widos 4955 User manual

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
Working Instructions
Translation
Heating element butt welding machine
WIDOS 4955
Keep for further use!

Identification of product
19.09.19 Working instructions WIDOS 4955 Page 2 of 39
Version: Ditch machine
Type: WIDOS 4955
Serial number / year of construction: see type label
Customer's entries
Inventory- No.:
Place of working:
Address of manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
Phone: ++49 7152 9939 0
Fax: ++49 7152 9939 40
E-Mail: [email protected]
http://www.widos.de

Introduction
19.09.19 Working instructions WIDOS 4955 Page 3 of 39
Purpose of the document
These working instructions give you information about all important questions which refer to the
construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our advisers in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest to continuously improve our products and working instructions, we kindly ask
you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters, which belong to the different using phases of the machine.
Therefore the searched information can be easily found.
WIDOS 9/19/2019
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes are subject to technical innovations.

Contents
19.09.19 Working instructions WIDOS 4955 Page 4 of 39
1.DESCRIPTION OF PRODUCT .......................................................................................................... 6
1.1.Application and prescribed use ......................................................................................................... 6
1.2.Machine overview ............................................................................................................................... 6
1.3.Safety measures .................................................................................................................................. 7
1.4.Conformity ............................................................................................................................................ 7
1.5.Designation of product ........................................................................................................................ 7
1.5.1Technical Data ...................................................................................................................................................7
1.6.Equipment and accessories: ............................................................................................................... 9
2.SAFETY RULES .............................................................................................................................. 10
2.1.Explanation of the different symbols................................................................................................10
2.2.Obligations of the owner ................................................................................................................... 11
2.3.Obligations of the worker .................................................................................................................. 11
2.4.Organizational measures .................................................................................................................. 11
2.5.Informal security measures .............................................................................................................. 11
2.6.Instruction of 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 ................................................................................................... 12
2.11.Special dangers ................................................................................................................................. 13
2.11.1Danger of catching clothes by the planer...................................................................................................13
2.11.2Danger of combustion at heating element, protective box and welding area ....................................13
2.11.3Danger of stumbling over hydraulic and electric wires ...........................................................................13
2.11.4Risk of injury by noises ...................................................................................................................................13
2.11.5Danger of crushing by clamping tool and guideways...............................................................................14
2.12.Structural modifications on the machine ........................................................................................14
2.13.How to clean the machine ................................................................................................................ 14
2.14.Guarantee and liability ...................................................................................................................... 14
3.FUNCTIONAL DESCRIPTION ........................................................................................................ 15
4.OPERATING AND INDICATING ELEMENTS ................................................................................ 16
4.1.Elements on the hydraulic aggregate .............................................................................................. 16
4.2.Basic machine ................................................................................................................................... 17
4.2.1How to open/close the clamping ring ..........................................................................................................18
4.2.2Separating device for heating element .......................................................................................................18
4.3.Elements at the heating element ...................................................................................................... 19
4.4.Elements at the planer ...................................................................................................................... 20

Contents
19.09.19 Working instructions WIDOS 4955 Page 5 of 39
4.5.Stub end holder (optional) ................................................................................................................ 21
5.STARTING AND OPERATING ....................................................................................................... 22
5.1.Starting ............................................................................................................................................... 22
5.1.1How to mount the reduction inserts .............................................................................................................23
5.1.2How to use small and large reduction inserts............................................................................................23
5.1.3How to remove clamping ring with basic frame part 2 .............................................................................24
5.2.Welding process ................................................................................................................................ 25
6.WELDING LOGS AND TABLES ..................................................................................................... 28
7.MAINTENANCE AND REPAIR ...................................................................................................... 30
7.1.Maintenance and inspection, repair ................................................................................................ 30
7.2.Clamping elements ............................................................................................................................ 30
7.3.Planer ................................................................................................................................................. 30
7.4.Storing ................................................................................................................................................ 30
7.5.How to vent the hydraulic cylinders ................................................................................................ 31
7.6.How to check the hydraulic oil level ................................................................................................ 32
7.7.Used hydraulic oil .............................................................................................................................. 32
7.8.Disposal .............................................................................................................................................. 32
8.TRANSPORT .................................................................................................................................. 33
9.ELECTRIC AND HYDRAULIC DIAGRAMS .................................................................................... 34
10.SPARE PARTS LIST ...................................................................................................................... 38
11.DECLARATION OF CONFORMITY ................................................................................................. 39

