widos HRG 6 Segment User manual

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
Working Instructions
Translation
Heat Ring Welding Device
WIDOS HRG 6, Segment
Keep for further use!

Product identification
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 2 of 47
Type: WIDOS HRG 6, Segment
Serial number / year of construction: see nameplate
Customer entries
Inventory No.:
Place of working:
Order of spare parts and after sales service
Address of the manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstr. 5
D -71254 Ditzingen
Telefon: ++49 71 52 99 39 - 0
Telefax: ++49 71 52 99 39 - 40

Introduction
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 3 of 47
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 service team 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.
Due to this structure, the searched information can be easily found.
WIDOS 06/06/2019
Wilhelm 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
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 4 of 47
1DESCRIPTION OF PRODUCT ............................................................................................... 6
1.1General.........................................................................................................................................6
1.2Safety measures...........................................................................................................................6
1.3Conformity ....................................................................................................................................7
1.4Designation of the product............................................................................................................7
1.4.1Technical data ......................................................................................................................7
1.4.1.1WIDOS HRG 6, Segment general data ...............................................................................7
1.4.1.2Hydraulic aggregat............................................................................................................7
1.4.1.3Planer: .............................................................................................................................8
1.4.1.4Heating element................................................................................................................8
1.4.1.5Basic machine ..................................................................................................................8
1.4.1.6Reception box...................................................................................................................8
1.5Equipment and accessories ..........................................................................................................9
2SAFETY RULES................................................................................................................. 10
2.1Explanation of the symbols and indications................................................................................ 10
2.2Obligations of the owner ............................................................................................................ 10
2.3Obligations of the worker........................................................................................................... 11
2.4Measures of organisation .......................................................................................................... 11
2.5Information about safety precautions......................................................................................... 11
2.6Instructions for the staff ............................................................................................................ 11
2.7Dangers while handling the machine ......................................................................................... 11
2.8Dangers caused by electric energy............................................................................................ 12
2.9Specific dangers........................................................................................................................ 12
2.9.1Danger of combustion by heating element and welding area .................................................. 12
2.9.2Danger of stumbling over electric wires................................................................................ 12
2.9.3Danger of bruising by the guideways.................................................................................... 12
2.9.4Danger of bruising during planing ........................................................................................ 12
2.9.5Danger of noise .................................................................................................................. 12
2.9.6Danger of catching clothes by the planer.............................................................................. 13
2.10Structural modifications on the machine ............................................................................... 13
2.11Warranty and liability ............................................................................................................ 13
3FUNCTIONAL DESCRIPTION............................................................................................. 14
4OPERATING AND INDICATING ELEMENTS ....................................................................... 15
4.1Elements on the standard version .............................................................................................. 15
4.2Heating element ................................................................................................................. 16
4.3Planer........................................................................................................................................ 17
4.3.1How to work with the planer ................................................................................................ 18
4.4Angle setting at the clamping device ......................................................................................... 19

Contents
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 5 of 47
5STARTING AND OPERATING ............................................................................................ 20
5.1Safety indications ...................................................................................................................... 20
5.2Starting ..................................................................................................................................... 20
5.3Setting the heating element temperature ................................................................................... 21
5.4Welding process........................................................................................................................ 21
5.5Welding angles.......................................................................................................................... 23
6WELDING LOG AND TABLES ............................................................................................ 24
7MAINTENANCE / REPAIR / TRANSPORT ........................................................................... 28
7.1In general .................................................................................................................................. 28
7.2Basic machine........................................................................................................................... 28
7.3Clamping elements .................................................................................................................... 28
7.4Checking and refilling the hydraulic oil ...................................................................................... 28
7.5Planer........................................................................................................................................ 29
7.6Transport................................................................................................................................... 29
7.7Disposal .................................................................................................................................... 29
8ELECTRIC AND HYDRAULIC DIAGRAMS ........................................................................... 30
9SPARE PARTS LIST .......................................................................................................... 45
10DECLARATION OF CONFORMITY ...................................................................................... 47

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 6 of 47
1Description 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 General
The WIDOS HRG 6, Segment has been designed for heating element butt welding of pipes and fittings
out of PE from OD 315 - 630.
This machine is a light-weight solid heat ring welding machine for usage particularly in cramped
problematic places.
The basic machine HRG 6 can be provided with reducer inserts (315 -560 mm) for clamping and
welding smaller dimensions.
Both welding cylinders are plugged.
A second hydraulic aggregate with hydraulic clamping cylinders is optionally available.
The ring heating element is nonstick-coated, electronically controlled and supervised according to
DVS guideline 2208.
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 intended, safety- and
danger-conscious in compliance with the working instructions and the relevant safety regulations
(especially the regulations for the prevention of accidents).
The manufacturer is not liable for damages due to a wrong handling.
Only the user is liable for damages resulting out of this!
Also part of the appropriate usage are
following all 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 thoroughly read and the corresponding safety
regulations must be necessarily adhered to.

