Widos 4400 User manual

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

Headquarters: D-71254 Dit ingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer, Dr. Kai Dombrowski

Working Instructions

Working InstructionsWorking Instructions

Working Instructions

Translation

TranslationTranslation

Translation

Heating Element Butt Welding Machine

Heating Element Butt Welding MachineHeating Element Butt Welding Machine

Heating Element Butt Welding Machine

WIDOS 4400

WIDOS 4400WIDOS 4400

WIDOS 4400

Keep for further use!

Product Identification

15.11.18 Working Instructions WIDOS 4400 Page 2 of 44

Model: Heating element butt welding machine

Type: WIDOS 4400

44004400

4400

Serial number / year of construction: see type lable

Customer

CustomerCustomer

Customer

e

ee

entries

ntriesntries

ntries

Inventory-No.:

Place of working:

Order of

Order ofOrder of

Order of

s

ss

spare

parepare

pare

p

pp

parts and

arts andarts and

arts and

a

aa

after

fterfter

fter

s

ss

sales

alesales

ales

s

ss

service:

ervice:ervice:

ervice:

Address of

Address ofAddress of

Address of

m

mm

manufacturer

anufactureranufacturer

anufacturer

WIDOS

WIDOSWIDOS

WIDOS

Wilhelm Dommer Söhne GmbH

Einsteinstrasse 5

D-71254 Dit ingen

Phone: ++49 7152 99 39 0

Telefax: ++49 7152 99 39 40

Introduction

15.11.18 Working Instructions WIDOS 4600 Page 3 of 44

Purpose of the

Purpose of thePurpose of the

Purpose of the

d

dd

document

ocumentocument

ocument

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 teams 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 during exercise.

Thank you.

Structure of the

Structure of theStructure of the

Structure of the

w

ww

working

orkingorking

orking

i

ii

instructions

nstructionsnstructions

nstructions

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

WIDOSWIDOS

WIDOS 15.11.2018

Wilhelm Dommer Söhne GmbH

Einsteinstraße 5

D-71254 Dit ingen

Reprinting only allowed with permission of the corporation.

Any changes prior to technical innovations.

Contents

15.11.18 Working Instructions WIDOS 4400 Page 4 of 44

1.

1.1.

1.

DESCRIPTION OF THE P

DESCRIPTION OF THE PDESCRIPTION OF THE P

DESCRIPTION OF THE PRODUCT

RODUCTRODUCT

RODUCT

................................

................................................................

..................................

....

..

6

66

6

1.1.

1.1.1.1.

1.1.

Usage and purpose oriented use

Usage and purpose oriented useUsage and purpose oriented use

Usage and purpose oriented use

................................

................................................................

............................................

........................

............

6

66

6

1.2.

1.2.1.2.

1.2.

S

SS

Safety measures

afety measuresafety measures

afety measures

................................

................................................................

.......................................

..............

.......

6

66

6

1.3.

1.3.1.3.

1.3.

Conformity

ConformityConformity

Conformity

................................

................................................................

.................................................

..................................

.................

6

66

6

1.4.

1.4.1.4.

1.4.

Machine overview

Machine overviewMachine overview

Machine overview

................................

................................................................

....................................

........

....

7

77

7

1.5.

1.5.1.5.

1.5.

Designation of the product

Designation of the productDesignation of the product

Designation of the product

................................

................................................................

......................................................

............................................

......................

7

77

7

1.5.1.

Technical data ....................................................................................................................................................... 7

1.5.1.1.

WIDOS 4400

44004400

4400 General data ...................................................................................................................... 7

1.5.1.2.

Heating element ......................................................................................................................................... 8

1.5.1.3.

Planer ............................................................................................................................................................ 8

1.5.1.4.

Hydraulic aggregate .................................................................................................................................. 9

1.5.1.5.

Basic frame ................................................................................................................................................. 9

1.5.1.6.

Reception box ............................................................................................................................................. 9

1.6.

1.6.1.6.

1.6.

Equipment and accessories:

Equipment and accessories:Equipment and accessories:

Equipment and accessories:

................................

................................................................

....................................................

........................................

....................

9

99

9

2.

2.2.

2.

SAFETY RULES

SAFETY RULESSAFETY RULES

SAFETY RULES

................................

................................................................

..............................................................

............................................................

..............................

10

1010

10

2.1.

2.1.2.1.

2.1.

Explanation of the symbols and indications

Explanation of the symbols and indicationsExplanation of the symbols and indications

Explanation of the symbols and indications

................................

................................................................

.........................................................

..................................................

.........................

10

1010

10

2.2.

2.2.2.2.

2.2.

