widos 4001 Working Instructions Translation
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
www.widos.de
Working instructions
Translation
Heating element-butt welding machine
WIDOS 4001
Kunststoff schweißtechnik
Keep for further use !
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing Director: Jürgen Dommer
Identification of product
Model: Workshop machine
Kunststoff schweißtechnik
Type:
Serial number: / year: see type plate
WIDOS 4001
Customer entries
Inventory- No.:
Location:
Order of spare parts and after sales service
Address of manufacturer WIDOS
W. Dommer Söhne GmbH
Einsteinstr. 5
D - 71254 Ditzingen-Heimerdingen
Phone: +49 / 71 52 - 99 39 - 0
Fax: +49 / 71 52 - 99 39 - 40
E-mail: info@widos.de
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: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73
25.06.12 Working instructions WIDOS 4001 Page 2 of 59
Introduction
Kunststoff schweißtechnik
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 advisers in the factory or in our subsidiary companies.
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.
WIDOS 25.06.2012
W. Dommer 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.
25.06.12 Working instructions WIDOS 4001 Page 3 of 59
Contens
Kunststoff schweißtechnik
1. DESCRIPTION OF PRODUCT ...................................................................................... 6
1.1. Mounting and purpose-oriented use ..................................................................................6
1.2. Safety measures....................................................................................................................7
1.3. Conformity .............................................................................................................................7
1.4. Marking of product ...............................................................................................................7
1.4.1.
Technical data ................................................................................................................7
1.4.1.1. WIDOS 4001 general data.......................................................................................7
1.4.1.2. Heating element.........................................................................................................8
1.4.1.3. Planer.........................................................................................................................8
1.4.1.4. Hydraulic aggregate...................................................................................................8
1.4.1.5. Basic unit....................................................................................................................8
1.5. Equipment and accessories: ...............................................................................................9
2. SAFETY RULES .......................................................................................................... 10
2.1. Explanation of the different symbols................................................................................10
2.2. Obligations of the owner....................................................................................................11
2.3. Obligations of the worker...................................................................................................11
2.4. Measure of organization.....................................................................................................11
2.5. Information about safety precautions...............................................................................11
2.6. Instructions for the staff.....................................................................................................11
2.7. Dangers while handling the machine................................................................................12
2.8. Gefahren durch die Hydraulik............................................................................................12
2.9. Special dangers...................................................................................................................12
2.9.1.
Danger of stumbling over hydraulic and electric cables...............................................12
2.9.2.
Danger of being burned at the heating element and at the welding point ....................13
2.9.3.
Danger of clothes being grapped by the planer............................................................13
2.9.4.
Danger of crushing by clamping tools and guide rods .................................................13
2.9.5.
Risk of injury by noise...................................................................................................14
2.10. Structural modifications on the machine .........................................................................14
2.11. Warranty and liability..........................................................................................................14
3. DESCRIPTION OF PROCESS .................................................................................... 15
4. OPERATING AND INDICATING ELEMENTS.............................................................. 16
4.1. Elements on the front side.................................................................................................16
4.2. Elements on the right side .................................................................................................17
4.3. Elements on the heating element......................................................................................18
4.4. Wells at the table.................................................................................................................19
5. STARTING AND OPERATING..................................................................................... 20
5.1. Safety indications and Starting .........................................................................................20
5.2. Welding process .................................................................................................................21
5.2.1.
Plane girder for planing only at one side ......................................................................23
25.06.12 Working instructions WIDOS 4001 Page 4 of 59
Contens
Kunststoff schweißtechnik
5.3. Welding logs and tables.....................................................................................................23
5.4. Welding segmented bends ................................................................................................23
5.5. Welding of Cross- and T-pieces ........................................................................................24
6. WELDING LOGS AND TABLES.................................................................................. 26
7. MAINTENANCE AND REPAIR .................................................................................... 31
7.1. Maintenance, Inspection and repair.................................................................................31
7.2. Planer ...................................................................................................................................31
7.3. Checking the level of the hydraulic oil .............................................................................32
7.3.1.
