info @ widos.de Working instructions Translation · 2017. 3. 13. · Kunststoffschweißtechnik Introduction 25.06.12 Working instructions WIDOS 4001 Page 3 of 59 Purpose of the document

Kunststoffschweißtechnik

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

Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing Director: Jürgen Dommer

Working instructions Translation

Heating element-butt welding machine

WIDOS 4001

Keep for further use !


Identification of product

25.06.12 Working instructions WIDOS 4001 Page 2 of 59

Model: Workshop machine

Type: WIDOS 4001

Serial number: / year: see type plate

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: [email protected]

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


Introduction


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.


Contens


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


Contens


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


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


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.


Description of product Chapter 1


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




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

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




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




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.

The acc iden t p reven t ion measures a re va l i d (UVV) .


Safety rules Chapter 2


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.




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!).




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.




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.




3. Description of process

Bas ica l l y , t he i n t e rna t i ona l and na t i ona l p rocess gu ide l i nes a re to

be fo l l ow ed ! 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




4. Operating and indicating elements

4.1. Elements on the front side

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.

1

2

4

5

6

9

11

7

3 8

10

12


Operating and indicating elements Chapter 4



8 Valve lever For opening / closing the slide. There are 4 different

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.

9 Place for stop watch - Place for the delivered stop watch giving a good view

on it.

10 Oil dipstick - Oil filler neck / checking the oil level. Oil level must be

between the two marks.

11 Manometer - Indication of the hydraulic pressure

12 Setscrew for pressure relief

valve

- Limitation of the hydraulic pressure onto the desired

value. (adjustable from 0 - 250 bar)

4.2. Elements on the right side


1 Clamping lever - Loosen for moving the right table half, for horizontal mismatch compensation.

1




4.3. Elements on the heating element


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.

2 Control lamp green - Indication for mains operated

3 Control knob - Temperature control

1 2

3




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

Fixing for table

Angle marks for clamping tools front / back

Fixing for clamping tool front

Fixing for clamping tool back

Screws for clamping tool front / back

Centering bolt for clamping tool / swiveling axle




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.


Starting and operating Chapter 5


5.2. Welding process

Bas ica l l y , t he cor respond ing va l i d w e ld ing p resc r ip t i ons ( ISO / CEN

/ DVS . . . ) have to be fo l l ow ed .

• 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.




• Check the misalignment and the gap between the two pipes touching one the other.

According to DVS 2207, the misalignment at the pipe outside should not be higher than 0,1 x pipe wall thickness, the acceptable gap not bigger than 0,5 mm.

The right half of the table can be pushed backwards and forwards for the misalignmentcheck.

Release both clamping levers at the front side of the table.

• In case of a misalignment compensation, a new planing should be performed.

• Take the adjustment pressure for the pipe dimensions to be welded from the table and add the travel pressure.

• Set the so defined pressure value at the pressure limitation valve and check by actioning the valve lever.

• Open the machine again somewhat.

• Take heat up time, max. change over time, cooling down time and bead height for the pipe dimension to be welded from the welding table (Chapter: 6)

• Swivel in the cleaned heating element, brought onto desired temperature, between the pipes, if necessary wait until the desired temperature has been reached.

• Drive the machine halfs together schock-free under the set adjusting pressure.

• When the prescribed circular bead height is being reached, reduce the pressure.

• For this purpose put the valve lever into position „pressureless“ until the desired heating pressure is set (heating pressure = approx. 10% of the adjusting pressure).

• Now the heat up time begins. Press the stop watch and compare the actual time with the desired time taken out of the table.

• Open the machine after completion of the heating time, pull the heating element out as quickly as possible and drive the machine together without schock-free.

• The maximum time range for this process is given by the value for the change over time taken out of the table.

• After completion of the welding pressure up-building, press the stop watch and maintain the control lever for about 10 s in position „pressure“ so that the hydro tank may be filled.

• If required set the pressure again during cooling (the pressure for cooling is the same like the set adjusting pressure).

• After completion of the cooling time release pressure, remove the welded parts and open the machine.

The welding process is finished.




5.2.1. Plane girder for planing only at one side

If planing is necessary only at one side (e.g. at use of a fitting) the plane girder for planing (A) is used.

Center the centering bolt of the girder in the central drill.

Of the planer and hold tightly the girder during planing.

5.3. Welding logs and tables

If welding angles, the welding surface of the pipe and thus the necessary pressure changes. Calculate the necessary pressure as follows:

• Take the prescribed value for adjusting or cooling from the table.

• Multiplicate the pressure value with factor /cos (angle).

This will give the following factors:

Welding 15° (chamfered pipe with 7,5°): 1,01 Welding 22,5° (chamfered pipe with 11,25°): 1,02 Welding 30° (chamfered pipe with 15°): 1,04 Welding 45° (chamfered pipe with 22,5°): 1,08 Welding 60° (chamfered pipe with 30°): 1,15 Welding 90° (chamfered pipe with 45°): 1,41

• Add the motional pressure as usual.

All the other welding parameters remain as usual.

5.4. Welding segmented bends Calculate the sawing angle to be set (corresponding to the required angle at the clamping tools or clamping inserts) as follows:

angle of the bend

sawing angle = ---------------------------------------------

number of all welding surfaces

Example 1: bend of 90° 4 segments (6 welding surfaces)

90° sawing angle = ----- = 15°

6

Example 2: bend of 45° in 3 segments (4 welding surfaces)

45° sawing angle = ----- = 11,25°

4

A

angle




5.5. Welding of Cross- and T-pieces The optional available clamping device for angles is screwed on together with the adapter plate and standard tools.

T - pieces (45°, 60° and 90°) and Cross-pieces up to OD=250 mm can be welded.







