widos 2500 / OD 250 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
Headquarters: D 71254 Ditzingen Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating element butt welding machine
WIDOS 2500 / OD 250
Keep for further use!

Kunststoffschweißtechnik
Product identification
01.02.2012 Working instructions WIDOS 2500 / OD 250 Page 2 of 45
Type: WIDOS 2500 / OD 250
Serial number: / year of construction: see type plate
Customer entries
Inventory no.:
Place of working:
Order o spare parts and a ter sales service:
Address o manu acturer WIDOS
W. Dommer Söhne 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 Söhne AG
An der Wiesenmühle 15 St. Gallerstr. 93
D 09224 Grüna / 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

Kunststoffschweißtechnik
Introduction
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 3 of 45
Purpose o 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 o the working instructions
This manual is arranged in chapters, which belong to the different using phases of the
machine.
Therefore the searched information can be easily found.
01.02.2012 WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D 71254 Ditzingen Heimerdingen
All rights reserved.
Reprinting only allowed with permission of the corporation.
Any changes are subject to technical innovations.

Kunststoffschweißtechnik
Contents
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 4 of 45
1. DESCRIPTION OF PRODUCT............................................................................... 6
1.1. Usage and purpose-oriented use ........................................................................................6
1.2. Sa ety measures....................................................................................................................6
1.3. Con ormity .............................................................................................................................6
1.4. Marking o the product .........................................................................................................7
1.4.1.Technical data .............................................................................................................................7
1.4.1.1.WIDOS 2500 / OD 250 General data....................................................................................7
1.4.1.2.Heating element ....................................................................................................................7
1.4.1.3.Planer ....................................................................................................................................7
1.4.2.Equipment and accessories ........................................................................................................8
2. SAFETY RULES .................................................................................................... 9
2.1. Explanation o the symbols and indications......................................................................9
2.2. Obligations o the owner....................................................................................................10
2.3. Obligations o the worker...................................................................................................10
2.4. Measures o organization...................................................................................................10
2.5. In ormation about sa ety precautions...............................................................................10
2.6. Instructions or the sta .....................................................................................................10
2.7. Speci ic dangers .................................................................................................................11
2.7.1.Danger of combustion by heating element and welding area ...................................................11
2.7.2.Danger of stumbling over electric wires ....................................................................................11
2.7.3.Danger of injury, crushing by turret ...........................................................................................11
2.7.4.Danger of cutting and catching clothes by the planer, danger of crushing at the guide rods....11
2.7.5.Risk of injury by noise................................................................................................................12
2.8. Structural modi ications on the machine .........................................................................12
2.9. 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 planer and heating element....................................................................15
5. STARTING AND OPERATING............................................................................. 16
5.1. Starting.................................................................................................................................16
5.1.1.Assembly of the machine ..........................................................................................................16
5.2. How to mount the pipe supports.......................................................................................17
5.3. Aluminum pipe supports (optional) ..................................................................................17
5.4. How to set the heating element temperature ...................................................................17
5.5. Welding process .................................................................................................................18
5.5.1.How to align and clamp the pipes .............................................................................................18
5.5.2.How to plane the pipes..............................................................................................................18

Kunststoffschweißtechnik
Contents
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 5 of 45
5.5.3.Mismatch compensation ...........................................................................................................18
5.5.4.Adjusting....................................................................................................................................19
5.5.5.Heating ......................................................................................................................................19
5.5.6.Change over..............................................................................................................................19
5.5.7.Cooling ......................................................................................................................................19
5.5.8.End of welding...........................................................................................................................20
5.6. Welding o angles ...............................................................................................................20
5.7. Welding o segmented bends ............................................................................................20
6. WELDING LOG AND TABLES ............................................................................ 21
7. MAINTENANCE / STORAGE / TRANSPORT ...................................................... 26
7.1. General.................................................................................................................................26
7.2. Clamping elements .............................................................................................................26
7.3. Planer ...................................................................................................................................26
7.4. Storage.................................................................................................................................26
7.5. Transport .............................................................................................................................26
7.6. Disposal ...............................................................................................................................26
8. WIRING DIAGRAM .............................................................................................. 27
8.1. Wiring diagram 230 V..........................................................................................................27
8.2. Wiring diagram 110 V..........................................................................................................28
9. SPARE PARTS LIST............................................................................................ 29
9.1. Basic machine with motion................................................................................................29
9.2. Clamping device..................................................................................................................32
9.3. Pipe supports ......................................................................................................................34
9.4. Planer ...................................................................................................................................37
9.5. Planer holder .......................................................................................................................39
9.6. Heating element ..................................................................................................................41
9.7. Heating element holder ......................................................................................................43
10. DECLARATION OF CONFORMITY..................................................................... 45

