widos SPA 600 User manual

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
Weld log recording apparatus
WIDOS SPA 600
Keep for further use !

Product identification
08.05.2019 Working Instructions WIDOS SPA 600 Page 2 of 42
Model: Weld Log Recording Apparatus
Type: WIDOS SPA 600
Serial number, year of construction: see nameplate
Customer entries
Inventory No.:
Place of working:
Order of spare parts and after sales service
Address of manufacturer WIDOS
Wiolhelm Dommer Söhne GmbH
Einsteinstr. 5
D -71254 Ditzingen
Phone: ++49 7152 9939 0
Fax: ++49 7152 9939 40
[email protected]
http://www.widos.de

Introduction
08.05.2019 Working Instructions WIDOS SPA 600 Page 3 of 42
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 apparatus.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your apparatus economically but also to avoid damages and injuries.
Should questions arise, contact our service team in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest to continuously improve our products and working instructions, we kindly ask
you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters which belong to the different using phases of the apparatus.
Due to this structure, the searched information can be easily found.
08.05.2019 WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 4 of 42
1.DESCRIPTION OF THE PRODUCT....................................................................................... 6
1.1.Usage and purpose-oriented use................................................................................................6
1.2.Safety measures.........................................................................................................................6
1.3.Conformity..................................................................................................................................6
1.4.Structure of the SPA...................................................................................................................7
1.5.Designation of the product .........................................................................................................7
1.5.1.Technical data ..................................................................................................................7
1.5.1.1.WIDOS SPA 600 General data ......................................................................................8
1.6.Equipment and accessories:.......................................................................................................8
2.SAFETY RULES ................................................................................................................. 9
2.1.Explanation of the symbols and indications ................................................................................9
2.2.Obligations of the owner ............................................................................................................9
2.3.Obligations of the worker ........................................................................................................ 10
2.4.Measures of organisation........................................................................................................ 10
2.5.Information about safety precautions ...................................................................................... 10
2.6.Instructions for the staff .......................................................................................................... 10
2.7.Dangers while handling the apparatus..................................................................................... 10
2.8.Dangers due to electric energy ............................................................................................... 11
2.9.Specific dangers ..................................................................................................................... 11
2.9.1.Danger of stumbling over electric wires ........................................................................... 11
2.10.Structural modifications on the apparatus ............................................................................... 11
2.11.Warranty and liability .............................................................................................................. 11
3.FUNCTIONAL DESCRIPTION ........................................................................................... 12
4.OPERATING AND INDICATING ELEMENTS...................................................................... 13
5.STARTING, OPERATING.................................................................................................. 14
5.1.Safety indications.................................................................................................................... 14
5.2.Connecting the SPA 600 with the hydraulic aggregate for machines from 250C up to
315C and 4400 up to 6100 ......................................................................................................... 14
5.3.How to connect the SPA to the hydraulic aggregate from 6100 steel version ........................... 15
5.4.How to connect the SPA to the closed hydraulic aggregate, from WIDOS 6100 steel
version upwards...................................................................................................................... 16
5.5.Description of the display........................................................................................................ 17
5.6.Programming the SPA ............................................................................................................. 18
5.6.1.Setting the machine types ............................................................................................... 19
5.6.2.Setting the pipe data....................................................................................................... 21
5.7.Welding process ..................................................................................................................... 22
5.7.1.Drag pressure measurement ........................................................................................... 22
5.7.2.Dimension ..................................................................................................................... 23

Description of product Chapter 1
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5.7.3.Weather / protection (except for workshop machines)....................................................... 24
5.7.4.Planing.......................................................................................................................... 24
5.7.5.Compensation of mismatch ............................................................................................. 25
5.7.6.Bead up......................................................................................................................... 25
5.7.7.Heating up ..................................................................................................................... 26
5.7.8.Change over .................................................................................................................. 26
5.7.9.Pressure ramp ............................................................................................................... 26
5.7.10.Joining / cooling............................................................................................................. 27
5.7.11.Completion of welding .................................................................................................... 27
5.7.12.Signification of the error codes........................................................................................ 28
5.7.13.Copying the internal data on SD - card and deleting internal data (RAM) ............................. 28
5.7.14.Welding double pipes ..................................................................................................... 29
5.7.15.Setting the pipe data for welding double pipes.................................................................. 30
5.8.SD card and drive.................................................................................................................... 31
5.9.Bar code (Optional) ................................................................................................................. 32
5.10.Read out WICON with USB card reader (Optional) .................................................................. 32
5.11.Reading the welding data ........................................................................................................ 32
6.DIAGNOSIS PROGRAM................................................................................................... 33
7.EQUIPMENT CARE / MAINTENANCE / REPAIR ................................................................ 35
7.1.Storage ................................................................................................................................... 35
7.2.Cleaning the apparatus............................................................................................................ 35
7.3.Maintenance and inspection, repair ........................................................................................ 35
7.4.Saving the welding data .......................................................................................................... 35
7.5.Disposal .................................................................................................................................. 36
8.TRANSPORT................................................................................................................... 37
9.WIRING DIAGRAMS ....................................................................................................... 38
10.SPARE PARTS LIST......................................................................................................... 41
11.DECLARATION OF CONFORMITY ..................................................................................... 42

