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widos 26000 Working Instructions

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 26000
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 26000 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 28.10.13 Working Instructions WIDOS 26000 Page 2 of 101...
  • Page 3 Due to this structure, the searched information can be easily found.  10/28/2013 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. 28.10.13 Working Instructions WIDOS 26000 Page 3 of 101...

  • Page 4: 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 26000 General data..................9 1.5.1.2. Basic frame ........................9 1.5.1.3. Heating element.......................10 1.5.1.4. Pipe cutter ........................10 1.5.1.5. Reception box ......................10 1.6.
  • Page 5 Clamping elements ......................42 7.4. How to clean the machine....................42 7.5. How to check the hydraulic oil level for welding.............42 7.6. Used hydraulic oil .......................42 7.7. How to vent the hydraulic cylinders .................43 28.10.13 Working Instructions WIDOS 26000 Page 5 of 101...
  • Page 6 How to rebuild the basic machine for truck transport............45 8.2. How to rebuild the basic machine for container transport ..........46 8.3. Assembly of the basic machine ..................48 ELECTRIC AND HYDRAULIC DIAGRAMS ..............49 10. DECLARATION OF CONFORMITY ................101 28.10.13 Working Instructions WIDOS 26000 Page 6 of 101...

  • 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 26000 has been designed for the heating element butt welding of pipes and fittings with a diameter range from OD 2200 mm (optional) up to OD 2600 mm.

  • Page 8: Machine Overview

    They contain the type, the serial number and the year of construction of the machine. 1.5.1. Technical data All important technical data of each single component are displayed. They allow rapid information about the working capacity and the structure. 28.10.13 Working Instructions WIDOS 26000 Page 8 of 101...

  • Page 9: Widos 26000 General Data

    Description of the product Chapter 1 Kunststoffschweißtechnik 1.5.1.1. WIDOS 26000 General data Pipe diameter range: OD 2200 mm (optional) – OD 2600 mm Material which can be PP, PE 80, PE 100 welded: Emissions: - Noise occurs over 80 dB (A); when working with the...

  • Page 10: Heating Element

    Reduction insert OD 2500 mm in clamping tool OD 2600 mm 1 set Reduction insert OD 2400 mm in clamping tool OD 2600 mm 1 set Reduction insert OD 2200 mm in reduction insert OD 2600 mm Bolt for reduction insert 28.10.13 Working Instructions WIDOS 26000 Page 10 of 101...

  • Page 11: Wear Parts, Tools And Accessories

    Heating cartridge Ø 16 x 700 mm / 1150 W / 400 V / AL 1,5 m on request H09086 Temperature probe PT1000 Semi conductor relay 100 A ES20010 Hydraulic oil HLPD 35 on request 28.10.13 Working Instructions WIDOS 26000 Page 11 of 101...

  • 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). 28.10.13 Working Instructions WIDOS 25000 mobil Page 12 of 101...

  • Page 13: Obligations Of The Owner

     A person who is being trained may only work at the machine under supervision of an experienced person. 28.10.13 Working Instructions WIDOS 26000 Page 13 of 101...

  • Page 14: Maintenance And Inspection, Repair

    2.8. Dangers while handling the machine The machine WIDOS 26000 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. 28.10.13 Working Instructions WIDOS 26000 Page 15 of 101...

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

     Make sure that nobody can activate the remote control while you are driving the pipe cutter back and forth with the cordless screwdriver!  Make sure that nobody can touch the pipe cutter at the blades while being transported from machine to heat-protected box. 28.10.13 Working Instructions WIDOS 26000 Page 16 of 101...

  • 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 28.10.13 Working Instructions WIDOS 26000 page 18 of 101...

  • Page 19: Operating And Indicating Elements

    - to separate the heating element from the pipe ends after heating Hydraulic aggregate - for applying the welding pressure and clamping pressure - for all hydraulic motions Hydraulic couplings - quick-action couplings, free couplings e.g. for pipe brackets 28.10.13 Working Instructions WIDOS 26000 page 19 of 101...