Used hydraulic oil .........................................................................................................32
7.4. Transport .............................................................................................................................32
7.5. Venting the hydraulic cylinders.........................................................................................33
7.6. Clamping elements .............................................................................................................33
7.7. Cleaning of the machine ....................................................................................................33
7.8. Disposal ...............................................................................................................................33
8. WIRING AND HYDRAULIC DIAGRAMS ..................................................................... 34
9. SPARE PARTS LIST ................................................................................................... 37
9.1. Basic machine .....................................................................................................................37
9.2. Clamping tool ......................................................................................................................40
9.3. Planer ...................................................................................................................................42
9.4. Heating element ..................................................................................................................45
9.5. Heating element holder ......................................................................................................47
9.6. Conversion kit for clamping tool.......................................................................................49
9.7. Conversion kit for planer ...................................................................................................51
9.8. Conversion kit for heating element...................................................................................53
9.9. Hydraulic box ......................................................................................................................55
9.10. Plane girder for planing only at one side .........................................................................57
10.
DECLARATION OF CONFORMITY......................................................................... 59
25.06.12 Working instructions WIDOS 4001 Page 5 of 59
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
http://www.widos.de
Kunststoff schweißtechnik
1. Description of 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. Mounting and purpose-oriented use
The WIDOS 4001 is a workshop machine and especially designed for the heating element butt
welding of pipes and fittings from Ø = 90 mm - 315 mm (standard diameters are 90 / 110 / 125
/ 140 / 160 / 180 / 200 / 225 / 250 / 280 / 315 mm).
The machine is equipped with an electrohydraulic adjusting device for control and application
of the welding pressure, a planer and a heating element, two transport handles, a basic
clamping device (swivelling on each side up to 15° for the fabrication of segmented bends and
fittings).
For the compensation of diameter tolerances the right-hand clamping tools is axially movable.
Hydraulic unit, planer, heating element and clamping tools can be easily removed for
transporting the machine even into difficulty accessible rooms.
By means of an optional available conversion kit with 2nd cylinder, larger planer and heating
element, even the diameters 355 / 400 and 450 mm can be clamped and welded.
T- and cross pieces up to OD 250 can be welded with an additional special angle clamping
device.
Any other use of this control unit is considered not to be 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 accidents).
The described plastic welding machine may only be operated, maintained and repaired by
persons who are trained and informed about the dangers.
For personal injuries, material and immaterial damages resulting herefrom, only the user is
responsible!
Also part of the appropriate usage are
•
following all indications of the working instructions and
•
performing the inspection and maintenance works.
25.06.12 Working instructions WIDOS 4001 Page 6 of 59
Description of product Chapter 1
Kunststoff schweißtechnik
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance the machine itself or products
being in the surrounding can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thouroughly read and the corresponding
safety advices must necessarilly be 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.
1.4. Marking of product
The product is marked by a type-plate at the basic machine.
It contains the machine type, the serial number and the year of construction.
1.4.1. Technical data
1.4.1.1. WIDOS 4001 general data
Material: PP; PE 80; PE 100, PVDF
Pipe dimension: Outside-∅ = 90 – 315 mm;
with conversion kit: Outside-∅ = 90 – 450 mm
Total weight (without packing): 285 kg
Fuse protection: 16 A
Power section: 2,5 mm²
Emissions - Noises exceeding 80 dB (A) may occur; during
planing it is obligatory to wear ear protection!
- When using the named plastic materials and
when welding below 260 °C no toxicant damp
arises.
