B E 16000 Optional_SPA_Hydr.aggr. Open-closed_Stub End Holder

Kunststo ffschweitechni k

WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0

W. Dommer Shne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40

website: http://www.widos.de email: [email protected]

Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jrgen Dommer

Working Instructions

Translation Heating element butt welding machine

WIDOS 16000 Optional: SPA-600, hydraulic aggregate, naked / enclosed

Keep for further use!


Product identification

23.03.12 Working Instructions WIDOS 16000 with SPA Page 2 of 88

Model: Heating element butt welding machine

Type: WIDOS 16000 with SPA

Serial number, year of construction: see type label

Customer Entries

Inventory-No.:

Place of working:

Order of spare parts and after sales service:

Address of manufacturer WIDOS

W. Dommer Shne GmbH Einsteinstrasse 5

D-71254 Ditzingen-Heimerdingen

Phone: ++49 7152 / 99 39 - 0

Fax: ++49 7152 / 99 39 - 40

[email protected]

http://www.widos.de

Address of the subsidiary companies:

WIDOS

WIDOS GmbH W. Dommer Shne AG An der Wiesenmhle 15 St. Gallerstr. 93

D-09224 Grna / Sachsen CH 9201 Gossau

Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79

Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73


Introduction


Purpose of the document

These working instructions give you information about all important questions which refer to the construction and the safe working of your machine.

Just as we are, you are obliged to engage in these working instructions, as well.

Not only to run your machine economically but also to avoid damages and injuries.

Should questions arise, contact our service team in the factory or in our subsidiary companies.

We will help you with pleasure.

According to our interest to continuously improve our products and working instructions, we kindly ask you to inform us about problems and defects which occur in exercise.

Thank you.

Structure of the working instructions

This manual is arranged in chapters, which belong to the different using phases of the machine. Due to this structure, the searched information can be easily found.

3/23/2012 WIDOS

W. Dommer Shne GmbH

Einsteinstrae 5

D-71254 Ditzingen-Heimerdingen

All rights reserved.

Reprinting only allowed with permission of the corporation.

Any changes are subject to technical innovations.


Contents


1. DESCRIPTION OF THE PRODUCT .................................................................................... 7

1.1. Usage and purpose-oriented use ...................................................................................7

1.2. Safety measures ..............................................................................................................7

1.3. Conformity........................................................................................................................7

1.4. Machine overview............................................................................................................8

1.5. Designation of the product..............................................................................................8

1.5.1. Technical data................................................................................................................8

1.5.1.1. WIDOS 16000 with SPA General data ................................................................9

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

1.5.1.3. Hydraulic aggregate naked (optional) .....................................................................9

1.5.1.4. Hydraulic aggregate enclosed (optional) ..............................................................10

1.5.1.5. Heating element...................................................................................................10

1.5.1.6. Planer..................................................................................................................10

1.5.1.7. Reception box......................................................................................................10

1.6. Accessories....................................................................................................................11

2. SAFETY RULES................................................................................................................... 12

2.1. Explanation of the symbols and indications ................................................................12

2.2. Obligations of the owner................................................................................................13

2.3. Obligations of the worker ..............................................................................................13

2.4. Measures of organization..............................................................................................13

2.5. Information about safety precautions ..........................................................................13

2.6. Instructions for the staff................................................................................................13

2.7. Dangers while handling the machine............................................................................14

2.8. Dangers caused by electric energy ..............................................................................14

2.9. Specific dangers ............................................................................................................14

2.9.1. Danger of stumbling over electric / hydraulic wires .......................................................14

2.9.2. Dangers caused by the hydraulics................................................................................14

2.9.3. Danger of combustion by heating element, reception box and welding area..................15

2.9.4. Danger of crushing by the guideways...........................................................................15

2.9.5. Danger of catching clothes by the planer......................................................................15

2.9.6. Risk of injury by noise ..................................................................................................15

2.10. Structural modifications on the machine .....................................................................16

2.11. Warranty and liability .....................................................................................................16

3. FUNCTIONAL DESCRIPTION............................................................................................ 17

4. OPERATING AND INDICATING ELEMENTS .................................................................. 18

4.1. Elements on the aggregate ...........................................................................................18

4.2. Elements on the naked aggregate (optional)...............................................................19

4.3. Weld log recording apparatus SPA 600 .......................................................................20

4.4. Elements at heating element.........................................................................................21


Contents


4.5. Elements at the planer...................................................................................................22

4.5.1. Protective motor switch at the planer ...........................................................................22

4.6. Basic machine................................................................................................................23

4.6.1. Tear-off bar for heating element ...................................................................................23

4.7. Special accessory: Stub end holder.............................................................................24

5. STARTING AND OPERATING........................................................................................... 25

5.1. Safety indications...........................................................................................................25

5.2. How to connect the machine with the naked hydraulic aggregate (optional) ............26

5.3. How to connect the machine with the enclosed hydraulic aggregate (optional) .......26

5.4. How to replace the reduction inserts............................................................................27

5.5. How to set the heating element temperature ...............................................................27

6. WELDING PROCESS .......................................................................................................... 28

6.1. Welding with SPA (optional) ..........................................................................................28

6.1.1. Connect the SPA to the hydraulic aggregate ................................................................28

6.1.2. Description of the display .............................................................................................29

6.1.3. How to program the SPA..............................................................................................30

6.1.4. How to set the machine type and pipe data ..................................................................31

6.1.5. How to set the pipe date ..............................................................................................32

6.1.6. Welding process ..........................................................................................................34

6.1.7. How to insert the pipes.................................................................................................34

6.1.8. Drag pressure measurement ........................................................................................34

6.1.9. Dimension....................................................................................................................35

6.1.10. Weather / protection ....................................................................................................36

6.1.11. Planing.........................................................................................................................36

6.1.12. Compensation of mismatch ..........................................................................................37

6.1.13. Bead up .......................................................................................................................37

6.1.14. Heating up....................................................................................................................38

6.1.15. Change over ................................................................................................................38

6.1.16. Pressure ramp .............................................................................................................39

6.1.17. Joining and cooling.......................................................................................................39

6.1.18. Completion of welding ..................................................................................................39

6.1.19. Signification of the error codes ....................................................................................40

6.1.20. How to copy the internal data on SD card and delete internal data (RAM) ....................40

6.2. SD card and drive (optional) .........................................................................................41

6.3. Bar code (optional) ........................................................................................................41

6.4. Read out WICON with USB card reader (optional) .......................................................42

6.5. How to read the welding data ........................................................................................42

6.6. Diagnosis program ........................................................................................................42

6.7. Welding process without SPA.......................................................................................44

7. WELDING LOG AND TABLES........................................................................................... 47


Contents


8. MAINTENANCE, CARE AND REPAIR ............................................................................. 51

8.1. Maintenance and inspection, repair..............................................................................51

8.2. Storage ...........................................................................................................................51

