widos 20000 Working Instructions Translation
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating element butt welding machine
WIDOS 20000
Keep for further use!
Kunststoff schweißtechnik
Product identification
16.01.12 Working Instructions WIDOS 20000 Page 2 of 98
Model: Heating element butt welding machine
Type:
WIDOS 20000
Serial number, year of construction: see type label
Customer Entries
Inventory-No.:
Place of working:
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
info@widos.de
www.widos.de
Address of the subsidiary companies:
WIDOS
WIDOS GmbH W. Dommer Söhne AG
An der Wiesenmühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH – 9201 Gossau
Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73
Kunststoff schweißtechnik
Introduction
16.01.12 Working Instructions WIDOS 20000 Page 3 of 98
Purpose of the document
These working instructions give you information about all important questions which refer to
the construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our service team in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest to continuously improve our products and working instructions, we
kindly ask you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters, which belong to the different using phases of the
machine.
Due to this structure, the searched information can be easily found.
1/16/2012 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.
Kunststoff schweißtechnik
Contents
16.01.12 Working Instructions WIDOS 20000 Page 4 of 98
1. DESCRIPTION OF THE PRODUCT .............................................................................. 7
1.1. Usage and purpose-oriented use ........................................................................................7
1.2. 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 20000 General data .....................................................................................9
1.5.1.2. Basic frame ................................................................................................................9
1.5.1.3. Hydraulic aggregate enclosed for welding (optional) .................................................9
1.5.1.4. Hydraulic aggregate naked for welding (optional)....................................................10
1.5.1.5. General date for crane (optional) .............................................................................10
1.5.1.6. Hydraulic aggregate for crane (optional)..................................................................10
1.5.1.7. Heating element.......................................................................................................11
1.5.1.8. Planer.......................................................................................................................11
1.5.1.9. Reception box (optional) ..........................................................................................11
1.6. Accessories .........................................................................................................................11
2. SAFETY RULES .......................................................................................................... 12
2.1. Explanation of the symbols and indications....................................................................12
2.2. Obligations of the owner....................................................................................................13
2.3. Obligations of the worker...................................................................................................13
2.4. Measures of organization...................................................................................................13
2.5. Information about safety precautions...............................................................................13
2.6. Instructions for the staff.....................................................................................................13
2.7. Maintenance and inspection, repair..................................................................................14
2.8. Dangers while handling the machine................................................................................14
2.9. Dangers caused by electric energy...................................................................................14
2.10. Specific dangers .................................................................................................................14
2.10.1. Danger of stumbling over electric / hydraulic wires ..........................................................14
2.10.2. Dangers caused by the hydraulics....................................................................................15
2.10.3. Danger of combustion by heating element, reception box and welding area...................15
2.10.4. Danger of crushing at clamping tools and guide rails.......................................................15
2.10.5. Danger of catching clothes by the planer .........................................................................16
2.10.6. Risk of injury by noise.......................................................................................................16
2.11. Structural modifications on the machine .........................................................................16
2.12. Warranty and liability..........................................................................................................16
3. FUNCTIONAL DESCRIPTION..................................................................................... 17
4. OPERATING AND INDICATING ELEMENTS.............................................................. 18
4.1. Basic machine .....................................................................................................................18
4.2. Hydraulic aggregate, enclosed, for welding (optional) ...................................................19
4.3. Weld log recording apparatus SPA 600 (optional) ..........................................................21
Kunststoff schweißtechnik
Contents
16.01.12 Working Instructions WIDOS 20000 Page 5 of 98
4.4. Hydraulic aggregate, naked, for welding (optional) ........................................................22
4.5. Heating element ..................................................................................................................23
4.6. Planer ...................................................................................................................................24
4.6.1. Protective motor switch at the planer................................................................................25
4.7. Crane (optional)...................................................................................................................26
5. STARTING AND OPERATING..................................................................................... 27
5.1. Safety indications ...............................................................................................................27
5.2. How to install the base frame ............................................................................................28
5.3. Lifting crane.........................................................................................................................29
5.4. How to operate the crane ...................................................................................................30
5.5. How to connect the machine with the naked hydraulic aggregate (optional) ..............31
5.6. How to connect the machine with the enclosed hydraulic aggregate (optional) .........31
5.7. How to set the heating element temperature ...................................................................32
6. WELDING PROCESS WITH SPA 600......................................................................... 33