Environmental 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 the pipe ends
25.06.12 Working instructions WIDOS 4001 Page 7 of 59
Description of product Chapter 1
1.4.1.2. Heating element
Power: 3,6 kW / 5,4 kW (for conversation kit)
Voltage: 230 V (± 10%) / 400 V (for conversation kit)
Amperage: 16 A (± 10%)
Frequency: 50 Hz
Surface: antisticking coated
Mounted elements: - electronic temperature control
- control lamps
- on/off switch (for conversation kit)
1.4.1.3. Planer
Motor: Monophase universal motor
Power: 1,05 kW / 1,4 kW for conversion kit
Voltage: 230 V (± 10%)
Amperage: 3,8 A / 4,9 A for conversation kit
Frequency: 50 Hz (± 10%)
Gear: Gear ratio: approx. 0,12
Revolutions of planer [1/min] 50 - 70
1.4.1.4. Hydraulic aggregate
Kunststoff schweißtechnik
Power: 300 Watt
Voltage: 230 V (± 10%)
Amperage: 2,7 A
Frequency: 50 Hz
Phase displacement: approx.18°
Hydraulic oil tank: approx. 1 l
Type of protection IP 54
Electric motor and pump:
Engine revolution: 1380 U/min
max. working pump: approx. 250 bar
Working pressure: adjustable up to 250 bar
1.4.1.5. Basic unit
Dimension l x w x h: 1220 x 1000 x 1355 (mm)
Frame material: Constructin steel
Cylinder-∅: 25 mm
Piston rod-∅: 18 mm
max.force (F=P*A) 236 N (at 100 bar)
5,9 kN (at 250 bar)
Moving speed of the piston: approx. 5,6 cm/s
25.06.12 Working instructions WIDOS 4001 Page 8 of 59
Description of product Chapter 1
1.5. Equipment and accessories:
The following tools and accessories are part of the first delivery:
1 Tool bag for 10 parts
1 Socket wrench size 27
1 each Allan key angled size 3 / 6 / 7 / 8
1 each Allan key with T-grip size 4 / 5 / 6
1 Fork wrench size 17 / 19
1 x Plane girder for planing only at one side
1 Screw driver with Torx drive T10
optional different reduction inserts, rollerstands as pipe support, clamping tools
for fabrication of T-pieces
For order numbers and single parts see spare parts list
Kunststoff schweißtechnik
25.06.12 Working instructions WIDOS 4001 Page 9 of 59
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
http://www.widos.de
Kunststoff schweißtechnik
2. Safety rules
The basic condition for the safety conscious handling and the fault free operation of this
machine is the knowledge of the basic safety advises and rules.
• These working instructions contain the most important indications for running the machine
according to the safety regulations.
• The safety indications need to be followed by all persons working on the machine.
2.1. Explanation of the different symbols
In the working instructions, the following designations and signs are used for potential
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 in order to use all the functions on your machine in an optimal
way and helps you to make the job easier.
T he ac c id e nt pr e ve n ti o n m e as u re s a r e v al i d ( U VV ) .
25.06.12 Working instructions WIDOS 4001 Page 10 of 59
Safety rules Chapter 2
Kunststoff schweißtechnik
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. 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 disposal at any time and without much 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, and
starting the operation.
• A person who is being trained may only work at the machine under supervision of an
experienced person.
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Safety rules Chapter 2
Kunststoff schweißtechnik
2.7. Dangers while handling the machine
The machine WIDOS 4001 has been constructed according to the latest standards of the
technology and according to the recognized technical rules.
Although, during the operation dangers for the user or for persons standing close as well
as damages for items may occur.
The machine should only be used
• purpose oriented
• in a perfect technical safety condition
Disturbances which may affect the safety of the machine must be cleared immediately.
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.
• Protect the machine from rain and dropping water.
• According to VDE 0100, operation on building sites is only allowed with a current distributor
with FI-security protective switch.
2.8. Gefahren durch die Hydraulik
System sections which have to be opened in case of repair work have to be
depressurized before starting to repair.
There is a danger of hurting your eyes because of a sudden flow compressed
air resp. squirting hydraulic oil. The hydraulic oil can be hot!
