widos 5100 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
Headquarters: D-71254 Ditzingen-Hei erdingen Country court Stuttgart HRB 200973 Managing director: Dieter Do er, Jürgen Do er
Working Instructions
Translation
Heating Element Butt Welding Machine
WIDOS 5100
Keep for further use!

Kunststoffschweißtechnik
Identification of product
30.06.11 Working instructions WIDOS 5100 Page 2 of 45
Model: Heating ele ent butt welding achine
Type: WIDOS 5100
Serial nu ber: / year of construction: see type lable
Customer entries
Inventory-No.:
Place of working:
Order o spare parts and sales service:
Address o manu acturer WIDOS
W. Do er Söhne G bH
Einsteinstraße 5
D-71254 Ditzingen-Hei erdingen
Phone: [phone] / 99 39 – 0
Fax: [phone] / 99 39 – 40
[email protected]
www.widos.de
Adress of the Subsidiary Co panies:
WIDOS
WIDOS G bH W. Do er Söhne AG
An der Wiesen ühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH-9201 Gossau
Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 3 88 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 3 88 89 73

Kunststoffschweißtechnik
Introduction
30.06.11 Working instructions WIDOS 5100 Page 3 of 45
Purpose o the document
These working instructions give you infor ation about all i portant questions which refer to
the construction and the safe working of your achine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your achine econo ically but also to avoid da ages and injuries.
Should questions arise, contact our advisers in the factory or in our subsidiary co panies.
We will help you with pleasure.
According to our interest to continuously i prove our products and working instructions, we
kindly ask you to infor us about proble s and defects which occur in exercise.
Thank you.
Structure o the working instructions
This anual is arranged in chapters, which belong to the different using phases of the
achine.
Therefore the searched infor ation can be easily found.
 WIDOS 30.06.2011
W.Do er Söhne G bH
Einsteinstraße 5
D- 71254 Ditzingen- Hei erdingen
All rights reserved
Reprinting only allowed with per ission of the corporation.
Any changes prior to technical innovations.

Kunststoffschweißtechnik
Contents
30.06.11 Working Instructions WIDOS 5100 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. Machine overview .................................................................................................................7
1.5. Designation o the product ..................................................................................................7
1.5.1 Technical data ....................................................................................................................8
1.5.1.1 WIDOS 5100 General data ......................................................................................8
1.5.1.2 Heating ele ent.........................................................................................................8
1.5.1.3 Planer.........................................................................................................................9
1.5.1.4 Hydraulic aggregate ...................................................................................................9
1.5.1.5 Basic fra e ................................................................................................................9
1.5.1.6 Protective box ..........................................................................................................10
1.6. Equipment and accesories: ...............................................................................................10
2. SAFETY RULES .......................................................................................................... 11
2.1. Explanation o the di erent symbols................................................................................11
2.2. Obligations o the owner....................................................................................................12
2.3. Obligations o the worker...................................................................................................12
2.4. Measures o organization...................................................................................................12
2.5. In ormation about sa ety precautions...............................................................................12
2.6. Instructions or the sta .....................................................................................................12
2.7. Dangers while handling the machine................................................................................13
2.8. Maintenance, inspection and repair..................................................................................13
2.9. Dangers caused by electric energy...................................................................................13
2.10. Dangers caused by the hydraulic......................................................................................13
2.11. Speci ic dangers .................................................................................................................14
2.11.1 Danger of catching clothes by the planer .....................................................................14
2.11.2 Danger of being burnt by heating ele ent, reception box and welding area ...............14
2.11.3 Danger of Stu bling over electric / hydraulic wires......................................................14
2.11.4 Danger of squeezing by cla ping devices and guideways ..........................................14
2.11.5 Risk of injury by noises.................................................................................................15
2.12. Structural modi ications on the machine .........................................................................15
2.13. Cleaning the machine.........................................................................................................15
2.14. Guarantee and liability........................................................................................................15
3. FUNCTIONAL DESCRIPTION..................................................................................... 16
4. OPERATING AND INDICATING ELEMENTS.............................................................. 17
4.1. Elements on the aggregate ................................................................................................17
4.2. Elements at heating element and planer ..........................................................................18
4.3. Separating device or heating element .............................................................................18

Kunststoffschweißtechnik
Contents
30.06.11 Working Instructions WIDOS 5100 Page 5 of 45
5. STARTING AND OPERATING..................................................................................... 19
5.1. Starting.................................................................................................................................19
5.2. Connection hydraulic aggregate with the basic machine ..............................................20
5.2.1 Exchanging the reduction inserts......................................................................................20
5.2.2 Using s all and large reduction inserts............................................................................20
5.3. Welding process .................................................................................................................21
6. WELDING LOGS AND TABLES.................................................................................. 24
7. MAINTENANCE AND REPAIR .................................................................................... 29
7.1. Clamping elements .............................................................................................................29
7.2. Planer ...................................................................................................................................29
7.3. Storing..................................................................................................................................29
7.4. Used hydraulic oil ...............................................................................................................29
7.5. Checking the hydraulic oil level ........................................................................................29
7.6. Venting the hydraulic cylinders.........................................................................................30
8. TRANSPORT ............................................................................................................... 31
9. HYDRAULIC AND ELECTRIC DIAGRAMS ................................................................. 32
10. SPARE PARTS LIST ................................................................................................... 34
10.1. Basic machine .....................................................................................................................34
10.2. Hydraulic aggregat..............................................................................................................36
10.3. Planer ...................................................................................................................................39
10.4. Heating element ..................................................................................................................41
10.5. Reception box .....................................................................................................................43
11. DECLARATION OF CONFORMITY............................................................................. 45