  • Page 20: Reducer Inserts

    Elastic pressure piece 4.1.2. Puller  Take care that the heating element lies within the throat of the puller.  If necessary you can shift the puller horizontally. 28.10.13 Working Instructions WIDOS 26000 Page 20 of 101...

  • Page 21: Hydraulic Couplings For Clamping Cylinder And Pipe Cutter

    Oil level indicator Pump M40 P Denomination Denomination Pressure changeover valve Valve generative circuit Table (slide) open Pressure release Table (slide) close Pressure relief valve Pipe cutter M40P Proportional valve pipe cutter 28.10.13 Working Instructions WIDOS 26000 Page 21 of 101...

  • Page 22: Switch Cabinet

    Interface for heating element zone 1 XS22 Interface for heating element zone 2 XS23 Interface for heating element zone 3 XS24 Interface for heating element zone 4 XS40 Interface for pipe cutter 28.10.13 Working Instructions WIDOS 26000 Page 22 of 101...

  • Page 23: Control Lamp For Heating Element Zone 1 - 4

    <safety lock>, then fix the pressed button e.g. by a padlock (image showing a cable tie). Passive safety lock Active safety lock Shut down the machine and secure switch against unintentional activation while working within the machine. 28.10.13 Working Instructions WIDOS 26000 Page 23 of 101...

  • Page 24: Emergency Stop

    Circuit breaker 3 pieces, B40A heating element zone 2 Circuit breaker 3 pieces, B40A heating element zone 3 Circuit breaker 3 pieces, B40A heating element zone 4 Control voltage supply rotating field clockwise rotation Main switch 28.10.13 Working Instructions WIDOS 26000 Page 24 of 101...

  • Page 25: Basic Machine Without Fourth Clamping Ring

     Detach the hexagon socket screws (4x4 pieces) by which the outer fix clamping ring is mounted to the inner fix clamping ring.  Now you may lift off the clamping ring e.g. by a crane. 28.10.13 Working Instructions WIDOS 26000 Page 25 of 101...

  • Page 26: Heating Element

    Set up the heating temperature in the lab menu. Lift the heating element e.g. with a crane, insert the heating element between the clamped pipes and into one of the throats of the puller (chapter: 4.1.2). 28.10.13 Working Instructions WIDOS 26000 Page 26 of 101...

  • 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! 28.10.13 Working Instructions WIDOS 26000 Page 27 of 101...

  • Page 28: How To Work With The Pipe Cutter

     Lift the pipe cutter out of the basic machine and insert it back into the heat-protected box. Recommendation: Put the hydraulic hoses underneath the holder in order to protect them Recommendation: Put the plug of the cable into the connector. 28.10.13 Working Instructions WIDOS 26000 Page 28 of 101...

  • Page 29: Remote Control

    - short pushing: to shorten the overtravel of the pump - longer pushing during welding: aborts welding free - not assigned P1 – P3 - Regulator, to adjust the different welding pressures min - max 28.10.13 Working Instructions WIDOS 26000 Page 29 of 101...

  • Page 30: Meaning Of Control Levers 1 - 6 Within Mode Select 1 - 6

    Depressurized welding cylinders  Lever 2 Release Pressure Idle valve e.g. for pipe spreader, spread  / release  Lever 3 Not assigned Lever 4 Lever 5 Not assigned Not assigned Lever 6 28.10.13 Working Instructions WIDOS 26000 Page 30 of 101...

  • Page 31: Accumulator For Operator Console

     Fix the ladders with the support at the top of the base frame in a way that it the ladder is standing safe (left image). Support Ladder 28.10.13 Working Instructions WIDOS 26000 Page 31 of 101...