8.3. Clamping elements ........................................................................................................52

8.4. How to clean the machine .............................................................................................52

8.5. How to check and refill the hydraulic oil .......................................................................52

8.6. How to vent the hydraulic cylinders..............................................................................53

8.7. Planer..............................................................................................................................54

8.8. Disposal..........................................................................................................................54

9. TRANSPORT ....................................................................................................................... 55

10. HYDRAULIC AND ELECTRIC DIAGRAMS...................................................................... 56

10.1. Electric diagram with enclosed hydraulic aggregate...................................................56

10.2. Electric diagram with naked hydraulic aggregate........................................................65

11. SPARE PARTS LIST ........................................................................................................... 71

11.1. Basic machine................................................................................................................71

11.2. Heating element .............................................................................................................73

11.3. Planer..............................................................................................................................75

11.4. Hydraulic aggregate......................................................................................................77

11.5. Hydraulic aggregate naked (optional)...........................................................................79

11.6. SPA-600 ..........................................................................................................................81

11.7. Protection box................................................................................................................84

11.8. Stub end holder (optional).............................................................................................86

12. DECLARATION OF CONFORMITY .................................................................................. 88






1. Description of the 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 16000 has been designed for heating element butt welding of pipes and fittings with a diameter range of = 500mm 1600 mm / option =24 (609 mm) - 48 (1600 mm).

Pipes with = 1600 mm / option = 48 can be clamped without any reducer insert.

It is a machine for construction sites and particularly designed for the usage on-site, as well as in the workshop. For this reason, the frame is kept small so that it can be used even under difficult conditions (e.g. ditch).

All use going beyond is not purpose-oriented.

The manufacturer is not responsible for damages caused by misuse.

The risk is held only by the user.

Also part of the purpose oriented use is

respecting all the indications of the working instructions and

performing the inspection and maintenance work.

1.2. Safety measures

In case of wrong use, wrong operation or wrong maintenance, the machine itself or products standing nearby can be damaged or destroyed.

Persons being in the endangered area may be injured.

Therefore these working instructions have to be thoroughly read and the corresponding safety regulations must be necessarily adhered to.

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 the product Chapter 1


1.4. Machine overview

1 Basic machine with clamping devices

2 Planer

3 Heating element

4 Protection box

5 SPA-600

6 Hydraulic aggregate enclosed (optional)

7 Hydraulic aggregate naked (optional)

no picture Lift (optional)

1.5. Designation of the product

The product is designated by type labels which are attached at the aggregate, at the heating element, at the planer and at the basic machine. They contain the type, the serial number and the year of construction of the machine.

1.5.1. Technical data

All important technical data of each machine part is listed.

This allows quick information on performance and installation.

4

3

6

2

1

5

7




1.5.1.1. WIDOS 16000 with SPA General data

Pipe diameter range: outside = 1000 - 1600 mm

Material which can be welded: PP, PE80, PE 100

Weight (without accessories): appr. 2200 kg

Emissions - Noise 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 260C no toxicant damp arises

Ambient conditions in the welding

area

- take care for cleanness (no dust at the welding area)

- If secured by an appropriate measurement that allowed

conditions for welding are indicated, it is possible to work

in any outside temperature condition as far as the welder

is not constrained in its manual skill. avoid humidity, if

necessary use a welding tent

- avoid strong sun rays influence

- protect from wind, shut the pipe ends

1.5.1.2. Basic frame

Material frame: Structural steel

Material reduction inserts: Steel

cylinder / piston rod: 63 / 32

Stroke length of cylinder: 450 mm

Max. force (F=P*A): 46 kN (at p= 100 bar)

Weight appr. 1400 kg

1.5.1.3. Hydraulic aggregate naked (optional)

Feeding CEE-16A - Phase converter

Power: 2 kW

Voltage: 400 V ( 10%)

Frequency: 50 Hz

Hydraulic oil tank: ca. 10 L

Power hydraulic pump 1,8 kW

Nominal current 3,52 A

Speed: 1380 - 2820 rpm

Max. working pressure of pump: appr. 160 bar

Working pressure: 0-160 bar adjustable

Weight: appr. 45 kg




1.5.1.4. Hydraulic aggregate enclosed (optional)

Feeding CEE-63 A - Phase converter

Power: 50 kW

Voltage: 400 V ( 10%)

Frequency: 50 Hz

Hydraulic oil tank: ca. 10 L

Power hydraulic pump 2,6 /3,1 kW

Nominal current 5,5 / 7,6 A

Speed: 1380 - 2820 rpm

Max. working pressure of pump: appr. 160 bar

Working pressure: 0-160 bar adjustable

Weight: appr. 56 kg

1.5.1.5. Heating element

Feeding CEE 63A - Phase converter

Power: 41 kW

Voltage: 400V (+-10%)

Current: 63 A (+-10%)

Frequency: 50 Hz

Outside-: 1750 mm

Surface: non-stick-coated

Attached elements: - Electronic temperature control

- Control lamps, on/off-switch

- Connecting cable with 63 A plug

Weight: appr. 245 kg

1.5.1.6. Planer

Motor: Three-phase alternating current motor

Power: 4,0 kW

Voltage: 400 V (+-10%)

Nominal current 9,1 A

Feeding CEE-16A - Phase converter

Frequency: 50 Hz (+-10%)


1.5.1.7. Reception box

Dimension: appr. 2050 x 1090 x 2050 mm





1.6. Accessories

Following tools and accessories are part of the delivery:

1 Socket spanner size 46

1 Allan key size 14

1 Allan key size 8

1 Fork wrench size 19

1 Fork wrench size 36

1 Wire rope galvanized 1 single wire 0,5m 10 mm

8 16

Reduction insert OD 1400 in clamping devices OD 1600 mm Pan-head screw M 16 x 60 DIN 912

8 16

Reduction insert OD 1200 in clamping devices OD 1600 mm Pan-head screw M 16 x 60 DIN 912

8 16

Reduction insert OD 1000 in reduction insert OD 1600 mm Pan-head screw M 16 x 60 DIN 912






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.

These working instructions contain the most important indications to run the machine safely.

The safety indications are to be followed by all persons working on the machine.

2.1. Explanation of the symbols and indications

In the working instructions, following denominations and signs are used for dangers:

This symbol means a possibly danger for the life and the health of persons.

The disrespect of these indications may have heavy consequences for the health.

This symbol means a possible dangerous situation.

The disrespect of these indications may cause slight injuries or damages on goods.

This symbol means a possible dangerous situation by moving parts of the machine

The disrespect of these indications may cause heavy crushings of parts of the body resp. damages of parts of the machine.

This symbol means a possible dangerous situation due to hot surfaces.