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 6 of 45
1. Description o product
This chapter gives i portant basic infor ation about the product and its prescribed use.
All technical details of the achine are put together as a general arrange ent.
1.1. Usage and purpose-oriented use
The WIDOS 5100 has been designed for heating ele ent butt welding of pipes and fittings
with a dia eter range of Ø = 200 - 450 .
(standard dia eters: 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 )
It is a achine for construction sites and particulary designed for the use on-site, as well as in
the workshop.
For this reason, the fra e is kept s all so that it can be used even under difficult conditions
(e.g. ditch).
All use going beyond is not purpose-oriented.
The anufacturer is not responsible for da ages caused by isuse.
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
• perfor ing the inspection and aintenance works.
1.2. Sa ety measures
In case of wrong use, wrong operation or wrong aintenance the achine itself or products
standing nearby can be da aged or destroyed.
Persons being in the endangered area ay be injured.
Therefore these working instructions have to be thouroughly read and the corresponding
safety regulations ust be necessarily adhered to.
1.3. Con ormity
The achine corresponds in its construction to the valid reco endations of the European
Co unity as well as to the according European standard specifications.
The develop ent, anufacturing and ounting of the achine were ade very carefully.

Kunststoffschweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 7 of 45
1.4. Machine overview
1 Planer
2 Heating ele ent
3 Reception box
4 Hydraulic aggregate
5 Basic achine
1.5. Designation o the product
The product is designated by two type labels which are attached at the aggregate and at the
basic achine.
They contain the type, the serial nu ber and the year of construction of the achine.
1
2
3
4
5

Kunststoffschweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 8 of 45
1.5.1 Technical data
1.5.1.1 WIDOS 5100 General data
Material wich can be welded: PE80, PE 100, PVDF, PP
Pipe dia eter range: ∅
outside
= 200 - 450
Di ension transport box (l x w x h):
Weight:
1360 x 1300 x 1005
99 kg
Total weight (without packing): 240 kg
Fuse: 16 A
Wire cross section: 1.5 ²
E issions: - Noises exceeding 80 dB (A) ay occur; during
planing it is obligatory to wear ear protection!
- When using the na ed pipe aterials and when
welding below 260° C no toxicant da p arises
Environ ent: - take care for cleanness (no dust at the welding
area)
If secured by an appropriate easure ent that
allowed conditions for welding are indicated, it is
possible to work in any outside te perature
condition as far as the welder is not constrained
in its anual skill.
- avoid hu idity, if necessary use a welding tent
- avoid strong sun rays influence
- protect fro wind, shut the pipe ends
1.5.1.2 Heating ele ent
Power: 3,6 kW
Voltage: 230 V (± 10%)
Current: 15,6 A (± 10%)
Frequency: 50 Hz
Outside-∅ : 500
Surface: nonstick-coated
Attached ele ents: - Eectronic te perature control
- Control la ps
- Connecting cable with plug
Weight: approx. 20 kg
Due to the high current consu ption, the heating ele ent ust not be
connected to the aggregate, but to an external plug box with separate fuse
protection.

Kunststoffschweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 9 of 45
1.5.1.3 Planer
Motor: Monophase-alternating current- otor
Power: 1400 Watt
Voltage: 230 V (± 10%)
No inal current: 6.1 A
Frequency: 50 Hz (± 10%)
RPM n2 of planer: 230 revs/ in.
Gear: Gear ratio: approx. 0.12
Max. RPM 28 revs / in
Attached ele ents: - Switch on/off
- Connecting cable with plug
With earthing contact
Weight: Approx. 37 kg
1.5.1.4 Hydraulic aggregate
Power: 0,3 Watt
Voltage: 230 V (± 10%)
Current: 2,7 A
Frequency: 50 Hz
Phase displace ent: Approx.18°
Hydraulic oil tank: Approx. 1 l
Protective syste : IP 54
Electro otor and pu p:
RPM: 1380 (revs / in)
Max. pressure of the pu p: Approx. 120 bar
Working pressure: 0 – 100 bar adjustable
Volu e velocity: 1.9 l/ in
Weight: 23 kg
1.5.1.5 Basic fra e
Reduction insert: Di ensions can be selected
Material fra e: Machine steel
Material cla ping shells: Alu iniu
Weight: 109 kg
Cylinder-Ø: 50
Piston rod-Ø: 40
Length of stroke of cylinder: 195
Max. force: (F=P*A) 14140 N (at 100 bar)
Velocity of piston rod: 2.2 c /s
For article numbers and component parts see spare parts list

