widos 4900 Working Instructions Translation
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WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
www.widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen County court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating element butt welding machine
WIDOS 4900
Keep for further use!
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Identification of product
02.11.11 Working instructions WIDOS 4900 Page 2 of 46
Version: Ditch machine
Type: WIDOS 4900
Serial number / year of construction: see type lable
Customer's entries
Inventory- No.:
Place of working:
Address of manufacturer
WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
Phone: +49 (0) 71 52 / 99 39 – 0
Fax: +49 (0) 71 52 / 99 39 – 40
Order of spare parts and sales service:
Directly at the manufacturer or at the subsidiary companies:
WIDOS
WIDOS GmbH W. Dommer 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) 71 / 388 89 79
Fax: +49 (0) 3 71 / 8 15 73 - 20 Fax: +41 (0) 71 / 388 89 73
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Introduction
02.11.11 Working instructions WIDOS 4900 Page 3 of 46
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 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.
Therefore the searched information can be easily found.
WIDOS 02.11.2011
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.
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Contents
02.11.11 Working instructions WIDOS 4900 Page 4 of 46
1. DESCRIPTION OF PRODUCT ............................................................................................. 6
1.1. Application and prescribed use ......................................................................................6
1.2. Machine overview ............................................................................................................6
1.3. Safety measures ..............................................................................................................7
1.4. Conformity........................................................................................................................7
1.5. Designation of product ....................................................................................................7
1.5.1 Technical Data...............................................................................................................7
1.5.1.1 WIDOS 4900 General data..................................................................................7
1.5.1.2 Planer....................................................................................................................8
1.5.1.3 Heating element.....................................................................................................8
1.5.1.4 Hydraulic aggregate...............................................................................................9
1.5.1.5 Basic frame ...........................................................................................................9
1.6. 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. Organizational measures...............................................................................................11
2.5. Informal security measures...........................................................................................11
2.6. Instruction of the staff ...................................................................................................11
2.7. Dangers while handling the machine............................................................................12
2.8. Maintenance and inspection, repair..............................................................................12
2.9. Dangers caused by electric energy ..............................................................................12
2.10. Dangers caused by the hydraulics ...............................................................................12
2.11. Special dangers .............................................................................................................13
2.11.1 Danger of catching clothes by the planer..................................................................13
2.11.2 Danger of noise .......................................................................................................13
2.11.3 Danger of burning at heating element, heat protective box and welding area...........13
2.11.4 Danger of stumbling over hydraulic and electric wires ..............................................13
2.11.5 Danger of squeezing by clamping tool and guideways ..............................................14
2.12. Structural modifications on the machine .....................................................................14
2.13. Cleaning the machine ....................................................................................................14
2.14. Guarantee and liability ...................................................................................................14
3. FUNCTIONAL DESCRIPTION............................................................................................ 15
4. OPERATING AND INDICATING ELEMENTS ..................................................................16
4.1. Elements on the hydraulic aggregate...........................................................................16
4.2. Elements at the heating element ..................................................................................17
4.3. Separating dev ice for heating element.........................................................................17
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Contents
02.11.11 Working instructions WIDOS 4900 Page 5 of 46
4.4. Elements at the planer...................................................................................................18
5. STARTING AND OPERATING........................................................................................... 19
5.1. Starting ...........................................................................................................................19
5.1.1 Replacing the reduction inserts ....................................................................................20
5.1.2 Using small and large reduction inserts.........................................................................20
5.2. Welding process ............................................................................................................21
6. WELDING LOGS AND TABLES........................................................................................23
7. MAINTENANCE AND REPAIR .......................................................................................... 28
7.1. Clamping elements ........................................................................................................28
7.2. Planer..............................................................................................................................28
7.3. Storing ............................................................................................................................28
7.4. Used hydraulic oil...........................................................................................................28
7.5. Checking the hydraulic oil level ....................................................................................28
7.6. Venting the hydraulic cylinders .....................................................................................29
8. TRANSPORT .......................................................................................................................30
9. ELECTRIC AND HYDRAULIK DIAGRAMS...................................................................... 31
10. SPARE PARTS LIST ...........................................................................................................35
10.1. Basic machine................................................................................................................35
10.2. Planer..............................................................................................................................37
10.3. Hydraulic aggregate .......................................................................................................39
10.4. Heating element .............................................................................................................42
10.5. Reception box ................................................................................................................44
11. DECLARATION OF CONFORMITY .................................................................................. 46
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WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
www.widos.de
02.11.11 Working instructions WIDOS 4900 Page 6 of 46
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. Application and prescribed use
The WIDOS 4900 is made for heating element butt welding of pipes and fittings with a diameter
range of Ø = 90 - 315 mm.