The disrespect of these indications may conduct to heavy burns, respectively to self-ignition or even fire.

This symbol means a possible risk of injury by noise 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 will get tips and particularly important information.

This shall help you to use all functions of the machine in an optimal way and makes the work easier for you.

The regu l a t i on s for t h e preven t i on o f acc i den ts a re va l i d (UVV) .


Safety rules Chapter 2


2.2. Obligations of the owner

The owner is obliged only to let persons work at the machine, who

know about basic safety and accident prevention rules and are instructed in the handling of the machine, as well as who

have read and understood the safety chapter of this manual and certify this by their signature.

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

2.3. Obligations of the worker

All persons who are to work at the machine are obliged before working:

To follow the basic safety and accident protection rules.

To have read and understood the safety chapter and the warnings in this manual and to confirm by their signature that they have well understood them.

To inform themselves about the functions of the machine before using it.

2.4. Measures of 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 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 to third persons, the working instructions are to be sent along with and their importance is to be emphasized.

2.6. Instructions for the staff

Only skilled and trained persons are allowed to work at the machine.

It must be clearly defined who is responsible for transport, mounting and dismounting, starting the operation, setting and tooling, operation, maintenance and inspection, repair and dismounting.

A person who is being trained may only work at the machine under supervision of an experienced person.




2.7. Dangers while handling the machine

The machine WIDOS 16000 with SPA is constructed according to the latest technical standard and the acknowledged technical safety rules. However, dangers for the operator or other persons standing nearby may occur. Also material damages are possible.

The machine may only be used

according to the purpose-oriented usage

in safety technical impeccable status

Disturbances which may affect the safety of the machine must be cleared immediately.

2.8. Dangers caused by electric energy

Only skilled persons are allowed to work at electrical appliances! The electrical equipment of the machine has to be checked regularly. Loose connections and damaged cables have to be replaced immediately.

All electric tools (heating element, planer and aggregate) have to be protected from rain and dropping water (if need be use a welding tent).

If work at alive parts are necessary, a second person has to assist who can disconnect the machine from the mains if necessary.

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 / hydraulic wires

Pay attention that nobody has to step over the lines.

Logically lay the lines in order that the danger is minimized. Do not squeeze and kink the lines or anything likewise.

2.9.2. 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!




2.9.3. Danger of combustion by heating element, reception box and

welding area

You can burn yourself, inflammable materials may ignite.

The heating element temperature is heated up to more than 200C!

Do not leave the heating element unsupervised.

Do not touch the surfaces of the heating element

Take enough safety distance to inflammable materials.

Do wear safety gloves.

Switch the heating element off after usage.

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

Transport the heating element at the handle only.

2.9.4. Danger of crushing by the guideways

There is a danger of serious injuries: on the one hand between the inner clamping devices and on the other hand between the outer clamping device and the end of the guideway.

Do not stand or put hands between clamped pipe ends.

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

Do not block opening and closing of the machine slides.

2.9.5. Danger of catching clothes by the planer

You can cut yourself or even get bones broken! With some machines there is a short rubbing of the planer by activating the machine although the planer is not switched on!

Only wear clothes tight to the body.

Do not wear rings or jewellery during the work.

If necessary, wear a hair-net.

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

Transport the planer at the handle only. Do not touch the surfaces.

2.9.6. Risk of injury by noise

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




2.10. Structural modifications on the machine

No modifications, extensions or reconstructions may be made on the machine without permission of the manufacturer.

Machine parts which are not in a perfect condition are to be replaced immediately.

Only use original WIDOS spare and wear parts.

In case of purchase orders please always state the machine number!

2.11. Warranty and liability

Fundamentally our "General Sales and Delivery Conditions" are valid.

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

Guarantee and liability demands referring to personal injuries or damages on objects are excluded if they are caused by one or several of the following reasons:

not using the machine according to the prescriptions

inexpert transport, mounting, starting, operating, and maintenance of the machine

running the machine with defective or not orderly mounted safety appliances

ignoring the information given in this manual

structural modifications on the machine without permission

unsatisfactory checking of parts of the machine, which are worn out

repairs performed in an inexpert way

In case of catastrophes and force majeure





23.03.12 Working Instructions WIDOS 16000 with SPA page 17 of 88

3. Functional description

Basical ly, the in ternational and national process gu idel ines are to

be fol lowed!

The plastic pipes are clamped in the clamping devices.

Then the front sides of the pipes are cut plane and parallel by means of the planer and the misalignment of the pipes is checked.

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

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

After the prescribed bead height being reached, pressure is reduced, the heating time begins. The function of this time is to heat up the pipe ends.

After expiration of the heating time, the slides are opened, the heating element is removed quickly and the pipes are driven together again.

The time gap from the removal of the heating element to joining the pipes is called change over

time.

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

(cooling time).

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

Heating element heats

the pipes up to welding

temperature

Finished welding with

internal and external

bead






4. Operating and indicating elements

4.1. Elements on the aggregate

No. Denomination Function

1 Push-button - By pressing the push-button the motor switches over to high speed

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

- To the left side: slides close.

- in the middle (usual position): the pressure which is currently achieved is kept (also by means of the built-in hydraulic accumulator)

- slightly to the right side (depressurized position): a possibly existing pressure is released without Moving the slides. Due to the hydraulic accumulator, It takes about 10 s until the pressure is completely released.

- to the right side: slides open

3 Setting screw for pressure relief valve

- Limitation of the pressure to the desired value.

4 Electrical socket 63 A connection for heating element

5 Pressure gauge Display of the hydraulic pressure

6 Electrical socket 230 V connection for SPA 600 (optional)

7 Electrical socket 16 A, connection for planer

8 SPA 600 Surveillance and the logging of butt welds

9 Sealing cap - open in order to e.g. check the oil level

10 Screw with oil dipstick - to determine the oil level - oil filler neck

11 Hydraulic connections Connection for hydraulic hoses from basic machine

5 2

3

11

4

7

6

8 1

9 - 10


Operating and indicating elements Chapter 4


4.2. Elements on the naked aggregate (optional)


12 Push-button - By pressing the push-button the motor switches over to high speed

- Without pressing the push-button, the motor drives with normal speed.

13 Valve lever To open the slides. There are 4 different positions:

- To the left side: slides close.

- in the middle (usual position): the pressure which is currently achieved is kept (also by means of the built-in hydraulic accumulator)

- slightly to the right side (depressurized position): a possibly existing pressure is released without Moving the slides. Due to the hydraulic accumulator, It takes about 10 s until the pressure is completely released.

- to the right side: slides open

14 Setting screw for pressure relief valve

- Limitation of the pressure to the desired value.

