widos 5000 WM User manual

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH Website: www.widos.de Email: [email protected]
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing directors: Jürgen Dommer, Dr. Kai Dombrowski
Working instructions
Translation
Heating element butt welding machine
WIDOS 5000 WM
15°-clamping tool, additional cylinder and T-90° / T-60° / T-45° (option)
Keep for further use!

Product identification
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Model: Workshop machine
Type: WIDOS 5000 WM
Serial number, year of construction: see type label
Customer entries
Inventory-No.:
Location:
Order of spare parts and sales services
Address of manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstrasse 5
D-71254 Ditzingen-Heimerdingen
Phone: [phone]
Telefax: [phone]
Website: www.widos.de
E-mail: [email protected]

Introduction
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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 this working instruction, 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.
6/23/2015 WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

Contens
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1. DESCRIPTION OF PRODUCT ....................................................................................................................7
1.1. Usage and purpose-oriented use.................................................................................................................. 7
1.2. Safety measures............................................................................................................................................. 7
1.3. Conformity....................................................................................................................................................... 7
1.4. Marking of product......................................................................................................................................... 8
1.4.1. Technical data ................................................................................................................................................................ 8
1.4.1.1. WIDOS 5000 WM general data ..................................................................................................................... 8
1.4.1.2. Basic unit .............................................................................................................................................................. 8
1.4.1.3. Heating element .................................................................................................................................................. 9
1.4.1.4. Planer .................................................................................................................................................................... 9
1.4.1.5. Hydraulic aggregate ........................................................................................................................................... 9
1.5. Wear Parts...................................................................................................................................................... 9
1.6. Tools and Accessories .................................................................................................................................10
2. SAFETY RULES ........................................................................................................................................ 11
2.1. Explanation of the different symbols ...........................................................................................................11
2.2. Obligations of the owner ..............................................................................................................................12
2.3. Obligations of the worker .............................................................................................................................12
2.4. Measure of Organization ..............................................................................................................................12
2.5. Information about safety precautions .........................................................................................................12
2.6. Instructions for the staff...............................................................................................................................12
2.7. Dangers while handling the machine ..........................................................................................................13
2.8. Dangers by electrical energy.......................................................................................................................13
2.9. Dangers by pneumatic and hydraulic ..........................................................................................................13
2.10. Specific dangers ...........................................................................................................................................13
2.10.1. Danger of combustion by heating element and welding area........................................................................13
2.10.2. Danger of crushing between machine tables / clamping tools......................................................................14
2.10.3. Danger of drawing-in of clothes by the planer.................................................................................................. 14
2.10.4. Danger of stumbling over electric wire and pneumatic hose ........................................................................ 14
2.10.5. Risk of injury by noises .......................................................................................................................................... 14
2.11. Structural modifications on the machine ....................................................................................................15
2.12. Warranty and Liability...................................................................................................................................15
3. FUNCTIONAL DESCRIPTION .................................................................................................................. 16
4. OPERATING AND INDICATING ELEMENTS .......................................................................................... 17
4.1. Machine overview.........................................................................................................................................17
4.1.1. How to work with the optional additional cylinder ................................................................................................ 18
4.2. Elements on the operating panel .................................................................................................................19
4.2.1. Emergency - stop - switch.......................................................................................................................................... 20
4.3. Horizontal adjustment (mismatch compensation) ......................................................................................20
4.4. Service unit and pneumatic valves..............................................................................................................21
4.4.1. How to adjust the regulator:....................................................................................................................................... 21