6. Welding logs and tables


Welding logs and tables Chapter 6



Foundation: 2207, 2208 DIN 16932 German association for weldingUse for: 4000 / 4001 / 4002

1 bar on manometer: 23 N

PE 80 The value for heating element temperature is between 200° C - 220° C.The smaller the pipe wall the higher the temperature.

PE 100 The standard value for heating element temperature is 220° C.Increase the change-over time and the welding pressure time at PE 100 as fast as possible !

time to

change- reach full

over welding cool-down time

0,15 (PE) time pressure pressure in

Tdesired temperature

time

pipe pipe SDR bead-up circular heat-up max. time welding cool-diameter wall pressure bead time change- to reach pressure downOD (s) [bar] min. [s] over welding [bar] time[mm] [mm] [mm] time pressure [min]

[s] [s] �

90 2,2 41 4 0,5 22 4 4 4 2

90 2,8 33 6 0,5 28 4 4 6 3

90 3,5 26 7 0,5 35 5 5 7 4

90 4,3 21,0 8 0,5 43 5 5 8 6

90 5,1 17,6 9 1,0 51 5 5 9 7

90 5,4 17 10 1,0 54 5 5 10 7

90 6,7 13,6 12 1,0 67 6 6 12 10

90 8,2 11 14 1,5 82 6 6 14 11

90 10,1 9,0 17 1,5 101 7 7 17 14

90 12,3 7,4 20 2,0 123 8 8 20 16

110 2,7 41 6 0,5 27 4 4 6 3

110 3,4 33 8 0,5 34 5 5 8 4

110 4,2 26 10 0,5 42 5 5 10 6

110 5,3 21,0 12 1,0 53 5 5 12 7

110 6,3 17,6 14 1,0 63 6 6 14 9

110 6,6 17 14 1,0 66 6 6 14 9

110 8,1 13,6 17 1,5 81 6 6 17 11

110 10,0 11 21 1,5 100 7 7 21 14

110 12,3 9,0 25 2,0 123 8 8 25 16

110 15,1 7,4 30 2,0 151 9 9 30 20

in welding area

Table for PE

bead-up heat-up

Additional to the given bead-up force and to the welding force the moving force of the support must be added !

welding area

P (N/mm²)