Obligations of the owner

Obligations of the ownerObligations of the owner

Obligations of the owner

................................

................................................................

........................................................

................................................

........................

11

1111

11

2.3.

2.3.2.3.

2.3.

Obligations of the worker

Obligations of the workerObligations of the worker

Obligations of the worker

................................

................................................................

.......................................................

..............................................

.......................

11

1111

11

2.4.

2.4.2.4.

2.4.

Measures of organisation

Measures of organisationMeasures of organisation

Measures of organisation

................................

................................................................

......................................................

............................................

......................

11

1111

11

2.5.

2.5.2.5.

2.5.

Information about safety pr

Information about safety prInformation about safety pr

Information about safety precautions

ecautionsecautions

ecautions

................................

................................................................

...................................

......

...

11

1111

11

2.6.

2.6.2.6.

2.6.

Instructions for the staff

Instructions for the staffInstructions for the staff

Instructions for the staff

................................

................................................................

........................................................

................................................

........................

11

1111

11

2.7.

2.7.2.7.

2.7.

Dangers while handling the machine

Dangers while handling the machineDangers while handling the machine

Dangers while handling the machine

................................

................................................................

...................................

......

...

12

1212

12

2.8.

2.8.2.8.

2.8.

Danger caused by electric energy

Danger caused by electric energyDanger caused by electric energy

Danger caused by electric energy

................................

................................................................

........................................

................

........

12

1212

12

2.9.

2.9.2.9.

2.9.

Dangers caused by the hydraulic aggregate

Dangers caused by the hydraulic aggregateDangers caused by the hydraulic aggregate

Dangers caused by the hydraulic aggregate

................................

................................................................

.......................................................

..............................................

.......................

12

1212

12

2.10.

2.10.2.10.

2.10.

Specific dangers

Specific dangersSpecific dangers

Specific dangers................................

................................................................

.....................................

..........

.....

13

1313

13

2.10.1.

Danger of catching clothes by the planer ..................................................................................................... 13

2.10.2.

Risk of injury by noises ....................................................................................................................................... 13

2.10.3.

Danger of being burnt by heating element, reception box and welding area ...................................... 13

2.10.4.

Danger of stumbling over hydraulic and electric wires .............................................................................. 13

2.10.5.

Danger of squee ing by clamping devices and guideways ....................................................................... 13

2.11.

2.11.2.11.

2.11.

Structural modifications on the machine

Structural modifications on the machineStructural modifications on the machine

Structural modifications on the machine

................................

................................................................

.............................................................

..........................................................

.............................

14

1414

14

2.12.

2.12.2.12.

2.12.

Cleaning the machine

Cleaning the machineCleaning the machine

Cleaning the machine

................................

................................................................

.............................................................

..........................................................

.............................

14

1414

14

2.13.

2.13.2.13.

2.13.

Warranty and liability

Warranty and liabilityWarranty and liability

Warranty and liability

................................

................................................................

.............................................................

..........................................................

.............................

14

1414

14

3.

3.3.

3.

FUNCTIONAL DESCRIPTI

FUNCTIONAL DESCRIPTIFUNCTIONAL DESCRIPTI

FUNCTIONAL DESCRIPTION

ONON

ON

................................

................................................................

........................................

................

........

15

1515

15

4.

4.4.

4.

OPERATING AND INDICA

OPERATING AND INDICAOPERATING AND INDICA

OPERATING AND INDICATING ELEMENTS

TING ELEMENTSTING ELEMENTS

TING ELEMENTS................................

................................................................

................................................

................................

................

16

1616

16

4.1.

4.1.4.1.

4.1.

Elements on the aggregate

Elements on the aggregateElements on the aggregate

Elements on the aggregate

................................

................................................................

....................................................

........................................

....................

16

1616

16

4.1.1.

Hydraulic aggregat with manometer analog ................................................................................................. 17

4.2.

4.2.4.2.

4.2.

Elements on the side of the aggregate

Elements on the side of the aggregateElements on the side of the aggregate

Elements on the side of the aggregate

................................

................................................................

.................................

..

.

17

1717

17

Contents

15.11.18 Working Instructions WIDOS 4400 Page 5 of 44

4.3.

4.3.4.3.

4.3.

Elements at planer and heating element

Elements at planer and heating elementElements at planer and heating element

Elements at planer and heating element

................................

................................................................

..............................................................

............................................................

..............................

18

1818

18

5.

5.5.

5.

STARTING AND OPERATI

STARTING AND OPERATISTARTING AND OPERATI

STARTING AND OPERATING

NGNG

NG

................................

................................................................

.......................................

..............

.......

19

1919

19

5.1.

5.1.5.1.

5.1.