6.1. Connect the SPA 600 to the hydraulic aggregate............................................................33
6.2. Description of the display ..................................................................................................34
6.3. Programming of the SPA 600.............................................................................................35
6.3.1. Selection of the pipe data .................................................................................................36
6.3.2. Setting menu.....................................................................................................................37
6.3.2.1. Parameter menu / Laboratory menu ........................................................................39
6.4. Welding process .................................................................................................................41
6.4.1. How to insert the pipes .....................................................................................................41
6.4.2. Drag pressure measurement ............................................................................................41
6.4.3. Dimension.........................................................................................................................42
6.4.4. Weather / protection .........................................................................................................43
6.4.5. Planing..............................................................................................................................43
6.4.6. Compensation of mismatch ..............................................................................................44
6.4.7. Bead up.............................................................................................................................44
6.4.8. Heating up.........................................................................................................................45
6.4.9. Change over .....................................................................................................................45
6.4.10. Pressure ramp ..................................................................................................................46
6.4.11. Joining and cooling ...........................................................................................................46
6.4.12. Completion of welding ......................................................................................................46
6.4.13. Signification of the error codes .........................................................................................47
6.4.14. Copying the internal data on SD - card and deleting internal data (RAM)........................47
6.5. SD card and drive................................................................................................................48
6.6. Bar code reading pen (optional)........................................................................................48
6.7. How to read out WICON with USB card reader (optional) ..............................................49
6.8. How to read the welding data ............................................................................................49
6.9. Diagnosis program .............................................................................................................49
7. WELDING PROCESS WITHOUT SPA ........................................................................ 51
Kunststoff schweißtechnik
Contents
16.01.12 Working Instructions WIDOS 20000 Page 6 of 98
8. WELDING LOG AND TABLES.................................................................................... 54
9. MAINTENANCE, CARE AND REPAIR ........................................................................ 57
9.1. Maintenance and inspection, repair..................................................................................57
9.2. Storage.................................................................................................................................58
9.3. Clamping elements .............................................................................................................58
9.4. How to clean the machine..................................................................................................58
9.5. How to check the hydraulic oil level for welding .............................................................58
9.6. How to check the hydraulic oil level / refilling .................................................................59
9.7. Used hydraulic oil ...............................................................................................................59
9.8. How to lubricate the guide rods ........................................................................................59
9.9. How to vent the hydraulic cylinders .................................................................................60
9.10. Planer ...................................................................................................................................61
9.11. Protect machine parts against corrosion .........................................................................61
9.12. Disposal ...............................................................................................................................61
10. TRANSPORT ............................................................................................................... 62
11. HYDRAULIC AND ELECTRIC DIAGRAMS ................................................................. 63
11.1. Electric diagram with enclosed hydraulic aggregate ......................................................63
11.2. Electric diagram with naked hydraulic aggregate ...........................................................72
11.3. Hydraulic diagram for welding aggregates ......................................................................80
11.4. Hydraulic diagram for crane aggregat:.............................................................................80
12. SPARE PARTS LIST ................................................................................................... 81
12.1. Basic machine .....................................................................................................................81
12.2. Heating element ..................................................................................................................83
12.3. Planer ...................................................................................................................................85
12.4. Hydraulic aggregate, enclosed (optional) ........................................................................87
12.5. SPA-600................................................................................................................................89
12.6. Hydraulic aggregate, naked (optional)..............................................................................92
12.7. Protection box .....................................................................................................................94
12.8. Assembly frame for crane (optional).................................................................................96
13. DECLARATION OF CONFORMITY............................................................................. 98
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
16.01.12 Working Instructions WIDOS 20000 Page 7 of 98
1. Description of the product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS 20000 has been designed for the heating element butt welding of pipes and
fittings with a diameter range from Ø 1200 mm up to Ø = 2000 mm.