25.06.2012 Working instructions WIDOS 4000 - 4002 Page 28 / 1 of 59






time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

125 3,1 41 8 0,5 31 4 4 8 4

125 3,9 33 10 0,5 39 5 5 10 5

125 4,8 26 12 1,0 48 5 5 12 6

125 6,0 21,0 15 1,0 60 6 6 15 8

125 7,1 17,6 18 1,5 71 6 6 18 10

125 7,4 17 18 1,5 74 6 6 18 10

125 9,2 13,6 22 1,5 92 7 7 22 13

125 11,4 11 27 1,5 114 8 8 27 15

125 14,0 9,0 32 2,0 140 9 9 32 18

125 17,1 7,4 38 2,0 171 9 10 38 22

140 3,5 41 10 0,5 35 5 5 10 4

140 4,3 33 12 0,5 43 5 5 12 6

140 5,4 26 15 1,0 54 5 5 15 7

140 6,7 21,0 19 1,0 67 6 6 19 10

140 8,0 17,6 22 1,5 80 6 6 22 11

140 8,3 17 23 1,5 83 7 7 23 12

140 10,3 13,6 28 1,5 103 7 7 28 14

140 12,7 11 34 2,0 127 8 8 34 17

140 15,7 9,0 40 2,0 157 9 10 40 20

140 19,2 7,4 48 2,5 192 10 11 48 24







time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

160 4,0 41 13 0,5 40 5 5 13 5

160 4,9 33 16 1,0 49 5 5 16 7

160 6,2 26 20 1,0 62 6 6 20 9

160 7,7 21,0 25 1,5 77 6 6 25 11

160 9,1 17,6 29 1,5 91 7 7 29 13

160 9,5 17 30 1,5 95 7 7 30 13

160 11,8 13,6 36 2,0 169 9 10 36 22

160 14,6 11 44 2,0 146 9 9 44 19

160 17,9 9,0 53 2,0 179 10 11 53 23

160 21,9 7,4 62 2,5 219 11 12 62 27

180 4,4 41 16 0,5 44 5 5 16 6

180 5,5 33 20 1,0 55 5 5 20 8

180 6,9 26 25 1,0 69 6 6 25 10

180 8,6 21,0 31 1,5 86 7 7 31 12

180 10,2 17,6 36 1,5 102 7 7 36 14

180 10,7 17 38 1,5 107 7 7 38 14

180 13,3 13,6 46 2,0 136 8 9 46 18

180 16,4 11 55 2,0 164 9 10 55 21

180 20,1 9,0 66 2,5 201 10 11 66 25

180 24,6 7,4 79 2,5 246 12 13 79 30







time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

200 4,9 41 20 1,0 49 5 5 20 7

200 6,2 33 25 1,0 62 6 6 25 9

200 7,7 26 31 1,5 77 6 6 31 11

200 9,6 21,0 38 1,5 96 7 7 38 13

200 11,4 17,6 45 1,5 114 8 8 45 15

200 11,9 17 46 1,5 119 8 8 46 16

200 14,7 13,6 56 2,0 147 9 9 56 19

200 18,2 11 68 2,0 182 10 11 68 23

200 22,4 9,0 82 2,5 224 11 12 82 28

200 27,4 7,4 97 3,0 274 13 15 97 34

225 5,5 41 25 1,0 55 5 5 25 8

225 6,9 33 31 1,0 69 6 6 31 10

225 8,6 26 39 1,5 86 7 7 39 12

225 10,8 21,0 48 1,5 108 8 8 48 15

225 12,8 17,6 56 2,0 128 8 8 56 17

225 13,4 17 59 2,0 134 8 9 59 18

225 16,6 13,6 71 2,0 166 9 10 71 21

225 20,5 11 86 2,5 205 10 12 86 26

225 25,2 9,0 104 2,5 252 12 14 104 31

225 30,8 7,4 123 3,0 308 14 16 123 38







time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

250 6,2 41 31 1,0 62 6 6 31 9

250 7,7 33 39 1,5 77 6 6 39 11

250 9,6 26 48 1,5 96 7 7 48 13

250 11,9 21,0 59 1,5 119 8 8 59 16

250 14,2 17,6 69 2,0 142 9 9 69 19

250 14,8 17 72 2,0 148 9 9 72 19

250 18,4 13,6 88 2,0 184 10 11 88 23

250 22,7 11 106 2,5 227 11 13 106 28

250 27,9 9,0 127 3,0 279 13 15 127 34

250 34,2 7,4 152 3,0 342 15 18 152 42

280 6,9 41 39 1,0 69 6 6 39 10

280 8,6 33 48 1,5 86 7 7 48 12

280 10,7 26 60 1,5 107 7 7 60 14

280 13,4 21,0 74 2,0 134 8 9 74 18

280 15,9 17,6 87 2,0 159 9 10 87 20

280 16,6 17 90 2,0 166 9 10 90 21

280 20,6 13,6 110 2,5 206 10 12 110 26

280 25,4 11 133 2,5 254 12 14 133 31

280 31,3 9,0 160 3,0 313 14 16 160 38

280 38,3 7,4 190 3,5 383 16 20 190 47







time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

315 7,7 41 49 1,5 77 6 6 49 11

315 9,7 33 61 1,5 97 7 7 61 13

315 12,1 26 76 2,0 121 8 8 76 16

315 15,0 21,0 93 2,0 150 9 9 93 19

315 17,9 17,6 109 2,0 179 10 11 109 23

315 18,7 17 114 2,0 187 10 11 114 24

315 23,2 13,6 139 2,5 232 11 13 139 29

315 28,6 11 168 3,0 286 13 15 168 35

315 35,2 9,0 202 3,0 352 15 18 202 43

315 43,1 7,4 241 3,5 431 18 22 241 52

355 8,7 41 62 1,5 87 7 7 62 12

355 10,9 33 77 1,5 109 8 8 77 15

355 13,6 26,0 96 2,0 136 8 9 96 18

355 16,9 21,0 118 2,0 169 9 10 118 22

355 20,1 17,6 138 2,5 201 10 11 138 25

355 21,1 17 145 2,5 211 11 12 145 26

355 26,1 13,6 176 3,0 261 12 14 176 32

355 32,2 11,0 213 3,0 322 14 17 213 39

355 39,7 9,0 257 3,5 397 17 20 257 48

355 48,5 7,4 305 3,5 485 20 24 305 58







time to

change- reach full




time


[s] [s] �

in welding area

Table for PE

bead-up heat-up


welding area

P (N/mm²)

400 9,8 41 79 1,5 98 7 7 79 13

400 12,3 33 98 2,0 123 8 8 98 16

400 15,3 26,0 121 2,0 153 9 9 121 20

400 19,1 21,0 150 2,5 191 10 11 150 24

400 22,7 17,6 176 2,5 227 11 13 176 28

400 23,7 17,0 183 2,5 237 11 13 183 29

400 29,4 13,6 224 3,0 294 13 16 224 36

400 36,3 11,0 271 3,0 363 16 19 271 44

400 44,7 9,0 326 3,5 447 18 23 326 54

400 54,7 7,4 387 4,0 547 21 27 387 65

450 11,0 41 99 1,5 110 8 8 99 15

450 13,8 33 124 2,0 138 9 9 124 18

450 17,2 26,0 153 2,0 172 9 10 153 22

450 21,5 21,0 189 2,5 215 11 12 189 27

450 25,5 17,6 222 2,5 255 12 14 222 31

450 26,7 17,0 232 3,0 267 12 14 232 33

450 33,1 13,6 283 3,0 331 15 17 283 40

450 40,9 11,0 343 3,5 409 17 21 343 49

450 50,3 9,0 412 4,0 503 20 25 412 60

450 61,5 7,4 490 4,0 615 23 31 490 71

�� Remaining under the cool-down time for up to 50% is allowed under the following conditions:

• prefabrication under workshop conditions• low additional pressure at unclamping• no additional pressure during further cooling down• load onto the workpieces only after being completely cooled down• Join parts with wall thickness ≥15 mm





time to

change- reach full


0,10 (PP) time pressure pressure in


time


[s] [s] �

90 2,2 41 3 0,5 94 4 5 3 2

90 2,8 33 4 0,5 104 4 5 4 3

90 3,5 26 5 0,5 117 5 6 5 4

90 5,1 17,6 6 0,5 145 5 6 6 7

90 8,2 11 10 1,0 192 6 8 10 14

90 12,3 7,4 14 1,0 249 7 11 14 20

90 15,0 6 16 1,0 281 8 14 16 24

110 2,7 41 4 0,5 103 4 5 4 3

110 3,4 33 5 0,5 115 5 6 5 4

110 4,2 26 7 0,5 130 5 6 7 6

110 6,3 17,6 9 0,5 164 6 7 9 10

110 10,0 11 14 1,0 217 7 9 14 17

110 15,1 7,4 20 1,0 283 8 14 20 24

110 18,3 6 23 1,0 322 9 16 23 29

125 3,1 41 6 0,5 110 4 5 6 4

125 3,9 33 7 0,5 124 5 6 7 5

125 4,8 26 8 0,5 140 5 6 8 7

125 7,1 17,6 12 1,0 176 6 7 12 12

125 11,4 11 18 1,0 237 7 11 18 19

125 17,1 7,4 26 1,0 307 8 15 26 27

125 20,8 6 30 1,5 348 10 18 30 33

Table for PP


The standard value for heating element temperature is 210° C +/- 10° C.

welding area

in welding area

The smaller the pipe wall the higher the temperature.

