pipes,  transformer 42V,  crane for insertion and removal of heating element and planer 12.05.15 Working Instructions WIDOS 6113 Page 9 of 67...

  • Page 10: Safety Rules

    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 ) . 12.05.15 Working Instructions WIDOS 6113 Page 10 of 67...

  • Page 11: Obligations Of The Owner

    It must be clearly defined who is responsible for transport, mounting and dismounting, starting the operation, setting and tooling, operation, maintenance and inspection, repair and dismounting.  A person who is being trained may only work at the machine under supervision of an experienced person. 12.05.15 Working Instructions WIDOS 6113 Page 11 of 67...

  • Page 12: Dangers While Handling The Machine

    2.7. Dangers while handling the machine The machine WIDOS 6113 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 13: Specific Dangers

    Upon clamping the pipes  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. 12.05.15 Working Instructions WIDOS 6113 Page 13 of 67...

  • Page 14: Danger Of Stumbling Over Electric / Hydraulic Wires

     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! 2.13.

  • 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 12.05.15 Working Instructions WIDOS 6113 Page 15 of 67...

  • Page 16: Operating And Indicating Elements

     Pressing <button> (Nr. 1) and <control lever> on „FORWARDS“ or „BACKWARDS“. In order to carry out planing and for the joining you must select the slow speed:  With <control lever> on „FORWARDS“ or „BACKWARDS“ without pressing <button>. 12.05.15 Working Instructions WIDOS 6113 Page 16 of 67...

  • Page 17: Elements On Closed Hydraulic Aggregate (Optional)

    Hydraulic connections for - Non-dropping quick-acting couplings opening / closing the slides Connecting cable with plug - connection to power supply CEE-32 A Pressure gauge Display of the hydraulic pressure 12.05.15 Working Instructions WIDOS 6113 Page 17 of 67...
  • Page 18  Pressing <button> (Nr. 1) and <control lever> on „FORWARDS“ or „BACKWARDS“. In order to carry out planing and for the joining you must select the slow speed:  With <control lever> on „FORWARDS“ or „BACKWARDS“ without pressing <button>. 12.05.15 Working Instructions WIDOS 6113 Page 18 of 67...

  • Page 19: Basic Machine

    Clamping nut with washer and spindle, for clamping pipes Base frame part 2, removable Puller, separates the heating element and the heated tubes Inner clamping ring movable Outer clamping ring movable Hydraulic hoses, connection with hydraulic aggregate 12.05.15 Working Instructions WIDOS 6113 Page 19 of 67...

  • Page 20: Puller For Heating Element

    How to set the heating element temperature Thermostat - to set the required temperature. Grips - To hold the heating element when lifting / removing. The basic machine / protection box 12.05.15 Working Instructions WIDOS 6113 Page 20 of 67...

  • Page 21: Starting And Operating

     If the surrounding temperature is under 5°C, 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. 12.05.15 Working Instructions WIDOS 6113 Page 21 of 67...

  • Page 22: Connection Of Hydraulic Aggregate To Basic Machine

     Detach the suspension bracket on the crane motor, put and fix the bracket to the lifting device with the bolts and SL clips. Holder above Suspension bracket Support below  Put the lifting device through the upper holder from above and downwards to the lower support. 12.05.15 Working Instructions WIDOS 6113 Page 22 of 67...

  • Page 23: How To Replace The Reduction Inserts

    Important, do not unscrew the hexagon socket screws! The hexagon socket screws hold a pressure piece in place within the square pipe by which both basic frames are fixed. Spacer Base frame Support Hexagon-head screws 12.05.15 Working Instructions WIDOS 6113 Page 23 of 67...

  • Page 24: How To Set The Heating Element Temperature

    (e.g. PE - cleaner) before every welding or if they are dirty. The anti-adhesive coating of the heating element has to remain undamaged in the working area. 12.05.15 Working Instructions WIDOS 6113 Page 24 of 67...
  • Page 25  Put the workpieces into the clamping tools, tighten the clamping nuts tightly and align the workpieces with respect to one another. In case of long pipe ends, use WIDOS rollerstands for alignment.  Close the slide, with <valve lever> on: “forwards”, thereby reading the movement pressure on the pressure gauge.
  • Page 26  Open the slide with <valve lever> on: “backwards”. T h e w e l d i n g p r o c e s s i s f i n i s h e d 12.05.15 Working Instructions WIDOS 6113 Page 26 of 67...

