widos 3511 Working Instructions
WIDOS Einsteinstraße 5 Phone +49 (0) 71 52 / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 / 99 39 - 40
info@widos.de Internet: www.widos.de
Kunststoffschweißtechnik
Working instructions
Translation
Heating element socket welding machine
WIDOS 3511
Keep for further use!
20.08.14 Working instructions WIDOS 3511 Page 1 of 39
Introduction
Kunststoffschweißtechnik
Model: Heating element socket welding machine
Type:
Serial number / year of construction:
WIDOS 3511
see type label
Customer entries
Inventory No.:
Location:
Order of spare parts and sales service:
Address of manufacturer WIDOS
W. Dom mer Söhne GmbH
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
Phone: +49 (0) 71 52 / 99 39 - 0
Fax: +49 (0) 71 52 / 99 39 - 40
Address of 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 (0) 3 71 / 8 15 73 - 0 Phone: +41 (0) 79 432 5737
Fax: +49 (0) 3 71 / 8 15 73 - 20
20.08.14 Working instructions WIDOS 3511 Page 2 of 39
Introduction
Kunststoffschweißtechnik
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 instruction s, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise , contact our advisers in the factory or in our subsidiary compa nies.
We will help you with pleasure.
According to our interest in making our products and working instructions continuously better,
we kindly ask you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
The working instructions are arranged in chapters, which belong to the different using phases
of the machine.
Therefore the searched information can be found easily.
8/20/2014 WIDOS
W. Dom mer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved.
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.
20.08.14 Working instructions WIDOS 3511 Page 3 of 39
Contents
Kunststoffschweißtechnik
1.
DESCRIPTION OF PRODUCT ............................................................................6
1.1. Usage and purpose-oriented use .........................................................................................6
1.2. Safety measures .....................................................................................................................6
1.3. Conformity ..............................................................................................................................6
1.4. Designation of the product.................................................................................................... 7
1.4.1. Technical data..................................................................................................................7
1.4.1.1. WIDOS 3511 General data ............................................................................. 7
1.4.1.2. Heating element.............................................................................................. 7
1.5. Equipment and accessories .................................................................................................. 8
2. SAFETY RULES ..................................................................................................9
2.1. Explanation of the different symbols...................................................................................9
2.2. Obligations of the owner ..................................................................................................... 10
2.3. Obligations of the worker....................................................................................................10
2.4. Measure of organization......................................................................................................10
2.5. Information about safety precautions ................................................................................ 10
2.6. Instructions for the staff......................................................................................................10
2.7. Dangers while handling the machine................................................................................. 11
2.8. Dangers caused by electric energy....................................................................................11
2.9. Special dangers....................................................................................................................11
2.9.1. Danger of stumbling over electric cables .......................................................................11
2.9.2. Danger of burning at heating element and welding area ...............................................11
2.9.3. Danger of squeezing by clamping tool and guideways.................................................. 12
2.10. Structural modifications on the machine .......................................................................... 12
2.11. Warranty and liability...........................................................................................................12
3. FUNCTIONAL DESCRIPTION ...........................................................................13
4. OPERATING AND INDICATING ELEMENTS................................................... 14
4.1. Elements at the front............................................................................................................14
4.2. Elements on the heating element.......................................................................................15
4.3. Accessories ..........................................................................................................................15
4.4. Clamping tool left for pipe...................................................................................................16
4.5. Clamping tool for fitting.......................................................................................................16
4.6. Support..................................................................................................................................17
5. STARTING AND OPERATING ..........................................................................18
5.1. Starting..................................................................................................................................18
5.1.1. Assembly of the machine...............................................................................................18
5.2. Welding process...................................................................................................................19
6. WELDING LOG AND TABLES ..........................................................................22
6.1. Table for PP...........................................................................................................................22
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Contents
Kunststoffschweißtechnik
6.2. Table for PVDF ......................................................................................................................22
6.3. Table for PEHD .....................................................................................................................23
6.4. Table for PB (Polybutene) ...................................................................................................23
6.5. Weld log.................................................................................................................................24
7. MAINTENANCE / STORAGE / TRANSPORT ...................................................25
7.1. Maintenance..........................................................................................................................25
7.2. Storage..................................................................................................................................25
7.3. Transport...............................................................................................................................25
7.4. Cleaning of the machine ......................................................................................................25
7.5. Adjusting of the mismatch compensation......................................................................... 26
7.6. Disposal.................................................................................................................................26
8. ELECTRIC DIAGRAMS .....................................................................................27
9. SPARE PARTS LIST .........................................................................................29
9.1. Basic machine ......................................................................................................................29
9.2. Prism clamping tool for pipes .............................................................................................31
9.3. Prism clamping tool for fitting with support .....................................................................33
9.4. Heating element....................................................................................................................35
9.5. Spigot and socket.................................................................................................................37
10. DECLARATION OF CONFORMITY ..................................................................39
20.08.14 Working instructions WIDOS 3511 Page 5 von 39
WIDOS Einsteinstraße 5 Phone +49 (0) 71 52 / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 / 99 39 - 40
info@widos.de Internet: www.widos.de
Kunststoffschweißtechnik
1. Description of product
This chapter gives important basic information about the product and its prescribed use.