P (N/mm²)

bead-up heat-up





time to

change- reach full




time


[s] [s] �

Table for PP



welding area

in welding area


P (N/mm²)

bead-up heat-up

140 3,5 41 7 0,5 117 5 6 7 4

140 4,3 33 8 0,5 131 5 6 8 6

140 5,4 26 10 0,5 149 5 6 10 8

140 8,0 17,6 15 1,0 189 6 8 15 14

140 12,7 11 23 1,0 254 7 12 23 21

140 19,2 7,4 32 1,5 332 9 17 32 30

140 23,3 6 38 1,5 373 10 20 38 36

160 4,0 41 9 0,5 126 5 6 9 5

160 4,9 33 11 0,5 141 5 6 11 7

160 6,2 26 14 0,5 162 6 7 14 10

160 9,1 17,6 19 1,0 204 6 9 19 15

160 14,6 11 29 1,0 277 8 13 29 24

160 21,9 7,4 42 1,5 359 10 19 42 34

160 26,6 6 49 2,0 405 11 23 49 41

180 4,4 41 11 0,5 133 5 6 11 6

180 5,5 33 14 0,5 151 5 6 14 8

180 6,9 26 17 0,5 173 6 7 17 12

180 10,2 17,6 24 1,0 220 7 10 24 17

180 16,4 11 37 1,0 298 8 15 37 26

180 24,6 7,4 53 1,5 386 11 21 53 38

180 29,0 6 60 2,0 423 12 25 60 44





time to

change- reach full




time


[s] [s] �

Table for PP



welding area

in welding area


P (N/mm²)

bead-up heat-up

200 4,9 41 14 0,5 141 5 6 14 7

200 6,2 33 17 0,5 162 6 7 17 10

200 7,7 26 21 1,0 185 6 8 21 13

200 11,4 17,6 30 1,0 237 7 11 30 19

200 18,2 11 46 1,0 320 9 16 46 29

200 27,4 7,4 65 2,0 411 11 23 65 42

200 33,2 6 76 2,0 456 13 29 76 50

225 5,5 41 17 0,5 151 5 6 17 8

225 6,9 33 21 0,5 173 6 7 21 12

225 8,6 26 26 1,0 197 6 8 26 15

225 12,8 17,6 38 1,0 255 7 12 38 21

225 20,5 11 58 1,5 345 9 18 58 32

225 30,8 7,4 82 2,0 437 12 26 82 47

225 37,4 6 96 2,5 487 14 32 96 55

250 6,2 41 21 0,5 162 6 7 21 10

250 7,7 33 26 1,0 185 6 8 26 13

250 9,6 26 32 1,0 211 7 9 32 16

250 14,2 17,6 46 1,0 272 8 13 46 23

250 22,7 11 71 1,5 367 10 20 71 35

250 34,2 7,4 101 2,0 463 13 29 101 51

280 6,9 41 26 0,5 173 6 7 26 12

280 8,6 33 32 1,0 197 6 8 32 15

280 10,7 26 40 1,0 227 7 10 40 18

280 15,9 17,6 58 1,0 292 8 14 58 26

280 25,4 11 89 1,5 394 11 22 89 39

280 38,3 7,4 127 2,5 493 14 33 127 57





time to

change- reach full




time


[s] [s] �

Table for PP



welding area

in welding area


P (N/mm²)

bead-up heat-up

315 7,7 41 33 1,0 185 6 8 33 13

315 9,7 33 41 1,0 213 7 9 41 16

315 12,1 26 51 1,0 246 7 11 51 20

315 17,9 17,6 73 1,0 317 9 16 73 28

315 28,6 11 112 2,0 420 12 24 112 44

355 8,7 41 42 1,0 199 6 8 42 15

355 10,9 33 52 1,0 230 7 10 52 18

355 13,6 26 64 1,0 264 7 12 64 22

355 20,1 17,6 92 1,5 341 9 18 92 32

355 32,2 11 142 2,0 448 13 28 142 48

400 9,8 41 53 1,0 214 7 9 53 16

400 12,3 33 66 1,0 249 7 11 66 20

400 15,3 26 81 1,0 221 7 10 81 17

400 22,7 17,6 117 1,5 367 10 20 117 35

400 36,3 11 181 2,0 480 14 31 181 54

450 11,0 41 66 1,0 231 7 10 66 18

450 13,8 33 83 1,0 267 8 13 83 23

450 17,2 26 102 1,0 308 8 15 102 27

450 25,5 17,6 148 1,5 395 11 22 148 39

450 40,9 11 229 2,5 508 15 35 229 59

�� Remaining under the cool-down time for up to 50% is allowed under the following conditions:

• prefabrication under workshop conditions• low additional pressure at unclamping• no additional pressure during further cooling down• load onto the workpieces only after being completely cooled down• Join parts with wall thickness ≥15 mm



Table for PVDF

Foundation: 2208, 2207 Part 15 German association for weldingUse for: 4000 / 4001 / 4002


time to

reach full

bead-up welding cool-down time

0,10 (PVDF) pressure pressure in

welding area


time

pipe pipe bead-up circular heat-up time welding cool-diameter wall pressure bead time to reach pressure downOD (s) [bar] min. [s] welding [bar] time[mm] [mm] [mm] pressure [min]

[s]