Description of product Chapter 1
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 7 of 47
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 Designation of the product
The product is designated by a nameplate.
It contains the type, the serial number and the year of construction of the machine.
1.4.1 Technical data
1.4.1.1 WIDOS HRG 6, Segment general data
Material: - PE-HD, (PP)
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.
Ambient 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.
Weight (with 2 reduction inserts): appr. 870 kg
1.4.1.2 Hydraulic aggregat
Feeding: CEE 32 A – phase inverter
Voltage: 400 V
Power: 12 kW
Frequency: 50 Hz (± 10 %)
Motor speed: 1450 / 2900 min-1
Operating pressure: 0 - 160 bar, adjustable
max. working pressure 160 bar
Current hydraulic pump: 5,2 / 4 A
Power hydraulic pump: 2,0 / 1,5 kW
Volume flow rate 3,8 l/min
Weight: appr. 47 kg

Description of product Chapter 1
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 8 of 47
1.4.1.3 Planer:
Motor: Three-phase alternating current motor
Power: 1,1 kW
Voltage: 400 V
Nominal current 2,66 A
Feeding: CEE-16 A – phase inverter
Frequency: 50 Hz (± 10%)
Number of revolutions of planer disk: 9,3 rpm
Weight: 112 kg
1.4.1.4 Heating element
Power: 4,1 kW
Voltage: 400 V
Frequency: 50 Hz (± 10 %)
Feeding: CEE-16 A – phase inverter
Outside : 684 mm (active surface)
Surface: nonstick-coated
Attached elements: - Electronic temperature control
- Control lamp
- Connecting cable
Weight: appr. 40 kg
1.4.1.5 Basic machine
Material base: Steel
Material Clamping tool: Steel
of cylinder / of piston 50 / 25 mm
max. force: (F=P*A) 29,45 KN (at 100 bar)
Dimensions: (L x W x H) appr. 1060 x 950 x 360 mm (height without
clamping ring)
appr. 950 mm (height with clamping ring)
Weight: appr. 279 kg
Movement speed: 2,3 cm/s
1.4.1.6 Reception box
Material: Steel
Dimensions: (L x W x H) appr. 780 x 700 x 880 mm
Weight: appr. 30 kg

Description of product Chapter 1
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 9 of 47
1.5 Equipment and accessories
Following tools and accessories are part of the delivery:
1 Allan key, short size 7
1 Fork-fork wrench size 24
1 Socket spanner size 27
For article numbers and spare parts contact the WIDOS company.

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 10 of 47
2Safety 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.
These working instructions contain the most important indications to run the machine safely.
The safety indications are to be followed 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 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 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.
This symbol means a possible risk of injury by noises exceeding 80 dB (A).
Ear protection is obligatory
Under this symbol you get user tips and particularly useful information.
It is a help for using all the functions on your machine in an optimal way and helps you to
make the job easier.
The regulations for the prevention of accidents are valid (UVV).
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.

Safety rules Chapter 2
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 11 of 47
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 organisation
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.
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.
2.7 Dangers while handling the machine
The machine WIDOS HRG 6, Segment 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 material 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.

Safety rules Chapter 2
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 12 of 47
2.8 Dangers caused by electric energy
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 heating element 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.
2.9 Specific dangers
2.9.1 Danger of combustion by heating element and welding area
You can burn yourself, inflammable materials can ignite!
The heating element is heated up to more than 200° C!
Do not touch the surfaces of the heating element.
Do not leave the heating element unattended.
Take enough safety distance to inflammable materials.
Wear safety gloves.
2.9.2 Danger of stumbling over electric wires
Make sure that no person has to step over the wires of heating element, planer and the hydraulic
aggregate.
Lay the wires in such a way that the danger is kept to a minimum.
2.9.3 Danger of bruising by the guideways
Do not stand or put hands between clamped pipe ends.
Do not touch the piston rod of the cylinder and the linear guides during operation.
2.9.4 Danger of bruising during planing
Remove the safety bolt only during inserting the planer into the basic machine or
taking out of the basic machine (chapter: 4.3.1)!
During planing do not touch the machine.
2.9.5 Danger of noise
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!