It is a building site machine and is designed especially for the use on site as well as in the
workshop.
For this reason, the frame is kept small such that it can also be used in constrained positions
(e.g. building ditches).
All use going beyond is not prescribed.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Prescribed use also means:
taking notice of all remarks in this manual
performing of repair works.
1.2. Machine overview
1
Planer
2
Heating element
3
Protective box
4 Hydraulic aggregate
5
Basic machine with clamping tools
1
2
3
4
5
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Description of product Chapter 1
02.11.11 Working instructions WIDOS 4900 Page 7 of 46
1.3. 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 be necessary adhered to.
1.4. 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.
1.5. Designation of product
The product is designated by two signs at the frame.
The type-labels are fixed on the control unit and on the basic machine.
They contain the type of the machine, the serial number, and the year of construction.
1.5.1 Technical Data
1.5.1.1 WIDOS 4900 General data
Material: PP, PE 80, PVDF, PE 100
Pipe diameter range: outside-∅ = 90 – 315 mm
Transport box (l x w x h) / weight:
Partition boxes for reduction inserts:
4- partition:
7- partition:
9- partition:
approx. 1230 x 980 x 670 mm / approx. 67 kg
appr. 680 x 410 x 310 weight: appr. 10 kg
appr. 1160 x 410 x 310 weight: appr. 16 kg
appr. 1470 x 410 x 310 weight: appr. 21 kg
Total weight (without packing): approx. 130 kg
Protection: 16 A
Wire cross section: 1,5 mm²
Emissions - Noises 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.
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Description of product Chapter 1
02.11.11 Working instructions WIDOS 4900 Page 8 of 46
Environment: - keep the workshop clean (especially the welding
area must be clean)
- 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 put up a tent
- avoid strong sun beams
- if it is windy shut the pipe endings.
1.5.1.2 Planer
Motor: monophase-alternating current-motor
Power: 1,05 kW
Voltage: 230 V (± 10 %)
Current: 4,5 A
Frequency: 50 Hz (± 10 %)
RPM n2 of planer approx. 60 revs/min.
Elements: Switch on / off with fixing device
Connecting cable and plug with earthing contact
Weight: approx. 14 kg
1.5.1.3 Heating element
Power: 2,1 kW
Voltage: 230 V (± 10 %)
Current: 10 A (± 10 %)
Frequency: 50 Hz
Outside-∅: 350 mm
Surface: Antistick-coated
Elements: Electronic temperature control
Control lamps, switch on / off
Connecting cable and plug with earthing contact
Weight: approx. 13 kg
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Description of product Chapter 1
02.11.11 Working instructions WIDOS 4900 Page 9 of 46
1.5.1.4 Hydraulic aggregate
Power: 0,3 kW
Voltage: 230 V (± 10 %)
Current: 2,7 A
Frequency: 50 Hz
Hydraulic oil tank: approx. 1 l
Electromotor and pump:
RPM: 1380 (revs/min.)
max. pressure of pump: approx. 120 bar
Working pressure: 100 bar
Volume velocity: 1,9 l/min
Weight : approx. 23 kg
1.5.1.5 Basic frame
Dimensions (l x w x h): 800 x 460 x 500 mm
Reduction insert : Dimensions can be selected
Material frame: Machine steel
Material reduction inserts: Aluminium
Weight: approx. 60 kg
Cylinder-∅: 40 mm
Piston rod-∅: 35 mm
Length of stroke of cylinder: 175 mm
max. force: (F=P*A) 5900 N (at 100 bar)
Velocity of piston rod: 5,4 cm/s
Stock numbers for component parts see spare parts list
1.6. Equipment and accessories:
The following accessories are part of the first delivery:
1 Tool bag for 10 parts
1 Socket wrench size 27
1 each Allan key size 3; 6; 7; 8
1 each Allan key with T-grip size 5; 7
optional Reduction inserts, roller brackets for the pipes
1 Torx-screw driverT10
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WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
www.widos.de
02.11.11 Working instructions WIDOS 4900 Page 10 of 46
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.
