widos 2500 / OD 160 User manual

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
Working Instructions
Translation
Heating element butt welding machine
WIDOS 2500 / OD 160
Keep for further use!

Product identification
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 2 of 27
Type: WIDOS 2500 / OD 160
Serial number / year of construction: see type lable
Customer entries
Inventory-No.:
Place of working:
Order of spare parts and after sales service:
Address of manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstrasse 5
D-71254 Ditzingen
Phone: ++49 7152 9939 0
Fax: ++49 7152 9939 40
[email protected]
http://www.widos.de

Introduction
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 3 of 27
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.
30.04.2019 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.

Contents
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 4 of 27
ALL RIGHTS RESERVED. ......................................................................................................................... 3
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.Designation of the product ................................................................................................................. 7
1.4.1.Technical data ..............................................................................................................................................7
1.4.2.Equipment and accessories .......................................................................................................................8
2.SAFETY RULES ................................................................................................................................ 9
2.1.Explanation of the symbols and indications ...................................................................................... 9
2.2.Obligations of the owner ................................................................................................................... 10
2.3.Obligations of the worker .................................................................................................................. 10
2.4.Measure of organisation ................................................................................................................... 10
2.5.Information about safety precautions .............................................................................................. 10
2.6.Instructions for the staff ...................................................................................................................10
2.7.Dangers while handling the machine ............................................................................................... 11
2.8.Specific dangers................................................................................................................................11
2.8.1.Danger of stumbling over electric wires................................................................................................11
2.8.2.Danger of being burnt by heating element and welding area............................................................11
2.8.3.Danger of Cutting and Catching Clothes by the Planer, Danger of Squeezing at the Guide Rods12
2.9.Structural modifications on the machine.........................................................................................12
2.10.Cleaning the machine ........................................................................................................................ 12
2.11.Warranty and liability ........................................................................................................................ 12
3.FUNCTIONAL DESCRIPTION ........................................................................................................ 13
4.OPERATING AND INDICATING ELEMENTS ................................................................................ 14
4.1.Elements on the basic machine ........................................................................................................ 14
4.2.Elements at the heating element ...................................................................................................... 15
4.3.Elements at the planer ...................................................................................................................... 15
4.4.Elements for welding bends- / fittings .............................................................................................16
5.STARTING AND OPERATING ....................................................................................................... 17
5.1.Starting ............................................................................................................................................... 17
5.2.Welding process ................................................................................................................................ 18
5.3.Welding of angles .............................................................................................................................. 20
5.4.Welding segmented bends ................................................................................................................ 20

Contents
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 5 of 27
6.WELDING LOG AND TABLES ....................................................................................................... 21
7.MAINTENANCE / STORAGE / TRANSPORT ................................................................................ 23
7.1.General ............................................................................................................................................... 23
7.2.Clamping elements ............................................................................................................................ 23
7.3.Planer ................................................................................................................................................. 23
7.4.Cleaning the machine ........................................................................................................................ 23
7.5.Transport ............................................................................................................................................ 23
7.6.Disposal .............................................................................................................................................. 23
8.ELECTRIC DIAGRAM .................................................................................................................... 24
9.SPARE PARTS LIST ...................................................................................................................... 26
10.DECLARATION OF CONFORMITY ............................................................................................ 27