Safety rules Chapter 2
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 13 of 47
2.9.6 Danger of catching clothes by the planer
You can cut yourself or even get bones broken!
Wear clothes tight to the body.
Do not wear rings or jewellery during the work.
If necessary, wear a hair-net.
Always put the planer back into the reception box after and before each use.
Transport the planer by means of a lifting device. Do not touch the surfaces.
Always secure the planer by means of the safety bolt when planing or when it is placed in the
reception box.
Switch the planer on only for usage.
If the planing pressure is too high, there is the danger that the planer tilts! For that reason do not
press the pipe ends stronger than necessary against the planer.
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 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!
2.11 Warranty 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 checking of parts of the machine which are worn out;
repairs performed in an inexpert way;
in case of catastrophes and force majeure.

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 14 of 47
3Functional description
Basically, the international and national guidelines are to be followed!
The plastic pipes are clamped in the clamping rings.
If the pipe ends are not plane and parallel, the front sides of the pipes should be cut plane and parallel
by means of a planer and the misalignment of the pipes is to be checked.
Then the heating element is inserted 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, 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 under prescribed welding pressure and then cool down under pressure (cooling
time).
The welded joint can be unclamped, the welding process is finished.
Finished welding with
internal and external
bead
Heating element heats
the pipes up to welding
temperature

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 15 of 47
4Operating and indicating elements
4.1 Elements on the standard version
No. Name Function
1 Locking fork - Heating element and planer are laid with their supporting forks
onto the clamping devices.
2 Clamping nut + spindle - Tight clamping of the pipes during the welding process.
3 Clamping cylinder
(left / right)
- Application of the welding force.
- Easy dismounting and mounting of the cylinders by
loosening or attaching the locking cotter pins.
4 Pressure gauge - Display of the hydraulic pressure.
5 Push-button - By pressing the push-button the motor switches over from 1450 rpm
up to 2900 rpm (high speed)
6 Control valve - Opening and closing the movable clamping ring,
there are four different positions:
- To the left side: movable clamping ring closes;
- In the middle (usual position): the pressure which is currently
achieved is kept (also by means of the built-in hydraulic
accumulator);
- Slightly to the right side (position pressureless): a possibly
existing pressure is released without opening the machine.
Due to the hydraulic accumulator, it takes about 10 s until
the pressure is completely released.
- To the right side: movable clamping ring opens.
7 Set screw for pressure
relief valve
- Limitation of the pressure to the desired value.
8 Couplings - Connect the hydraulic hoses
9 Sockets - Connection for planer and heating element
4 5
6
8
7
1
2
3
9

Operating and indicating elements Chapter 4
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 16 of 47
4.2 Heating element
Heating element in basic machine: Heating element in reception box:
Adjust the puller rings in a way that they rest against the clamping rings (arrows) while in heating
position; then the heated pipes are separated from the heating element during change-over.
No. Denomination Function
10 Suspension - For lifting-off the heating element
11
Supporting bolt - Insert the heating element with supporting bolts on the clamping
beams / on the reception box
12 Grip - Holding and guidance the heating element
13 Controller - Setting the heating element temperature
14 Connecting cable wtih
plug CEE-16A
- Connect with socket 400 V / 16 A on hydraulic aggregat
15 Tear-off ring - seperate heating element and heated pipes
As soon as the heating element is connected to the mains (400 V / 16A), it starts
heating up to the desired temperature.
You may insert the heating element deeper into the basic machine, e.g. in case you intend to weld
an angle. Detach the suspension pins and shift it into one of the lower drill holes.
14
13
10
11
12
15