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 6 of 42
1. Description of the product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the apparatus are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS SPA 600 has been designed only for the surveillance and the logging of butt welds in
combination with a butt welding machine designed by WIDOS.
All use of the SPA going beyond is not purpose oriented.
The described SPA may only be operated, maintained and repaired by persons who are trained and
informed about the dangers.
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!
The SPA is reliable in the use when it is used according to the prescriptions in connection with a
welding machine designed by WIDOS.
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. Safety measures
In case of wrong use, wrong operation or wrong maintenance, the apparatus 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. Conformity
The apparatus 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 apparatus were made very carefully.

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1.4. Structure of the SPA
No. Denomination
1 Display
2 SD card
3 Bar code reading pen (optional)
1.5. Designation of the product
The product is designated by a nameplate.
It contains the type, the serial number and the year of construction of the apparatus.
1.5.1. Technical data
All important technical data of each single component are listed. This allows a quick information about
working capacity and structure.
1
3
2

Description of product Chapter 1
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1.5.1.1. WIDOS SPA 600 General data
Dimension (l x w x h):
Weight:
appr. 390x270x210 (mm)
6.3 kg
appr. 390x270x210 (mm)
6.3 kg
Power: 15 Watt 15 Watt
Voltage: 230 V (10%) 110 V (10%)
Current: 100 mA 200 mA
Frequency: 50 Hz 60 Hz
Insulation system: IP 44 IP 44
See spare parts list for order numbers and single pieces.
1.6. Equipment and accessories:
Optional - Drive for SD card
- Bar code reading pen with accessories
- Adapter for NTC heating element
- Heating element adapter necessary when welding without SPA

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 9 of 42
2. Safety rules
The base for the safe handling and the fault-free operation of this apparatus is the knowledge of the
basic safety indications and rules.
These working instructions contain the most important indications to run the apparatus
safely.
The safety indications are to be followed by all persons working with the apparatus.
2.1. Explanation of the symbols and indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possible danger for the life and the health of persons.
The non-respect of these indications may have heavy consequences for the health.
This symbol means a possible dangerous situation.
The non-respect of these indications may cause light injuries or damages on goods.
This symbol gives important indications for the proper use of the apparatus.
The non-respect of these indications may conduct to misfunctions and damages on
the apparatus 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 apparatus in an optimal way and helps
you to make the job easier.
The regulations for the prevention of accidents are valid (UVV).
2.2. Obligations of the owner
The owner is obliged only to let persons work with the apparatus who
know about basic safety and accident prevention rules and are instructed in the handling of the
apparatus, as well as who
have read and understood the safety chapter of this manual and certify this by their signature.
The safety-conscious working of the staff has to be checked in regular intervals.

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2.3. Obligations of the worker
All persons who are to work with the apparatus 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 apparatus before using it.
2.4. Measures of organisation
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
The working instructions have to be permanently kept at the place of use of the apparatus.
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 apparatus have to be in a clear readable condition.
Every time the apparatus changes hands or is being rent to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
Only skilled and trained persons are allowed to work with the apparatus.
It must be clearly defined who is responsible for transport, mounting and dismounting,
starting the operation and dismounting.
A person who is being trained may only work with the apparatus under supervision of an
experienced person.
2.7. Dangers while handling the apparatus
The apparatus SPA 600 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 apparatus should only be used
According to the purpose oriented usage;
In safety technical impeccable status.
Disturbances which may affect the safety must be cleared immediately.