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 6 of 27
1. Description of the product
The 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 2500 / OD 160 has been designed for heating element butt welding of pipes and fittings out
of PE, PP and PVDF with a diameter range of OD = 50 – 160 mm, standart diameters: 50 / 63 / 75 / 90 / 110 /
125 / 160 mm.
(OD 20 / 25 / 32 / 40 mm, option).
The following pipes are weldable: OD 50 to 160 mm →SDR 7,25.
The basic clamping device is swivelling up to 15° on each side for welding segmented bends and fittings.
All use going beyond is not purpose-oriented.
The machine is only to be used in a technically perfect condition, as well as purpose-oriented, safety-
and danger-conscious in compliance with the working instructions and the
relevant safety regulations (especially the regulations for the prevention of accidents).
The described plastic welding machine 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!
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 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 thouroughly 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 product Chapter 1
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 7 of 27
1.4. Designation of the product
The product is marked by a type-label at the basic frame.
It contains the type, the serial number and the year of construction of the machine.
1.4.1. Technical data
1.4.1.1. WIDOS ASM 2500 / OD 160 General data
Dimensions of pipes: Outside-Ø = 50 - 160 mm (20 – 40 mm option
Material: PP, PE 80, PE 100
Fuse protection: 16 A
Wire cross section: 1.5 mm²
Emissions - The sound intensity level is appr. 86 dB (A)
- When using the named plastic materials and when
welding within the temperature range up to 260° C no
toxicant damp arises.
Environment - Take care for cleanness (no dust at the welding area)
- Do not weld below 5° C, if necessary preheat
- Avoid humidity, if necessary use a welding tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends
1.4.1.2. Heating element
Power: 800 Watt
Current: 3.5 A (± 10 %)
Voltage: 230 V (± 10 %)
Frequency: 50 Hz
Surface: Nonstick-coated
Attached elements: - Electronic temperature control
- Control lamp
- Connecting cable with plug

Description of product Chapter 1
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 8 of 27
1.4.1.3. Planer
Power: 950 Watt
Current: 4.1 A (± 10 %)
Voltage: 230 V (± 10 %)
Frequency: 50 Hz
Attached elements: - connecting cable with plug
1.4.2. Equipment and accessories
The following tools and accessories are part of the first delivery:
1 Tool bag for 10 parts
1 each Allan key with T-grip, size 4 / 5 / 6 for mounting / dismounting the reduction
inserts
1 each Allan key tilted, size 5 / 6 / 8
1 Fork wrench size 13 (for clamping devices)
1 Torx screw driver T10
For article no. and component parts please see the „spare parts list“, in case of order please always give the machine
number!

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
30.04.19 Working instructions WIDOS 2500 / OD 160 page 9 of 27
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of the basic
safety advises and rules.
These working instructions contain the most important indications 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 due to hot surfaces.
The disrespect of these indications may conduct to heavy burns, respectively to self-
ignition or even fire.
This symbol gives important indications for the proper use of the machine.
The disrespect of these indications may conduct to malfunctions and damages on the
machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
It is a help for using all the functions on your machine in an optimal way and helps you
to make the job easier.
The regulations for the prevention of accidents are valid (UVV).

Safety rules Chapter 2
30.04.19 Working instructions WIDOS 2500 / OD 160 page 10 of 27
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. Measure 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 machine.
They are to be at the operator's disposal at any time and without much effort.
In addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
All safety and danger indications on the machine have to be in a clear readable condition.
Every time the machine changes hands or is being rent 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, and starting
the operation.
A person who is being trained may only work at the machine under supervision of an experienced
person.

Safety rules Chapter 2
30.04.19 Working instructions WIDOS 2500 / OD 160 page 11 of 27
2.7. Dangers while handling the machine
The machine WIDOS 2500 / OD 160 is constructed according to the latest technical standard and the
acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby may occur. Also
material damages are possible.
The machine may only be used
according to the purpose-oriented use
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately
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.
Protect the heating element from rain and dropping water.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-safety switch.
2.8. Specific dangers
2.8.1. Danger of stumbling over electric wires
Make sure that no person has to step over the wires of the heating element and the planer.
2.8.2. Danger of being burnt by heating element and welding area
You can burn yourself, inflammable materials can be ignited.
The heating element temperature is heated up to more than 250° C !
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.
Take care that no person is standing in the swivelling area of the heating element.
When cleaning the hot heating element with detergents (e.g. with PE cleaner) there is the danger of
inflammation. For this reason take care that the inflammation point is above the actual temperature
of the heating element. Do not bring any fire sources (e.g. cigarettes) close thereto.