All technical details of th e machine are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS 351 1 is exclusively designed for the heating element socket welding of pipes and
fittings out of PE, PP an d PVDF with an outside diameter range from 20 mm to 125 mm.
At heating element socket welding, pipe and fitting are welded overlapping.
The heated tool is adjusted to the siz e of the fitting in a way that a joining pressure is built up at
joining.
Heating element socket joints up to 50 mm pipe diameter can be performed manually.
For diameters as from 63 mm, the use of a weldi ng device is necessary due to the high joining
pressure.
The motion for socket welding is con trolled by means of a transport wheel and a toothed rack.
All use of this machine going beyond is not purpose oriented.
The machine is only to be used in a technically perfect condition, as well as purpose oriented,
safety- and danger-conscious in compliance with the working instructions and the relevant
safety regulations (especially the regulations for the prevention of accide nts).
The described plastic welding machine may only be operated, maintained and repaired by
persons trained and informed about the dangers.
The manufacturer is not responsible for any damages cause d by inexpert handling or
operation.
For personal injuries, material and immaterial damages resulting herefrom, only the user is
responsible!
Prescribed use also means:
following all indications in these working instructions and
performing the inspection and maintenance works.
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
advices 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 European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.
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Description of product Chapter 1
Kunststoffschweißtechnik
1.4. Designation of the product
The product is designated by a type label at basic machine and heating element.
The labels contain the type of the machine, the serial number and the year of construction.
1.4.1. Technical data
1.4.1.1.
Mat erial : PP, PE, PV DF, PB
Pipe diamete r ran ge: OD = 20 - 125 mm (optional up to OD 150mm)
Transport box (l x w x h): 850 x 670 x 680 mm
Total weight: 80 kg
Protection: 16 A
Emissions:
Ambient conditions: - Keep the workshop clean (especially the welding area
WIDOS 3511 General data
- When using the named pipe materials and when
welding below 260° C or 500° F no toxic damp arises.
must be clean)
- If secured by an appropriate measurement that allowed
conditions for welding are indicated, it is po ssible to
work in any outside temperature condition as far as the
welder is not constrained in its man ual skill- Avoid
humidity, if necessary put up a tent
- Avoid strong sun beams
- If it is windy shut the pipe endings
1.4.1.2. Heating element
Power: 1000 Watt 1000 Watt
Vo ltag e: 230 V ( 10%) 110 V ( 10%)
Current: 4,6 A ( 10%) 9,2 A ( 10%)
Wire cross section: 1,5 mm² 1,5 mm²
Frequency: 50 Hz 60 Hz
Attached elements: - electronic temperature
control
- control lamp
- connecting cable with
plug
Weight : approx. 2 kg approx. 2 kg
- electronic temperature
control
- control lamp
- connecting cable with
plug
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Description of product Chapter 1
1.5. Equipment and accessories
Pieces Denomination
1 Allan key size 5 (screw in / out the clamping elements)
1 Allan key size 4 (for changing the dial)
1 Allan key with T grip, size 6 (for changing spigots and socke ts)
1 set Gripping tools for pipes Ø 20 – 50 mm
1 set Gripping tools for pipes Ø 50 – 125 mm
1 set Gripping tools for fitting Ø 29 – 68 m m
1 set Gripping tools for fitting Ø 75 – 167 mm
1 set Gripping tools for fitting Ø 29 – 68 mm NIBCO (optional)
1 Dial DVS type B (optional)
1 Dial ASTM mm (optional)
1 Dial ASTM inch (optional)
Kunststoffschweißtechnik
20.08.14 Working instructions WIDOS 3511 Page 8 of 39
WIDOS Einsteinstraße 5 Phone +49 (0) 71 52 / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 / 99 39 - 40
info@widos.de Internet: www.widos.de
Kunststoffschweißtechnik
2. Safety rules
A basic premise for working safe ly and without disturbances is the knowledge of the basic
safety signs and safety rules.