Contens
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4.5. Switch cabinet...............................................................................................................................................22
4.5.1. Main switch................................................................................................................................................................... 23
4.6. How to clamp pipes of 15° (optional)...........................................................................................................23
4.6.1. How to install the reducer inserts (optional)........................................................................................................... 23
4.7. Small clamping tools (optional)....................................................................................................................24
Reduction inserts and pipe supports (optional)...................................................................................................................... 25
4.8. Stub end holder (optional) ............................................................................................................................26
4.9. Clamping tool on machine table...................................................................................................................27
4.9.1. Clamping tools for straight pipes............................................................................................................................... 27
4.9.2. Swivelling clamping tools for angles and bends.................................................................................................... 28
4.9.3. Welding more angles .................................................................................................................................................. 28
5. STARTING AND OPERATING ................................................................................................................. 29
5.1. Safety indications .........................................................................................................................................29
5.2. Starting...........................................................................................................................................................29
5.3. How to set the heating element temperature .............................................................................................30
5.4. Welding process ...........................................................................................................................................30
5.4.1. How to clamp the pipes .............................................................................................................................................. 31
5.4.2. Drag pressure measurement ..................................................................................................................................... 31
5.4.3. How to plane the pipes ............................................................................................................................................... 31
5.4.4. Mismatch compensation ............................................................................................................................................ 32
5.4.5. Adjusting........................................................................................................................................................................ 32
5.4.6. Heating-up..................................................................................................................................................................... 32
5.4.7. Change-over.................................................................................................................................................................. 32
5.4.8. Joining............................................................................................................................................................................ 33
5.5. How to weld angles.......................................................................................................................................33
5.6. How to weld segmented bends ....................................................................................................................34
6. WELDING TABLES .................................................................................................................................. 35
6.1. Formulas for the welding of pipes with different diameters......................................................................35
7. WELDING 90° / 45° / 60°- T .................................................................................................................... 42
7.1. Preparing pipes for t – pieces......................................................................................................................42
7.2. Clamping tools for T–piece 90° ....................................................................................................................44
7.3. Clamping tools for T – piece 45° ..................................................................................................................45
7.4. Clamping tools for T – piece 60° ..................................................................................................................47
8. EQUIPMENT CARE / MAINTENANCE / REPAIR .................................................................................... 49
8.1. Transport........................................................................................................................................................49
8.2. Maintenance, Inspection and repair ...........................................................................................................49
8.3. Clamping elements........................................................................................................................................50
8.4. Planer.............................................................................................................................................................50
8.5. How to check the oil level / how to refill.....................................................................................................50
8.5.1. Used hydraulic oil......................................................................................................................................................... 51

Contens
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8.6. Service unit....................................................................................................................................................51
8.7. Protect machine parts against corrosion....................................................................................................51
8.8. Disposal .........................................................................................................................................................51
9. ELECTRIC, HYDRAULIC AND PNEUMATIC DIAGRAMS .......................................................................52
10. DECLARATION OF CONFORMITY ......................................................................................................80

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH Website: www.widos.de Email: [email protected]
23.06.2015 Working instructions WIDOS 5000 WM Page 7 of 80
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. Usage and purpose-oriented use
The WIDOS 5000 WM is a workshop machine for heating element butt welding of pipes and fittings
OD = 160 – 500 mm.
(Standard-OD: 160 / 180 / 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 / 500 mm).
The machine is screwed tightly on a steel pipes frame in the right working height and has two movable
machine parts (floated supported) with two clamping tools.
For the balance of diameter tolerances the left table half is diagonally movable to the work direction.
For the production of fittings both clamping tools are movable to 15° each.
The machine can weld T-pieces with (optional) T – clamping tools 45° / 60° / 90°; with OD = 500 mm.
By means of an (optional) additional cylinder huge diameters with high nominal pressure ratings may also be
clamped and welded.
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.
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 may be damaged or destroyed.
Persons who stay in the danger area may suffer injuries.
Therefore the working instructions on hand are to be red thoroughly and the corresponding safety
instructions are to be observed by all means.
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.