  • Page 32: Support: Positioning Tool For Spindles

    The positioning tools can be stored in the holder at the right (blue) side of the machine. Positioning tool Put the positioning tool onto the lifting bolts; now you can swing the spindles resp. the clamping cylinders better. 28.10.13 Working Instructions WIDOS 26000 Page 32 of 101...

  • Page 33: 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 34: 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 28.10.13 Working Instructions WIDOS 26000 Page 34 of 101...
  • Page 35 Adjust cooling time You may adjust the cooling pressure by <+> and <-> Press <Start>: confirm and go to the next parameter WIDOS 26000 Display: Main menu 11:00 20.02.2012 line: 28.10.13 Working Instructions WIDOS 26000 Page 35 of 101...

  • Page 36: Welding Process

     Bring the upper clamping rings right above the lower parts. Swing the spindles and clamping cylinders into the upper parts by means of the positioning aid.  Manually clamp the pipe to the rear side with the spindles and clamping nuts. 28.10.13 Working Instructions WIDOS 26000 page 36 of 101...

  • Page 37: How To Plane The Pipe Ends

     Drive this blade back via cordless screwdriver.  Continue cutting until the second pipe is cut off.  Remove the second oddment, if necessary cut it through.  Also drive the other blade back via cordless screwdriver. 28.10.13 Working Instructions WIDOS 26000 Page 37 of 101...

  • Page 38: 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. 28.10.13 Working Instructions WIDOS 26000 Page 38 of 101...

  • Page 39: Aligning

    6.7. Change-over  Drive the pipes apart by pushing <Joystick> to: Open.  In case pipes have detached from the heating element, quickly lift the heating element out of the machine. 28.10.13 Working Instructions WIDOS 26000 Page 39 of 101...

  • Page 40: Cooling / Joining

     Lift the upper clamping rings down e.g. with a crane.  Lift the welded pipe out of the machine.  Drive the tables apart again, <Joystick> to: Open. Welding is completed. 28.10.13 Working Instructions WIDOS 26000 Page 40 of 101...

  • Page 41: 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. ...

  • Page 42: Storage

    7.6. 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. 28.10.13 Working Instructions WIDOS 26000 Page 42 of 101...

  • Page 43: 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). 28.10.13 Working Instructions WIDOS 26000 Page 43 of 101...

  • Page 44: Cutter

    Q-Cut cutting plate (151.2-800-4E, H13A) and clamping bolt (3212012-259). 7.10. 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. 28.10.13 Working Instructions WIDOS 26000 Page 44 of 101...

  • Page 45: Transport

     Drive the basic machine apart before you rebuild the machine for truck transport.  Cut off the main switch and disconnect the plug from the local power supply. Upper clamping rings Puller Inner fix clamping ring Hexagon-head screw Outer fix clamping ring 28.10.13 Working Instructions WIDOS 26000 Page 45 of 101...

  • Page 46: How To Rebuild The Basic Machine For Container Transport

     Drive the flexible clamping rings to the center of the basic machine. The base frame features drill holes for angles in order to fix the clamping rings; mount these angles to the right and left. 28.10.13 Working Instructions WIDOS 26000 Page 46 of 101...
  • Page 47 Adjusting ring arrow direction.  Attach an adjusting ring from both sides and fix the puller with it.  Mount the washers and countersunk screws back onto the puller. 28.10.13 Working Instructions WIDOS 26000 Page 47 of 101...

  • Page 48: Assembly Of The Basic Machine

    8.3. Assembly of the basic machine Reassemble the basic machine after the transport in reversed order according to the rebuilding for truck transport or container transport. Afterwards, check all screw connections if firmly seated. 28.10.13 Working Instructions WIDOS 26000 Page 48 of 101...

  • Page 49: 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 28.10.13 Working Instructions WIDOS 26000 Page 49 of 101...
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  • Page 101: 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, 10/28/2013 Martin Dommer (Technical director) 28.10.13 Working Instructions WIDOS 26000 Page 101 of 101...

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