Sta

StaSta

Starting

rtingrting

rting

................................

................................................................

....................................................

........................................

....................

19

1919

19

5.1.1.

Replacing the reduction inserts ....................................................................................................................... 20

5.1.2.

Using small and large reduction inserts ......................................................................................................... 20

5.2.

5.2.5.2.

5.2.

Welding process

Welding processWelding process

Welding process

................................

................................................................

.....................................

..........

.....

21

2121

21

6.

6.6.

6.

WELDING

WELDINGWELDING

WELDING

LOG AND TABLES

LOG AND TABLESLOG AND TABLES

LOG AND TABLES

................................

................................................................

.......................................

..............

.......

23

2323

23

7.

7.7.

7.

MAINTENANCE AND REPA

MAINTENANCE AND REPAMAINTENANCE AND REPA

MAINTENANCE AND REPAIR

IRIR

IR

................................

................................................................

......................................

............

......

28

2828

28

7.1.

7.1.7.1.

7.1.

Maintenance and inspection, repair

Maintenance and inspection, repairMaintenance and inspection, repair

Maintenance and inspection, repair

................................

................................................................

.....................................

..........

.....

28

2828

28

7.2.

7.2.7.2.

7.2.

Clamping elements

Clamping elementsClamping elements

Clamping elements

................................

................................................................

.................................

..

.

28

2828

28

7.3.

7.3.7.3.

7.3.

Planer

PlanerPlaner

Planer

................................

................................................................

......................................................

............................................

......................

28

2828

28

7.4.

7.4.7.4.

7.4.

Storage

StorageStorage

Storage

................................

................................................................

....................................................

........................................

....................

28

2828

28

7.5.

7.5.7.5.

7.5.

Used hydraulic oil

Used hydraulic oilUsed hydraulic oil

Used hydraulic oil

................................

................................................................

...................................

......

...

28

2828

28

7.6.

7.6.7.6.

7.6.

Checking the hydraulic oil

Checking the hydraulic oilChecking the hydraulic oil

Checking the hydraulic oil-

--

-level

levellevel

level

................................

................................................................

............................................

........................

............

29

2929

29

7.7.

7.7.7.7.

7.7.

Venting the hydraulic cylinders

Venting the hydraulic cylindersVenting the hydraulic cylinders

Venting the hydraulic cylinders

................................

................................................................

.............................................

..........................

.............

29

2929

29

8.

8.8.

8.

TRANSPORT

TRANSPORTTRANSPORT

TRANSPORT

................................

................................................................

..................................

....

..

30

3030

30

9.

9.9.

9.

HYDRAULIC AND ELECTR

HYDRAULIC AND ELECTRHYDRAULIC AND ELECTR

HYDRAULIC AND ELECTRIC DIAGRAMS

IC DIAGRAMSIC DIAGRAMS

IC DIAGRAMS

................................

................................................................

....................................................

........................................

....................

31

3131

31

10.

10.10.

10.

SPARE PARTS LIST

SPARE PARTS LISTSPARE PARTS LIST

SPARE PARTS LIST

................................

................................................................

..................................................

....................................

..................

33

3333

33

10.1.

10.1.10.1.

10.1.

Basic machine

Basic machineBasic machine

Basic machine

................................

................................................................

........................................

................

........

33

3333

33

10.2.

10.2.10.2.

10.2.

Planer

PlanerPlaner

Planer

................................

................................................................

......................................................

............................................

......................

35

3535

35

10.3.

10.3.10.3.

10.3.

Hydraulic aggregate

Hydraulic aggregateHydraulic aggregate

Hydraulic aggregate

................................

................................................................

...............................................................

..............................................................

...............................

37

3737

37

10.4.

10.4.10.4.

10.4.

Heating element

Heating elementHeating element

Heating element................................

................................................................

......................................

............

......

40

4040

40

10.5.

10.5.10.5.

10.5.

Protection box

Protection boxProtection box

Protection box................................

................................................................

.........................................

..................

.........

42

4242

42

11.

11.11.

11.

DECLARATION OF CONFO

DECLARATION OF CONFODECLARATION OF CONFO

DECLARATION OF CONFORMITY

RMITYRMITY

RMITY

................................

................................................................

............................................................

........................................................

............................

44

4444

44

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

15.11.18 Working Instructions WIDOS 4400 Page 6 of 44

1.

1.1.

1. Description of the

Description of theDescription of the

Description of the

p

pp

product

roductroduct

roduct

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.

1.1.1.1.