Description of product Chapter 1
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1.4. Marking of product
The product is marked by type-label.
They contain the machine type, the serial number and the year of construction.
1.4.1. Technical data
All important technical data of the single components are listed.
They permit a rapid information about output and structure.
1.4.1.1. WIDOS 5000 WM general data
Material: PP; PE, PVDF
Size of the pipe: OD = 160 – 500 mm
Power: 400 V (± 10%)
Power: 11,0 kW
Frequency: 50 Hz (± 10%)
Connection: CEE 32 A
Power section: 2,5 mm²
Weight: appr. 900 kg (without package and accessories)
Dimensions (W x H x D) 1600 (1900 with T-60°) x 1500 x 2575 mm
Emissions - Noise exceeding 80 dB (A) may occur; during planing it is
obligatory to wear ear protection!
- In case of use of the prescribed plastic materials and if the work
is performed inside the temperature range up to 260 °C no toxic
fumes will be generated.
Environmental conditions in the
welding area:
- Be aware of cleanliness (no dust at the welding point)
- 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.
- prevent from moisture influence
- avoid strong sun rays radiations
- prevent from strong wind
- Be careful when moving in and out heating element and planer
1.4.1.2. Basic unit
Frame material: Construction steel
Cylinder-/ Piston rod-: 35 / 18 mm
max. force (F = P*A): 14,2 kN at 200 bar
(1 bar on the pressure gauge = 71N)
Cylinder-Ø / Piston rod-Ø
Additional cylinder (optional):
25 / 18 mm
max. force with additional cylinder (F = P*A)
(optional):
18,8 kN at 200 bar
(1 bar on the pressure gauge = 94N)

Description of product Chapter 1
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1.4.1.3. Heating element
Power: 6,4 kW
Voltage: 400 V (10 %)
Amperage: 28,0 A (10 %)
Frequency: 50 Hz
Surface: anti-stick coated
1.4.1.4. Planer
Motor: Monophase-alternative current-universal motor
Power: 1,5 kW
Voltage: 400 V (10 %)
Amperage: 3,4 A
Frequency: 50 Hz (10 %)
Speed planer disc: 18 rpm
1.4.1.5. Hydraulic aggregate
Power: 1,8 kW
Voltage: 400 V (10 %)
Amperage: 3,5 A
Frequency: 50 Hz
Phase shift: appr. 18°
Hydraulic oil tank: appr. 1 L
Type of protection IP 55
Electric motor and pump:
Engine revolution: 1410 (U/min)
max. working pressure of pump: appr. 250 bar
Working pressure: 200 bar
1.5. Wear Parts
Pieces /
machine:
Name: Order no.:
1 Heating plate on request
1 Heating plate in exchange 3575321
8 Heating cartridge Ø 16 x 640 / 800 W / 230 V; AL 0,5 m on request
1 Temperature probe PT 1000 H09082
4 Blade 120 mm MES120
4 Blade 170 mm MES170
40 Flat-head screw M 3x8 (DIN 965) with Torx-drive 0965C008X
1 l Hydraulic oil HLDP35

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1.6. Tools and Accessories
The following tools and accessories is part of the original delivery:
Pieces: Name:
1 Screwdriver TX10
1 Key for switch cupboard
Attention! Hand over the key to authorized personnel only.
each 1 Fork wrench size 22 / 30
1 Socket spanner size 30
1 Allan key with T-grip size 8
1 Allan key tilted size 5

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH Website: www.widos.de Email: [email protected]
23.06.2015 Working instructions WIDOS 5000 WM Page 11 of 80
2. Safety rules
The basic condition for the safety conscious handling and the fault free operation of this machine is the
knowledge of the basic safety advises and rules.
These working instructions contain the most important indications for running the machine according to
the safety regulations.
The safety indications need to be followed by all persons working on the machine.
2.1. Explanation of the different symbols
In the working instructions the following designations and signs are used for potential dangers:
This symbol means a possibly danger for the life and the health of persons by electrical
energy.
The disrespect of these indications may have heavy consequences for the health.
This symbol means a general 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.
The accident prevention measures are valid (UVV).

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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
the workers also must have read and understood the safety chapter of this manual and certify this by their
signature
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged:
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, before working.
2.4. Measure of Organization
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
The working instructions have to be permanently kept at the place of use of the machine. They are to be at
the operator's disposal at any time and without much effort.
In addition to the manual, the common valid and the local accident protection rules and regulations for the
environmental protection must be available and followed.
All safety and danger indications on the machine have to be in a clear readable condition.
Every time the machine changes hands or is being rent by a third person, the working instructions are to
be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
Only skilled and trained persons are allowed to work at the machine.
It must be clearly defined who is responsible for transport, mounting and dismounting, and starting the
operation.
A person who is being trained may only work at the machine under supervision of an experienced person.