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
19.09.19 Working instructions WIDOS 4955 Page 6 of 39
1. Description of product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Application and prescribed use
The WIDOS 4955 is made for the heating element butt welding of pipes and fittings with a diameter
range of Ø = 90 - 355 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 also be used in constrained positions (e.g.
building ditches).
All use going beyond is not prescribed.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Prescribed use also means:
taking notice of all remarks in this manual
performing of repair work.
1.2. Machine overview
1Basic machine
2Planer
3Heating element
4 Protective box
5Hydraulic aggregate
1 3
4
5
2

Description of product Chapter 1
19.09.19 Working instructions WIDOS 4955 Page 7 of 39
1.3. Safety measures
In case of wrong use, wrong operation or wrong maintenance the machine itself or products being in
the surrounding can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety advices
must be necessary 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 product
The product is designated by two signs at the frame.
The type-labels are fixed on the control unit and on the basic machine.
They contain the type of the machine, the serial number, and the year of construction.
1.5.1 Technical Data
1.5.1.1 WIDOS 4955 General data
Material: PP, PE, PVDF
Pipe diameter range: outside-Ø = 90 – 355 mm
Total weight (without packing): approx. 175 kg (Machine+packaging box for machine)
Dimensions of packing boxes: machine 1250 x 965 x 680
clamping inserts
920 x 565 x 445
Protection: 16 A
Wire cross section: 1,5 mm²
Emissions - Noises exceeding 80 dB (A) may occur; during
planing it is obligatory to wear ear protection!
-When using the named pipe materials and when
welding below 260°C / 500°F no toxicant damp arises.
Environment: - keep the workshop clean (especially the welding
area must be clean)
-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 put up a tent
-avoid strong sun beams
-if it is windy shut the pipe endings.

Description of product Chapter 1
19.09.19 Working instructions WIDOS 4955 Page 8 of 39
1.5.1.2 Planer
Motor: monophase-alternating current-motor
Power: 1,75 kW
Voltage: 230 V (10 %)
Current: 7 A
Frequency: 50 Hz (10 %)
Revolutions per minutes, n2 of planer approx. 27 rpm
Elements: - Switch on / off with fixing device
- Safety micro switch
- Connecting cable with plug
Weight: approx. 26 kg
1.5.1.3 Heating element
Power: 3 kW
Voltage: 230 V (10 %)
Current: 13,1 A (10 %)
Frequency: 50 Hz
Outside-: 390 mm
Surface: Anti-stick coated
Elements: Electronic temperature control
Control lamps, switch on / off
Connecting cable with plug
Weight: approx. 12 kg
1.5.1.4 Hydraulic aggregate
Feeding max. 3,6 kW
Fuse protection max. 16 A
Voltage: 230 V (10 %)
Frequency: 50 / 60 Hz
Hydraulic oil tank: approx. 1 l
Electromotor and pump:
Power: 3,1 kW
Current: 2,7 A
Revolutions per minutes: 1380 (rpm)
max. pressure of pump: approx. 100 bar
Working pressure: 100 bar
Volume velocity: 1,9 l/min
Weight: approx. 23 kg