15 Hydraulic connection for closing the slides

- Non-dropping quick-action coupling

16 Hydraulic connection for opening the slides

- Non-dropping quick-action coupling

17 Pressure gauge - Display of the hydraulic pressure

18 Screw with oil dipstick - to check the oil level - oil filler neck

12

13

17

16 18

14

15




4.3. Weld log recording apparatus SPA 600

No. Denomination

19 Display

20 Bar code-reading pen (optional)

21 Buttons for operation

22 Drive for the SD card

23 Interface for barcode reading pen

24 Connecting cable

25 Holder for T-pieces

26 Plug box for the heating element (when 230 V)

Plug box for heating element probe (when400V)

27 Outside temperature probe

20

19

21

25 26 27 22 23

24




4.4. Elements at heating element


28 Lifting eye nut - Possibility to suspend the heating element

29 Grips - To hold and adjust the heating element into machine

or protective box

30 Visible type fuse Fuse protection for the temperature regulator

31 Temperature regulator - To set the required temperature.

32 Plug with connecting cable - To connect to the power supply

33 Temperature sensor cable - Connection to SPA 600 (option)

34 On / off switch with control lamp red

- to switch the heating element on / off

31

29

28

34

32

30

33




4.5. Elements at the planer


35 Lifting eye nut Possibility to suspend the planer

36 Eye To suspend from the basic machine

37 ON / OFF Switch To switch the planer on / off

38 Locking device To secure planer in the basic machine

39 Connecting cable CEE 16 A Power supply for planer with plug

4.5.1. Protective motor switch at the planer

Always activate/deactivate the planer with the switch (27) at the motor.

Switching-off the planer at the motor protective plug should only happen in exceptional circumstances since the red push button work as overload protection at the same time.

This means if e.g. the pressure of the planer is too high, it shuts off automatically.

In this case reduce the pressure on the planer and start the planer by the power switch at the protective motor switch.

If the red control lamp lightens, the planer turns in the wrong direction. Necessarily change the turning direction.

OFF

ON

Control lamp

36

35

39

37

38




4.6. Basic machine


40 Clamping ring fix - Maintains clamped pipe

41 Spindle with clamping nut - To clamp the pipes

42 Lifting eye nut - Possibility to suspend the basic machine

43 Support - may be disassembled if necessary

44 Tear-off bar - to separate the heating element from the pipe ends after heating

45 Clamping ring flexible - Maintains clamped pipe) - Drives clamped pipe to and fro

46 Couplings - to connect with the hydraulic aggregate

47 Couplings - to connect with the hydraulic aggregate

4.6.1. Tear-off bar for heating element

There is a tear-off bar mounted between the movable and the fixed clamping shells 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).

40

42

41

43

45

46

47

44




4.7. Special accessory: Stub end holder

In order to weld a cap or flange to a pipe you must use the stub end holder to fix the pieces. Clamp the stub end e.g. into the left clamping tool with its front face towards the center of the machine.

Open the clamping tool.

Pick up the stub end holder with belts from a crane and place it with its stub end into the lower clamping tool.

Fix the stub end holder to the lower clamping tool by three countersunk screws.

Shut and tighten the clamping tool again.

Fix the cap/flange onto the stub end holder by the clamping claws.

Mount the clamping claws according to the outer diameter of the cap/flange onto the stub end holder.

Drill holes to hang up

Clamping claws to clamp the pieces

Countersunk drilling to fix to the clamping tool

Stub end to clamp

Put cap / flange here

Hexagon socket nut for the clamping

Screw to adjust the distance of clamping claw to stub end holder






5. Starting and operating

The instructions of this chapter are supposed to initiate in the operation of the machine and lead during the appropriate starting of the machine.

This includes:

- the safe operation of the machine

- using all the possible options of the machine

- economic operation of the machine

5.1. Safety indications

The machine may only be operated by initiated and authorized persons. For the qualification, a plastic welding exam can be taken according to DVS and DVGW. In situations of danger for persons and the machine, the mains plug has to be unplugged immediately. After completion of the welding work and during breaks the machine has to be switched off. Further take care that no unauthorized person has access. Protect the machine from wetness and humidity!

Only skilled labors 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.

System parts and pressure hoses must be depressurized before the beginning of any repair work. Even if the machine is switched off, there could still be pressure in the hydraulic accumulator! There is a danger of injuring the eyes by hydraulic oil squirting out. Check the oil level of the hydraulic system before each starting in order to avoid damages on the pump. The oil level has to be between the two marks on the oil

level measuring bar. The oil must be absolutely located above the lower red marking and appr. In the middle of the inspection glass.

Replace defective hydraulic hoses immediately. Before starting the welding operations, make a visual check of the hydraulic lines. The hydraulic oil is inedible!

The heating element surfaces must be clean, especially non greasy, therefore they need to be cleaned shortly before each welding or in case of dirtiness by

means of a fiber-free paper and a cleaning agent (e.g. PE cleaner or pipe cleaning tissues which are available at the WIDOS company).

The anti-adhesive coating of the heating element must remain undamaged in the working area.

Take into account the surrounding conditions: The welding may not be performed under direct sun rays influence. Use a welding umbrella if necessary.

If the surrounding temperature is under 5C / 41F, measures have to be taken: - Use a welding tent or preheat the pipe ends if necessary. - In addition, take measures against rain, wind and dust.


Starting and operating Chapter 5


5.2. How to connect the machine with the naked hydraulic

aggregate (optional)

Put the hydraulic hoses of the basic machine into the quick-action couplings of the hydraulic aggregate in order to weld (chapter: 4.2, no: 15 + 16).

Connect the mains plug of the planer to the local power supply, observe correct mains voltage (CEE 16A / 400 V / 50 Hz, right-hand rotary field).

Connect the mains plug of the heating element to the local power supply (125 A / 400 V / 50 Hz).

Connect the mains plug of the naked hydraulic aggregate to the local power supply observe correct mains voltage (CEE 125 A / 400 V / 50 Hz, right-hand rotary field).

Connect the mains plug of the SPA - 600 to the local power supply (230 V / 50 Hz).

Observe correct mains voltages. Lay the hydraulic and electric wires carefully (danger of stumbling).

Verify whether hydraulic pump and planer are connected clockwise

5.3. How to connect the machine with the enclosed hydraulic

aggregate (optional)

Put the hydraulic hoses of the basic machine into the quick-action couplings of the hydraulic aggregate in order to weld (chapter: 4.1 no: 11).

Connect the mains plug of the planer to the enclosed hydraulic aggregate, observe correct mains voltage (CEE 16A / 400 V / 50 Hz, right-hand rotary field).

Connect the mains plug of the heating element to the enclosed hydraulic aggregate, observe correct mains voltage (125 A / 400 V / 50 Hz).

