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- Page 1 WIDOS Einsteinstraße 5 Phone +49 7152 9939 0 Wilhelm Dommer Söhne D-71254 Ditzingen +49 7152 9939 40 GmbH info@widos.de Internet: www.widos.de Working Instructions Translation Heating element butt welding machine WIDOS 4955 Keep for further use!
- Page 2 Customer's entries Inventory- No.: Place of working: Address of manufacturer WIDOS Wilhelm Dommer Söhne GmbH Einsteinstraße 5 D-71254 Ditzingen Phone: ++49 7152 9939 0 Fax: ++49 7152 9939 40 E-Mail: info@widos.de http://www.widos.de 19.09.19 Working instructions WIDOS 4955 Page 2 of 39...
- Page 3 Therefore the searched information can be easily found. WIDOS 9/19/2019 Wilhelm Dommer Söhne GmbH Einsteinstraße 5 D-71254 Ditzingen All rights reserved Reprinting only allowed with permission of the corporation. Any changes are subject to technical innovations. 19.09.19 Working instructions WIDOS 4955 Page 3 of 39...
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Page 4: Table Of Contents
How to open/close the clamping ring ......................18 4.2.2 Separating device for heating element ....................... 18 4.3. Elements at the heating element ...................... 19 4.4. Elements at the planer ........................20 19.09.19 Working instructions WIDOS 4955 Page 4 of 39... - Page 5 Used hydraulic oil ..........................32 7.8. Disposal .............................. 32 8. TRANSPORT ..........................33 9. ELECTRIC AND HYDRAULIC DIAGRAMS ..................34 10. SPARE PARTS LIST ........................38 11. DECLARATION OF CONFORMITY ....................39 19.09.19 Working instructions WIDOS 4955 Page 5 of 39...
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Page 6: Description Of Product
1.1. Application and prescribed use The WIDOS 4955 is made for the heating element butt welding of pipes and fittings with a diameter range of Ø = 90 - 355 mm. It is a building site machine and is designed especially for the use on site as well as in the workshop. -
Page 7: Safety Measures
The type-labels are fixed on the control unit and on the basic machine. They contain the type of the machine, the serial number, and the year of construction. 1.5.1 Technical Data 1.5.1.1 WIDOS 4955 General data Material: PP, PE, PVDF Pipe diameter range: outside-Ø = 90 – 355 mm Total weight (without packing): approx. - Page 8 Electromotor and pump: Power: 3,1 kW Current: 2,7 A Revolutions per minutes: 1380 (rpm) max. pressure of pump: approx. 100 bar Working pressure: 100 bar Volume velocity: 1,9 l/min Weight: approx. 23 kg 19.09.19 Working instructions WIDOS 4955 Page 8 of 39...
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Page 9: Equipment And Accessories
Allan key tilted, size 8 Allan key with T-grip, size 5 Fork wrench, size 17 / 19 Torx-screw driver, T10 optional - Reduction inserts, - Stub end holder - Roller brackets for the pipes 19.09.19 Working instructions WIDOS 4955 Page 9 of 39... -
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 ) . 19.09.19 Working instructions WIDOS 4955 Page 10 of 39... -
Page 11: Obligations Of The Owner
Workers who are to be trained are only allowed to work at the machine under control of an experienced worker. 19.09.19 Working instructions WIDOS 4955 Page 11 of 39... -
Page 12: Dangers While Handling The Machine
Chapter 2 2.7. Dangers while handling the machine The machine WIDOS 4955 is constructed according to the actual technical standard and the 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: Special Dangers
Make sure that the cables lie in such a way that the danger is maintained at a minimum. 2.11.4 Risk of injury by noises Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear protection! 19.09.19 Working instructions WIDOS 4955 Page 13 of 39... -
Page 14: Danger Of Crushing By Clamping Tool And Guideways
Machine parts that are not in perfect condition are to be replaced immediately. Only use original WIDOS spare and wear parts. In case of purchase orders please always note the machine and version number. -
Page 15: Functional Description
The pipes are joined with the prescribed welding pressure and then cool down under pressure (cooling time). The weld joint can be unclamped, the welding process is finished. Heating element heats the pipes up to welding temperature Finished weld joint with internal and external bead 19.09.19 Working instructions WIDOS 4955 Page 15 of 39... -
Page 16: Operating And Indicating Elements
Due to the hydraulic accumulator it takes about 10 s until the pressure is completely released. - <Backwards>: slide opens Power socket (2 pieces) Connection for planer or heating element 19.09.19 Working instructions WIDOS 4955 Page 16 of 39... -
Page 17: Basic Machine
Clamping nut with washer and spindle, for clamping the pipes Basic frame part 2, removable Tear off bar, separates the heating element and the heated tubes Inner clamping ring fixed Outer clamping ring fixed Hydraulic hoses, connection with hydraulic aggregate 19.09.19 Working instructions WIDOS 4955 Page 17 of 39... -
Page 18: How To Open/Close The Clamping Ring