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 6 of 45
1. Description o 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 250 is made for the heating element butt welding of pipes and fittings
out of PE, PP and PVDF with a diameter range of Ø = 50 250 mm (optional Ø = 20 – 40 mm).
(Standard diameters: 50 / 63 / 75 / 90 / 110 / 125 / 140 / 160 / 180 / 200 / 225 / 250 mm).
The following pipes are weldable:
Pipe size PE PP
OD 50 up to OD 180 SDR 11 SDR 6
up to OD 250 SDR 21 SDR 17,6
All use going beyond is not prescribed.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Also part of the purpose oriented use is
• respecting all the indications of the working instructions and
• performing the inspection and maintenance work.
1.2. Sa ety measures
In case of wrong use, wrong operation or wrong maintenance the machine itself or products
being in the surrounding can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
advices must necessarily be adhered to.
1.3. Con ormity
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.

Kunststoffschweißtechnik
Description of product Chapter 1
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 7 of 45
1.4. Marking o the product
The product is marked by a type label.
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 2500 / OD 250 General data
Dimensions of pipes: outside Ø = 50 250 mm (optional, outside Ø = 20 40 mm)
Material: PP, PE , PVDF
Fuse protection: 16 A
Wire cross section: 1.5 mm²
Packing case: 960 x 690 x 710 mm
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 260°C / 500°F 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
1.4.1.2. Heating element
Power: 1500 Watt 1500 Watt
Current: 6.5 A (± 10 %) 13,6 A (± 10 %)
Voltage: 230 V (± 10 %) 110 V (± 10 %)
Frequency: 50 Hz 60 Hz
Surface: nonstick coated
Attached elements: - electronic temperature control
- control lamp
- connection cable with plug
1.4.1.3. Planer
Power: 1050 Watt 1050 Watt
Current: 4.5 A (± 10 %) 9,5 A (± 10 %)
Voltage: 230 V (± 10 %) 110 V (± 10 %)
Frequency: 50 Hz 60 Hz
Attached elements: connecting cable with plug

Kunststoffschweißtechnik
Description of product Chapter 1
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 8 of 45
1.4.2. Equipment and accessories
The following tools and accessories are part of the first delivery:
1 each Hexagonal socket screw key size 4 / 5 / 6 with T grip for mounting /
dismounting the reduction inserts
1 each Hexagonal socket screw key size 5 / 6 / 8
1 Annular fork wrench size 13 (for clamping device)
1 Torx screw driver T10
1 Tool bag for 10 parts
See spare parts list or order numbers and single parts. In case o an order please always give the machine
number!

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 9 of 45
2. Sa ety 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 o 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 means a possible dangerous situation by moving parts of the
machine
• The disrespect of these indications may cause heavy crushing’s of parts of the
body resp. damages of parts of the machine.
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 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.
T h e r e g u l a t i o n s o r t h e p r e v e n t i o n o a c c i d e n t s a r e v a l i d ( U V V ) .

Kunststoffschweißtechnik
Safety rules Chapter 2
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 10 of 45
2.2. Obligations o 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 o 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 o 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. In ormation about sa ety 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 or the sta
• 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, setting, tooling, operation, maintenance, inspection and repair.
• A person who is being trained may only work at the machine under supervision of an
experienced person.