Connect the mains plug of the enclosed hydraulic aggregate to the local power supply observe correct mains voltage (CEE 125 A / 400 V / 50 Hz, right-hand rotary field)

Connect the mains plug of the SPA 600 to the enclosed hydraulic aggregate, observe correct mains voltage

Observe correct mains voltages. Lay the hydraulic and electric wires carefully (danger of stumbling).

Verify whether hydraulic pump is connected clockwise!


Starting and operating Chapter 5


5.4. How to replace the reduction inserts

Pipes with OD (1600 / option 48) have to be clamped in the basic clamping devices.

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

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

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

5.5. How to set the heating element temperature

Display = Display of the actual value Push shortly button P (1), the display shows , change desired value with buttons (3) (2). Push shortly button P (1), the actual temperature is displayed again (or automatic change after 30s). During heating up to desired value, the control lamp K2 (4) is on. As soon as the desired temperature is reached, the control lamp K2 (4) is blinking.

Material Temperature

PE 80 The value for heating element temperature is between (200C 220C *).

PE 100

The standard value for heating element temperature is (220C).

Increase the change-over time and the welding pressure time at PE 100 as fast

as possible!

PP The standard value for heating element temperature is (210C 10C *).

PVDF The standard value for heating element temperature is (240C +/- 8C *).

* The smaller the pipe wall the higher the temperature.

Spacer shaft

Support

Fix reducer inserts here






6. Welding process

The respec t i ve l y va l i d w e l d i n g prescr i p t i on s ( ISO / CEN / DVS. . . ) a re

t o be bas i ca l l y f o l l ow ed.



Do wear safety gloves as a protection against combustion.

There is danger of catching by the planer! Dont touch the planer surfaces.

You may run the machine quickly in order to drive the slides back and forth as well as for the change-over by:

Pressing (Chapter:4.1, Nr. 6) and on FORWARDS or BACKWARDS.

In order to carry out planing and for the joining you must select the slow speed:

With on FORWARDS or BACKWARDS without pressing

.

6.1. Welding with SPA (optional)

6.1.1. Connect the SPA to the hydraulic aggregate

5

2

3

4

6

1 7


Welding process Chapter 6


Put the SPA onto the hydraulic aggregate (arrow) and screw 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 1600 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 (63 A / 400 V / 50 Hz / right hand rotary field).

6.1.2. Description of the display


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




6.1.3. How to program 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 initialized).

Display: 2nd line:

WIDOS GmbH Germany

after 3 s:

Display: 2nd line:

version 0.00.0 sernr 000000

Number of the software version Serial number of the machine

after 3 s:

Display: 2nd line:

000 free weldings 0000 SD card

Number of free memory capacity (RAM) Number of free memory capacity SD card

after 3 s:

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Display of the currently set machine type Current time and date

alternating with: 21C HE= - - - C current outside and heating element temperature

B a s i c m e n u

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 .

Diagnosis menu by pressing simultaneously and .




6.1.4. How to set the machine type and pipe data

Abort and back to basic menu by pressing button .

You can one step back by pressing buttons (keeping pressed) and .

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011



by pressing simultaneously buttons and Next menu

Display: 2nd line:

Copy _

The data is stored from internal RAM to SD-card by Next menu by pressing button

Display: 2nd line:

lang. English ?

Select the language

Select the language with buttons and Next menu by pressing button

Display: 2nd line:

Traceability No

Traceability can be select

Press button for Yes

Confirm Yes or No by pressing button In case traceability has been confirmed with yes, the display indicates:

Display: 2nd line:

Pipe length No

Select pipe length for traceability

Press button for Yes

Confirm Yes or No by pressing button

Display: 2nd line:

shortened cooling no

Select the shortened cooling time




Press button to select for Yes

Confirm Yes or No by pressing button

It is allowed to use the shortened cooling time under the following

conditions:

- Welding material: PE and PP

- Prefabrication 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: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Select the machine type

Select the machine type with buttons and Next menu by pressing button

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Enter the time

Enter the time with buttons and Next menu by pressing button

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Enter the date

Enter the date with buttons and

Next menu by pressing button

6.1.5. How to set the pipe date

You can abort the process and back to basic menu by pressing button .

One step back by pressing button (keeping pressed) and button .

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011



By pressing simultaneously buttons and , the pipe data can be changed over the keyboard

or if a reading pen is available, the pipes data can be read with the reading pen (do not press any other button before and move the pen quickly over the bar code).




Display: 2nd line:

mat diam wall PE80 16000 14.6

Set the pipe material

Change the material by pressing buttons and , confirm with button the material and jump to next parameter

Display: 2nd line:


Set the pipe diameter

Change the pipe diameter by pressing buttons and , confirm with button and jump to next parameter.

Display: 2nd line:


Set the wall thickness

Change the wall thickness by pressing buttons and , confirm with button and jump to next parameter.

Display: 2nd line:

angle temp 0.00 214C

Set the angle (appears only if angles can be welded with the set machine)

Change the angle by pressing buttons and , confirm with button ; the heating element temperature according to DVS cannot be changed.

Display: 2nd line:

name of project WIDOS.............

Change the name of project by pressing buttons and , confirm with button .

Display: 2nd line:

number of joint 0000

Change the joint number by pressing buttons and , (during welding process, the counter continues starting from the set joint number) confirm with button .

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011






6.1.6. Welding process

As soon as the SPA 600 is programmed and connected to the hydraulic aggregate / mains as described, you can start welding. Please proceed as follows: Switch on the heating element and heat it up to welding temperature. Open and close the basic machine two or three times by means of the valve lever of the hydraulic aggregate.(FORWARDS and BACKWARDS).

6.1.7. How to insert the pipes

Lay the pipes into the clamping devices and take care that the upper clamping rings are mounted with the locking forks showing to the machine center. Tighten firmly the clamping nuts, respectively close the clamping cylinders and align the pipe ends with respect to each other.

Always use WIDOS rollerstands for the alignment.

6.1.8. Drag pressure measurement

When the pressure is > 2 bar, the SPA switches from basic menu to drag pressure measurement. Slowly press the valve lever until the slide of the basic machine is closed. The drag pressure must be determined properly since a too high pressure on small pipe diameters leads to incorrect joining forces. Release the valve lever.

Drag pressure must be at least 3 bar!

Display: 2nd line:

drag pressure OK? P0=0 Pi=4

Display of the actual pressure P0 = desired pressure; Pi = actual pressure

When pressing , the actual pressure is taken over as drag pressure.




6.1.9. Dimension

In case traceability has been confirmed with yes, the display indicates.

Display: 2nd line:

please read in 1st pipe

Either: Read in traceability of the first pipe via the bar code reading pen Or: Simultaneously pres all buttons .

Then manually enter barcode of 1st pipe: Select first digit with and

jump to the next digit with .