  • Page 27: Welding Log And Tables

    WIDOS Einsteinstr. 5 Phone ++49 7152 9939 0 Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen ++49 7152 9939 40 GmbH website: http://www.widos.de email: info@widos.de 6. Welding log and tables 12.05.15 Working Instructions WIDOS 6113 Page 27 of 67...
  • Page 28 Welding Log and Tables Chapter 6 12.05.15 Working Instructions WIDOS 6113 Page 28 of 67...
  • Page 29 Table for PE Foundation: 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 30 Table for PE Foundation: 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 31 Table for PE Foundation: 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 32 Table for PE Foundation: 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 33 Table for PP Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N The standard value for heating element temperature is 210° C ± 10° C / 410 °F ± 50 °F.
  • Page 34 Table for PP Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 6100 / 6100 mobile / 6200 / 6111 / 6113 / 6113 mobile 1 bar on manometer: 173 N The standard value for heating element temperature is 210° C ± 10° C / 410 °F ± 50 °F.

  • Page 35: Maintenance 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. 7.2.

  • Page 36: Used Hydraulic Oil

     Connect the transparent venting hose and insert it in the collecting vessel of the aggregate.  Press the <valve lever> to “backwards” drive the carriage together until there is no air visible in the venting hose.  Afterwards tighten the screw (A1) again. 12.05.15 Working Instructions WIDOS 6113 Page 32 of 67...

  • Page 37: Planer

    Check the lifting device according to the inspection and service plan of ABUS Co. (working instructions is included). 7.9. 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. 12.05.15 Working Instructions WIDOS 6113 Page 33 of 67...

  • Page 38: Transport

     Lift the lifting device out of the holder from above for a transport.  If necessary disconnect the crane motor from the crane mast by demounting the suspension bracket on the crane motor. Suspension bracket Crane mast 12.05.15 Working Instructions WIDOS 6113 Page 34 of 67...

  • Page 39: Hydraulic And Electric Diagrams

    WIDOS Einsteinstr. 5 Phone ++49 7152 9939 0 Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen ++49 7152 9939 40 GmbH website: http://www.widos.de email: info@widos.de 9. Hydraulic and electric diagrams 12.05.15 Working Instructions WIDOS 6113 Page 35 of 67...

  • Page 40: Electric Diagrams With Hydraulic Aggregate Closed

    Hydraulic and electric diagrams Chapter 9 9.1. Electric diagrams with hydraulic aggregate closed 12.05.15 Working Instructions WIDOS 6113 Page 36 of 67...
  • Page 41 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 37 of 67...
  • Page 42 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 38 of 67...
  • Page 43 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 39 of 67...
  • Page 44 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 40 of 67...
  • Page 45 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 41 of 67...
  • Page 46 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 42 of 67...
  • Page 47 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 43 of 67...
  • Page 48 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 44 of 67...

  • Page 49: Electric Diagrams With Hydraulic Aggregate Open

    Hydraulic and electric diagrams Chapter 9 9.2. Electric diagrams with hydraulic aggregate open 12.05.15 Working Instructions WIDOS 6113 Page 45 of 67...
  • Page 50 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 46 of 67...
  • Page 51 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 47 of 67...
  • Page 52 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 48 of 67...
  • Page 53 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 49 of 67...
  • Page 54 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 50 of 67...
  • Page 55 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 51 of 67...
  • Page 56 Hydraulic and electric diagrams Chapter 9 12.05.15 Working Instructions WIDOS 6113 Page 52 of 67...

  • Page 57: Spare Parts List

    10.1. Basic machine 15 - 16 7 - 9 18 - 19 12 - 14 20 - 22 25 - 26 27 - 29 30 - 35 39 - 40 41 - 43 12.05.2015 Working Instructions WIDOS 6113 Page 53 of 67...
  • Page 58 Spare parts list Chapter 10 Basic Machine WIDOS 6113 Pos. Name Piece Order no. Upper clamp 0811255 Outer clamp, fixed 0811251 Inner clamp, fixed 0811252 Inner clamp, movable 0811253 Outer clamp, movable 0811254 Thread insert M 10 GEW-M10 Thread spindle...
  • Page 59 Spare parts list Chapter 10 Basic Machine WIDOS 6113 Pos. Name Piece Order no. Hexagon-head screw M 16x25 DIN 933 0933P025 Washer M 16 DIN 125 0125P Terminal Strip 811242 Reduction insert OD 315-560 0808…* Pan head screw M 10 x 20 DIN 912...