90 2,8 4 0,5 68 4 4 5,5

90 4,3 6 0,5 83 4 6 7,0

90 5,4 7 0,5 94 5 7 8,5

110 3,4 5 0,5 74 4 5 6,0

110 5,3 8 0,5 93 5 8 8,5

110 6,6 10 0,6 106 5 10 10,0

125 3,9 7 0,5 79 4 7 6,5

125 6,0 10 0,6 100 5 10 9,0

140 4,3 8 0,5 83 4 8 7,0

140 6,7 13 0,6 107 6 13 10,0

160 4,9 11 0,5 89 5 11 8,0

160 7,7 17 0,7 117 6 17 11,0

180 5,5 14 0,5 95 5 14 8,5

180 8,6 21 0,8 126 6 21 12,5

200 6,2 17 0,6 102 5 17 9,5

200 9,6 25 1,0 136 7 25 13,5

225 6,9 21 0,7 109 6 21 10,5

225 10,8 32 1,0 148 7 32 15,0

250 7,7 26 0,7 117 6 26 11,0

250 11,9 39 1,1 159 8 39 16,5

280 8,6 32 0,8 126 6 32 12,5

280 13,4 49 1,2 174 8 49 18,0

315 9,7 41 1,0 137 7 41 13,5

The standard value for heating element temperature is 240° C +/- 8° C.The smaller the pipe wall the higher the temperature.


P (N/mm²) change-

in welding area

change-over

4

4

4

4

3

4

3

heat-up over

time

max.

3

3

3

4

3

4

3

4

4

time

[s]

4

4

4

4

4

4

3

25.06.2012 Working instructions WIDOS 4000 - 4002 Page 30 of 59




7. Maintenance and repair

Goal of the chapter is to:

• keep the nominal condition and the operation capacity of the machine.

• increase the efficiency by avoiding non-planned outage.

• Efficient planning of the maintenance works and the maintenance tools

7.1. 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.

Should for machines with a specially high usage percentage the testing cycle be shortened .

The works should be performed at the WIDOS GmbH company or by an authorized partner.

The linear guides for heating element and planer must be cleaned every week e.g. with a brush.

Check the linear guide carriages every 3 months and grease them over the lubricating nipple if necessary. Chips or other impurities in the guides can be the cause if the heating element or the planer jam or run heavily.

• Clean the piston rods every month with an oily tissue.

• Check the hydraulic connections every month for tightness, tighten again if necessary.

• The operating staff has to be informed before the starting of the maintenance works.

• Check the tightness of loosened screws.

• Check the function of the safety devices after completion of the maintenance works. Especially insulation, tension resistence and protective cables resistence.

7.2. Planer

• Check the driving chain in the planer from time to time and lubricate it. For that purpose screw off the housing of the planer.

• Check the cutting ability of the planer, exchange it if necessary (double sided polished section, max. chip thickness = 0,2 mm!)


Maintenance and repair Chapter 7


7.3. Checking the level of the hydraulic oil

• Before each starting of the machine check the oil level of the hydraulic pump in order to avoid damages.

• Unscrew the red closing screw (with integrate oil dipstick) on the top of the aggregate.

Clean the oil dipstick with a dry cloth and insert it again into the tank, do not screw.

• Remove the oil dipstick again and check the level by means of the two marks (the oil

level must be between the two marks). In case of oil level being beyond the lower mark

refill oil of the quality HLPD 32 (Chapter:7.3.1) .

• The oil level must not surpass the upper mark because otherwise there is the danger

of overflowing in certain situations.

• Oil level check being finished, tighten again firmly the red closing screw.

7.3.1. Used hydraulic oil

Only use oil of the quality HLPD 32. Properties: anticorrosive, resistant to ageing, contains wearing resistant agents, high rating and partly water binding. The hydraulic oil must be disposed of professionnally.

7.4. Transport

• Take care that the machine is not exposed to hurts.

• Handle the machine carefully, take especially care for the electro cables.

• Do not tilt the machine too much, in order to prevent oil slick.

• If need be, dismount the planer and the heating element:

For that purpose remove the heating Remove the four screws (S) from the planer element from the holder (see arrow) and then the planer itself

S


Maintenance and repair Chapter 7


7.5. Venting the hydraulic cylinders

Necessary: If a new cylinder has been built in.

Condition: A vent hose must exist preventing oil coming out uncontrolled.

Procedure: Open the slides completely, loosen the vent screw for closing at the cylinder and connect the vent hose.

Close the slides until there is no air in the vent hose. Repeat the same process at the vent screw for opening.

There are 2 drilled holes at the right table, one of it is in the middle under the horizontal movable plate.

The cylinder has to be dismounted completely from the movable table on the left side.

Then open completely the cylinder:

Open the rear vent screw (seen from the cylinder) and screw the vent hose to it.

Move backwards and forwards until there is only oil left in the hose and no more air bubbles.

Unscrew the vent hose and tighten again the screw.

Repeat the same process at the frontal screw.

To be sure that the air has left the cylinder completely, you can perform the following the test:

Drive out the cylinder for the half way as soon as both vent screws are tightened again.

Move slowly forwards and backwards the piston rod.

A continuous resistance signifies that there is no more air in the cylinder.

Jerking means there is still left air in the cylinder.

7.6. Clamping elements

• For a long service life clean and grease regularly the treaded spindles and the joint parts which are used for clamping the pipes.

7.7. Cleaning of the machine

The used materialis and clothes have to be handled and disposed off properly especially

• when cleaning with solvents

• when lubricating with oil and grease

7.8. Disposal

At the end of their life time, the machine and the wear parts have to be disposed of properly and non-polluting, and in accordance with the national laws of waste disposal.