Display: 2nd line:

please read in 2nd pipe

Either Read in traceability of the second pipe via the bar code reading pen Or: Simultaneously pres all buttons .

Then manually enter barcode of 1st pipe: Select first digit with and

jump to the next digit with .

Display: 2nd line:

dimension PE80 90 2.2

Display of: Material, pipe diameter and wall thickness

Confirm the dimensions by pressing , or interrupt the welding process by pressing and enter new dimensions.

Only appears in case the pipe length has been selected:

Display: 2nd line:

length pipe 1 +000.00 mm

Enter pipe length of the 1

st pipe by .

Or: Simultaneously pres all buttons . Then manually enter barcode of 1

st pipe: Select first digit with and jump to

the next digit with .

Display: 2nd line:

length pipe 2 +000.00 mm

Either: Enter pipe length of the 1

nd pipe by

Or: Simultaneously pres all buttons . Then manually enter barcode of 1

st pipe: Select first digit with and jump to

the next digit with .




6.1.10. Weather / protection

Display: 2nd line:

weather protect 34 24

Weather character and protective measures to be taken (according to DVS prescriptions).

Weather character Protective measures

1 = sunny 1 = none

2 = dry 2 = umbrella

3 = rain or snow fall 3 = tent

4 = wind 4 = heater In case of multiple statement respect the above mentioned

order of the numbers (e.g.: 34 = rain and wind)

Set the weather data by pressing buttons and ; confirm the weather data by pressing button

Display: 2nd line:

atten! shortened cooling time

Display of shortened cooling time

6.1.11. Planing


Lift planer with the crane and insert it between the pipe ends, lock it and switch it on; the pressure onto the planer may not exceed 20 bar.

Display: 2nd line:

planer OK? P0=0 Pi=14

Display of: Drag pressure and actual pressure

Move the pipe ends onto each other by means of the valve lever and cut them plane until a circular cutting running 2-3 times around the pipe ends is formed and the pipe ends are plane.

The planing pressure should be at appr. 15 - 20 bar + drag pressure.

Move the pipes away from each other.

In case there are too many chips stop planer and remove them.

Necessarily take care that no chips will be drawn-in between the planer

discs.

You must carry out planing as long as a revolving chip (three times) has formed.

Separate the pipes, with on BACKWARDS until the chip

will tear off, only then switch off planer.

Detach the planer locking device and lift crane out of the machine again. Remove the produced chips without contacting the worked surfaces.




Confirm planing by pressing .

Abort and back to basic menu by pressing .

One menu step back by pressing (keep pressed) and .

6.1.12. Compensation of mismatch

Move pipe ends onto each other, press the control lever on FORWARDS.

Display: 2nd line:

alignment T=210C Pi=12

Display of: Heating element temperature and actual pressure

After releasing the pressure, the following message appears:

Display: 2nd line:

alignment OK? T=210C Pi=12


If alignment of the pipes is correct, open the machine and confirm with button . The mismatch may not exceed 10 % of the wall thickness. In case of higher mismatch, readjust the pipe ends in the clamping devices and repeat the planing process. Open pipe ends with on BACKWARDS Abort the welding process by pressing button .

6.1.13. Bead up

Lift planer with the crane and insert it between the pipe ends.

Close pipes, < control lever > on FORWARDS.

Take care that the heating element lies in the zone of the

diminution of the tear-off bar.




Display: 2nd line:

bead up Ps=15 Pi=3

Display of: desired and actual pressure

alternating with

Display: 2nd line:

bead up T=210C Pi=3


Slowly increase pressure until actual pressure = desired pressure (when desired pressure is reached, a beep sound can be heard). Maintain pressure until the pipe end lays completely at the heating element and a bead according to DVS has been formed.

6.1.14. Heating up

Reduce pressure with < control lever> on:Pressure release until the heating pressure is = 0 the SPA control switches to heating.

Important ! Do not open the basic machine.

Display: 2nd line:

heat up t=54s Pi=0

Display of: Remaining time for heating and actual pressure

alternating with

Display: 2nd line:

heat up T=210C Pi=0


At the end of the heating time, the button flashes and a beep sound can be heard.

6.1.15. Change over

Press button .

Open tables quickly therefore press the button and move on BACKWARDS until the heating element detaches from both pipe ends.

Remove heating element out of the machine quickly and move pipe ends together on FORWARDS.

Display: 2nd line:

chg. over t=4s Pi=0

Remaining change over time and actual pressure




6.1.16. Pressure ramp

Increase continuously pressure up to desired pressure within the prescribed time for the pressure ramp.

Display: 2nd line:

ramp t=2s Pi=6


6.1.17. Joining and cooling

Display: 2nd line:

cooling t=3:32 Pi=12

Remaining cooling time (minutes) and actual pressure

alternating with

Display: 2nd line:

cooling Ps=12 Pi=12

Comparison desired and actual pressure

In case of decrease of pressure during cooling time, a beep sound can be heard. Readjust pressure onto desired pressure.

6.1.18. Completion of welding

Display: 2nd line:

SD card 0000

Welding parameters will be saved on the SD card (if present). 0000 = Number of weldings saved on the SD card.

Welding parameters are stored to the SD card (if available).

Display: 2nd line:

tabl. of errors parameter OK

Display in case of a fault-free welding.

Only appears if shortened cooling time has been selected:

Display: 2nd line:

shorten cooling t parameter OK

Or:

Display: 2nd line:

tabl. of errors TAWURtp9

Display of the errors occurred during welding (s. chapter 6.1.19 ).




Release pressure, with on Pressure release

Do not open the basic machine!

Release clamping nuts and remove upper clamping rings.

Remove welded part.

Open machine with auf BACKWARDS.

Confirm the end of the welding with .

6.1.19. Signification of the error codes

T Heating element temperature

A Bead up

W Heating

U Change over

R Pressure ramp

t Cooling time

p Cooling pressure

9 Environmental temperature < 0 C

6.1.20. How to copy the internal data on SD card and delete internal data

(RAM)

Abort and back to basic menu by pressing button . One step back by pressing buttons (keeping pressed) and .

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Basic menu

Next step by pressing simultaneously buttons and .

Display: 2nd line:

copy _

By pressing you can copy the data from the internal memory onto the SD card. Only displayed if no card is in the drive:

Display: 2nd line:

error SD card

Message appears if there is no SD card in the drive

Confirm the error message by pressing .

When an error occurs, these error codes are also displayed in the first line of the display during the welding process.




Next step by pressing button .

Display: 2nd line:

delete SPA-RAM?

Delete internal memory (RAM) by pressing button .

When pressing button , the internal memory (RAM) will not be deleted.

Display: 2nd line:

copy _

Press several times button or after a short while appears automatically:

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011



bas ic menu

6.2. SD card and drive (optional)

The SPA 600 can be equipped optionally with a drive for a SD card.

