widos 4600 User manual

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH E-mail: [email protected] Webside: www.widos.de
Working Instructions
Translation
Heating Element Butt Welding Machine
WIDOS 4600
Keep for further use!

Idendification of Product
30.08.19 Working Instructions WIDOS 4600 Page 2 of 32
Model: Heating element butt welding machine
Type: WIDOS 4600
Serial number / year of construction: see type plate
Customer Entries
Inventory-no.:
Place of working:
Order of Spare Parts and After Sales Service:
Address of Manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstr. 5
D-71254 Ditzingen
Phone: [phone]
Telefax: [phone]
[email protected]
http://www.widos.de

Introduction
30.08.19 Working Instructions WIDOS 4600 Page 3 of 32
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 make our products and working instructions continuously better, we kindly
ask you to inform us about problems and defects which occur during operation.
Thank you.
Structure of the Working Instructions
This manual is arranged in chapters, which refer to the different operating phases of the machine.
Due to this structure, the searched information can be easily found.
WIDOS 30.08.2019
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

Contents
30.08.19 Working Instructions WIDOS 4600 Page 4 of 32
1.DESCRIPTION OF THE PRODUCT .................................................................................................. 6
1.1.Usage and Purpose-oriented Use ...................................................................................................... 6
1.2.Machine Overview............................................................................................................................... 6
1.3.Safety Measures.................................................................................................................................. 7
1.4.Conformity ............................................................................................................................................ 7
1.5.Designation of the Product ................................................................................................................. 7
1.5.1Technical Data ...................................................................................................................................................7
1.6.Equipment and Accessories: .............................................................................................................. 9
2.SAFETY RULES .............................................................................................................................. 10
2.1.Explanation of the Symbols and Indications ................................................................................... 10
2.2.Obligations of the Owner .................................................................................................................. 11
2.3.Obligations of the Worker ................................................................................................................. 11
2.4.Measures of Organisation ................................................................................................................ 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.Maintenance and Inspection, Repair ............................................................................................... 12
2.9.Dangers Caused by Electric Energy ................................................................................................. 12
2.10.Dangers Caused by the Hydraulics .................................................................................................. 13
2.11.Special Dangers ................................................................................................................................ 13
2.11.1Danger of Catching Clothes by the Planer ..................................................................................................13
2.11.2Danger of being burnt by Heating Element, Reception Box and Welding Area ...................................13
2.11.3Danger of Stumbling over Hydraulic and Electric Wires..........................................................................14
2.11.4Danger of Squeezing by Clamping Devices and Guideways ...................................................................14
2.12.Structural Modifications on the Machine........................................................................................14
2.13.Cleaning the Machine ....................................................................................................................... 14
2.14.Warranty and Liability ....................................................................................................................... 14
3.FUNCTIONAL DESCRIPTION ........................................................................................................ 15
4.OPERATING AND INDICATING ELEMENTS ................................................................................ 16
4.1.Elements on the Hydraulic Aggregate ............................................................................................. 16
4.1.1Hydraulic aggregat with pressure gauge analog ......................................................................................17
4.2.Elements on the side of the aggregate ............................................................................................ 17
4.3.Separating device for heating element ............................................................................................ 17
4.4.Elements at heating element and planer ......................................................................................... 18
5.STARTING AND OPERATING ....................................................................................................... 19
5.1.Starting ............................................................................................................................................... 19

Contents
30.08.19 Working Instructions WIDOS 4600 Page 5 of 32
5.1.1Replacing the Reduction Inserts...................................................................................................................20
5.1.2Using Small and Large Reduction Inserts ...................................................................................................20
5.2.Welding Process................................................................................................................................ 21
6.WELDING LOG AND TABLES ....................................................................................................... 23
7.MAINTENANCE AND REPAIR ...................................................................................................... 25
7.1.Clamping Elements ............................................................................................................................ 25
7.2.Planer ................................................................................................................................................. 25
7.3.Storage ............................................................................................................................................... 25
7.4.Used Hydraulic Oil ............................................................................................................................. 25
7.5.Checking the Hydraulic Oil-Level ..................................................................................................... 25
7.6.Venting the Hydraulic Cylinders ....................................................................................................... 26
8.TRANSPORT .................................................................................................................................. 27
9.HYDRAULIC AND ELECTRIC DIAGRAMS .................................................................................... 28
10.SPARE PARTS LIST ...................................................................................................................... 31
11.DECLARATION OF CONFORMITY ................................................................................................. 32