It is a machine for construction sites and particularly designed for the usage on-site, as well as
in the workshop.
For this reason, the frame is kept small so that it can be used even under difficult conditions
(e.g. ditch).
All use going beyond is not purpose-oriented.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Also part of the purpose oriented use is
• respecting all the indications of the working instructions and
• performing the inspection and maintenance work.
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
regulations must be necessarily adhered to.
1.3. Conformity
The machine corresponds in its construction to the valid recommendations of the
European Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very
carefully.
Kunststoff schweißtechnik
Description of the product Chapter 1
16.01.12 Working Instructions WIDOS 20000 Page 8 of 98
1.4. Machine overview
1 Crane (optional)
2 Planer
3 Heating element
4 Reception box
5 Basic machine
6 clamping devices, upper part
7 SPA (optional)
8 Hydraulic aggregate enclosed (optional)
- Hydraulic aggregate naked (optional)
1.5. Designation of the product
The product is designated by type labels which are attached at the crane, at the aggregate, at
the heating element, at the planer and at the basic machine.
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 a rapid information about the working capacity and the structure.
1
2
3
4
5
6
7
8
Kunststoff schweißtechnik
Description of the product Chapter 1
16.01.12 Working Instructions WIDOS 20000 Page 9 of 98
1.5.1.1. WIDOS 20000 General data
Pipe diameter range:
∅∅∅∅
outside
1200 - 2000 mm
Material which can be welded: PP, PE 80, PE 100
Weight (without accessories): appr. 10800 kg
Emissions - Noise exceeding 80 dB (A) may occur; during
planing it is obligatory to wear ear protection!
- When using the named pipe materials and when welding
below 260°C no toxicant damp arises
Ambient conditions in the
welding area:
- take care for cleanness (no dust at the welding area)
- If secured by an appropriate measurement that allowed
conditions for welding are indicated, it is possible to work
in any outside temperature condition as far as the welder
is not constrained in its manual skill.
- Avoid humidity, if necessary use a welding tent
- avoid strong sun rays influence
- protect from wind, shut pipe ends
1.5.1.2. Basic frame
Material frame: Structural steel
Material reduction inserts: Steel
∅ cylinder / ∅ piston rod: 80 mm / 50 mm
Stroke length of cylinder: 500 mm
Max. force (F=P*A):
61,3 kN (at p= 100 bar)
153,25 kN (at p= 250 bar)
Weight appr.2000 kg
1.5.1.3. Hydraulic aggregate enclosed for welding (optional)
Power: 2,6 / 3,1 kW
Voltage: 400 V (+-10%)
Current 5, 5 / 7, 6 A (± 10 %)
Feeding CEE 125 A – phase converter
Frequency: 50 Hz
Hydraulic oil tank: appr. 10 L
Insulation system IP 54
Electromotor and pump:
Speed: 1450 rpm
Max. working pressure of pump: appr. 250 bar
Working pressure: 0-250 bar adjustable
Weight: appr. 56 kg
Kunststoff schweißtechnik
Description of the product Chapter 1
16.01.12 Working Instructions WIDOS 20000 Page 10 of 98
1.5.1.4. Hydraulic aggregate naked for welding (optional)
Power: 2,6 / 3,1 kW
Voltage: 400 V (+-10%)
Current 5, 5 / 7, 6 A (± 10 %)
Feeding CEE 16 A – phase converter
Frequency: 50 Hz
Hydraulic oil tank: appr. 10 L
Insulation system IP 54
Electromotor and pump:
Speed: 1450 rpm
Max. working pressure of pump: appr. 160 bar
Working pressure: 0-160 bar adjustable
Weight: appr. 45 kg
1.5.1.5. General date for crane (optional)
Power: 18,0 kW
Voltage: 400 V (+-10%)
Feeding CEE 63 A – phase converter
Frequency: 50 Hz
1.5.1.6. Hydraulic aggregate for crane (optional)
Power: 15 kW
Voltage: 400 V (+-10%)
Current 27,28 / 15,71 A (± 10 %)
Hydraulic oil tank: appr. 100 l
Insulation system IP 55
Electromotor and pump:
Speed: 1445 rpm
Max. working pressure of pump: appr. 250 bar
Working pressure: 0-250 bar adjustable
Weight: appr. 190 kg
Kunststoff schweißtechnik
Description of the product Chapter 1