The apparatus then stores the welding data in the internal memory as well as on the SD card if a card is in the drive.

On a card with 64 MB memory capacity, the welding data of about 32000 weldings can have place.

The SD card must be formatted with FAT16 before usage.

Insert the card with the arrow to the top and in direction of the arrow (socket side) carefully and with a low pressure into the reading unit.

The card can be read out with a WICON program (optional).

The card may not be bent, opened, overheated and become wet!

Please only use SD cards purchased from WIDOS. We will not be liable for any cards from other manufactures!

6.3. Bar code (optional)

For reading the bar code, glide smoothly over the bar code with the bar code reading pen (maintained vertically).

The reading pen is ready as soon as the red light at its end is on.




6.4. Read out WICON with USB card reader (optional)

You may read out the welding data onto a PC by the USB card reader. Remove the card from the SD card drive of the ESI 4000.

Remove the rear cap and plug card according to the image into the USB card reader. Remove the front cap and plug USB card reader into the USB interface in your PC. As soon as the USB card reader has been plugged, it appears as removable medium in the drive list. Open the WIDOS folder, there you will find: - WICON2000 viewer for considering and printing the welding data,

- working instructions for WICON2000 viewer as PDF file.

6.5. How to read the welding data

The battery-buffered memory (RAM) can store about 400 weldings.

Make sure not to go over this quantity (in the display the error message "memory full appears) because otherwise the first stored welding (001) will be overwritten (if necessary, read the welding data on the SD card out in time).

6.6. Diagnosis program

The purpose of the diagnosis program is the control and the modification of stored machine parameters. In the following lines all important diagnosis numbers for the function tests are described.

Inappropriate operation of the diagnosis functions may lead to disturbances in the machine and may destroy components. The diagnosis functions allow a direct access to the specific parameters of the machine and have to be operated only by skilled staff.

Display: 2nd line:

WIDOS 16000 SPA 09:43 03.09.2011

Basic menu

Press simultaneously buttons and to enter the diagnosis program from the basic menu.

Display: 2nd line:

WIDOS 16000 SPA 0000

Enter the diagnosis number




Enter the required diagnosis number by pressing buttons , and . One step back by pressing buttons (keeping pressed) and .

No. Signification

0010 - The actual temperature (C) of the heating element is displayed

0011 - The environmental temperature (C) is displayed

0012 - The pressure or the force (bar or N) is displayed

0014 - The required heating time which was calculated by the programmed welding parameters is displayed

0015 - The required change over time which was calculated by the programmed welding parameters is displayed

0016 - The required time for pressure ramp which was calculated by the programmed welding parameters is displayed

0017 - The required cooling time which was calculated by the programmed welding parameters is displayed

0018 - The required cooling pressure is displayed

0022 - Selection of SDR / wall thickness in the display

0000 mm 0002 SDR

0023 - The automatic change to summer or winter time may be switched on or off

0000: change summer / winter time switched off 0001: change summer / winter time switched on

0027 - All internal values, such as printing offset, temperature straight line ramp, etc. are displayed on the laptop

0030 - All stored weldings are deleted

When entering 0001, all weldings stored in the RAM memory up to that time are deleted

0034 - Bit values from 0-1023 appear which will change together with the change of the corresponding analogue values

8 Environmental temperature 9 Heating element temperature NTC 10 Pressure (4-20 mA) 11 Heating element temperature PT 1000




6.7. Welding process without SPA

The respec t i ve l y va l i d w e l d i n g prescr i p t i on s ( ISO / CEN / DVS. . . ) a re

t o be bas i ca l l y f o l l ow ed.


Do wear safety gloves as a protection against burning.

There is danger of catching by the planer! Dont touch the planer surfaces.


You may run the machine quickly in order to drive the slides back and forth as well as for the change-over by:

Pressing (Chapter: 4.1, Nr. 6) and on FORWARDS or BACKWARDS.

In order to carry out planing and for the joining you must select the slow speed:

With on FORWARDS or BACKWARDS without pressing

.

A stop-watch must be available for recording the actual times for heating and cooling.

A welding table must be available from which the parameters for the pipe dimensions to be welded prescribed by the welding prescriptions may be taken.

The heating element surfaces must be clean, especially non greasy, therefore they need to be cleaned shortly before each welding or in case of dirtiness by means of a fiber-free paper and a cleaning agent (e.g. PE cleaner).

The anti-adhesive coating of the heating element must remain undamaged in the working area.

Switch on the heating element and set the required welding temperature (standard value for

PE-HD: 210C) at the thermo regulator (chapter:5.5).

Screw in the reduction inserts according to the outside diameter of the pipes to be welded.

Lay the pipes to be welded into the clamping devices, tighten firmly the clamping nuts and align the pipes with respect to each other. In case of long pipe ends, use WIDOS roller stands for that purpose.

Close the slides on FORWARDS thereby reading the movement pressure on the pressure gauge. The movement pressure is displayed exactly when the slide with the clamped pipe passes, over into its movement.

Open slides on BACKWARDS.




Lift planer with the crane between the clamping tools and fix with the planer locking device into the basic machine. Switch the planer on and cut the pipes until a surrounding (triple) chip is

formed. The pressure onto the planer may not exceed 15 bar. You must carry out planing as long as a revolving chip (three times) has formed.

In case there are too many chips stop planer and remove them.

Necessarily take care that no chips will be drawn-in between the planer

discs!

Separate the pipes, with on BACKWARDS until the chip will tear off, only

then switch off planer.

Detach the planer locking device and lift crane out of the machine again. Remove the produced chips without contacting the worked surfaces.

Shut slides, on FORWARDS.

Check pipe mismatch and gap on the joining pipe ends. According to DVS 2207, the mismatch on the pipe outer side must not exceed 0.1 x pipe wall thickness, the admissible gap must not exceed 1.5 mm. The mismatch compensation is carried out by further tightening or releasing of the clamping nuts. In case mismatch compensation was carried out, planing must be repeated afterwards.

The adjustment pressure for the pipe dimension to be welded can be gathered from the welding table. Add the movement pressure.

Set the resulting pressure value at the pressure relief valve and check it by actuating the valve lever.

Open slides again slightly, on BACKWARDS.

Gather heating time, maximum change over time, cooling time and bead height for the pipe dimension to be welded from the table.

Move the heating element which has been cleaned and brought to desired temperature between the pipes with the crane.

Shut slides smoothly to the set adjustment pressure, on FORWARDS. When the prescribed revolving bead height is reached, reduce pressure. For this purpose, move the Pressure release until the desired heating pressure is built up (heating pressure = approx. 10% of the adjustment pressure).

Important! Do not open the basic machine!

Take care that it lies in the zone of the diminution

of the tear-off bar, if required displace the shaft.




