widos 5100 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
info @ widos.de
http://www.widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Dieter Dommer, Jürgen Dommer
Working Instructions
Translation
Heating Element Butt Welding Machine
WIDOS 5100
Keep for further use!
Kunststoff schweißtechnik
Identification of product
30.06.11 Working instructions WIDOS 5100 Page 2 of 45
Model: Heating element butt welding machine
Type: WIDOS 5100
Serial number: / year of construction: see type lable
Customer entries
Inventory-No.:
Place of working:
Order of spare parts and sales service:
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
info@widos.de
www.widos.de
Adress 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 / 3 88 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 3 88 89 73
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Introduction
30.06.11 Working instructions WIDOS 5100 Page 3 of 45
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 30.06.2011
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.
Kunststoff schweißtechnik
Contents
30.06.11 Working Instructions WIDOS 5100 Page 4 of 45
1. DESCRIPTION OF PRODUCT ...................................................................................... 6
1.1. Usage and purpose-oriented use ........................................................................................6
1.2. Safety measures....................................................................................................................6
1.3. Conformity .............................................................................................................................6
1.4. Machine overview .................................................................................................................7
1.5. Designation of the product ..................................................................................................7
1.5.1 Technical data ....................................................................................................................8
1.5.1.1 WIDOS 5100 General data ......................................................................................8
1.5.1.2 Heating element.........................................................................................................8
1.5.1.3 Planer.........................................................................................................................9
1.5.1.4 Hydraulic aggregate...................................................................................................9
1.5.1.5 Basic frame ................................................................................................................9
1.5.1.6 Protective box ..........................................................................................................10
1.6. Equipment and accesories: ...............................................................................................10
2. SAFETY RULES .......................................................................................................... 11
2.1. Explanation of the different symbols................................................................................11
2.2. Obligations of the owner....................................................................................................12
2.3. Obligations of the worker...................................................................................................12
2.4. Measures of organization...................................................................................................12
2.5. Information about safety precautions...............................................................................12
2.6. Instructions for the staff.....................................................................................................12
2.7. Dangers while handling the machine................................................................................13
2.8. Maintenance, inspection and repair..................................................................................13
2.9. Dangers caused by electric energy...................................................................................13
2.10. Dangers caused by the hydraulic......................................................................................13
2.11. Specific dangers .................................................................................................................14
2.11.1 Danger of catching clothes by the planer .....................................................................14
2.11.2 Danger of being burnt by heating element, reception box and welding area ...............14
2.11.3 Danger of Stumbling over electric / hydraulic wires......................................................14
2.11.4 Danger of squeezing by clamping devices and guideways..........................................14
2.11.5 Risk of injury by noises.................................................................................................15
2.12. Structural modifications on the machine .........................................................................15
2.13. Cleaning the machine.........................................................................................................15
2.14. Guarantee and liability........................................................................................................15
3. FUNCTIONAL DESCRIPTION..................................................................................... 16
4. OPERATING AND INDICATING ELEMENTS.............................................................. 17
4.1. Elements on the aggregate ................................................................................................17
4.2. Elements at heating element and planer ..........................................................................18
4.3. Separating device for heating element .............................................................................18
Kunststoff schweißtechnik
Contents
30.06.11 Working Instructions WIDOS 5100 Page 5 of 45
5. STARTING AND OPERATING..................................................................................... 19
5.1. Starting.................................................................................................................................19
5.2. Connection hydraulic aggregate with the basic machine ..............................................20
5.2.1 Exchanging the reduction inserts......................................................................................20
5.2.2 Using small and large reduction inserts............................................................................20
5.3. Welding process .................................................................................................................21
6. WELDING LOGS AND TABLES.................................................................................. 24
7. MAINTENANCE AND REPAIR .................................................................................... 29
7.1. Clamping elements .............................................................................................................29
7.2. Planer ...................................................................................................................................29
7.3. Storing..................................................................................................................................29
7.4. Used hydraulic oil ...............................................................................................................29
7.5. Checking the hydraulic oil level ........................................................................................29
7.6. Venting the hydraulic cylinders.........................................................................................30
8. TRANSPORT ............................................................................................................... 31
9. HYDRAULIC AND ELECTRIC DIAGRAMS ................................................................. 32
10. SPARE PARTS LIST ................................................................................................... 34
10.1. Basic machine .....................................................................................................................34
10.2. Hydraulic aggregat..............................................................................................................36
10.3. Planer ...................................................................................................................................39
10.4. Heating element ..................................................................................................................41
10.5. Reception box .....................................................................................................................43
11. DECLARATION OF CONFORMITY............................................................................. 45
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 6 of 45
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. Usage and purpose-oriented use
The WIDOS 5100 has been designed for heating element butt welding of pipes and fittings
with a diameter range of Ø = 200 - 450 mm.
(standard diameters: 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 mm)
It is a machine for construction sites and particulary designed for the use 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 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 thouroughly 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 product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 7 of 45
1.4. Machine overview
1 Planer
2 Heating element
3 Reception box
4 Hydraulic aggregate
5 Basic machine
1.5. Designation of the product
The product is designated by two type labels which are attached at the aggregate and at the
basic machine.
They contain the type, the serial number and the year of construction of the machine.