Safety rules Chapter 2
30.04.19 Working instructions WIDOS 2500 / OD 160 page 12 of 27
2.8.3. Danger of Cutting and Catching Clothes by the Planer, Danger of Squeezing at
the Guide Rods
You can cut yourselve or even get bones broken.
Only wear clothes tight to the body.
Do not wear jewellery during the work.
If necessary, wear hair-net.
Do not touch the faces of the planer.
Take care that no person is standing in the swivelling area of the planer.
Do not grip between clamped pipe endings.
2.9. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer. In cases of non-compliance, any guarantee and liability
demands expire.
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 and version number!
2.10. Cleaning the machine
The used materials and tissues are to be handled and disposed of properly, especially:
when cleaning with solvents
when lubricating with oil and grease
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, starting and operation of the machine and maintenance.
Ignoring the information given in this manual.
Structural changes 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.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 13 of 27
3. Functional description
Basically, the international and national process guidelines are to be followed.
The plastic pipes are clamped by means of 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 heating element is inserted and the pipes are pressed against the heating element under defined
adjusting pressure. This process is called „adjusting“.
The applied force can be read on the scale mounted at the machine.
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
t
emperature
Finished welding
with internal and
external bead

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 14 of 27
4. Operating and indicating elements
4.1. Elements on the basic machine
No. Denomination Function
1 Clamping device, left-hand - Clamping the pipe / fitting
2 Heating element - Heating up the pipes
- Can be swivelled in and out
3 Pipe support, left-hand - Supporting the pipe / fitting
4 Scale - Display of the applied welding force
- max. display: 150 daN (kp)
5 Tension lever - Arresting the support
6 Clamping device, right-hand - Clamping the pipe / fitting
7 Planer - Planing the pipes
- Can be swivelled in and out.
8 Pipe support, right-hand - Supporting the pipe / fitting
9 Cross handle - Opening / closing the support.
- Application of the adjusting force and of the
jointing force.
9
2 7
4
5
1
3
6
8

Operating and indicating elements Chapter 4
30.04.19 Working instructions WIDOS 2500 / OD 160 page 15 of 27
4.2. Elements at the heating element
No. Denomination Function
10 Switch on/off with lamp - As soon as the heating element is switched on, it is heated up.
- The red lamp lightens when the heating element is
connected to the mains.
11 Control lamp, green - There are three different states:
off: signalizes that the heating element is not
heated up at the moment or that it cools down
blinking: the heating element temperature is
maintained by a certain pulse-position ratio
on: signalizes that the heating element is heated up at the moment. It
has not yet reached the desired temperature
12 Adjusting screw - Setting the temperature of the heating element.
13 Grip - Swinging the heating element into / out of the machine
4.3. Elements at the planer
No. Denomination Function
14 Taster - Wenn der Planhobel eingeschaltet ist und der Taster gedrückt wird,
dreht sich die Fräserscheibe
15 Ein / Aus - Schalter - schaltet den Planhobel ein / aus
10
12
11
13
14
15

Operating and indicating elements Chapter 4
30.04.19 Working instructions WIDOS 2500 / OD 160 page 16 of 27
4.4. Elements for welding bends- / fittings
There are severals bore holes on the machine slide as well as an engraved scale for welding bends /
fittings. Tee angles have three bore holes and one long hole.
View onto left table:
When welding straight pipes, the pieces with
the following bore holes are screwed together:
Table 1with angle 6
Table 2with angle 7
When welding bends 0 – 7,5°, the following
bore holes are screwed:
Table 5with angle 8
Table 3with angle 9
When welding bends 7,5 – 15°, the following
bore holes are screwed:
Table 4with angle 8
Table 3with angle 9
View onto left angle:
Tee desired can be read at the reading edge.
Readding edge
for scale

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
30.04.2019 Working instructions WIDOS 2500 / OD 160 page 17 of 27
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. Starting
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 DVWG.
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.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a
FI-security protective switch.
Connect the heating element to the mains (230 V / 50 Hz).
Lay electric lines thoroughly (danger of stumbling) !
Take into account the surrounding conditions:
The welding may not be performed under direct sun rays influence.
If the surrounding temperature is under 5° C, measures have to be taken:
If need be, heat-up the pipe ends.
In addition, take measures against rain, wind and dust.