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2.8. Dangers due to electric energy
Only skilled persons are allowed to work at electrical appliances.
If works at alive parts are necessary, a second person has to assist who can disconnect
the apparatus from the mains if necessary.
The electrical equipment of the apparatus has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-safety switch.
2.9. Specific dangers
2.9.1. Danger of stumbling over electric wires
Make sure that no person has to step over the wire connection to the heating element.
2.10. Structural modifications on the apparatus
No modifications, extensions or reconstructions may be made on the apparatus without permission
of the manufacturer. In case of non-compliance, any guarantee and liability demands shall expire.
Parts of the apparatus which are not in a perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
In case of purchase orders please always state the number of the apparatus and the version!
2.11. Warranty and liability
Fundamentally our "General Sales and Delivery Conditions" are valid.
They are at the owner's disposal latest when signing the contract.
Guarantee and liability demands referring to personal injuries or damages on objects are
excluded if they are caused by one or several of the following reasons:
Not using the apparatus according to the prescriptions;
Inexpert transport, mounting, starting, operating, and maintenance of the apparatus;
Ignoring the information given in this manual;
Structural modifications on the apparatus without permission;
Unsatisfactory checking of parts of the apparatus which are worn out;
Repairs performed in an inexpert way;
In case of catastrophes and force majeure.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 12 of 42
3. Functional description
After entering the type of the plastic material, the pipe diameter and the wall thickness (if necessary
also of the environmental temperature), the weld log recording apparatus (SPA) 600 calculates the
respective parameters which are necessary for performing a welding process with a corresponding
welding machine of company WIDOS.
The welding processes are logged and can be stored on a SD - card.
The respective pipe data are entered manually by means of the four buttons or with the corresponding
pipe data card provided with a bar code which has to be read by the (optional) bar code reading pen.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 13 of 42
4. Operating and indicating elements
No. Denomination
1 Bar code reading pen (optional)
2 Display
3 Buttons for operation
4 Drive for the SD card
5 Interface for barcode readind pen
6 Connecting cable
7 Holder for T-pieces
8 -Plug box for the heating element (when 230 V)
-Plug box for heating element probe (when 400 V)
9 Outside temperature probe
1
2
3
78 9
4 5
6

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
08.05.2019 Working Instructions WIDOS SPA 600 Page 14 of 42
5. Starting, operating
The instructions of this chapter are supposed to initiate in the operation of the apparatus and lead
during the appropriate starting of the apparatus.
This includes:
- The safe operation of the apparatus;
- Using all the possible options of the apparatus;
- Economic operation of the apparatus.
5.1. Safety indications
The apparatus may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and DVGW.
After completion of the welding work and during breaks the apparatus has to be switched
off. Further take care that no unauthorized person has access.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-security protective switch.
Take care that all hydraulic and electric connections are connected.
Secure the heating element connection (connection to the temperature probe) by means of the
safety stirrup.
Be sure of safe power supply. Only use regulated power aggregates with 40% standby
capacity (= appr. 3 kW) !
5.2. Connecting the SPA 600 with the hydraulic aggregate for
machines from 250C up to 315C and 4400 up to 6100
Put the SPA onto the hydraulic
aggregate (arrow) and screw it (1).
Connect the T-piece (2) with the frontal hydraulic connection of the hydraulic aggregate.
Connect the corresponding hose (3) of the basic machine, e.g. WIDOS 4600 or another
type of WIDOS machines.
1
2
3
4
5
1
1

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Connect the heating element with the special plug to the SPA (5).
Connect the power plug of the SPA (4) with one of both plug boxes of the hydraulic aggregate or an
external plug box.
Connect the planer with the remaining plug box of the hydraulic aggregate or an external plug box.
Connect the power plug of the hydraulic aggregate to the mains and be sure to have the correct
voltage (230 V (400 V) / 50 Hz).
5.3. How to connect the SPA to the hydraulic aggregate from 6100
steel version
Put the SPA onto the hydraulic aggregate (arrow) and screw it (1).
Connect the T-piece (2) to the upper hydraulic connector of the hydraulic aggregate
Connect the suitable hydraulic hose (3) of the basic machine e.g. WIDOS 6100 steel version to this
spot.
Put the special plug of the heating element into the multipolar power socket at the SPA (5) and
secure by the bracket.
Connect the plug (4) of the SPA to the power socket (6) at the hydraulic aggregate.
Connect the mains plug of the hydraulic aggregate to the power supply, observe the correct voltage
(230 V (400 V) / 50 Hz).
2
1
(2)
3
4
6
5