1.1. Usage and

Usage andUsage and

Usage and

p

pp

purpose oriented

urpose orientedurpose oriented

urpose oriented

u

uu

use

sese

se

The WIDOS

WIDOSWIDOS

WIDOS 4400

44004400

4400 has been designed only for heating element butt welding of pipes and fittings with a

diameter range of Ø = 50 - 160 mm (standard diameters: 50 / 63 / 75 / 90 / 110 / 125 / 140 / 160 mm).

It is a building site machine and is designed especially for the use on site as well as in the workshop.

For this reason, the frame is kept small such that it can be used also in constrained positions (e.g.

building ditches).

All use going beyond is not purpose oriented.

The manufacturer is not responsible for any damages caused by inexpert handling or operation.

For personal injuries, material and immaterial damages resulting herefrom, only the user is

responsible!

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.

1.2.1.2.

1.2. Safety

SafetySafety

Safety

m

mm

measures

easureseasures

easures

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.

1.3.

1.3.1.3.

1.3. Conformity

ConformityConformity

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.

Description of Product

Chapter 1

Chapter 1Chapter 1

Chapter 1

15.11.18 Working Instructions WIDOS 4400 Page 7 of 44

1.4.

1.4.1.4.

1.4. Machine overview

Machine overviewMachine overview

Machine overview

No.

No.No.

No.

Description

DescriptionDescription

Description

1 Hydraulic aggregate

2

Basic machine with clamping devices

3

Heating element

4

Reception box

5

Planer

1.5.

1.5.1.5.

1.5. Designation of the

Designation of theDesignation of the

Designation of the

p

pp

product

roductroduct

roduct

The product is designated by two type labels.

The type labels 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.

1.5.1.1.5.1.

1.5.1. Technical

TechnicalTechnical

Technical

d

dd

data

ataata

ata

1.5.1.1. WIDOS 4400

44004400

4400 General data

Material: PE, PP, PVDF,

Pipe diameter range:: outside-∅ = 50 – 160 mm

Packing box (l x w x h):

Weight:

appr. 820 x 680 x 750 mm

appr. 14 kg

Weight (without boxes): appr. 60 kg

Protection: 10 A

Wire cross section: 1,5 mm²

Emissions - Noises exceeding 80 dB (A) may occur; during planing it is

obligatory to wear ear protection!

- When using the named pipe materials and when welding

below 260 °C / 500 °F no toxicant damp arises.

1

2

3

5

4

Description of Product

Chapter 1

Chapter 1Chapter 1

Chapter 1

15.11.18 Working Instructions WIDOS 4400 Page 8 of 44

Environmental conditions at the

welding area:

- Keep the workshop clean (no dust at the welding area)

- If secured by an appropriate measurement that allowed

conditions for welding are indicated, it is possible to work

in any outside temperature condition as far as the welder

is not constrained in its manual skill.

- Avoid humidity, if necessary use a welding tent

- Avoid strong sun rays influence

- Protect from wind, shut the pipe ends.

1.5.1.2. Heating element

Power: 800 Watt

Voltage: 230 V (± 10 %)

Current: 3,5 A (± 10 %)

Frequency: 50 H

Outside-∅: 200 mm

Surface: Nonstick-coated

Attached elements: - Electronic temperature control

- On / off switch red illuminated

- Control lamp green

- Connecting cable and plug

Weight: appr. 3,5 kg

1.5.1.3. Planer

Motor: Monophase-alternating current-motor

Power: 950 Watt

Voltage: 230 V (± 10 %)

Current: 4,1 A

Frequency: 50 H (± 10 %)

RPM n of planer: 100 rpm

Attached elements: - Switch on/off with fixing device

- Connecting cable and plug

Weight: appr. 7,5 kg

Description of Product

Chapter 1

Chapter 1Chapter 1

Chapter 1

15.11.18 Working Instructions WIDOS 4400 Page 9 of 44

1.5.1.4. Hydraulic aggregate

Power: 0,315 kW

Voltage: 230 V (± 10 %)

Current: 1,5 A

Frequency: 50 H

Phase shift: appr. 18°

Hydraulic fluid tank: appr. 1 L

System of protection: IP 54

Electro motor and pump:

Rotation speed: 1380 rpm

Max. working pressure of pump: appr. 120 bar

Working pressure: 100 bar

Volume velocity: 1,0 L/min

Weight: 23 kg

1.5.1.5. Basic frame

Dimension (l x w x h): 600 x 320 x 300 (mm)

Reductions insert: Dimension upon request

Material of frame: Construction steel

Material of reduction inserts: Aluminium

Weight: 25 kg

∅ of cylinder: 28 mm

∅ of piston rod: 25 mm

Length of stroke of cylinder: 100 mm

max. force (F=P*A): 2500 N (at 100 bar)

Velocity of piston rod: 6,7 cm/s

1.5.1.6. Reception box

Weight: appr. 4,0 kg

For article numbers and component parts

For article numbers and component partsFor article numbers and component parts

For article numbers and component parts

see spare parts list

see spare parts listsee spare parts list

see spare parts list

1.6.