The heating up time starts now. Press the stop-watch and compare the actual time with the nominal time taken from the table.

After expiration of the heating time, open the slide quickly with button on valve lever and on BACKWARDS, remove the heating element as quickly as possible. Then close the slide smoothly, on FORWARDS.

The maximum time frame for this process is predetermined by the value for the change over time taken from the table.

When the welding pressure is built up, press the stop-watch and keep the for approximately 10s on position FORWARDS so that the hydraulic accumulator can be filled. During the cooling time re-adjust pressure, if necessary (the pressure for cooling is the same as the set adjustment pressure).

After expiration of the cooling time release pressure with on Pressure release and remove the upper reducer inserts.

Important! Do not open the basic machine!

Release clamping nuts.

Remove upper clamping rings.

Remove the welded part and open the slide with on BACKWARDS.

Weld i n g i s compl e ted .






7. Welding log and tables


Foundation: 2207, 2208 DIN 16932 German association for weldingUse for: 16000

1 bar on manometer: 463 N

PE 80 The value for heating element temperature is between 200 C - 220 C.The smaller the pipe wall the higher the temperature.

PE 100 The standard value for heating element temperature is 220 C.Increase the change-over time and the welding pressure time at PE 100 as fast as possible !

time to

change- reach full

over welding cool-down time

0,15 (PE) time pressure pressure in

Tdesired temperature

time

pipe pipe SDR bead-up circular heat-up max. time welding cool-diameter wall pressure bead time change- to reach pressure downOD (s) [bar] min. [s] over welding [bar] time[mm] [mm] [mm] time pressure [min]

[s] [s]

1000 24,5 41 25 2,5 245 12 13 25 30

1000 30,6 33 31 3,0 306 14 16 31 37

1000 38,2 26 38 3,5 382 16 20 38 46

1000 56,7 17,6 55 4,0 567 22 28 55 67

1000 59,3 17 57 4,0 593 22 30 57 69

1200 29,4 41 36 3,0 294 13 16 36 36

1200 36,7 33 44 3,0 367 16 19 44 45

1200 45,9 26 54 3,5 459 19 23 54 55

1200 68,0 17,6 79 4,0 680 24 34 79 78

1400 34,4 41 48 3,0 344 15 18 48 42

1400 42,9 33 60 3,5 429 18 22 60 52

1400 53,5 26 74 4,0 535 21 27 74 64

1600 39,2 41 63 3,5 392 17 20 63 48

1600 49,0 33 78 3,5 490 20 25 78 59

1600 57,2 28 90 4,0 572 22 29 90 67

1600 61,2 26 96 4,0 612 23 31 96 71

Remaining under the cool-down time for up to 50% is allowed under the following conditions: prefabrication under workshop conditions low additional pressure at unclamping no additional pressure during further cooling down load onto the workpieces only after being completely cooled down

in welding area

Table for PE

bead-up heat-up

Additional to the given bead-up force and to the welding force the moving force of the support must be added !

welding area

P (N/mm)

23.03.2012 Working instructions WIDOS 16000 Page 49 of 88


Foundation: 2207, 2208 DIN 16932 German association for weldingUse for: 16000

1 bar on manometer: 463 N

time to

change- reach full

over welding cool-down time

0,10 (PP) time pressure pressure in

Tdesired temperature

time

pipe pipe SDR bead-up circular heat-up max. time welding cool-diameter wall pressure bead time change- to reach pressure downOD (s) [bar] min. [s] over welding [bar] time[mm] [mm] [mm] time pressure [min]

[s] [s]

1000 24,5 41 17 1,5 385 11 21 17 38

1000 30,6 33 21 2,0 436 12 26 21 46

1000 38,2 26 25 2,5 492 14 33 25 56

1200 29,4 41 24 2,0 426 12 25 24 45

1200 36,7 33 29 2,0 483 14 32 29 55

1200 45,9 26 36 2,5 536 16 40 36 65

1400 34,3 41 32 2,0 464 13 30 32 51

1400 42,9 33 40 2,5 519 15 37 40 62

1400 53,5 26 49 3,0 574 18 46 49 73

1600 39,2 41 42 2,5 498 15 34 42 58

1600 49,0 33 52 2,5 554 17 42 52 69

1600 61,2 26 64 3,0 605 19 52 64 81

Remaining under the cool-down time for up to 50% is allowed under the following conditions: prefabrication under workshop conditions low additional pressure at unclamping no additional pressure during further cooling down load onto the workpieces only after being completely cooled down

in welding area

The smaller the pipe wall the higher the temperature.

P (N/mm)

bead-up heat-up

Table for PP

Additional to the given bead-up force and to the welding force the moving force of the support must be added !

The standard value for heating element temperature is 210 C +/- 10 C.

welding area

23.03.2012 Working instructions WIDOS 16000 Page 50 of 88






8. Maintenance, care and repair

Goal of the chapter is:

Keeping the nominal state and the operation capacity of the machine.

Increasing the efficiency by avoiding non-planned outage.

Efficient planning of the maintenance work and the maintenance tools.

8.1. 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 a specially high usage percentage the testing cycle should be shortened. The work should be performed at the WIDOS GmbH company or by an authorized partner.

The operators are to be informed prior to the maintenance and repair work.

In general, take care for cleanness!

Handle the machine carefully.

Check the tightness of detached screws every 3 months.

Immediately replace damaged parts, take especially care with electric parts.

The linear guides for heating element and planer must be cleaned every week

e.g. with a brush. Check the linear guide carriages every 3 months and grease them over the lubricating nipple if necessary. Chips or other impurities in the guides can be the cause if the heating element or the planer jam or run heavily.

Clean the piston rods every month with an oily tissue.

Check the hydraulic connections every month on their tightness, tighten again if necessary.

Check the tightness of detached screws every 3 months.

Having completed the maintenance work, check the security devices on their function. Especially check the resistance of isolation, electric strength and protective conductor.

8.2. Storage

The cylindrical waves of the basic machine are to be kept free from dirtiness and need to be covered with a thin oil film if they are not being used.

Store dry.


Maintenance, care and repair Chapter 8


8.3. Clamping elements

For a long service life clean and grease regularly the threaded spindles and the joint parts which are used for clamping the pipes.

8.4. How to clean the machine

The used material and substances for cleaning the machine are to be properly handled and disposed of, especially:

upon cleaning with solvents

upon lubricating with oil and grease.

8.5. How to check and refill the hydraulic oil

Prior to each starting of the machine check oil level of the hydraulic unit in order to avoid damages.

Open the cover of hydraulic aggregate.

Detach the red cover screw on the top of the tank.

Clean the oil di

Documents

B E 16000 Optional_SPA_Hydr.aggr. Open-closed_Stub End Holder