16.01.12 Working Instructions WIDOS 20000 Page 11 of 98
1.5.1.7. Heating element
Power: 42 kW
Voltage: 400V (+-10%)
Current: 182 A (+-10%)
Frequency: 50 Hz
Outside-∅: 2180 mm
Inside-Ø: 900 mm
Surface: non-stick-coated
Attached elements: - Electronic temperature control
- Fuse for temperature control
- On/off-switch with control lamp,
- Connecting cable with CEE – plug (125A)
Weight: appr. 500 kg
1.5.1.8. Planer
Motor: Three-phase alternating current motor
Power: 4,0 kW
Voltage: 400 V (+-10%)
Nominal current 8,4 A
Frequency: 50 Hz (+-10%)
Speed: appr. 4,2 rpm
Attached elements: CEE 16A – motor protective
Weight: appr. 1100 Kg
1.5.1.9. Reception box (optional)
Dimension: appr. 2400 x 1500 x 2100 mm
Weight: appr. 500 kg
1.6. Accessories
Following tools and accessories are part of the delivery:
1 Tool bag for 10 parts
1 hexagonal socket screw key angle, size 4 / 5 / 14
1 each Spanner wrench size 13 / 19 / 24 / 30
1 Torx-Screw driver T10
1 Socket spanner size 65
1 Wire rope with hook (J9994)
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
16.01.12 Working Instructions WIDOS 20000 Page 12 of 98
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety indications and rules.
• These working instructions contain the most important indications to run the machine
safely.
• The safety indications are to be followed by all persons working on the machine.
2.1. Explanation of the symbols and indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possibly danger for the life and the health of persons.
• The disrespect of these indications may have heavy consequences for the
health.
This symbol means a possible dangerous situation.
• The disrespect of these indications may cause slight injuries or damages on
goods.
This symbol means a possible dangerous situation due to hot surfaces.
• The disrespect of these indications may conduct to heavy burns, respectively
to self-ignition or even fire.
This symbol means a possible dangerous situation by moving parts of the
machine
• The disrespect of these indications may cause heavy crushing’s of parts of the
body resp. damages of parts of the machine.
This symbol means a possible risk of injury by noise exceeding 80 dB (A).
• Ear protection is obligatory
This symbol gives important indications for the proper use of the machine.
• The disrespect of these indications may conduct to malfunctions and
damages on the machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
• 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).
Kunststoff schweißtechnik
Safety rules Chapter 2
16.01.12 Working Instructions WIDOS 20000 Page 13 of 98
2.2. Obligations of the owner
The owner is obliged only to let persons work at the machine, who
• know about basic safety and accident prevention rules and are instructed in the handling of
the machine, as well as who
• have read and understood the safety chapter of this manual and certify this by their
signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged before working:
• To follow the basic safety and accident protection rules.
• To have read and understood the safety chapter and the warnings in this manual and to
confirm by their signature that they have well understood them.
• To inform themselves about the functions of the machine before using it.
2.4. Measures of organization
• All equipment required for personal safety is to be provided by the owner.
• All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
• The working instructions have to be permanently kept at the place of use of the machine.
They are to be at the operator's disposal at any time and without effort.
• In addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
• All safety and danger indications on the machine have to be in a clear readable condition.
• Every time the machine changes hands or is being rent to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
• Only skilled and trained persons are allowed to work at the machine.
• 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.