1.6.1.6.

1.6. Equipment and

Equipment andEquipment and

Equipment and

a

aa

accessories:

ccessories:ccessories:

ccessories:

The following accessories are part of the first delivery:

1 Tool bag for 10 parts

1 Socket spanner si e 24

1 Torx srew driver T10

1 each Allen key angulate si e 3 / 5 / 6

1 each Allen key with T grip si e 3 / 4

option Reduction inserts (large, extra large), roller brackets for the pipes, transformer

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

15.11.18 Working Instructions WIDOS 4400 Page 10 of 44

2.

2.2.

2. Safety

SafetySafety

Safety

r

rr

rules

ulesules

ules

The base for the safe handling and the fault-free operation of this machine is the knowledge of the

basic safety indications and rules.

The security notices of this chapter represent the general part.

Particular indications are listed directly at the description of the corresponding actions.

• These working instructions provide you with the most important information to run the machine

safely.

• The safety indications must be read by all persons working on the machine.

2.1.

2.1.2.1.

2.1. Explanation of the

Explanation of theExplanation of the

Explanation of the

s

ss

symbols and

ymbols andymbols and

ymbols and

i

ii

indications

ndicationsndications

ndications

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 means a possible risk of injury by noises exceeding 80 dB (A).

• Ear protection is obligatory

This symbol gives important indications for the proper use of the machine.

• The disrespect of these indications may conduct to malfunctions and damages on the

machine or on goods in the surrounding.

Under this symbol you get user tips and particularly useful information.

• It is a help for using all the functions on your machine in an optimal way and helps you

to make the job easier.

T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) .

T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) .T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) .

T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) .

Safety Rules

Chapter 2

Chapter 2Chapter 2

Chapter 2

15.11.18 Working Instructions WIDOS 4400 Page 11 of 44

2.2.

2.2.2.2.

2.2. Obligations of the

Obligations of theObligations of the

Obligations of the

o

oo

owner

wnerwner

wner

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 with their signature.

The safety-conscious working of the staff has to be checked in regular intervals.

2.3.

2.3.2.3.

2.3. Obligations of the

Obligations of theObligations of the

Obligations of the

w

ww

worker

orkerorker

orker

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.

2.4.2.4.

2.4. Measures of

Measures ofMeasures of

Measures of

o

oo

organisation

rganisationrganisation

rganisation

• All equipment required for personal safety is to be provided by the owner.

• All available safety equipment is to be inspected regularly.

2.5.

2.5.2.5.

2.5. Information about

Information aboutInformation about

Information about

s

ss

safety

afetyafety

afety

p

pp

precautions

recautionsrecautions

recautions

• The working instructions have to be permanently kept at the place of use of the machine.

They are to be at the operator‘s disposal at any time and without effort.

• In addition to the manual, the common valid and the local accident protection rules and

regulations for the environmental protection must be available and followed.

• All safety and danger indications on the machine have to be in a clear readable condition.

• Every time the machine changes hands or is being rented to third persons, the working

instructions are to be sent along with and their importance is to be emphasi ed.

2.6.

2.6.2.6.

2.6. Instructions for the

Instructions for theInstructions for the

Instructions for the

s

ss

staff

tafftaff

taff

• 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.

Safety Rules

Chapter 2

Chapter 2Chapter 2

Chapter 2

15.11.18 Working Instructions WIDOS 4400 Page 12 of 44

2.7.

2.7.2.7.

2.7. Dangers while

Dangers whileDangers while

Dangers while

h

hh

handling the

andling theandling the

andling the

m

mm

machine

achineachine

achine

The machine WIDOS 4400

WIDOS 4400WIDOS 4400

WIDOS 4400 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 damages to the machine itself or to other things 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 eliminated immediately.

2.8.

2.8.2.8.

2.8. Danger caused by

Danger caused byDanger caused by

Danger caused by

e

ee

electric

lectriclectric

lectric

e

ee

energy

nergynergy

nergy

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.

• If works at alive parts are necessary, a second person has to assist who can disconnect the

machine from the mains if necessary.

• All electric tools (heating element, planer and aggregate) have to be protected from rain

and dropping water (if need be use a welding tent).

• According to VDE 0100, the use on construction sites is only allowed with a power distributor with a

FI-safety switch.

2.9.

2.9.2.9.