  • Page 60: Hydraulic Aggregate Open (Optional)

    Spare parts list Chapter 10 10.2. Hydraulic aggregate open (optional) 3 - 4 9 - 11 12 - 13 15 - 16 25 - 26 17 - 18 23 - 24 12.05.2015 Working Instructions WIDOS 6113 Page 55 of 67...
  • Page 61 Spare parts list Chapter 10 Hydraulic aggregat, open WIDOS 6113 Pos. Name Piece Article No. Pushbutton ES3801 Grip with thread H09061 Grip for hydraulic aggregate 1060061 Skintop-screwing M 12 x 1,5 EV1012 Button for pressure setting 101022 Valve box on request...

  • Page 62: Hydraulic Aggregate Enclosed (Optional)

    Spare parts list Chapter 10 10.3. Hydraulic aggregate enclosed (optional) 9 - 11 5 - 8 14 - 15 26 - 27 23 - 24 28 - 29 33 - 38 12.05.2015 Working Instructions WIDOS 6113 Page 57 of 67...
  • Page 63 Spare parts list Chapter 10 Hydraulic aggregat, closed WIDOS 6113 Pos. Name Piece Order no. Press button ES3801 Grip with thread H09061 Button for pressure relief valve 101022 Plate "pressure gauge adjusting value" SCHM6100 Grip for hydraulic aggregate 1060061 Skintop screwing M 12x1,5...

  • Page 64: Planer

    Chapter 10 10.4. Planer 9 – 17 3 - 5 18 – 21 24 - 25 35 - 36 37 - 39 40 - 41 26 - 27 29 - 34 12.05.2015 Working Instructions WIDOS 6113 Page 59 of 67...
  • Page 65 Hexagon nut M 10 DIN 985 0985J Washer M 10 DIN 125 0125J Pan-head screw M 10x45 DIN 7984 7984J045 Suspension plate for planer 081406 Counter plate 081407 Torx-screw driver TX10 12.05.2015 Working instruction WIDOS 6113 Page 60 of 67...

  • Page 66: Heating Element

    Spare parts list Chapter 10 10.5. Heating element 18 - 21 4 - 8 22 - 23 9 - 11 13 - 16 25 - 26 27 - 29 31 - 33 12.05.2015 Working Instructions WIDOS 6113 Page 61 of 67...
  • Page 67 Spare parts list Chapter 10 Heating Element WIDOS 6113 Pos. Name Piece Order no. Heating element (400 V) H6113E Heating plate new HP6113E Heating plate in exchange HPT6113E Lifting screw M 12 DIN 580 0580L Angle long 08152551 Grip 071508...

  • Page 68: Protection Box

    Spare parts list Chapter 10 10.6. Protection box 12.05.2015 Working Instructions WIDOS 6113 Page 63 of 67...
  • Page 69 Spare parts list Chapter 10 Proection Box WIDOS 6113 Pos. Name Piece Order no. Reception box EIN6100 Sheet steel 0815201 Lifting screw M 16 DIN 580 0580P Fitting cap 60x60 on request 12.05.2015 Working instructions WIDOS 6113 Page 64 of 67...

  • Page 70: Lift Off Device (Optional)

    Spare parts list Chapter 10 10.7. Lift off device (optional) 3 - 6 8 - 9 11 - 12 12.05.15 Working Instructions WIDOS 6113 Page 65 of 67...
  • Page 71 Spare parts list Chapter 10 Lift-off Device (optional) WIDOS 6113 Pos. Name Piece Order no. Jib crane GMC 100.12 on request Crane mast on request Limit stop for crane mast 081122 Grub screw M8x20 DIN 913 0913H020 Straight pin Ø 6x60 DIN 6325...

  • Page 72: 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, 5/12/2015 Martin Dommer (Technical director) 12.05.15 Working Instructions WIDOS 6113 Page 67 of 67...

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