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH E-mail: [email protected] Webside: www.widos.de
30.08.19 Working Instructions WIDOS 4600 Page 6 of 32
1. Description of the 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 4600 has been designed for heating element butt welding of pipes and fittings with a
diameter range of Ø = 75 - 250 mm.
It is a machine for construction sites and particularly designed for the usage 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.building ditches).
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. Machine Overview
1 Planer
2Reception box
3Heating element
4Basic machine with clamping tools
5Hydraulic aggregate
1
5
3
2
4

Description of Product Chapter 1
30.08.19 Working Instructions WIDOS 4600 Page 7 of 32
1.3. 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.
1.4. Conformity
The machine corresponds in its construction to the valid recommendations of the European Community
as well as to the European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.
1.5. Designation of 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.
1.5.1 Technical Data
1.5.1.1 WIDOS 4600 General Data
Material: PP, PE 80, PVDF, PE 100
Pipe diameter range: outside-= 75 - 250 mm
Transport box (lxwxh):
Weight:
Cases with compartments for reduction
inserts:
4 compartments:
7 compartments:
9 compartments:
appr. 950 x 850 x 570 mm
appr. 40 kg
appr. 680 x 410 x 310 weight: appr. 10 kg
appr. 1160 x 410 x 310 weight: appr. 16 kg
appr. 1470 x 410 x 310 weight: appr. 21 kg
Packing box (lxwxh):
Weight:
appr. 1230 x 980 x 670 mm
appr. 67 kg
Weight (without boxes): appr. 93 kg
Fuse: 16 A
Wire cross section: 1.5 mm²
Emissions - The sound intensity level while using the planer is
appr. 86 dB (A).
- When using the named pipe materials and when
welding below 260° C no toxicant damp arises.

Description of Product Chapter 1
30.08.19 Working Instructions WIDOS 4600 Page 8 of 32
Ambient conditions in the welding area: - Take care for cleanness (no dust at the welding
area)
- Do not weld below 5° C, if necessary preheat
- Avoid humidity, if necessary put up a tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends
1.5.1.2 Planer
Motor: Monophase-alternating current motor
Power: 1150 Watt
Voltage: 230 V (10 %)
Nominal current: 4.5 A
Frequency: 50 Hz (10 %)
Speed n1 of motor: 760 rpm
Speed n2 of planer: 60 - 100 rpm
Attached elements: On/off-switch with fixing device
Connecting cable and plug with earthing contact
Weight: appr. 14 kg
1.5.1.3 Heating Element
Power: 1500 Watt
Voltage: 230 V (10 %)
Current: 6.5 A (10 %)
Frequency: 50 Hz
Outside-: 320 mm
Surface: Nonstick coated
Elements: Electronic temperature control
Control lamps, on/off-switch
Connecting cable and plug with earthing contact
Weight: appr. 6 kg

Description of Product Chapter 1
30.08.19 Working Instructions WIDOS 4600 Page 9 of 32
1.5.1.4 Hydraulic Aggregate
Power: 0,3 kW
Voltage: 230 V (10 %)
Current: 2,7 A
Frequency: 50 Hz
Hydraulic oil tank: appr. 1 L
Electromotor and pump:
Speed: 1380 (rpm)
Max. working pressure of pump: appr. 120 bar
Working pressure: 100 bar
Volume velocity: 1.9 L/min
Weight : appr. 23 kg
1.5.1.5 Basic Frame
Dimensions (lxwxh): 800 x 420 x 460 mm
Reduction inserts: Dimensions can be selected
Material frame: Machinery steel
Material clamping shells: Aluminium
Weight: appr. 40 kg
cylinder: 35 mm
piston rod: 30 mm
Length of stroke of cylinder: 140 mm
Max. force: (F=P*A) 5200 N (at 100 bar)
Velocity of piston rod: 6.2 cm/s
See spare parts list for article numbers and single parts
1.6. Equipment and Accessories:
The following accessories are part of the first delivery:
1 Tool bag for 10 parts
1 Socket spanner size 27
1 Torx screw driver T10
1 each Allan key angulate, size 3 / 6 / 8
1 each Allan key with T grip size 4 / 5
optional Different sizes of reduction inserts, roller brackets for the pipes

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH E-mail: [email protected] Webside: www.widos.de
30.08.19 Working Instructions WIDOS 4600 Page 10 of 32
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 safety indications of this chapter represent the general part.
Particular information is listed directly before the corresponding actions are described.
These working instructions contain the most important information to run the machine safely.
The safety information must be read by all persons working on the machine.
2.1. Explanation of the Symbols and Indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possible danger for the life and the health of persons.
The non-respect of these indications may have heavy consequences for the health.
This symbol means a possible dangerous situation.
The non-respect of these indications may cause light 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 gives important information for the proper use of the machine.
The non-respect of these indications may conduct to misfunctions 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 work easier.
The regulations for the prevention of accidents are valid (UVV).