2.9. Dangers caused by the

Dangers caused by theDangers caused by the

Dangers caused by the

h

hh

hydraulic

ydraulicydraulic

ydraulic

a

aa

aggregate

ggregateggregate

ggregate

System parts and pressure hoses should be made pressureless before beginning of any

repair works. Even if the machine is switched off, pressure may be in the hydraulic

accumulator!

There is a danger of injuring the eyes by hydraulic oil squirting out.

• Damaged hydraulic hoses have to be immediately replaced.

• Make a visual inspection of the hydraulic hoses before each work beginning.

• The hydraulic oil is inedible !

Safety Rules

Chapter 2

Chapter 2Chapter 2

Chapter 2

15.11.18 Working Instructions WIDOS 4400 Page 13 of 44

2.10.

2.10.2.10.

2.10. Specific

SpecificSpecific

Specific

d

dd

dangers

angersangers

angers

2.10.1.

2.10.1.2.10.1.

2.10.1. Danger of

Danger ofDanger of

Danger of

c

cc

catching

atchingatching

atching

c

cc

clothes by the

lothes by thelothes by the

lothes by the

p

pp

planer

lanerlaner

laner

You can cut yourself or even get bones broken!

• Only 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 at the handle only

.

• Do not touch the planer surfaces.

• Switch the planer on only for usage. Otherwise the planer will start every time when the security

microswitch is pressed.

2.10.2.

2.10.2.2.10.2.

2.10.2. Risk of injury by noises

Risk of injury by noisesRisk of injury by noises

Risk of injury by noises

Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear

protection!

2.10.3.

2.10.3.2.10.3.

2.10.3. Danger of being burnt by

Danger of being burnt byDanger of being burnt by

Danger of being burnt by

h

hh

heating

eatingeating

eating

e

ee

element,

lement,lement,

lement,

r

rr

reception

eceptioneception

eception

b

bb

box and

ox andox and

ox and

w

ww

welding

eldingelding

elding

a

aa

area

rearea

rea

You can burn yourself, inflammable materials can be ignited!

The heating element temperature gets over

200

200200

200

°

°°

°C

CC

C

/ 392 °F

/ 392 °F/ 392 °F

/ 392 °F!

• Do not touch the surface of the heating element.

• Do not leave the heating element unsupervised.

• Take enough safety distance to inflammable materials.

• Do wear safety gloves.

•

Always put the heating element back into the reception box after and before each use.

• Transport the heating element at the holder only.

2.10.4.

2.10.4.2.10.4.

2.10.4. Danger of

Danger ofDanger of

Danger of

s

ss

stumbling over

tumbling overtumbling over

tumbling over

h

hh

hydraulic and

ydraulic andydraulic and

ydraulic and

e

ee

electric

lectriclectric

lectric

w

ww

wires

iresires

ires

• Make sure that no person has to step over the wires.

• Lay the wires in such a way that the danger is kept to a minimum.

2.10.5.

2.10.5.2.10.5.

2.10.5. Danger of

Danger ofDanger of

Danger of

s

ss

squee ing by

quee ing byquee ing by

quee ing by

c

cc

clamping

lampinglamping

lamping

d

dd

devices and

evices andevices and

evices and

g

gg

guideways

uidewaysuideways

uideways

There is a danger of serious injuries:

on the one hand between the inner clamping devices and on the other hand between

the outside clamping device and the end of the guideway.

• Do not stand or put hands between clamped pipe ends.

• Do not stand or put hands between the inner clamping tools with not yet clamped pipes.

• Do not block opening and closing of the machine slides.

Safety Rules

Chapter 2

Chapter 2Chapter 2

Chapter 2

15.11.18 Working Instructions WIDOS 4400 Page 14 of 44

2.11.

2.11.2.11.

2.11. Structural

StructuralStructural

Structural

m

mm

modifications on the

odifications on theodifications on the

odifications on the

m

mm

machine

achineachine

achine

• 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

WIDOSWIDOS

WIDOS spare and wear parts.

• In case of purchase orders please always state the machine number.

2.12.

2.12.2.12.

2.12. Cleaning the

Cleaning theCleaning the

Cleaning the

m

mm

machine

achineachine

achine

The used materials and tissues are to be handled disposed of properly, especially

• when cleaning with solvents

• when lubricating with oil and grease

2.13.

2.13.2.13.

2.13. Warranty and

Warranty andWarranty and

Warranty and

l

ll

liability

iabilityiability

iability

Our „General Sales and Delivery Conditions“ are principally valid.

They are at the owner's disposal at the latest when signing the contract.