• Damaged hydraulic / pneumatic hoses have to be immediately replaced.
• Before starting to work make a visual examination of the hydraulic / pneumatic lines.
• The hydraulic oil is brackish!
The hydraulic oil is to be handled and disposed of in appropriate manner
2.9. Special dangers
2.9.1. Danger of stumbling over hydraulic and electric cables
Pay attention that nobody has to step over the lines.
Favorably pass the lines in order that the danger is minimized.
Do not squeeze and kink the lines or anything likewise.
Avoid the heating-up of hydraulic lines (rise in pressure!).
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Safety rules Chapter 2
Kunststoff schweißtechnik
2.9.2. Danger of being burned at the heating element and at the welding
point
You can burn yourself, inflammable materials can be ignited.
• The heating element temperature is heated up to more than 200°C!
• Do not leave the machine with heated heating element unsupervised.
• Do not touch the surfaces of the heating element.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
• Switch off the heating element after use.
• No third persons should stay inside the range of the moving area of the heating element.
• Swivel and transport the heating element only at the grip.
2.9.3. Danger of clothes being grapped by the planer
System parts and pressure conducts which need to be opened are to be made
pressureless before any kind of repair.
• There is a danger of injuring the eyes by hydraulic oil squirting out.
• Wear tight-fitting clothes.
• Do not wear rings or jewelry during work.
• wear snood-type cap.
• Do not touch the surfaces of the planer.
• Keep away others from the drilling area.
2.9.4. Danger of crushing by clamping tools and guide rods
Heavy injuries can result from crushing:
• upon opening / closing the clamping tools
• upon driving in and out the heating element and planer
• upon opening / closing the slides
• upon mounting the reducer inserts
• Do not touch in-between clamped pipes
• Do not reach between the clamping rings in case the pipes are still to be clamped and in
case you move the clamping tools
• In case of working inside the machine, the mains plug always has to be switched off and
secured against unauthorized activation.
• During the installation of the reducer inserts use a lifting device, do not reach between
reducer insert and clamping tool
• Don’t hinder moving tables.
25.06.12 Working instructions WIDOS 4001 Page 13 of 59
Safety rules Chapter 2
Kunststoff schweißtechnik
2.9.5. Risk of injury by noise
You may sustain hearing damage; the drilling noise exceeds 80 dB A
considerably.
• Ear protection is obligatory during drilling!
2.10. 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 perfect condition have to be replaced immediately.
• Only use original WIDOS spare and wear parts.
• In case of order, always state the machine number!
2.11. Warranty and liability
Basically, our "General Terms of sale and delivery“ are valid.
They are at the owner’s disposal latest at conclusion of the contract.
Warranty and liability rights are excluding injuries of persons and property damages if they
are due to one or several of the following reasons:
• Not using the machine purpose oriented.
• Unsuitable transport, mounting, starting, operating and maintenance of the machine.
• Operating the machine without or with not correctly fixed safety devices.
• Not following the indications of the working instructions.
• Unallowed structural modifications on the machine.
• Unsatisfactory inspection of machine parts which are subject to wearing.
• Unsatisfactory performed repairs.
• In case of catastrophes through action of an external body or actions of God.
25.06.12 Working instructions WIDOS 4001 Page 14 of 59
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
http://www.widos.de
Kunststoff schweißtechnik
3. Description of process
B as i ca l l y , t h e i n te r na t io n al a nd na t io n al p r o c e s s g u id e li n es ar e to
b e f ol l o w e d !
At first, the clamping tools are fixed on the machine slide.
For the fabrication of angles and bows, the clamping tools can be turned on both sides.
The plastic pipes are clamped by means of the clamping tools.
If necessary, stabilize the pipes by means of roller stands or pipe supports (for bows, a
supporting angle is existing).
Then the front sides of the pipes are planed parallel by means of the planer and the
misalignment of the pipes is checked.
Now the heating element is swivelled in 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, heat up time begins.