Description of product Chapter 1
19.09.19 Working instructions WIDOS 4955 Page 9 of 39
1.5.1.5 Basic machine
Dimensions (l x w x h): 860 x 610 x 635 mm
Reduction insert: Dimensions can be selected
Material frame: Machine steel
Material reduction inserts: Aluminum
Weight: approx. 60 kg
Cylinder-: 40 mm
Piston rod-: 35 mm
Length of stroke of cylinder: 190 mm
max. force:(F=P*A) 5900 N (at 100 bar)
Velocity of piston rod: 5,4 cm/s
Stock numbers for component parts see spare parts list
1.6. Equipment and accessories:
The following accessories are part of the first delivery:
1 Tool bag for 10 parts
1 Socket wrench, size 30
1 Allan key tilted, size 8
1 Allan key with T-grip, size 5
1 Fork wrench, size 17 / 19
1 Torx-screw driver, T10
optional - Reduction inserts,
- Stub end holder
- Roller brackets for the pipes

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
19.09.19 Working instructions WIDOS 4955 Page 10 of 39
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of the
basic safety indications and rules.
The security notices of this chapter represent the general part.
Particular information is listed directly before the corresponding actions.
These working instructions provide you with the most important information to run the machine
safely.
The safety information must be read by all persons who work on the machine.
2.1. Explanation of the different symbols
The working instructions contain the following signs for certain situations:
This symbol means a possibly danger for the life and the health of persons.
The disrespect of these indications may have heavy consequences for the health.
This symbol means a possible dangerous situation.
The disrespect of these indications may cause slight injuries or damages on goods.
This symbol means a possible dangerous situation due to hot surfaces.
The disrespect of these indications may conduct to heavy burns, respectively to self-
ignition or even fire.
This symbol means a possible dangerous situation by moving parts of the machine
The disrespect of these indications may cause heavy crushing of parts of the body
resp. damages of parts of the machine.
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.
The regulations for the prevention of accidents are valid (UVV).

Safety rules Chapter 2
19.09.19 Working instructions WIDOS 4955 Page 11 of 39
2.2. Obligations of the owner
The owner is obliged only to let persons work on the machine, who
know about basic safety and accident prevention rules and are instructed in the handling of the
machine.
The workers also must have read and understood the safety chapter of this manual and certify this
with their signature.
The safety-conscious working of the staff should be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged before working:
To take care of the basic safety and accident protection rules.
To have read and understood the safety chapter and the warnings in this manual and to certify this
with their signature.
To inform themselves about the functions of the machine before using it.
2.4. Organizational measures
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Informal security measures
The manual has to be permanently kept at the place of use of the machine. It is to be at the
operator‘s disposal at any time and without effort.
As a supplement to the working instructions, the generally valid and also the local regulations for
the prevention of accidents and the protection of the environment are to be provided and adhered
to.
All security and danger notices on the machine have to be kept in a readable state.
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 emphasized.
2.6. Instruction of the staff
Only skilled and instructed persons are allowed to work at the machine.
The responsibilities of the staff are to be determined clearly concerning transport, mounting and
dismounting, starting, adjusting and tooling, operating, maintenance and inspection, repairs.
Workers who are to be trained are only allowed to work at the machine under control of an
experienced worker.