Kunststoff schweißtechnik
Safety rules Chapter 2
16.01.12 Working Instructions WIDOS 20000 Page 14 of 98
2.7. Maintenance and inspection, repair
All maintenance and repair work have to be basically performed with the
machine in off position.
During this, the machine has to be secured against unauthorized switching on.
Prescribed maintenance and inspection work should be performed in time.
The DVS gives the advice of inspection work after 1 year.
For machines with an 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.
2.8. Dangers while handling the machine
The machine WIDOS 20000 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.
The machine may only be used:
• according to the purpose-oriented usage
• in safety technical impeccable status
Disturbances, which may affect the safety of the machine, must be cleared immediately.
2.9. Dangers caused by electric energy
Only skilled persons are allowed to work at electrical appliances!
The electrical equipment of the machine has to be checked regularly. Loose
connections and damaged cables have to be replaced immediately.
• If work at alive parts are necessary, a second person has to assist who can disconnect the
machine from the mains if necessary.
• All electric tools (heating element, planer and aggregate) have to be protected from rain
and dropping water (if need be use a welding tent).
• According to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
2.10. Specific dangers
2.10.1. Danger of stumbling over electric / hydraulic wires
Make sure that no person has to step over the wires.
Lay the wires in such a way that the danger is kept to a minimum.
Do not kink or crush the lines.
Kunststoff schweißtechnik
Safety rules Chapter 2
16.01.12 Working Instructions WIDOS 20000 Page 15 of 98
2.10.2. Dangers caused by the hydraulics
System parts and pressure hoses should be depressurized before beginning of
any repair work. Even if the machine is switched off, pressure may be in the
hydraulic accumulator!
There is a danger of injuring the eyes by hydraulic oil squirting out.
• Damaged hydraulic hoses have to be immediately replaced.
• Make a visual inspection of the hydraulic hoses before each work beginning.
• The hydraulic oil is inedible!
2.10.3. Danger of combustion by heating element, reception box and
welding area
You can burn yourself, inflammable materials can be ignited.
The heating element temperature is heated up to more than 250°C!
• Do not leave the heating element unsupervised.
• Do not touch the surfaces of the heating element.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
• Make sure that no person is in the lifting area of the heating element.
• When cleaning the hot heating element with detergents (e.g. with PE cleaner) there is the
danger of inflammation. For this reason, please take care that the inflammation point is
above the actual temperature of the heating element. Do not approach it with any fire
sources (e.g. cigarettes).
2.10.4. Danger of crushing at clamping tools and guide rails
Heavy injuries can result from crushing:
- Upon opening / closing the clamping tools.
- Upon inserting the planer and heating element.
- Upon opening / closing the machine.
- Upon mounting the reducer inserts.
- Upon clamping the pipes.
- On the one hand between the inner clamping rings, on the other hand
between the outer clamping rings and the end of the guiding shaft.
• Do not stand or put your hands between the inner clamping tools with not yet clamped
pipes and between the end of the guiding shaft.
• Do not reach between the clamping rings in case the pipes are yet to be clamped and in
case you move the clamping tools.
• During the installation of the reducer inserts use a lifting device, do not reach between
reducer insert and clamping tool.
• Do not block the opening and closing of the machine carriages.
Kunststoff schweißtechnik
Safety rules Chapter 2
16.01.12 Working Instructions WIDOS 20000 Page 16 of 98
2.10.5. Danger of catching clothes by the planer
You can cut yourself or even get bones broken!
For some machines, the planer may shortly turn when switching the machine
on!
• Only wear clothes tight to the body.
• Do not wear rings or jewelry during the work.
• If necessary, wear a hair-net.
• Make sure that no person is in the lifting area of the planer.
• Do not reach or step between the clamped pipes
• Always put the planer back into the reception box after and before each use.
• Transport the planer at the suspension only and hold ist only at the grips. Do not touch the
surfaces.
2.10.6. Risk of injury by noise
Noise exceeding 80 dB (A) may occur; during planing it is obligatory to wear
ear protection!