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2.7. Dangers while handling the machine
The machine WIDOS 5000 WM 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 use
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately.
2.8. Dangers by electrical 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.
If work is to be done on the parts carrying voltage, a second person has to be consulted who disconnects
the current supply if necessary.
Protect the heating element and planer from rain and dropping water.
2.9. Dangers by pneumatic and hydraulic
System sections which have to be opened in case of repair works have to be depressurized
before starting to repair.
There is a danger of hurting your eyes because of a sudden flow compressed air resp.
squirting hydraulic oil. The hydraulic oil can be hot!
Damaged hydraulic or pneumatic hoses have to be immediately replaced.
Before starting to work make a visual examination of the hydraulic and pneumatic lines.
The hydraulic oil is brackish!
The hydraulic oil is to be handled and disposed of in appropriate manner.
2.10. Specific dangers
2.10.1. Danger of combustion by heating element and welding area
You can burn yourself, inflammable materials can be ignited.
The heating element temperature is heated up to more than 200° C!
Do not touch the surfaces of the heating element.
Do not leave the heating element unsupervised.
Take enough safety distance to inflammable materials.
Do wear safety gloves.

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2.10.2. Danger of crushing between machine tables / clamping tools
Heavy injuries can result from crushing:
upon closing the clamping tools
upon driving in of planer and heating element
upon closing the tables
upon closing the clamping tools
Do not touch in-between clamped pipes.
Do not touch in-between the machine tables during welding
Do not touch planer locking device resp. do not reach between planer locking device and tables while
they are closing resp. while planer or heating element drive in.
Do not interfere the driving in and out of planer and heating element.
Only activate buttons for driving in and out heating element and planer when no part of the body or object
is in the way.
Only close clamping tools when no part of the body is between clamping tool and pipe resp. between
upper and lower part.
2.10.3. Danger of drawing-in of clothes by the planer
You can carry away cut injuries up to fractures!
Do wear formfitting clothes.
Do not wear any rings or jewelry during work.
If necessary wear a snood-type cap.
Take care that no person is standing in the driving area of the planer.
2.10.4. Danger of stumbling over electric wire and pneumatic hose
Pay attention that nobody has to step over the lines or pneumatic hose.
Favorably pass the line and hose in order that the danger is minimized. Do not squeeze and
kink the lines or anything likewise.
2.10.5. Risk of injury by noises
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear protection!

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2.11. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without permission of the
manufacturer. In case of disrespect the warranty or liability will expire resp. the EC declaration of
conformity will get obsolete.
Machine parts which are not in a perfect condition are to be immediately replaced.
Only use original WIDOS spare and wear parts.
In case of purchase orders please always indicate the machine number!
2.12. Warranty and Liability
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 Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH Website: www.widos.de Email: [email protected]
23.06.2015 Working instructions WIDOS 5000 WM Page 16 of 80
3. Functional description
Basically the international and national process guidelines are to be
followed!
First the clamping tools are fixed onto the machine.
For welding angles and bows the clamping tools might be turned on both sides. The plastic pipes are
clamped by means of the clamping tools.
After this the front sides of the pipes are planed parallel and the misalignment of the pipes is checked.
Then the heating element is driven inside and the pipes are pressed onto the heating element under the
defined pressure (this process is called: „adjustment time“).
After reaching the prescribed bead height the pressure is being reduced and this is the start of the heating
time.
The function of this time is to bring the pipe ends onto the welding temperature.
After completion of the heating time the machine is opened the heating element quickly driven out and the
pipes are again driven together hydraulically.
The time gap from driving out the heating element to the joining of the pipes is called change over time.
They are put together with the prescribed welding pressure and then cool down under pressure (cooling
time).
The welding connection can now be unclamped: the welding process is completed.
Welded pipe with inside
and outside bead.
Heating element heats the pipes
up to welding temperature.