Starting and operating Chapter 5
30.04.19 Working instructions WIDOS 2500 / OD 160 page 18 of 27
5.2. Welding process
The respectively valid welding prescriptions (ISO / CEN / DVS ...) are to be basically followed.
Do wear safety gloves as a protection against burning!
A stop-watch must be available for recording the actual times for heating up and cooling.
A welding table is to be available from which the parameters (times and forces) for the pipe
dimensions to be welded prescribed by the welding prescriptions may be taken.
The heating element surfaces are to be clean and, above all, free from grease.
Therefore they need to be cleaned with fibre-free paper and a cleaning agent (e.g. PE cleaner) before
each welding or in case of dirtiness.
The anti-adhesive coating of the heating element must remain undamaged in the working area.
Switch on the heating element and set the necessary welding temperature at the adjusting screw at
the handle.
- If the control lamp blinks, the nominal temperature has been reached and is kept constant by
means of a defined pulse-position ratio.
Screw in the reduction inserts according to the outside diameter of the pipes to be welded.
Lay the workpieces into the clamping devices, tighten firmly the clamping nuts and align the pipes
with respect to each other.
Swivel the planer between the ends of the workpieces, switch it on and keep the on-key pressed.
Plane with low pressing force.
Planing has to be carried out until a revolving cutting has been formed on both sides.
Open again the support and swivel out the planer.
Remove the produced cuttings without touching the worked surfaces.
Close the support.
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 0.5 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 adjusting pressure for the pipe dimension to be welded can be gathered from the welding table.
Open support again slightly.
Gather heating time, maximum change over time, cooling time and bead height for the pipe
dimension to be welded from the table.
Swivel in the heating element which has been cleaned and brought to desired temperature.
If necessary wait until the control lamp at the heating element is blinking in regular intervals.

Starting and operating Chapter 5
30.04.19 Working instructions WIDOS 2500 / OD 160 page 19 of 27
Close the support smoothly to the set adjusting pressure.
The applied force can be seen on the scale (3) at the left-hand support.
By means of the tension lever (4), the support can be arrested and the adjusting pressure can be
maintained.
When the prescribed revolving bead height is reached, reduce pressure (heating pressure = approx.
10 % of adjusting pressure).
The heating time starts now. Press the stop-watch and compare the actual time with the nominal time
taken from the welding table.
After expiration of the heating time, loose the tension lever, open the support, swivel out the heating
element as quickly as possible and close the support smoothly.
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, arrest the support and press the stop-watch.
If necessary, re-adjust pressure during the cooling time (the pressure for cooling is the same as the
set adjusting pressure).
After expiration of the cooling time, release pressure, remove the welded parts and open the support.

Starting and operating Chapter 5
30.04.19 Working instructions WIDOS 2500 / OD 160 page 20 of 27
5.3. Welding of angles
When welding angles, the welding surface of the pipe and thus the necessary pressure changes.
Calculate the necessary pressure as follows:
Take the prescribed value for adjusting or cooling from the table.
Multiplicate the pressure value with factor /cos (angle).
This will give the following factors:
Welding 15° (chamfered pipe with 7,5°): 1,01
Welding 22,5° (chamfered pipe with 11,25°): 1,02
Welding 30° (chamfered pipe with 15°): 1,04
Welding 45° (chamfered pipe with 22,5°): 1,08
Welding 60° (chamfered pipe with 30°): 1,15
Welding 90° (chamfered pipe with 45°): 1,41
Add the motional pressure as usual.
All the other welding parameters remain as usual.
5.4. Welding segmented bends
Calculate the sawing angle to be set (corresponding to the required angle at the clamping tools or
clamping inserts) as follows:
Angle of the bend
Sawing angle = -----------------------------------------
number of all welding surfaces
Example: 1 bend of 90°, 4 segments ( 6 welding surfaces)
90°
Sawing angle = ----- = 15°
6
Example: 2 bend of 45°, 3 segments ( 4 welding surfaces)
45°
Sawing angle = ----- = 11,25°
4
Winkel