Operating and indicating elements Chapter 4
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 17 of 47
4.3 Planer
No. Name Function
15 Safety bolt - Is axially secured by means of a grub screw. For
removing the safety bolt, turn it until the lever shows
almost vertically upwards, then remove it.
16 Movable supporting fork - For inserting / lifting-off the planer. After removing the
safety bolt, the supporting fork moves into direction of
the arrow.
17 Supporting bolt - Insert the planer with the supporting bolts in the
locking forks of the clamping rings / reception box.
18 Connnecting cable with plug
CEE-16A
- Connect with socket 400 V / 16 A on hydraulic aggregat
19 Screw for chain tightening - Release the screw and move it in the slot for
tightening or releasing the planer chain. Tighten again
firmly the screw.
20 Switch on/off - The on/off switch of the planer is situated at the planer
plug.
21 Vent screw - Attention! Never put the planer on its side, there is
the risk of oil slick at the vent screw.
Remove the safety bolt only during inserting the planer into the basic machine or
taking out of the basic machine!
16
15
17
18
20
21
19

Operating and indicating elements Chapter 4
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 18 of 47
4.3.1 How to work with the planer
You must lock the flexible supporting fork of the planer by the safety bolt.
Prior to inserting the planer into the basic
machine you must turn the safety bolt for the
planer support upwards (left image).
Remove the safety bolt by pulling-out, the
supporting fork is now hanging downwards.
Suspend the planer from the ring bolt e.g. by a
crane and put it between the clamping tools in a
way that the supporting forks of the planer are
locked in the supporting forks of the basic
machine.
Necessarily put the safety bolt again into the drill
hole (upon releasing the safety bolt, the handle
must turn downwards otherwise it is not applied
correctly).
Switch the planer on/off by the on/off switch.
Turn and remove the safety bolt again before you
remove the planer from the basic machine and
put the safety bolt back in before inserting the
planer into the reception box.
You may insert the planer deeper into the basic machine e.g. in case you intend to weld an angle.
For this purpose suspend the planer from the ring bolt.
Turn and remove the safety bolt first.
Detach the hexagon socket screw and the hinge pin and shift it in one of the upper drill holes of the
outer hole pattern and tighten the bolt by the hexagon socket screws.
Remove both fix supporting forks and shift them upwards by the
same proportion than the flexible supporting fork.
Put in the safety bolt afterwards, except you insert the planer into
the basic machine.
Safety bolt
Hexagon-head screw
and hinge pin
Fix supporting fork

Operating and indicating elements Chapter 4
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 19 of 47
4.4 Angle setting at the clamping device
In order to weld angles you may swivel each clamping ring up to 11,25°.
For this purpose detach the hexagon socket screws at the adaptor plate in the front and rear, adjust
the clamping ring to the requested angle (up to 11.25°) by scale and marking (only attached to one
side).
Fix the angle by tightening the hexagon socket screws.
Make sure that both clamping rings do not have contact at the top!
22
Markin
g
Scale
Hexa
g
on-head screw

WIDOS Einsteinstraße 5 Phone +49 7152 9939 0
Wilhelm Dommer Söhne D-71254 Ditzingen Fax +49 7152 9939 40
06/06/19 Working Instructions WIDOS HRG 6, Segment Page 20 of 47
5Starting and operating
The instructions of this chapter are supposed to initiate in the operation of the machine and lead
during the appropriate starting of the machine.
This includes: - the safe operation of the machine;
- using all the possible options of the machine;
- economic operation of the machine.
5.1 Safety indications
The machine may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and DVGW.
In situations of danger for persons and the machine, the mains plug has to be unplugged
immediately.
After completion of the welding work and during breaks the machine has to be switched off. Further
take care that no unauthorized person has access.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-security protective switch.
5.2 Starting
Check the oil level of the hydraulic system before each starting of the machine in order to
avoid damages on the pump.
If necessary, add hydraulic oil of the quality HLPD 32.
The heating element surfaces must be clean, especially non greasy, therefore they need
to be cleaned shortly before each welding or in case of dirtiness by means of a fibre-
free paper and a cleaning agent (e.g. PE – cleaner or pipe cleaning tissues which are
available at the WIDOS company).
The anti-adhesive coating of the heating element must remain undamaged in the working
area.
For reason of a high fire risk, the heating element may be only cleaned in cold condition.
Connect the hydraulic hoses of the basic machine with the hydraulic aggregate.
Connect hydraulic aggregate to the mains supply 400 V / 50 Hz / 32 A.
Connect planer and heating element to the hydraulic aggregate.
Make sure that pump and planer are connected in a way that they turn in right-hand direction, if
need be correct it.
Replace the screw plug by the enclosed venting screw before starting the
planer (see arrow).
Do not throw away the screw plug, you need it again when transporting the
planer!
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