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5.4. How to connect the SPA to the closed hydraulic aggregate,
from WIDOS 6100 steel version upwards
Put the SPA onto the hydraulic aggregate (arrow) and screw it (1).
Put the SPA onto the hydraulic aggregate (arrow) and fix it (1).
In case the T-piece (2) is not mounted to position, remove it from holder (7) and connect it to the
upper hydraulic connector of the aggregate.
Connect both hydraulic hoses (3) of the basic machine e.g. WIDOS 6100 steel version there.
Put the special plug of the heating element into the multipolar power socket at the SPA (5) and
secure by the bracket.
Connect the plug (4) of the SPA to the power socket (6) at the hydraulic aggregate.
Connect the mains plug of the hydraulic aggregate to the power supply, observe the correct voltage
(32 A (400 V) / 50 Hz).
5
2
3
4
6
1 7

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5.5. Description of the display
No. Denomination Function
1 Display - Displays the necessary parameters (for welding and
programming).
- Two values can be displayed at the same time.
2 Buttons for operation - Drag pressure measurement;
- Setting the pipe data and the project number;
- Setting the type of the machine;
- Printing the welding data;
-Diagnosis menu;
-Reset to the previous item of the menu.
1
2

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5.6. Programming the SPA
As soon as the mains plug of the SPA 600 is connected to a plug box (mains / hydraulic aggregate), the
display is lightened (the computer is being initialised).
Display:
2. line:
WIDOS GmbH
Germany
after 3 s:
Display:
2. line:
version 0.00.0
sernr 000000
Number of the software version
Serial number of the machine
after 3 s:
Display:
2. line:
000 free weldings
0000 SD card
Number of free memory capacity (RAM)
Number of free memory capacity SD card
after 3 s:
Display:
2. line:
WIDOS 4600 SPA
09:43 03.05.2004
Display of the currently set machine type
Current time and date
alternating with: 21°C HE= - - - °C current
outside and heating element temperature
„Basic menu“
In the basic menu, following possibilities are given:
The welding process is started by the drag pressure measurement.
Setting the pipe data and the project number by pressing simultaneously <+> and <>.
The pipe data can also be read from the pipe data card with the bar code reading pen.
Setting the machine type and printing the welding data by pressing simultaneously
<> and <Enter>.
Diagnosis menu by pressing simultaneously <+> and <Enter>.

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5.6.1. Setting the machine types
Abort and back to basic menu by pressing button <C>.
One step back by pressing buttons <Enter> (keeping pressed) and <->.
Display:
2. line:
WIDOS 4600 SPA
09:43 03.05.2004
Display of the currently set machine type
Current time and date
alternating with: 21°C HE= - - - °C current
outside and heating element temperature
Next menu by pressing simultaneously buttons <-> and <Enter>
Display:
2. line:
Copy
_
The data is stored from internal RAM to SD-card by <+>
Next menu by pressing button<Enter>
Display:
2. line:
lang. english ?
Select the language
Select the language with buttons <+> and <->
Next menu by pressing button <Enter>
If welding double pipes is possible, the message appears:
Display:
2. line:
pipe in pipe
No
Select double pipe welding
Press button <+> for Yes
Confirm Yes or No by pressing button <Enter>
Display:
2. line:
Traceability
No
Traceability can be select
Press button <+> for Yes
Confirm Yes or No by pressing button <Enter>

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In case ttraceability has been confirmed with „yes“, the display indicates:
Display:
2. line:
Pipe length
No
Select pipe length for traceability
Press button <+> for Yes
Confirm Yes or No by pressing button <Enter>
Display:
2. line:
shortened cooling
no
Select the shortened cooling time
Press button <+> for Yes
Confirm Yes or No by pressing button <Enter>
It is allowed to use the shortened cooling time under the following conditions:
-Welding material: PE and PP
-Prefabrikation under workshop conditions
-Low additional pressure at unclamp
-No additional pressure during further cooling down
-Load onto the workpieces only after being completely cooled down
Display:
2. line:
WIDOS 4400 SPA
09:43 03.05.2004
Select the machine type
Select the machine type with buttons <+> and <->
Next menu by pressing button <Enter>
Display:
2. line:
WIDOS 4400 SPA
09:43 03.05.2004
Enter the time
Enter the time with buttons <+> and <->
Next menu by pressing button <Enter>
Display:
2. line:
WIDOS 4400 SPA
09:43 03.05.2004
Enter the date
Enter the date with buttons <+> and <->
Next menu by pressing button <Enter>