8. Wiring and hydraulic diagrams


Wiring and hydraulic diagrams Chapter 8



Wiring and hydraulic diagrams Chapter 8





9. Spare parts list

9.1. Basic machine

4 - 5

8 - 9

1 - 3

12

10 - 11 6

7

15

16 - 17

18 - 19

20

13 - 14


Spare parts list Chapter 9


31

32 - 36

29 - 30

24 - 25

40 - 42

48 - 49

21 - 22

43 - 47

37 - 39

26 - 28

50

23



WIDOS 4001 Basic unit

Pos. Name Piece Order no.

1 Linear guide with slide 2 L30600TR

2 Pan-head screw M 8x30 DIN 912 16 0912H030

3 Cap for linear guide 16 L30601

4 Rear girder 1 023104

5 Rivet nut M 10 10 N1002

6 Transport grip 2 020123


8 Frontal girder 1 023102

9 Rivet nut M 10 10 N1002

10 Crossgirder for basic frame 2 024103

11 Protective cap (50x50x4 mm) 4 J0208

12 Basic frame 1 024101

13 Slide 4 L20ELZ

14 Pan-head screw with low head M 6x14 DIN 7984 16 7984F014

15 Linear guide 2 L20700

16 Fitting cap 24 L20501

17 Pan-head screw M 5x16 DIN 912 24 0912E016

18 Stop pin 1 024105

19 Washer M 10 DIN 125 2 0125J

20 Parallel pin M 5x18 DIN 6325 4 6325E018

21 Hydraulic cylinder 1 023115

Seals for cylinder 1 set D023115


23 Grub screw M 6x10 DIN 913 1 0913F010

24 Shaft (d = 25, l= 275 mm) 1 023120

25 Guide bearing 1 LKH2540

26 Slide, left 1 023105

27 Thread insert M 12 short 2 GEWK-M12

28 Thread insert M 12 5 GEW-M12

29 Pan-head screw M 10x90 DIN 912 2 0912J090


31 Plate, horizontal movement 1 023108

32 Guide rod 2 023107


34 Thread insert M 10 4 GEW-M10

35 Counter nut M 10 DIN 985 2 0985J

36 Washer M 10 DIN 125 2 0125J

37 Holder for hydraulic box 1 024118

38 Flat-head screw M6x20 DIN 7991 2 7991F020

39 Flat-head screw M6x16 DIN 7991 2 7991F016

40 Clamping lever (threaded length 30 mm) 2 BM10030

41 Straight pin 8x120 DIN 6325 2 6325H120

42 Washer M 8 DIN 125 2 0125H

43 Angular screw coupling 2 VSWV8LL

44 Washer spring A 35,5x18,3x2 DIN 2093 2 2093R020

45 Distance tube 1 023116

25.06.2012 Working instructions WIDOS 4001 Page 39 / 1 of 59



WIDOS 4001 Basic unit


46 Hexagon nut M 14 DIN 934 3 0934N

47 Counter support 1 023117

48 Washer M10 DIN 9021 4 9021J

49 Hexagon head screw M 10x70 DIN 933 4 0933J070

50 Slide, right 1 023106

-- Type plate 1 SCHT4001

25.06.2012 Working instructions WIDOS 4001 Page 39 / 2 of 59




9.2. Clamping tool

1

2

4

3

5 - 6

8 - 9

(23)

(24)

11

12

13

14

15 - 16

17 - 18

19

20

21

22

10

7



WIDOS 4001 Clamping tools

Pos. Piece Order no.

1 Center pin 2 020117

2 Supporting angle 2 023712

3 Pipe support 1 Set 0206...*

4 Pipe support 2 023711

5 Clamping lever M 12/30° 2 BM1230

6 Insert nut 2 023713

7 Guide rail 2 023724


9 Straight pin 8x20 DIN 6325 4 6325H020

10 Clamping tool, left DO 335 1 S02335L

11 Clamping tool, right DO 335 1 S02335R

12 Thread spindle 2 091108

13 Nut 2 091109

14 Thrust washer 2 023708

15 Lock washer size 7 DIN 6799 2 6799G

16 Rivet for spindle 2 S0205

17 Hexagon screw M 12x35 DIN 933 6 0933L035


19 Rivet for joint 2 S0426

20 Knurled screw 1 S0318

21 Support for bow 1 020721

22 Knurled screw 1 S0222

23 Reduction insert, Ø90 - 280 1 Set 0208...*

-- Reduction insert wide, Ø90 - 280 1 Set 0218...*

-- Reduction insert super wide, Ø90 - 280 1 Set 0228...*

24 Pan-head screw for reduction inserts Ø90-280 4 0912F30X

-- Flat-head screw for reduction inserts Ø315 4 7991F20X

-- Allan key SW 27 1 ZRS27

* When ordering state dimension !