Warranty and liability demands referring to damages of persons or objects are suspended if they are

caused by one or several of the following reasons:

• not using the machine according to the prescriptions

• improper transport, building-up, starting and operating the machine and maintenance

• operating the machine with defective or improperly installed security measures

• ignoring the information given in this manual

• structural changes at the machine without permission

• unsatisfactory checking of machine parts which are worn out

• repairs performed in an inexpert way

• catastrophes by external influence and Acts of God.

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

15.11.18 Working Instructions WIDOS 4400 Page 15 of 44

3.

3.3.

3. Functional

FunctionalFunctional

Functional

d

dd

description

escriptionescription

escription

B a s i c a l l y t h e i n t e r n a t i o n a l a n d n a t i o n a l s t a n d a r d s p e c i f i c a t i o n s a r e t o

B a s i c a l l y t h e i n t e r n a t i o n a l a n d n a t i o n a l s t a n d a r d s p e c i f i c a t i o n s a r e t oB a s i c a l l y t h e i n t e r n a t i o n a l a n d n a t i o n a l s t a n d a r d s p e c i f i c a t i o n s a r e t o

B a s i c a l l y t h e i n t e r n a t i o n a l a n d n a t i o n a l s t a n d a r d s p e c i f i c a t i o n s a r e t o

b e f o l l o w e d .

b e f o l l o w e d .b e f o l l o w e d .

b e f o l l o w e d .

The plastic pipes are clamped in the clamping devices. Then the front sides of the pipes are cut plane

and parallel by means of the planer

planerplaner

planer and the misalignment of the pipes is checked.

The cleaned and heated heating element is inserted and the pipes are pressed against the heating

element under defined adjusting pressure. This process is called "adjusting"

"adjusting""adjusting"

"adjusting".

After the prescribed bead height being reached, pressure is reduced, the heating time

heating timeheating time

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

change over timechange over time

change over time.

The pipes are joined under prescribed welding pressure and then cool down under pressure (cooling

coolingcooling

cooling

time

timetime

time).

The welded joint can be unclamped, the welding process is finished.

Heating element heats the pipes up

to welding temperature

Finished welding with

internal and external bead

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

15.11.18 Working Instructions WIDOS 4400 Page 16 of 44

4.

4.4.

4. Operating and

Operating andOperating and

Operating and

i

ii

indicating

ndicatingndicating

ndicating

e

ee

elements

lementslements

lements

4.1.

4.1.4.1.

4.1. Elements on the

Elements on theElements on the

Elements on the

a

aa

aggregate

ggregateggregate

ggregate

No.

No.No.

No.

Denomination

DenominationDenomination

Denomination

Function

FunctionFunction

Function

6 Manometer, digital Display of the hydraulic pressure

7 Valve lever Opening the slides. There are 4 different positions:

- to the left side

to the left sideto the left side

to the left side: slides close.

- in the mid

in the midin the mid

in the middle

dledle

dle (usual position): the pressure which is currently

achieved is kept (also by means of the built-in hydraulic

accumulator)

- slightly to the right side

slightly to the right sideslightly to the right side

slightly to the right side (position pressureless): a possibly

existing pressure is released without moving the slides. Due to

the hydraulic accumulator, it takes about 10 s until the pressure

is completely released.

- to the right side

to the right sideto the right side

to the right side: slides open

8 Setting screw for pressure

relief valve

- Limitation of the pressure to the desired value

9 Hydraulic connection for

closing the slides

- Non-dropping quick-acting coupling

10 Hydraulic connection for

opening the slides

- Non-dropping quick-acting coupling

11 Screw with oil dipstick - checking the oil level

- oil filler neck

6

7

9

10

8

11

Label „opening/

closing“

Indicating label

„Setting the pressure

relief valve“

Operating and Indicating Elements

Chapter 4

Chapter 4Chapter 4

Chapter 4

15.11.18 Working Instructions WIDOS 4400 Page 17 of 44

4.1.1.

4.1.1.4.1.1.

4.1.1. Hydraulic aggregat with

Hydraulic aggregat withHydraulic aggregat with

Hydraulic aggregat with

pressure gauge

pressure gaugepressure gauge

pressure gauge

analog

analoganalog

analog

4.2.

4.2.4.2.

4.2. Elements on the

Elements on theElements on the

Elements on the

s

ss

side of the

ide of theide of the

ide of the

a

aa

aggregate

ggregateggregate

ggregate

No.

No.No.

No.

Denomination

DenominationDenomination

Denomination

Function

FunctionFunction

Function

12 Socket 230V/50 H Possibility for connecting the planer / heating element

13 Socket 230V/50 H Possibility for connecting the planer / heating element

14 Mains cable 230V/50H Power supply

12

13

14

(11)

(8)

(10)

(9)

(7)

Pressure gauge

analog (version)

Operating and Indicating Elements

Chapter 4

Chapter 4Chapter 4

Chapter 4

15.11.18 Working Instructions WIDOS 4400 Page 18 of 44

4.3.