The security notices of this chapter represent the general part.
Particular information is listed directly before the corresponding actions.
These working instructions provide you with the most important information to run the
machine safely.
The safety information must be read by all persons who work on the machine.
2.1. Explanation of the different symbols
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 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 crushings of parts of
the body resp. damages of parts of the machine.
This symbol means a possible risk of injury by noises 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).
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Safety rules Chapter 2
02.11.11 Working instructions WIDOS 4900 Page 11 of 46
2.2. Obligations of the owner
The owner is obliged only to let persons work on the machine, who
• know about basic safety and accident prevention rules and are instructed in the handling of
the machine.
• The workers also must have read and understood the safety chapter of this manual and
certify this with their signature.
The safety-conscious working of the staff should 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 take care of the basic safety and accident protection rules.
• To have read and understood the safety chapter and the warnings in this manual and to
certify this with their signature.
• To inform themselves about the functions of the machine before using it.
2.4. Organizational measures
• All equipment required for personal safety is to be provided by the owner.
• All available safety equipment is to be inspected regularly.
2.5. Informal security measures
• The manual has to be permanently kept at the place of use of the machine. It is to be at the
operator‘s disposal at any time and without effort.
• As a supplement to the working instructions, the generally valid and also the local regulations
for the prevention of accidents and the protection of the environment are to be provided and
adhered to.
• All security and danger notices on the machine have to be kept in a readable state.
• Every time the machine changes hands or is being rented to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instruction of the staff
• Only skilled and instructed persons are allowed to work at the machine.
• The responsibilities of the staff are to be determined clearly concerning transport, mounting
and dismounting, starting, adjusting and tooling, operating, maintenance and inspection,
repairs.
• Workers who are to be trained are only allowed to work at the machine under control of an
experienced worker.
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Safety rules Chapter 2
02.11.11 Working instructions WIDOS 4900 Page 12 of 46
2.7. Dangers while handling the machine
The machine WIDOS 4900 is constructed according to the actual technical standard and the
acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby may occur.
Also damages to the machine itself or to other things are possible.
The machine must only be used:
• according to the prescription
• in safety technical impeccable status
Disturbances, which may affect the safety of the machine must be eliminated immediately.
2.8. Maintenance and inspection, repair
All maintenance and repair works 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 works should be performed in time.
The DVS gives the advice of inspection works after 1 year.
For machines with a specially high usage percentage the testing cycle should be
shortened.
The works should be performed at the WIDOS GmbH company or by
an authorized partner.
2.9. Dangers caused by electric energy
Only skilled workers 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 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. Dangers caused by the hydraulics
System parts and pressure hoses should be made pressureless before beginning
of any repair works. 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!
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Safety rules Chapter 2
02.11.11 Working instructions WIDOS 4900 Page 13 of 46
2.11. Special dangers
2.11.1 Danger of catching clothes by the planer
There is the danger of cutting yourself or even breaking bones!
• Wear only tight clothes.
• Do not wear rings or jewellery during work.
• If necessary wear a hair-net.
• Always put the planer back into the reception case after and before each use.
• Only transport the planer at the handle.
• Do not touch the planer surfaces.
• Switch on the planer only for use. Otherwise the planer will start every time when the security
microswitch is pressed.
2.11.2 Danger of noise
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!
2.11.3 Danger of burning at heating element, heat protective box and
welding area
You can burn yourself, inflammable materials can be ignited!
The heating element is heated up to more than 200 °C / 392 °F!
• Do not touch the surface of the heating element.
• Do not leave the heating element unattended.
• Take enough safety distance to materials which might be ignited.
• Wear safety gloves.
• Insert the heating element into the heat protective box after use.
• Only transport the heating element at the handle.
2.11.4 Danger of stumbling over hydraulic and electric wires
• Make sure that no person has to step over the wires.
• Make sure that the cables lie in such a way that the danger is maintained at a minimum.