25.06.2012 Working instruction WIDOS 4001 Page 41 of 59




9.3. Planer

16

11

9

23 - 24

17 - 22

10

12

13 - 15

1 - 3

8

4 - 7




33

36

37

38 - 40

27 - 31

25

26

32

34 - 35



WIDOS 4001 Planer


1 Flat-head screw M 3x8 DIN 965 12 0965C008

2 Blade 2 MES170

3 Spacer 2 MU170

4 Ball bearing 2 L6003Z

5 Hexagon nut M 16x1,5 DIN 934 1 0934Y

6 Washer M16 DIN 125 4 0125P

7 Bolt 1 210410

8 Driving motor 1050 W, 230 V 1 AMBF16

Connecting cable 1 EK3220

Collector carbon 1 set EKMBF16

Switch for driving motor 1 on request

9 Planer disc, left 1 210403


11 Planer disc, right 1 210402



14 Blade 2 MES072

15 Spacer 2 MU072

16 Fastener for planer 1 023401

17 Ball bearing 1 L6020

18 Chain wheel, small (11 teeth) 1 K38011

19 Chain wheel, large 3/8" (95 teeth) 1 023406

20 Chain 3/8" (143 links) 1 K38143

21 Chain joint 3/8" 1 KSCH38

22 Flat-head screw M 8x12 DIN 7991 4 7991H012

23 Cover 1 023404

24 Pan-head screw M 4x12 DIN 912 4 0912D012

25 Ball button C 40 DIN 319 1 0319C40

26 Handle bar 1 071409

27 Guide bolt 1 023407

28 Bolt 1 023408

29 Stud bolt 1 023409

30 Claw 1 023410

31 Spring 1 023411

32 Pan-head screw M6x20 DIN 912 8 0912F020

33 Mounting plate 1 024405

34 Washer M10 DIN 125 6 0125J

35 Pan-head screw M10x25 DIN 912 2 0912J025

36 Retaining plate whith hole 1 024402

37 Retaining plate whith thread 1 024401


39 Washer M10 DIN 125 4 0125J

40 Bolt for retaining plate 1 024404





9.4. Heating element

21

17 - 20

23

22

28

27

26

24

5 - 8

1

2

4

3

10

14 - 15

11 9

25

16

12 - 13

29 - 35



WIDOS 4001 Heating element


1 Heating element H 4002, 230 V 1 H4002E

Heating plate new 1 HP4002E

Heating plate in exchange 1 HPT4002E

2 Stud bolt M 12 1 HGEW-M12

3 Grip for heating element 1 H0205

4 Handlebar 1 H0206

5 Sensor PT 1000 1 H09082

6 Holder for sensor 1 023536

7 French head screw M 4x 6 DIN 7985 2 7985D006

8 Toothead lock washer M 4 DIN 6797 1 679D

9 Guard plate for heating element 1 023535

10 Oval-head screw M 3x5 DIN 7985 6 7985C005

11 Cover plate 1 H2116

12 Antikink union joint PG11 1 EV0011

13 Connection cable with plug 1 EK3220

14 Cap for control 1 H2115

15 Housing with cap for control 1 H2114

16 Flat-head screw M 6x12 DIN 7991 8 7991F012

17 Pan-head screw M 5x25 DIN 912 2 0912E025

18 Washer M 5 DIN 125 2 0125E

19 Spring washer M 5 DIN 127 2 0127E

20 PTFE-distance washer 2 H2110

21 Blind rivet 4 7337D010

22 Control lamp yellow 1 H2106

23 Button for thermo regulator with cover cap 1 H2109

24 Frame for heating element 1 on request

25 PTFE-distance washer 1 H2103

26 Control lamp green 1 H2105

27 Screen 1 on request

28 Screen with temperature scale 180-280 1 on request

29 Electronic control GZ 4 without sensor 1 H0928220

30 Triac 1 H09083

31 Sensor PT 1000 1 H09082

32 Teminal lustre, triple 1 EA1001

33 Pan-head screw M 3x12 DIN 912 2 0912C012

34 Knee for terminal lustre 1 H2112

35 Flat-head screw M 4x10 DIN 7991 1 7991D010





9.5. Heating element holder

11

16

13 - 15

4 - 5

2 - 3

6 - 8

1

9 - 10

12



WIDOS 4001 Heating element holder


1 Retaining plate whith thread 1 024501

2 Roller 4 023503

3 O - ring 4 D18x4


5 Washer M10 DIN 125 6 0125J


7 Washer M10 DIN 9021 1 9021J

8 Hexagon nut M 10 DIN 934 1 0934J

9 Pan-head screw M5x20 DIN 912 1 0912E020

10 Hexagon nut M5 DIN 934 1 0934E

11 Mounting plate 1 024405

12 Pan-head screw M6x20 DIN 912 8 0912F020

13 Bolt for retaining plate 1 024404


15 Washer M10 DIN 9021 1 9021J

16 Retaining plate whith hole 1 024502





9.6. Conversion kit for clamping tool

1 - 3

6

8 - 9

7

10 / 11

4 - 5



WIDOS 4001 Conversion kit for clamping tools


1 Spindle nut 2 071109


3 Thread spindle 2 071108

4 Lock washer size 8 DIN 6799 2 6799H

5 Rivet for spindle 2 S0425

6 Set clamping tools OD 450 1 S04450

7 Rivet for joint 2 S0426

8 Pipe support conversion kit 2 040711

9 Pipe support OD 400 - 315 2 0406...*

10 Hexagon head screw M 12x35 DIN 933 6 0933L035


-- Allan key SW 27 1 ZRS27

-- Screw for reduction inserts 4 7984J30X

-- Reduction inserts 2 0708...*

* When ordering state dimension !