Safety rules Chapter 2
19.09.19 Working instructions WIDOS 4955 Page 12 of 39
2.7. Dangers while handling the machine
The machine WIDOS 4955 is constructed according to the actual 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 must only be used:
according to the prescription
in safety technical impeccable status
Disturbances, which may affect the safety of the machine must be eliminated immediately.
2.8. Maintenance and inspection, repair
All maintenance and repair work have to be basically performed with the machine in off
position.
During this the machine has to be secured against unauthorized switching on.
Prescribed maintenance and inspection work should be performed in time.
The DVS gives the advice of inspection work after 1 year.
For machines with an especially high usage percentage the testing cycle should be
shortened.
The work should be performed at the WIDOS GmbH company or by an authorized partner.
2.9. Dangers caused by electric energy
Only skilled workers are allowed to work at electrical appliances!
The electrical equipment of the machine has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
If work at alive parts is necessary, a second person has to assist who can disconnect the machine
from the mains if necessary.
All electric tools (heating element, planer and aggregate) have to be protected from rain and
dropping water (if need be use a welding tent).
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-safety switch.
2.10. Dangers caused by the hydraulics
System parts and pressure hoses should be depressurized before the beginning of any
repair work.
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
19.09.19 Working instructions WIDOS 4955 Page 13 of 39
2.11. Special dangers
2.11.1 Danger of catching clothes by the planer
There is the danger of cutting yourself or even breaking bones!
Wear only tight clothes.
Do not wear rings or jeweler during work.
If necessary wear a hair-net.
Always put the planer back into the reception case after and before each use.
Only transport the planer at the handle.
Do not touch the planer surfaces.
Switch on the planer only for use. Otherwise the planer will start every time when the security
micro switch is pressed.
2.11.2 Danger of combustion at heating element, protective box and
welding area
You can burn yourself, inflammable materials can ignite!
The heating element is heated up to more than 200°C / 392°F!
Do not touch the surface of the heating element.
Do not leave the heating element unattended.
Take enough safety distance to materials which might be ignited.
Wear safety gloves.
Insert the heating element into the heat protective box after use.
Only transport the heating element at the handle.
2.11.3 Danger of stumbling over hydraulic and electric wires
Make sure that no person has to step over the wires.
Make sure that the cables lie in such a way that the danger is maintained at a minimum.
2.11.4 Risk of injury by noises
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!

Safety rules Chapter 2
19.09.19 Working instructions WIDOS 4955 Page 14 of 39
2.11.5 Danger of crushing by clamping tool and guideways
There is a possibility of serious injury:
- On the one hand between the inner clamping tools and on the other hand between the
outside clamping tool and the end of the guideway.
- Upon opening / closing the clamping tools.
- Upon opening / closing the machine.
- Upon mounting the reducer inserts.
- Upon clamping the pipes.
Do not put hands or foot between clamped pipe ends.
Do not step or grab between the inner clamping tools with not yet clamped pipes.
Do not block opening and closing of the machine.
Keep away others from the clamping area.
2.12. Structural modifications on the machine
No modifications, extensions or reconstructions may be performed on the machine without
permission of the manufacturer.
Machine parts that are not in perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
In case of purchase orders please always note the machine and version number.
2.13. How to clean the machine
The used materials and cloths are to be handled properly and to be disposed of, especially:
during cleaning with solvents
when lubricating with oil and grease
2.14. Guarantee and liability
Fundamentally our "general sales and delivery conditions" are in force.
They are at the buyer's disposal latest before making the contract.
Guarantee and liability demands referring to damages of persons or things are excluded if they are
caused by one or several of the following reasons:
Not using the machine according to the prescription.
Unprofessional transport, building-up, starting, operating and maintenance of the machine.
Running the machine with defective or not properly mounted safety equipment.
Ignoring the information given in this manual.
Structural changes on the machine without permission.
Insufficient checking of machine parts that are worn out.
Unprofessionally performed repairs.
In case of catastrophes and acts of God.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
19.09.19 Working instructions WIDOS 4955 Page 15 of 39
3. Functional description
Basically the international and national standard specifications are to be
fulfilled.
The plastic pipes are clamped by means of the clamping tools.
Then the foreparts are planed parallel by means of the planer, and mismatch is checked.
Now the heating element is inserted and the pipes are pressed against the heating element with the
defined adjusting pressure. This operation is called "adjusting".
After the prescribed bead height is reached, the pressure is relieved and the heat-up time is starting.
Now the pipes are heated up to welding temperature.
After expiration of the heat-up time, the slide has to be opened, the heating element is removed quickly
and the pipes are rejoined. The time between removing the heating element and rejoining the pipes is
called change-over time.
The pipes are joined with the prescribed welding pressure and then cool down under pressure
(cooling time).
The weld joint can be unclamped, the welding process is finished.
Heating element heats the pipes up
to welding temperature
Finished weld joint with internal
and external bead