Kunststoffschweißtechnik
Safety rules Chapter 2
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 11 of 45
2.7. Speci ic dangers
2.7.1. Danger o combustion by heating element and welding area
You can burn yourself, inflammable materials may ignite!
The heating element is heated up to more that 250°C / 482°F!
• Do not leave the heating element unsupervised.
• 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.
• Make sure that no person is in the swinging 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, please 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.
2.7.2. Danger o stumbling over electric wires
• Make sure that no person must step over the wires of heating element and planer.
2.7.3. Danger o injury, crushing by turret
You may crush your fingers resp. be beaten by the turret upon releasing the
clamping lever during which the machine is under pressure.
• Hold the turret with one hand and only then release the clamping lever.
• Do not grip between clamped pipe endings..
2.7.4. Danger o cutting and catching clothes by the planer, danger o
crushing at the guide rods
You can cut yourself 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 swiveling area of the planer.

Kunststoffschweißtechnik
Safety rules Chapter 2
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 12 of 45
2.7.5. Risk o injury by noise
Noise exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!
2.8. Structural modi ications on the machine
• No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
• Machine parts that are not in perfect condition are to be replaced immediately.
• Only use original WIDOS spare and wear parts.
2.9. 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
• 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.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 13 of 45
3. Functional description
B a s i c a l l y , t h e i n t e r n a t i o n a l a n d n a t i o n a l g u i d e l i n e s a r e t o b e
f o l l o w e d .
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 cleaned and heated heating element is inserted and the pipes are pressed against the
heating element under defined adjusting force. This process is called "adjusting".
The applied force can be read on the scale. After the prescribed bead height being reached,
the force 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 slide is 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 force and then cool down under pressure
(cooling time).
The welded pipes can be unclamped, the welding process is finished.
Heating element heats
the pipes up to welding
temperature
Finished welding with
internal and external bead

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 14 of 45
4. Operating and indicating elements
4.1. Elements on the basic machine
No. Denomination Function
1 Heating element Heating up the pipes.
Can be swiveled in and out.
2 Scale Display of the applied welding force.
max. display: 150 kN
3 Tension lever to arrest the support.
4 Planer to plane the pipes
Can be swiveled in and out.
5 Clamping device, right / left hand to clamp the pipes
6 Support for pipes, right / left hand Support the pipes
7 Cross handle Opening / shutting of the support.
Application of the adjusting force and of the
jointing force
1
2
3
4
5
6
7

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 15 of 45
4.2. Elements at the planer and heating element
No. Denomination Function
Planer
8 Switch on/off For switching on / off the planer
9 Button As soon as the planer is switched on and the
button is pressed, the planer turns round
Heating element
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 Adjusting screw Adjusting the temperature of the heating element.
12 Control lamp, green There are three different states:
O : 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. The desired temperature has
not been reached yet.
8
9
10
11
12

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 0
W. Dommer Söhne GmbH D 71254 Ditzingen Heimerdingen Fax ++49 (0)7152 / 9939 40
website: www.widos.de email: [e-mail]
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 16 of 45
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
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 !
• 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 and planer to the mains supply (230 V / 50 Hz) / (110 V /
60Hz).
Lay electro wires carefully (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 / 41°F, measures have to be taken:
- Preheat the pipe ends if necessary.
• In addition, take measures against rain, wind and dust.
5.1.1. Assembly o the machine
• Detach the clamping handles of the transport case and lift off the case in an upward
direction.
• Turn the case upside down with the open space on top and put it on the floor.
• Put the case floor together with the machine onto the open case.
• Refit the screwed off heating element handle.
• Connect the planer to the local power supply (230 V / 16 A / 50 Hz) / (110 V / 16 A /
50 60 Hz).
• Connect the heating element to the local power supply (230 V / 16 A / 50 Hz) / (110 V / 16 A
/ 50 60 Hz).
The machine can be operated now.