The function of this time is to heat up the pipe ends.
After expiration of the heat up time, the slides are opened, the heating element is swivelled out
quickly and the pipes are closed again hydraulically.
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).
The welded joint can be unclamped, the welding process is finished.
Heating element heats
up the pipes up to
welding temperature
Finished welding with
inside and outside bead
25.06.12 Working instructions WIDOS 4001 Page 15 of 59
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
2
4
5
6
7
3
8
12
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
http://www.widos.de
Kunststoff schweißtechnik
4. Operating and indicating elements
4.1. Elements on the front side
1
No. Denomination Function
1 Clamping tool - swivable up to 15° on both sides.
- Clamping the pipes. By means of the respective
reduction inserts, pipes from OD=90 - 315 mm can be
clamped.
- when using reduction inserts with 22,5° obliquity the
clamping tools need not be turned.
2 Heating element - Bring the pipe up to welding temperature.
- Can be moved sidewards and be swivelled in
3 Pipe support - Clamped pipes can be supported with the corresponding
inserts.
- Bows can be supported on the supporting angles.
4 Supporting angle - Stabilization of bows and angles.
5 Clamping lever - Fixation for supporting angle
6 Carrying handle - Handcarrying the machine
- can be unscrewed if need be.
7 Planer - Planing the pipe ends to be welded.
- Is switched on over the switch at the control desk.
10
11
25.06.12 Working instructions WIDOS 4001 Page 16 of 59
No. Denomination Function
8 Valve lever For opening / closing the slide. There are 4 different
9 Place for stop watch - Place for the delivered stop watch giving a good view
10 Oil dipstick - Oil filler neck / checking the oil level. Oil level must be
11 Manometer - Indication of the hydraulic pressure
12 Setscrew for pressure relief
valve
Operating and indicating elements Chapter 4
positions:
- FORWARDS: slide is closed.
- in the center (without moving): the instantaneous
pressure is held (also by means of the built in pressure
reservoir).
- Pressure release: a possible pressure can be released
without opening the machine. Due to the pressure
reservoir it takes approx. 10 s until the complete
pressure is released.
- BACKWARDS: slide is opened.
on it.
between the two marks.
- Limitation of the hydraulic pressure onto the desired
value. (adjustable from 0 - 250 bar)
4.2. Elements on the right side
Kunststoff schweißtechnik
No. Denomination Function
1 Clamping lever - Loosen for moving the right table half, for horizontal
mismatch compensation.
1
25.06.12 Working instructions WIDOS 4001 Page 17 of 59
1
2
3
Operating and indicating elements Chapter 4
4.3. Elements on the heating element
No. Denomination Function
1 Control lamp yellow There are three different states:
- off: the heating element is not being heated up at the
moment or is cooling down.
- blinking: the temperature of the heating element is
maintained by a certain pulse-position ratio.
- on: the heating element is being heated up at the moment.
The desired temperature has not yet been reached.
Kunststoff schweißtechnik
2 Control lamp green - Indication for mains operated
3 Control knob - Temperature control
25.06.12 Working instructions WIDOS 4001 Page 18 of 59
Operating and indicating elements Chapter 4
Kunststoff schweißtechnik
4.4. Wells at the table
The clamping tool is fixed on one side by means of a centering bolt which serves as swivelling
axle if angles have to be adjusted.
The clamping tool can be moved forwards/backwards.
At the slooted hole on the clamping tool, any angles from 0-15° can be adjusted. For the exact
setting of 11,25° and 15°, figure stamps are existing.
M o v i n g d i r e c t i o n
Centering bolt for
clamping tool /
swiveling axle
Fixing for clamping tool
back
Fixing for clamping tool
front
Screws for clamping tool
front / back
Angle marks for
clamping tools front /
back
Fixing for table
25.06.12 Working instructions WIDOS 4001 Page 19 of 59
WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 / 71 52 99 39 - 40
info @ widos.de
http://www.widos.de
Kunststoff schweißtechnik
5. Starting and operating
The indications of this chapter are supposed to instruct you in the operation of the machine
and to lead you during the skilled starting of the machine.