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
19.09.19 Working instructions WIDOS 4955 Page 16 of 39
4. Operating and indicating elements
4.1. Elements on the hydraulic aggregate
No. Denomination Function
1 Adjusting screw for pressure
relief valve
- For the limitation of the hydraulic pressure to the desired value
2 Screw with oil level stick - Checking the oil-level
- Filling in oil
3 Hydraulic connection for
opening - Non-dropping quick-action hose coupling
4 Hydraulic connection for
closing - Non-dropping quick-action hose coupling
5 Pressure gauge Digital display of the hydraulic pressure
6 Valve lever Opening/closing the slide. There are 4 different positions:
- <Forwards>: slide closes
- in the middle (usual position): the pressure is currently
achieved is kept (also by means of the hydraulic accumulator)
- <Pressure release> (depressurized position): a
possibly existing pressure is released without moving the slide.
Due to the hydraulic accumulator it takes about 10 s until the
pressure is completely released.
- <Backwards>: slide opens
7 Power socket (2 pieces) Connection for planer or heating element
5
6
4
3
1
2
Mains cable
2
30
V
/
50
HZ
Indicating label for opening
/
closing / pressure release
Indicating label setting
t
he
p
ressure relief valve
7

Operating and indicating elements Chapter 4
19.09.19 Working instructions WIDOS 4955 Page 17 of 39
4.2. Basic machine
No. Denomination / Function
8 Inner clamping ring flexible
9 Outer clamping ring flexible
10 Clamping nut with washer and spindle, for clamping the pipes
11 Basic frame part 2, removable
12 Tear off bar, separates the heating element and the heated tubes
13 Inner clamping ring fixed
14 Outer clamping ring fixed
15 Hydraulic hoses, connection with hydraulic aggregate
10
9
11
8 13
14
12
15

Operating and indicating elements Chapter 4
19.09.19 Working instructions WIDOS 4955 Page 18 of 39
4.2.1 How to open/close the clamping ring
Loosen the lock nuts (in front and in the back) and swivel the spindle with locking nut and washer to
the front of the clamping ring (blue arrows).
Then remove the upper part of the clamping ring (red arrow).
4.2.2 Separating device for heating element
There is a tear-off bar mounted between the flexible and
the fixed clamping rings on the basic machine. It
prevents the heating element from sticking to the
heated-up pipe ends.
When inserting the heating element take care that it
lies in the zone of the diminution of the tear-off bar
(see arrow).
Spindle with lock nut and washer, swung in

Operating and indicating elements Chapter 4
19.09.19 Working instructions WIDOS 4955 Page 19 of 39
4.3. Elements at the heating element
No. Denomination Function
16 Control lamp green - There are three different states:
off: signalizes that the heating element is not heated up at
the moment or that it cools down
blinking: the heating element temperature is maintained
by a certain pulse-position ratio
on: signalizes that the heating element is heated up at the
moment. It has not yet reached the desired temperature
17 Setting screw - For regulating the temperature of the heating element
18 On/off-switch with red lamp - As soon as the heating element is switched on, the red
control lamp lightens
19 Connecting cable with plug - Connecting with a socket of hydraulic aggregate
18
17
16
19

Operating and indicating elements Chapter 4
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4.4. Elements at the planer
No. Denomination Function
20 Connecting cable with plug - Connecting with a socket of hydraulic aggregate
21 Locking lever - to lock the planer, thus avoiding a falling out.
- for unlocking pull the locking lever in direction of arrow
22 Safety micro switch - planer can only start when switch is pressed
23 Chain tightening bolt - in order to tighten the chain, disassemble the cap at
the rear of the planer, then tighten the chain sturdily
24 Locking button - if the switch is activated you may press the locking
button, thus the activation is maintained as long as the
switch is deactivated.
25 Switch on / off for planer - to switch on the planer.
- the planer has to be switched off before and after
use.
21 25
20
24
22
23