4.3.4.3.

4.3. Elements at

Elements atElements at

Elements at

p

pp

planer and

laner andlaner and

laner and

h

hh

heating

eatingeating

eating

e

ee

element

lementlement

lement

No.

No.No.

No.

Denomination

DenominationDenomination

Denomination

Function

FunctionFunction

Function

15 On/off switch - For switching on/off the planer.

- Planing is only possible if the security micro

switch is pressed

16 Security micro switch - Protection against unintended running of

the planer

17 Locking lever - Protection of the planer against jumping out of the

machine.

18 On/off switch with lamp - As soon as the heating element is switched on,

the red control lamp lightens

19 Setting screw - For regulating the temperature of the heating

element

18 Control lamp green - There are three different states:

•

off

offoff

off: signali es that the heating element is not

heated up at the moment or that it cools down

•

blinking

blinkingblinking

blinking: the heating element temperature is

maintained by a certain pulse-position ratio

•

on

onon

on: signali es that the heating element is heated

up at the moment. It has not yet reached the desired

temperature

15

16

20

18

19

17

WIDOS

WIDOSWIDOS

WIDOS

Einsteinstraße 5 Phone +49 7152 9939 0

Wilhelm Dommer Söhne D-71254 Dit ingen Fax +49 7152 9939 40

GmbH info@widos.de Internet: www.widos.de

15.11.18 Working Instructions WIDOS 4400 Page 19 of 44

5.

5.5.

5. Starting and operating

Starting and operatingStarting and operating

Starting and operating

The instructions of this chapter are supposed to initiate in the operation of the machine and to lead

during the approppriate starting of the machine.

This includes:

• the safe operation of the machine

• using all the possibilities

• running the machine economically

5.1.

5.1.5.1.

5.1. Starting

StartingStarting

Starting

The machine may only be operated by initiated and authori ed 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.

In case of power failure, there may still be pressure in the hydraulic system. For this

reason, release pressure if need be.

After completion of the welding work and during breaks the machine has to be switched

off. Further take care that no unauthori ed person has access.

Protect the machine from wetness and humidity !

According to VDE 0100, the use on construction sites is only allowed with a power

distributor with a FI-security protective switch.

Check the oil level of the hydraulic system before each starting of the control unit in

order to avoid damages on the pump. The oil-level must be between the two marks at the

oil dipstick.

• Connect the hydraulic aggregate to the mains (230 V / 50 H ).

• Connect heating element and planer to the corresponding socket at the aggregate.

• Push the hydraulic hoses of the basic machine into the quick-acting couplings of the hydraulic

aggregate.

Lay hydraulic and electric lines carefully (danger of stumbling) !

• Take into account the surrounding conditions:

• The welding may not be performed under direct sun rays influence,

• If necessary use a welding umbrella.

• If the surrounding temperature is under 5 °C / 41 °F, measures have to be taken:

• Use a welding tent or preheat the pipe ends if necessary.

• In addition, take measures against rain, wind and dust.

Starting and Operating Chapter 5

Chapter 5Chapter 5

Chapter 5

15.11.18 Working Instructions WIDOS 4400 Page 20 of 44

5.1.1.

5.1.1.5.1.1.

5.1.1. Replacing the

Replacing theReplacing the

Replacing the

r

rr

reduction

eductioneduction

eduction

i

ii

inserts

nsertsnserts

nserts

• Unscrew the mounted reduction inserts by means of the provided Allan key.

• Screw the reduction inserts with the corresponding diameter into the clamping devices.

• If necessary (e.g. for T-pieces) the outer fixed clamping device can be dismantled by unscrewing

the three hexagon socket screws.

Dismantling of the outer fixed clamping device

5.1.2.

5.1.2.5.1.2.

5.1.2. Using

UsingUsing

Using

s

ss

small and

mall andmall and

mall and

l

ll

large

argearge

arge

r

rr

reduction

eductioneduction

eduction

i

ii

inserts

nsertsnserts

nserts

Small

SmallSmall

Small

r

rr

reduction

eductioneduction

eduction

i

ii

inserts:

nserts:nserts:

nserts:

• Pipe fittings often have only a short straight surface area on which they can be clamped.

• Fittings mostly need to be clamped in the inner clamping devices with the small reduction inserts.

• When fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can also be

used flush to the inside or to the outside.

Small reduction insert,

centered (for pipes)

Shown here:

Small reduction insert,

flush to the inside

(for bends, T-pieces)

widos 4400 User manual

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