When inserting the heating element take care that it lies in the zone of the diminution of the tear-off bar (see arrow). 19.09.19 Working instructions WIDOS 4955 Page 18 of 39... -
Page 19: Elements At The Heating Element
On/off-switch with red lamp - As soon as the heating element is switched on, the red control lamp lightens Connecting cable with plug - Connecting with a socket of hydraulic aggregate 19.09.19 Working instructions WIDOS 4955 Page 19 of 39... -
Page 20: Elements At The Planer
Switch on / off for planer - to switch on the planer. - the planer has to be switched off before and after use. 19.09.19 Working instructions WIDOS 4955 Page 20 of 39... -
Page 21: Stub End Holder (Optional)
Move the pipe towards the cap / flange. Align the cap / flange to the pipe with the threaded spindles. Now you can start the welding process (see chapter: 5.2). (Example picture of the 4911) 19.09.19 Working instructions WIDOS 4955 Page 21 of 39... -
Page 22: Starting And Operating
In case of ambient temperatures below 5°C / 41°F the following measures have to be taken: - If need be, put up a welding tent and heat up the pipe ends. Take measures against rain, wind and dust. 19.09.19 Working instructions WIDOS 4955 Page 22 of 39... -
Page 23: How To Mount The Reduction Inserts
- Super large reduction inserts have a specially high guidance quality and are mainly used during the welding of fittings with long legs which can only be clamped with a single clamping tool. 19.09.19 Working instructions WIDOS 4955 Page 23 of 39... -
Page 24: How To Remove Clamping Ring With Basic Frame Part 2
2 in direction of arrow. Important, don’t unscrew the hexagon-head screws! The hexagon-head screws hold terminal strips into the square tubes. The terminal strips fixed the both basic frames with the hexagon-head screws. 19.09.19 Working instructions WIDOS 4955 Page 24 of 39... -
Page 25: Welding Process
Put the work pieces into the clamping tools, tighten the clamping nuts tightly and align the work pieces with respect to one another. In case of long pipe ends, use WIDOS rollerstands for alignment. Close the slide, <Control lever> on: “FORWARDS”, thereby reading the movement pressure on the pressure gauge. - Page 26 The maximum time frame for this process is predetermined by the value for the change- over time taken from the table. 19.09.19 Working instructions WIDOS 4955 Page 26 of 39...
- Page 27 Open the slide by <Control lever> on: “FORWARDS”. 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 . 19.09.19 Working instructions WIDOS 4955 Page 27 of 39...
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Page 28: Welding Logs And Tables
Internet: www.widos.de Welding logs and tables You can access our website and select our welding tables via the qr code shown here. Select ”WIDOS 4900” and the corresponding material (PE / PP /PVDF). 19.09.19 Working instructions WIDOS 4955 Page 28 of 39... - Page 29 Welding logs and tables Chapter 6 19.09.19 Working instructions WIDOS 4955 Page 29 of 39...
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Page 30: 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. Clamping elements ... -
Page 31: How To Vent The Hydraulic Cylinders
The lower venting screws must always be vented in the first position because there is a direct link between the upper and the lower cylinder. If there is still air in the lower cylinder this will ascent in the upper cylinder under pressure. 19.09.19 Working instructions WIDOS 4955 Page 31 of 39... -
Page 32: How To Check The Hydraulic Oil Level
The hydraulic oil has to be handled properly and to be disposed of. 7.8. 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. 19.09.19 Working instructions WIDOS 4955 Page 32 of 39... -
Page 33: Transport
During the transport of the machine there may be cold weldings between the piston rod and the eyes of the planer shell. These spots on the piston rod may damage the sealing. Therefore the eyes must be lubricated with PTFE-spray before transport! 19.09.19 Working instructions WIDOS 4955 Page 33 of 39... -
Page 34: Electric And Hydraulic Diagrams
WIDOS Einsteinstraße 5 Phone +49 7152 9939 0 Wilhelm Dommer Söhne D-71254 Ditzingen +49 7152 9939 40 GmbH info@widos.de Internet: www.widos.de Electric and hydraulic diagrams Working direction Hydraulic diagram 4955 19.09.19 Working instructions WIDOS 4955 Page 34 of 39... - Page 35 Electric and hydraulic diagrams Chapter 9 19.09.19 Working instructions WIDOS 4955 Page 35 of 39...
- Page 36 Electric and hydraulic diagrams Chapter 9 19.09.19 Working instructions WIDOS 4955 Page 36 of 39...
- Page 37 Electric and hydraulic diagrams Chapter 9 19.09.19 Working instructions WIDOS 4955 Page 37 of 39...
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Page 38: 10. Spare Parts List
+49 7152 9939 40 GmbH info@widos.de Internet: www.widos.de 10. Spare parts list You can access our website and select our spare parts lists via the qr code shown here. Select “4955” 19.09.19 Working instructions WIDOS 4955 Page 38 of 39... -
Page 39: 11. Declaration Of Conformity
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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