2.11. Structural modifications on the machine
• No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
• 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. Warranty and liability
Fundamentally our "General Sales and Delivery Conditions" are valid.
They are at the owner's disposal latest when signing the contract.
Guarantee and liability demands referring to personal injuries or damages on objects are
excluded if they are caused by one or several of the following reasons:
• not using the machine according to the prescriptions
• inexpert transport, mounting, starting, operating, and maintenance of the machine
• running the machine with defective or not orderly mounted safety appliances
• ignoring the information given in this manual
• structural modifications on the machine without permission
• unsatisfactory checking of parts of the machine, which are worn out
• repairs performed in an inexpert way
• In case of catastrophes and force majeure
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
16.01.12 working Instructions WIDOS 20000 page 17 of 98
3. Functional description
Bas i ca ll y, t he i nt erna t iona l a nd n at iona l p roce s s g ui deli n es are t o be
fol lo wed!
The plastic pipes are clamped in the clamping devices.
Then the front sides of the pipes are cut plane and parallel by means of the planer and the
misalignment of the pipes is checked.
The cleaned and heated heating element is inserted and the pipes are pressed against the
heating element under defined adjusting pressure. This process is called "adjusting".
After the prescribed bead height being reached, pressure is reduced, the heating time
begins. The function of this time is to heat up the pipe ends.
After expiration of the heating time, the slides are opened, the heating element is removed
quickly and the pipes are driven together again.
The time gap from the removal of the heating element to joining the pipes is called change
over time.
The pipes are joined under prescribed welding pressure and then cool down under pressure
(cooling time).
T h e w el d e d j o i n t c a n b e u nc l a m p e d , t h e w el d i n g p r o ce s s i s
f i n i s he d .
Heating element heats
the pipes up to welding
temperature
Finished welding with
internal and external
bead
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
16.01.12 working Instructions WIDOS 20000 page 18 of 98
4. Operating and indicating elements
4.1. Basic machine
No. Name Function
1 Clamping ring fix to maintain the left clamped pipe
2 Spindle with clamping nut to clamp the pipes
3 Support may be disassembled if necessary
4 Clamping ring flexible to drive the right clamped pipe to and fro
5 Tear-off bar to separate the heating element from the pipe ends
after heating
6 Hydraulic hoses to connect with the hydraulic aggregate
1
2
3
4
5
6
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 19 of 98
4.2. Hydraulic aggregate, enclosed, for welding (optional)
No. Name Function
7 Push-button - By pressing the push-button, the motor switches over
to high speed
- Without pressing the button, the motor drives with
normal speed
8 Valve lever To open the slides. There are 4 different positions:
- To the left side: slides close.
- in the middle (usual position): the pressure which is
currently achieved is kept (also by means of the
built-in hydraulic accumulator)
- slightly to the right side (depressurized position):
a possibly existing pressure is released without
Moving the slides. Due to the hydraulic accumulator,
It takes about 10 s until the pressure is completely
released.
- to the right side: slides open
9 Setting screw for pressure
relief valve
Limitation of the pressure to the desired value.
10 Pressure gauge Display of the hydraulic pressure
11 Plug 230V / 16A Connection for SPA-600
7
8
9
10
11
12
13
14
17
F10 / Q1 /
Q3 / Q2
F1 / F2 / F3
16
15
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 20 of 98
No. Name Function
12 Plug CEKON 16A Connection for planer
13 Plug CEKON 125A Connection for heating element
14 Connecting cable with plug
CEE 125 A
Connection to local power supply
15
SPA 600 The weldings are registered and logged
16
Plug-in couplings Connection for hydraulic hoses of the basic machine
17 Screw with oil dipstick Checking the oil level
Oil filler neck
F10 Motor protective Hydraulic pump 7,6 – 10 A
Q1 Contactor - Speed slow
Q3 Contactor - Speed fast 2
Q2 Contactor - Speed fast 1
F1 Circuit breaker - Fuse hydraulic pump 3x B16A
F2 Circuit breaker (3 pieces) - Fuse planer 3x K16A
F3 Circuit breaker (3 pieces) - Fuse plug socket SPA B16A
The fuses are mounted on the right side of the aggregate behind the power sockets.