This includes:
• the safe operation of the machine
• using all possibilities
• economic operation of the machine
5.1. Safety indications and Starting
The machine may only be operated by skilled and authorized persons.
A plastic welder exam according to DVS and DVGW can be taken for the
qualification.
• In danger situations for mankind and for the machine, the main power connection has to be
immediately removed.
• In case of power fall, there may still be pressure in the hydraulic system. If required release
pressure.
• At the end of the work and during breaks, the machine has to be switched off.
• Also take care that no unauthorized person have access to the machine.
• Protect the machine from wetness and humidity !
• According to VDE 0100, operation on building sites is only allowed with a current distributor
with FI-security protective switch.
Before starting the hydraulic check the level of the oil in order to avoid
damages on the pump.
If necessary add hydraulic oil of the quality HLPD 32 (Chapter: 7.3, 7.3.1).
The heating element surfaces should be clean, especially non greasy, that’s
why they need to be cleaned shortly before each welding or in case of
dirtiness by means of a fibre-free paper and cleaning agent (e.g. technical
pure alcool) or cleaning cloths which are available at the WIDOS company.
The anti-adhesive coating of the heating element should be undamaged in
the working area
Be sure that all hydraulic and electric connections are connected.
• Take care for the ambient conditions:
• Welding must not be performed at direct sunlight.
• If necessary, use a welding umbrella.
• At an ambient temperature under 5° C take the respective measures:
• if necessary use a welding tent or heat up the pipe ends.
• In addition, take measures against dust.
25.06.12 Working instructions WIDOS 4001 Page 20 of 59
Starting and operating Chapter 5
Kunststoff schweißtechnik
5.2. Welding process
B as i ca l l y , t h e c o r r e sp o nd i ng va l id w el d i ng p r e sc r ip t io n s ( I SO / C EN
/ D V S. . . ) h av e t o b e f o l lo w e d.
• Do wear safety gloves as protection against burning.
• A stop watch is needed for registrating the actual times for heating and cooling.
• A table with the prescribed parameters for the pipe dimensions to be welded has to be
available.
• The surfaces of the heating element should be clean, especially free from grease, and for
that purpose, in case of dirtiness, they have to be cleaned with a fibreless paper and
a cleaning agent.
The anti-adhesive coating of the heating element must be undamaged in the working area.
• Switch on heating element and set the required welding temperature on the rotary type
regulator. If the control light flashes, the nominal temperature has been reached and is held
at a constant level (Chapter4.3).
• Set the desired angle at the clamping tools.
• The left clamping tool can be moved forwards and backwards.
• The angle settings 11,25° and 15° can be read at the figure stamps.
• Screw the clambing tools according to the pipe outside diameter to be welded
• Lay the work pieces into the clamping shells, fasten the clamping screws and align the work
pieces to each other.
• Use the WIDOS rollerstand for the alignment of long pipe ends, for bows use the
supporting angle and pipe supports.
• Close the machine meanwhile reading the travel pressure at the manometer.
• The travel pressure is displayed exactly at that moment when the machine with the
clamped pipe starts moving.
• Then open the machine again in such a way that the planer fits in between.
• Swivel in the planer between the ends of the workpieces and let the planer lock.
• Switch on the planer, close the machine and plane with a pressure that lies between 1 and
15 bar over the travel pressure.
• If necessary, use the plane girder for planing only at one side (if planing to size or if using a
welding neck which means that only a little material may be removed).
• Planing should be carried out until a revolving cutting has been formed on both sides.
• Open the machine again, switch off the planer and swivel back the planer out of the
machine.
• Remove the formed chips without touching the surfaces.
• Close the machine.
25.06.12 Working instructions WIDOS 4001 Page 21 of 59
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