These working instructions provide you with the most important information to run the
machine safely.
The safety information must be followed by all persons who work at the machine.
2.1. Explanation of the different sym bols
The working instructions contain the following signs for certain situations:
This symbol means a possibly danger for the life and the health of persons.
The disrespect of these indications may have h eavy 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 gives important indications for the p roper use of the machine.
The disrespect of these indications may conduct to malfunctions and
damages on the machine or on goods in the sur rounding.
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
The regulations for the prevention of accidents are valid (UVV).
helps you to make the job easier.
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Safety rules Chapter 2
Kunststoffschweißtechnik
2.2. Obligations of the owner
The owner is obliged on ly 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. Measure 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 disp osal at any time and without much effort.
In addition to the manual, the common valid and the local a ccident protection rules and
regulations for the environmental protection must be available and followed.
All safety and danger indications on t he 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, and
starting the operation.
A person who is being trained may only work at the machine under supervision of an
experienced person.
20.08.14 Working instructions WIDOS 3511 Page 10 of 39
Safety rules Chapter 2
Kunststoffschweißtechnik
2.7. Dangers while handling the machine
The machine WIDOS 351 1 is constructed according to the latest technical standard and the
acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby m ay occur. Also material
damages are possible.
The machine may only be used
according to the purpose -oriented use
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately
Only skilled persons are allowed to w ork at electrical appliances.
The electrical equipment of the machine has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
Protect the heating element and planer from rain and dropp ing water.
According to VDE 0100, the use on c onstruction sites is only allowed with a power
distributor with a FI-safety switch.
2.8. 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 works at alive parts are necessary, a second p erson has to assist who can disconnect the
machine from the mains if necessary.
The heating element has to be protected from rain and dropping water (if need be use a
welding tent).
According to VDE 0100, the use on c onstruction sites is only allowed with a power
distributor with a FI-safety switch.
2.9. Special dangers
2.9.1. Danger of stumbling over electric cables
Make sure that no person must step over the wires.
Make sure that the cables lie in such a way that the danger is maintained at a minimum.
2.9.2. Danger of burning at heating element and welding area
You can burn yourself, inflammable materials can be ignited!
The heating element reaches temperatures of more than 260° C / 500° F!
Do not touch the surface of the heating element.
Do not leave the surfac es of the heating element unattended.
Take enough safety distance to materials which may be ignited.
Do wear safety gloves.
Only swivel the heating element at the handle.
20.08.14 Working instructions WIDOS 3511 Page 11 of 39
Safety rules Chapter 2
When cleaning the hot h eating element with detergents (e.g. with PE – cleaning agent)
there is the danger of inflammation. For this reas on, 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.
2.9.3. Danger of squeezing by clamping tool and guideways
There is the danger of serious injurie s. On the one hand between the clamping tools
and on the other hand between the ends of the guideways and the machine slide.
Do not grip between the workpieces.
Do not touch the guide ways.
Kunststoffschweißtechnik
2.10. Structural modifications on the machine
Without permission of the manufacturer, no modifications, extensions or reconstructions
may be performed on the machine. Any non-compliance makes expiring the guarantee and
liability demands (chapter 2.5.).
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!
2.11. Warranty and liability
Fundamentally, our "General sales and delivery conditions" are in force.
They are at the buyer's disposal latest when signing the contract.
Guarantee and liability demands referring to damages of persons or things are excluded if they
are caused by one or several of the following reasons:
Not using the machine according to the prescriptions.
Unprofessional transport, building-up, starting, operating and maintenance of the machine.
Running the machine with defective or not properly mounted safety equipment.
Ignoring the information given in these working instruction s.
Structural modifications on the machine without permission.
Unsatisfactory maintenance of parts of the machine which are worn out.
Unprofessionally performed repairs.
In case of c atastrophes and acts of god.
20.08.14 Working instructions WIDOS 3511 Page 12 of 39
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