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 17 of 45
5.2. How to mount the pipe supports
For pipes with OD 50 – 160 mm, the
small adjustable pipe supports out of
sheet steel are provided.
For pipes with OD 180 – 250, the large
adjustable pipe supports out of sheet steel are
provided.
The required outside diameter of the pipe is
adjusted by briefly lifting and displacing both
supports (2). The sizes are engraved on the
frontal and on the rear piece (3 + 4).
In order to change the pipe supports, release the
knurled screws (4), remove the supports with the
sliding blocks sideward out of the machine
tables, and mount the required pipe supports in
reverse order.
5.3. Aluminum pipe supports (optional)
You will need the optional pipe supports (5) for
pipes with OD 20 – 40 mm.
Put the necessary pipe supports (5) onto the pipe
bracket (7).
Align the pipes to each other.
Align the pipe bracket to the pipe (arrow) in
horizontal direction.
Fix the pipe bracket (7) by the knurled screw (6).
5.4. How to set the heating element temperature
Switch on the heating element with the switch
(no. 8) and set the necessary welding
temperature at the adjusting screw (no. 9) at the
handle, you can see the adjusting temperature
on scale (10).
If the control lamp (no. 11) blinks, the nominal
temperature has been reached and is maintained
by means of a defined pulse pause ratio.
3
1
2
4
9
10
8 11
5
6
7

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 18 of 45
5.5. Welding process
The r espective l y va l i d w e l d i n g p r e s c r i p t i o n s (I SO / C EN / DVS...) a r e t o
b e basically oll ow e d .
• Wear safety gloves as protection against combustion!
• 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.
The anti stick coating of the heating element is to be undamaged in the working area.
5.5.1. How to align and clamp the pipes
• Screw the reduction inserts according to the pipe outside diameter to be welded.
• Align the pipe brackets according to the pipe outside diameter (chapter: 5.2).
• Open the clamping tools. Put the pipes with the same overhang to the inside of the clamping
tools.
• Close them and clamp pipes.
5.5.2. How to plane the pipes
• Switch on the planer (chapter: 4.2, Nr. 8).
• Keep the button (no. 9) at the planer handle pressed.
• Drive workpieces to the planer with the cross handle and plane with low pressing force.
• You will have to carry out planing as long as a bilateral rotating chip has been produced.
• Open the support again, release button and swivel out the planer.
• Remove the produced cuttings without touching the worked surfaces.
• Close the support.
5.5.3. Mismatch compensation
• 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.

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 19 of 45
5.5.4. Adjusting
• 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.
• Check the heating temperature. If the control lamp blinks, the nominal temperature has been
reached and is kept constant by means of a defined pulse position ratio.
• 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.
• Drive the slides together by the hand wheel (chapter: 4.1 no. 7), shock free under the
determined aligning force.
Read the applied force from the scale (no. 2).
• Fix the slide by the lever (no. 3) and maintain the force.
Necessarily hold tight to the turnstile before you release the clamping lever and
if the slides have been driven together with force!
• As soon as the prescribed bead height is reached, reduce the force (heating force = appr.10
% of adjusting force).
Important! Do not open the slide.
5.5.5. Heating
• Now the heating time starts.
• Press the stop watch and compare the actual time with the nominal time taken from the
welding table.
5.5.6. Change over
• Quickly drive the slide apart after the heating time has elapsed, release the clamping lever;
necessarily hold tight to the turnstile.
• Swivel the heating element as quickly as possible back 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.
5.5.7. Cooling
• Built up the welding force, arrest the support by the lever and press the stop watch.
• If necessary, re adjust the force during the cooling time (cooling force = adjusting force).

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.02.2012 Working Instructions WIDOS 2500 / OD 250 Page 20 of 45
5.5.8. End o welding
Necessarily hold tight to the turnstile before you release the clamping lever and
if the slides have been driven together with force!
• Release the clamping lever after the cooling time has elapsed and reduce the force by the
turnstile.
• Open the clamping tools and remove the welded piece.
• Afterwards open the support.
Now the welding part is completed.
5.6. Welding o 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.
• Multiply 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
• Add the motional pressure as usual.
All the other welding parameters remain as usual.
5.7. Welding o segmented bends
Calculate the sawing angle to be set (corresponding to the required angle at the clamping tools
or clamping inserts) as follows:
Angle o the bend
Sawing angle = -----------------------------------------
number o all welding sur aces
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
Angle