9.7. Conversion kit for planer

1

2

3

4 - 8

9

10

11 - 14

15 - 18

19

20 - 21

22 - 24

25

26 - 28

29 - 34

35

36



WIDOS 4001 Conversion kit for planer


1 Ball button C 40 DIN 319 1 0319C40

2 Handle bar 1 040407

3 Hexagon nut M 16 DIN 934 1 0934P

4 Claw 1 023410

5 Bolt 1 023408

6 Guide bolt 1 023407

7 Stud bolt 1 023409

8 Spring 1 023411

9 Planer disc, right 1 043402

10 Fastener for planer 1 043401

11 Ball bearing 2 L6003Z

12 Hexagon nut M 16x1,5 DIN 934 1 0934Y

13 Disc M 16 DIN 125 4 0125P

14 Bolt 1 210410

15 Driving motor 1040 W, 230 V 1 AMBF23

16 Connection cable 1 EK3220

17 Collector carbon 1 set EKMBF23

18 Switch for driving motor 1 on request

19 Planer disc, left 1 043403

20 Cover 1 043404

21 Pan-head screw M 4x16 DIN 912 4 0912D016

22 Blade 4 MES085

23 Spacer 4 MU085



26 Blade 2 MES170

27 Spacer 2 MU170


29 Ball bearing 1 L61834

30 Chain wheel, small (11 teeth) 1 K38011

31 Chain wheel disc 3/8" (95 teeth) 1 023406

32 Chain 3/8" (151 links) 1 K38151

33 Chain joint 3/8" 1 KSCH38

34 Flat-head screw M 8x20 DIN 7991 4 7991H020

35 Plate 2 043429






9.8. Conversion kit for heating element

23 - 25

20 - 22

18

28 19

27

26

1 2

3

16

13

12

4 - 5

17

14 - 15

7

8 - 10

11

6



WIDOS 4001 Conversion kit for heating element


1 Heating element holder 1 HU4002E

Heating plate new 1 HPU4002E

Heating plate in exchange 1 HPTU4002E

2 Lifting eye screw M 10 DIN 580 1 0580J

3 Heat sink 1 on request

4 Frame 1 071558

5 Pan-head screw M 8 x 30 DIN 912 2 0912H030

6 Insulating piece 1 071556

7 Cover for heating element holder 1 3555478

8 Drive-in nut 4 05460098

9 Pan-hed screw M 6 x 16 DIN 7984 8 7984F016

10 Spring loxk washer M 6 DIN 127B 8 127F

11 Heating element holder 1 071558

12 Temperature probe PT 1000 1 H09082

13 Insertion nut 1 HGEW-M12

14 Hexagon nut M 12 DIN 439B 1 0439L

15 Guard plate 1 355549

16 Handlebar 1 355544

17 Ball button Ø 40 1 on request

18 Controller G4 with triac 1 H0908230D1

19 Window, tinted 1 H09071

20 Screw connection HKL 1 EVH21201615

21 Rubber cable 5 x 1,5², 3,2 m 1 EL02515

22 Cekon - plug 16A 1 EST0116

23 Distance piece 4 081554

24 Tapped bushing 4 081553

25 Pan-head screw M 6x45 DIN 912 4 0912F045

26 Upper and lower part of housing 1 081551


28 PTFE - joining piece 1 211505





9.9. Hydraulic box

1

4

2 - 3

13 18

17

16

12

5

6

10 - 11

14 - 15

19

20

21

25 - 30

31 - 34

22 - 24

7 - 9



WIDOS 4001 Hydraulic box


1 Hydraulic box 1 024227

2 French head screw M 3,5x13 DIN 7983 12 7983C013

3 Disc of roses M 3,5 12 ROSM 3.5

4 Cover for hydraulic box 1 024226

5 Pressure gauge (0-250 bar) 1 020204

6 Bellows 1 101035

7 Hook for removable hydraulic unit 2 024119

8 Counter plate for hook 2 0241191

9 Flat-head screw M 6x16 DIN 7991 4 7991F016

10 Fastener for stop-watch 1 023917

11 Flat-head screw M 4x10 DIN 965 3 0965D010

12 Cylinder knob 1 on request

13 Screw coupling for mini measuring tube 1 VSK02

14 Screw connection for WIDOS 4001 2 1010242

15 O-ring 18x1,5 2 D18x15

16 Mini measuring tube 1 V0400140

17 Hydraulic unit 1 023203

18 Accumulator (10 bar) 1 103206

19 Pipe duct size 22 1 EKT22

20 Coupling plug, flat packing 1 VST14

21 Coupling box, flat packing 1 VMU14

22 Bow type handle 2 BG565201

23 Pan-head screw M 6x14 DIN 7984 4 7984F014

24 Washer M 6 DIN 9021 4 9021F

25 Sealing nipple 2 VB306

26 Bow shaped nipple 2 VB386

27 Compressed bushing 4 VP256

28 Hydraulic hose 1,7 m VSCHL61

29 Hydraulic hose 1,9 m VSCHL61

30 Protective hose (28x2 mm) 1,2 m EA08011

31 HKL-screw connection Pg 13/11 1 EVH1311

32 Counter nut (brass) for Pg 13.5 1 EV0213

33 Cable H07RN-F (3x1,5 mm²) 3,0 m EL02315

34 Plug with earthing contact (230 V) 1 EST0702

-- Stop-watch 1 TMZ1000





9.10. Plane girder for planing only at one side

6

5

3 - 4

1

2



WIDOS 4001 Plane girder for planing only at one side


1 Centering bolt 1 023418

2 Bearing 1 L51103

3 Plane girder for planing only at one side 1 023427

4 Protective cap (25x25x3) 2 J0205

5 Washer M 10 DIN 125 2 0125J

6 Counter nut M 10 DIN 985 1 0985J





10. Declaration of conformity

In the sense of the EC-guideline, EG-MRL 2006/42/EG

Corporation

WIDOS GmbH

Einsteinstr. 5

D-71254 Ditzingen-Heimerdingen

declares in allone responsibility that the product

Plastic welding machine

WIDOS 4001

to which this declaration refers to, is conform with the following norms and norming

documents:

1. DIN EN ISO 12100 – 1 and 2 (substitute for DIN EN 292 Parts 1 and 2) Safety of machines, basic meanings, general regulations of design

2. DIN EN 60204.1 Electrical equipment of industrial machines

3. DIN EN 4413 Safety requirements for fluid power systems and components

4. EN 60555, EN 50082, EN 55014

Electromagnetic compatibility The technical documentation is completely available.

The working instructions in the language of the user is available.

Ditzingen-Heimerdingen, the 25.06.12

Martin Dommer (Technical director)

Documents

info @ widos.de Working instructions Translation · 2017. 3. 13. · Kunststoffschweißtechnik Introduction 25.06.12 Working instructions WIDOS 4001 Page 3 of 59 Purpose of the document