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH Website: www.widos.de Email: [email protected]
23.06.2015 Working instructions WIDOS 5000 WM Page 17 of 80
4. Operating and indicating elements
4.1. Machine overview
Machine with 15° clamping tools:
No. Denomination / Function
1 Heating element for heating the pipe ends
2 Protective shield for heating element
3 Left clamping tool, for clamp the pipes
4 Hydraulic pump and tank
5 Left table with horizontal adjustment
6 Hand wheel, for compensating of horizontal mismatch
7 Locking bolt for locking the planer
8 Additional cylinder
9 Planer for planing the pipe ends
10 Right clamping tool, for clamp the pipes
11 Electric switch cabinet
12 Service unti and pneumatic valves
13 Right table
14 Operator panel with scanner and emergency-off switch
15 Holder for additional cylinder
16 Distributor block for connecting additional cylinder
17 Adjusting screw for aligning the machine
1
4
8
9
2
12
6
3 10
7
5
13
11
14
15
16
17

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Machine with small clamping tools:
No. Denomination / Function
18 Left small clamping tool (optional)
19 Right small clamping tool (optional)
4.1.1. How to work with the optional additional cylinder
The additional cylinder is needed for pipes with large diameter and high nominal pressure degree in order to
prevent formation of a gap during an unbalanced strain of the clamping tool.
Plug the pneumatic hoses of the additional cylinder to the distributer block (chapter: 4.1, no. 16) in order to
weld.
The additional cylinder is always mounted on the right machine side onto the clamping tool, even in case the
clamping tools have been exchanged.
Only apply the additional cylinder onto the clamping tools after clamping of the pipes.
You must remove the cylinder and put it on its holder at the right side after welding and before
you open the clamping tools.
Distance between flanges and fork: appr. 20-30 mm
(1 + 2)
(4)
(6)
(5)
18
(7)
19
(8)
(9)
(11)
(12)
14
Holder

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Always disconnect the hydraulic hoses of the additional cylinder from the hydraulic unit if the
cylinder is placed onto the holder on the right side.
In case you disconnect the hoses of the additional cylinder from the machine you are not to
move the tables since the additional cylinder cannot move along.
In case you have driven the machine without connected additional cylinder, then plug the
additional cylinder to the distributor block, drive the tables and the additional cylinder entirely
apart and mount the additional cylinder onto the clamping tools only afterwards.
4.2. Elements on the operating panel
No. Denomination / Function
20 Pressure relief valve, adjust the table pressure (read value from pressure gauge)
21 Stop watch, magnetic (option)
22 Pressure gauge – pressure indication [0 – 250 bar]
23 Emergency - stop – switch,
24* Button: <heater out>, open up heating element and drive it out of machine
25* Sensor: <heater in>, open up heating element and drive it into machine
24 Switch – <limitation> on (1): control lamp illuminates / off (0): control lamp extinguishes
25 Control lever for tables: <Backwards> / <Forwards> / <Pressure release>
26 Switch – <planer> on (1) / off (0)
27* Sensor <Planer out>, drive planer out of machine
28* Sensor – <Planer in> drive planer into machine
* Please keep buttons pressed until the tools have reached their final position.
20
21
22
23
24
25
26
27
28
29
30

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4.2.1. Emergency - stop - switch
The machine has an emergency switch integrated on the operator console.
By pressing an emergency switch, the working process can be interrupted in case of danger for working
piece, tool or person caused by the working pressure.
The emergency switch locks in when activated, the machine stops.
After eliminating the danger, the emergency switch has to be unlocked by rotating or pulling.
In order to return to normal operation, the main switch has to be switched off and on again, and the buttons
<Planer out > and <Heater out > has to be pressed.
There is acute danger of combustion for man and welding parts if the emergency switch is
activated with driven-in heating element since it is heated up and only cools down slowly.
4.3. Horizontal adjustment (mismatch compensation)
The left machine table has a horizontal adjustment in order to
compensate a mismatch of the pipes (arrow).
Loosen the clamping lever and than turn the handwheel for
makeing the misalignment compensation.
Tighten the locking lever again.
Clamping lever (2 pieces)
Hand wheel