In case a fuse has been activated, thus:
• Eliminate the malfunction.
• Disconnect the aggregate from the mains afterwards.
• Detach the screws from the panel with the power sockets.
• Activate the fuse again.
• Mount the panel with the power sockets again.
• Reconnect the aggregate to the power supply.
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 21 of 98
4.3. Weld log recording apparatus SPA 600 (optional)
No. Name
18 Display
19 Bar code-reading pen (optional)
20 Buttons for operation
21 Drive for the SD – card
22 Interface for barcode reading pen (optional)
23 Connecting cable
24 Holder for T-piece
25 - Plug box for the heating element (when 230 V)
- Plug box for heating element probe (when 400V)
26 Outside temperature probe
19
18
20
24
25
26
21
22
23
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 22 of 98
4.4. Hydraulic aggregate, naked, for welding (optional)
No. Name Function
27 Push-button By pressing the push-button the motor switches over to
high speed
28 Valve lever To open / close the slides. There are 4 different
positions:
- To the left side: slides close.
- in the middle (usual position): the pressure which is
currently achieved is kept (also by means of the
built-in hydraulic accumulator)
- slightly to the right side (depressurized position):
a possibly existing pressure is released without
Moving the slides. Due to the hydraulic accumulator,
It takes about 10 s until the pressure is completely
released.
- to the right side: slides open
29 Pressure gauge Display of the hydraulic pressure
30 Setting screw for pressure
relief valve
Limitation of the pressure to the desired value.
31 Hydraulic connection for
closing the slides
Non-dropping quick-action coupling
32 Hydraulic connection for
opening the slides
Non-dropping quick-action coupling
33 Screw with oil dipstick - Checking the oil level
- Oil filler neck
27
28
30
32
33
29
31
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 23 of 98
4.5. Heating element
No. Name Function
34 Holder Possibility to hinge the heating element.
35 Grip To hold and adjust the heating element.
36 Visible type fuse Fuse protection for the regulator of temperature (2 A)
37 Connecting cable Power supply for heating element with CEE125A plug.
38
Connecting for
temperature sensor cable
Connection to SPA 600 (optional).
39 Thermostat To set the required temperature.
40 On / off switch with control
lamp red
To switch the heating element on / off.
w/o
image
Steel wire with hook To transport the heating element.
36
39
40
34
35
(35)
37
38
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 24 of 98
4.6. Planer
No. Name Function
41 Eye Possibility to hinge the planer
42 Connecting cable Power supply for planer with CEE16A plug
43 * Locking device To secure planer in the basic machine
44 Knife To make the pipe ends plane and parallel
45 Grab handle To hold and adjust the planer
46 Holder Possibility to hinge the planer
* Pull the rod with the ball knob in arrow direction in order to release the locking and to lift the
planer out of the base frame.
41
43
42
46
44
45
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 25 of 98
4.6.1. Protective motor switch at the planer
The planer is switched on/off at the protective motor switch.
The black switch starts the planer and the red one stops the
planer again.
The red button serves also as overload protection which
means that it switches the planer off automatically if the
pressure onto the planer is too high. In this case, release
pressure and start again the planer with the black button.
If the red control lamp lightens, the planer turns in the wrong direction.
Absolutely change the turning direction by turning the phase changing switch.
Control
lamp
OFF
ON
Phase changing switch
Kunststoff schweißtechnik
Operating and indicating elements Chapter 4
16.01.12 Working Instructions WIDOS 20000 Page 26 of 98
4.7. Crane (optional)
No. Name Function
47 Transport lock To lock the crane arm
48 Anti-drop device To secure the operator against falling
49 Frame Fixing for the single element
50 Operator console To operate the crane arm
51 Tread plate To hinge/unhinge planer and heating element
52 Fixing hook To fix the crane console to the base frame
53 Rope winch To roll up the rope with brake
54 Inspection glass To check the oil level
55 Ring bolt To transport
48
47
53
50
54
49
55
51
52
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
website: www.widos.de email: info@widos.de
16.01.12 working Instructions WIDOS 20000 page 27 of 98
5. Starting and operating
The instructions of this chapter are supposed to initiate in the operation of the machine and
lead during the appropriate starting of the machine.