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Safety rules Chapter 2
02.11.11 Working instructions WIDOS 4900 Page 14 of 46
2.11.5 Danger of squeezing by clamping tool and guideways
There is a possibility of serious injury:
On the one hand between the inner clamping tools and on the other hand
between the outside clamping tool and the end of the guideway.
• Do not put hands or foot between clamped pipe ends.
• Do not step or grab between the inner clamping tools with not yet clamped pipes.
• Do not block opening and closing of the machine.
2.12. Structural modifications on the machine
• No modifications, extensions or reconstructions may be performed on the machine without
permission of the manufacturer.
• 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.
2.13. Cleaning the machine
• The used materials and cloths are to be handled properly and to be disposed of, especially
• during cleaning with solvents
• when lubricating with oil and grease
2.14. Guarantee and liability
Fundamentally our "general sales and delivery conditions" are in force.
They are at the buyer's disposal latest before making 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 prescription.
• 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 this manual.
• Structural changes on the machine without permission.
• Unsatisfactory checkings of parts of the machine, which are worn out.
• Unprofessionally performed repairs.
• In case of catastrophes and acts of God.
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WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
www.widos.de
02.11.11 Working instructions WIDOS 4900 Page 15 of 46
3. Functional description
Ba s i c a l l y th e i n t e rn at i on al a n d n a t io n a l st a n d a r d spe c i f i c a t i o n s a re t o b e
fu l f il le d .
The plastic pipes are clamped by means of the clamping tools.
Then the foreparts are planed parallel by means of the planer, and mismatch is checked.
Now the heating element is inserted and the pipes are pressed against the heating element with
the defined adjusting pressure. This operation is called "adjusting".
After the prescribed bead height is reached, the pressure is relieved and the heat-up time is
starting. Now the pipes are heated up to welding temperature.
After expiration of the heat-up time, the slide has to be opened, the heating element is removed
quickly and the pipes are rejoined. The time between removing the heating element and rejoining
the pipes is called change-over time.
The pipes are joined with the prescribed welding pressure and then cool down under pressure
(cooling time).
The weld joint can be unclamped, the welding process is finished.
Heating element heats the pipes
up to welding temperature
Finished weld joint with
internal and external bead
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WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
www.widos.de
02.11.11 Working instructions WIDOS 4900 Page 16 of 46
4. Operating and indicating elements
4.1. Elements on the hydraulic aggregate
No. Denomination Function
7 Pressure gauge Digital display of the hydraulic pressure
8 Valve lever Opening/closing the slide. There are 4 different positions:
- to the left side: slide closes
- in the middle (usual position): the pressure is currently
achieved is kept (also by means of the hydraulic
accumulator)
- slightly to the right side (position pressureless): a
possibly existing pressure is released without moving the
slide. Due to the hydraulic accumulator it takes about 10 s
until the pressure is completely released.
- to the right side: slide opens
9 Adjusting screw for pressure
relief valve
- For the limitation of the hydraulic pressure to the
desired value
10 Hydraulic connection for
closing
- Non-dropping quick-action hose coupling
11 Hydraulic connection for
opening
- Non-dropping quick-action hose coupling
12 Screw with oil level stick - Checking the oil-level
- Filling in oil
7
8
10
11
9
12
Mains cable
230V / 50HZ
power supply
for hydraulic
aggregate
Label
„opening/
closing“
Indicating label
setting the
pressure relief
valve
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Operating and indicating elements Chapter 4
02.11.11 Working instructions WIDOS 4900 Page 17 of 46
4.2. Elements at the heating element
No. Denomination Function
16 Control lamp green - There are three different states:
•
off: signalizes that the heating element is not
heated up at the moment or that it cools down
•
blinking: the heating element temperature is
maintained by a certain pulse-position ratio
• on: signalizes that the heating element is heated
up at the moment. It has not yet reached the
desired temperature
17 Setting screw - For regulating the temperature of the heating
element
18 On/off-switch with red lamp - As soon as the heating element is switched on,
the red control lamp lightens
4.3. Separating device for heating element
There is a tear-off bar mounted between the
movable and the fixed clamping shells on the basic
machine. It prevents the heating element from
sticking to the heated-up pipe ends.
When inserting the heating element take care that it
lies in the zone of the throat of the tear-off bar (see
arrow).
16
17
18
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