1
2
3
4
5
Kunststoff schweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 8 of 45
1.5.1 Technical data
1.5.1.1 WIDOS 5100 General data
Material wich can be welded: PE80, PE 100, PVDF, PP
Pipe diameter range:
∅
outside
= 200 - 450 mm
Dimension transport box (l x w x h):
Weight:
1360 x 1300 x 1005 mm
99 kg
Total weight (without packing): 240 kg
Fuse: 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
Environment: - 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
1.5.1.2 Heating element
Power: 3,6 kW
Voltage: 230 V (± 10%)
Current: 15,6 A (± 10%)
Frequency: 50 Hz
Outside-∅ : 500 mm
Surface: nonstick-coated
Attached elements: - Eectronic temperature control
- Control lamps
- Connecting cable with plug
Weight: approx. 20 kg
Due to the high current consumption, the heating element must not be
connected to the aggregate, but to an external plug box with separate fuse
protection.
Kunststoff schweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 9 of 45
1.5.1.3 Planer
Motor: Monophase-alternating current-motor
Power: 1400 Watt
Voltage: 230 V (± 10%)
Nominal current: 6.1 A
Frequency: 50 Hz (± 10%)
RPM n2 of planer: 230 revs/min.
Gear: Gear ratio: approx. 0.12
Max. RPM 28 revs / min
Attached elements: - Switch on/off
- Connecting cable with plug
With earthing contact
Weight: Approx. 37 kg
1.5.1.4 Hydraulic aggregate
Power: 0,3 Watt
Voltage: 230 V (± 10%)
Current: 2,7 A
Frequency: 50 Hz
Phase displacement: Approx.18°
Hydraulic oil tank: Approx. 1 l
Protective system: IP 54
Electromotor and pump:
RPM: 1380 (revs / min)
Max. pressure of the pump: Approx. 120 bar
Working pressure: 0 – 100 bar adjustable
Volume velocity: 1.9 l/min
Weight: 23 kg
1.5.1.5 Basic frame
Reduction insert: Dimensions can be selected
Material frame: Machine steel
Material clamping shells: Aluminium
Weight: 109 kg
Cylinder-Ø: 50 mm
Piston rod-Ø: 40 mm
Length of stroke of cylinder: 195 mm
Max. force: (F=P*A) 14140 N (at 100 bar)
Velocity of piston rod: 2.2 cm/s
For article numbers and component parts see spare parts list
Kunststoff schweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 10 of 45
1.5.1.6 Protective box
Weight heat protective box: Approx. 25 kg
1.6. Equipment and accesories:
The following accessories are part of the first delivery:
1 x Socket wrench size 27 (for clamping the pipes)
2 each Hexagonal socket screw short size 3; 10
2 each Hexagonal socket screw size 4; 5; 7 with T-grip (for reduction
inserts and adapters)
1 x Torx srew driver T10
optional Reduction inserts, roller brackets for the pipes,
current transformer for model 42 V
Kunststoff schweißtechnik
WIDOS Einsteinstr. 5 Phone +49 7152 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 7152 9939 - 40
info @ widos.de
http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 11 of 45
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 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 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 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.
T h e r e gu l a t io n s fo r t h e pr e ve nt i on o f a c c i de n ts a r e va l id ( U VV ) .
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Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 12 of 45
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.
• have read and understood the safety chapter of this manual and certify this by 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 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
30.06.11 Working Instructions WIDOS 5100 Page 13 of 45
2.7. Dangers while handling the machine
The machine WIDOS 5100 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 materials
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.
2.8. Maintenance, inspection and 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 hydraulic
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 !
Kunststoff schweißtechnik
Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 14 of 45
2.11. Specific dangers
2.11.1 Danger of catching clothes by the planer
You can cut yourself or even get bones broken
• Only wear clothes tight to the boddy.
• Do not wear rings or jewellery during work.
• If necessary wear a hair-net.
• Always put the planer back into the reception box after and before each use.
• Transport the planer at the handle only. Do not touch the surfaces.
• Switch on the planer only for use. If the planing pressure is too high, there is the danger
that the planer tills and falls out of the machine during planing. For that reason do not press
the pipe ends stronger than necessary against the planer. If necessary, hold the planer
firmly.
2.11.2 Danger of being burnt by heating element, reception box and
welding area
You can burn yourself, inflammable materials can be ignited!
The heating element is heated up to more than 250°C!
• Do not touch the surface of the heating element.
• Do not leave the heating element unsupervised.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
• Allways put the heating element into the heat reception box after and before use.
• Transport the heating element at the handle only.
2.11.3 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.
2.11.4 Danger of squeezing by clamping devices and guideways
There is a danger of serious injuries: On the one hand between the inner
clamping devices and on the other hand between the outer clamping device and
the end of the guideway.
• Do not stand or put hands or foot between clamped pipe ends.
• Do not stand or put hands between the inner clamping devices with not yet clamped pipes.
• Do not block opening and closing of the machine slides.
Kunststoff schweißtechnik
Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 15 of 45
2.11.5 Risk of injury by noises
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!
2.12. Structural modifications on the machine
• No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
• Machine parts wich 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!
2.13. Cleaning the machine
• The used materials and tissues are to be handled properly and disposed of properly,
especially:
• when cleaning with solvents
• when lubricating with oil and grease.
2.14. Guarantee 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 checkings of parts of the machine, which are worn out.
• unsatisfactory checking of parts of the machine, wich 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
info @ widos.de
http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 16 of 45
3. Functional description
Bas i ca l ly , t he in t er na t io n al a n d na t io n al st an d ar d s pec if i ca ti ons a r e t o be
ful fi l le d.
The plastic pipes are clamped in the clamping devices.
Then the front side of the pipes are cut plane and parallel by means of the planer, and
missalignment 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 operation is called "adjusting".
After the prescribed bead height is 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 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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