This includes:
- The safe operation of the machine
- using all the possible options of the machine
- economic operation of the machine
5.1. Safety indications
The machine may only be operated by initiated and authorized persons. For the
qualification, a plastic welding exam can be taken according to DVS and DVGW.
In situations of danger for persons and the machine, the mains plug has to be
unplugged immediately.
In case of power failure, there may still be pressure in the hydraulic system.
Therefore release pressure if need be.
After completion of the welding work and during breaks the machine has to be
switched off.
Further take care that no unauthorized person has access.
Protect the machine from wetness and humidity!
According to VDE 0100, the use on construction sites is only allowed with a
power distributor with a FI-security protective switch.
Check the oil level of the hydraulic system before each starting of the control
unit in order to avoid damages on the pump. The oil level must be between the
two marks at the oil dipstick.
If necessary add hydraulic oil of the quality HLPD 32.
The heating element surfaces must be clean, especially non greasy, therefore
they need to be cleaned shortly before each welding or in case of dirtiness by
means of a fiber-free paper and a cleaning agent (e.g. PE cleaner or pipe
cleaning cloths which are available at the WIDOS company).
Never discard the heating element unprotected onto its coated surfaces.
The anti-adhesive coating of the heating element must remain undamaged in
the working area.
Take care that all hydraulic and electric connections are connected.
Make sure that pumps and planer are connected in a way that they turn in righthanded direction otherwise change turning direction.
• Take into account the surrounding conditions:
- The welding may not be performed under direct sun rays influence.
- Use a welding umbrella if necessary.
• 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.
Kunststoff schweißtechnik
Starting and operating Chapter 5
16.01.12 Working Instructions WIDOS 20000 Page 28 of 98
5.2. How to install the base frame
The base frame has been packed separately; the left clamping ring with support was
detached.
• Detach screws, lift up base frame by a lifting device and take base frame to its destination.
• Take up clamping ring with support at the ring screws, remove transport lugs and put
clamping ring with support next to the other base frame.
• Put all three spacer shafts into the drillings at both clamping rings and screw them each
from the outside by the cylinder head screw M20.
• Mount base frame and holder to each other by 12 Pan-head screws M20 + washers.
The clamping rings have been prepared with aliphatic rust-protective agent for
the transport.
• Necessarily degrease the inner surfaces prior to welding in order that correct
clamping is warranted.
Clamping ring
with support
Spacer shaft
Ring screw
Ring screw
Mount base
frame here
Degrease
clamping rings
Clamping
ring upper
parts
Kunststoff schweißtechnik
Starting and operating Chapter 5
16.01.12 Working Instructions WIDOS 20000 Page 29 of 98
5.3. Lifting crane
The lifting crane has been fixed to a wooden floor by four screws.
• Remove the fixing screws and fix the four ring screws into the threaded drillings.
• Lift up the crane by a lifting device and put it behind the base frame.
• Fix the lifting crane to the base frame according to the image.
Fix ring screws here
Fixing screws to lift the
crane at the base frame
Kunststoff schweißtechnik
Starting and operating Chapter 5
16.01.12 Working Instructions WIDOS 20000 Page 30 of 98
5.4. How to operate the crane
Necessarily read the working instructions of Palfinger Crane prior to the
first operation of the crane.
Make sure that the transport lock has been removed.
• If you want to work with the Palfinger crane, turn the crane button on: <1> and make sure
that the transport look has been removed.
• Please refer to the separately enclosed working instructions from Palfinger for operation
and maintenance.
Main switch
Detach the pan-head screw and necessarily
remove the transport lock.
Transport lock
Loading...