Kunststoffschweißtechnik
Description of product Chapter 1
30.06.11 Working Instructions WIDOS 5100 Page 10 of 45
1.5.1.6 Protective box
Weight heat protective box: Approx. 25 kg
1.6. Equipment and accesories:
The following accessories are part of the first delivery:
1 x Socket wrench size 27 (for cla ping the pipes)
2 each Hexagonal socket screw short size 3; 10
2 each Hexagonal socket screw size 4; 5; 7 with T-grip (for reduction
inserts and adapters)
1 x Torx srew driver T10
optional Reduction inserts, roller brackets for the pipes,
current transfor er for odel 42 V

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 11 of 45
2. Sa ety rules
The base for the safe handling and the fault-free operation of this achine is the knowledge of
the basic safety indications and rules.
The security notices of this chapter represent the general part.
Particular infor ation is listed directly before the corresponding actions.
• These working instructions provide you with the ost i portant infor ation to run the
achine safely.
• The safety infor ation ust be read by all persons who work on the achine.
2.1. Explanation o the di erent symbols
The working instructions contain the following signs for certain situations:
This sy bol eans a possibly danger for the life and the health of persons.
The disrespect of these indications ay have heavy consequences for the
health.
This sy bol eans a possible dangerous situation.
•
••
• The disrespect of these indications ay cause slight injuries or da ages on
goods.
This sy bol eans a possible dangerous situation by oving parts of the
achine
• The disrespect of these indications ay cause heavy crushings of parts of
the body resp. da ages of parts of the achine.
This sy bol eans a possible dangerous situation due to hot surfaces.
• The disrespect of these indications ay conduct to heavy burns, respectively
to self-ignition or even fire.
This sy bol eans a possible risk of injury by noises exceeding 80 dB (A).
• Ear protection is obligatory
This sy bol gives i portant indications for the proper use of the achine.
• The disrespect of these indications ay conduct to alfunctions and
da ages on the achine or on goods in the surrounding.
Under this sy bol you get user tips and particularly useful infor ation.
• It is a help for using all the functions on your achine in an opti al way and
helps you to ake 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
30.06.11 Working Instructions WIDOS 5100 Page 12 of 45
2.2. Obligations o the owner
The owner is obliged only to let persons work on the achine, who
• know about basic safety and accident prevention rules and are instructed in the handling of
the achine.
• have read and understood the safety chapter of this anual and certify this by their
signature.
The safety-conscious working of the staff should be checked in regular intervals.
2.3. Obligations o the worker
All persons who are to work at the achine 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 anual and to
confir by their signature that they have well understood the .
• to infor the selves about the functions of the achine before using it.
2.4. Measures o organization
• All equip ent required for personal safety is to be provided by the owner.
• All available safety equip ent is to be inspected regularly.
2.5. In ormation about sa ety precautions
• The working instructions have to be per anently kept at the place of use of the achine.
They are to be at the operator's disposal at any ti e and without effort.
• In addition to the anual, the co on valid and the local accident protection rules and
regulations for the environ ental protection ust be available and followed.
• All safety and danger indications on the achine have to be in a clear readable condition.
• Every ti e the achine changes hands or is being rent to third persons, the working
instructions are to be sent along with and their i portance is to be e phasized.
2.6. Instructions or the sta
• Only skilled and trained persons are allowed to work at the achine.
• It ust be clearly defined who is responsible for transport, ounting and dis ounting,
starting the operation, setting and tooling, operation, aintenance and inspection, repair
and dis ounting.
• A person who is being trained ay only work at the achine under supervision of an
experienced person.

Kunststoffschweißtechnik
Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 13 of 45
2.7. Dangers while handling the machine
The achine WIDOS 5100 is constructed according to the latest technical standard and the
acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby ay occur, also aterials
da ages are possible.
The achine ay only be used:
• according to the purpose-oriented usage
• in safety technical i peccable status
Disturbances, which may affect the safety of the machine must be cleared immediately.
2.8. Maintenance, inspection and repair
All aintenance and repair works have to be basically perfor ed with the
achine in off position.
During this, the achine has to be secured against unauthorized switching on.
Prescribed aintenance and inspection works should be perfor ed in ti e.
The DVS gives the advice of inspection works after 1 year.
For achines with a specially high usage percentage, the testing cycle should
be shortened.
The works should be perfor ed at the WIDOS G bH co pany or by an
authorized partner.
2.9. Dangers caused by electric energy
Only skilled workers are allowed to work at electrical appliances!
• The electrical equip ent of the achine has to be checked regularly.
Loose connections and da aged cables have to be replaced i ediately.
• If works at alive parts are necessary, a second person has to assist who can disconnect the
achine fro the ains if necessary.
• All electric tools (heating ele ent, planer and aggregate) have to be protected fro rain
and dropping water (if need be use a welding tent).
• According to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
2.10. Dangers caused by the hydraulic
Syste parts and pressure hoses should be ade pressureless before
beginning of any repair works. Even if the achine is switched off, pressure ay
be in the hydraulic accu ulator!
There is a danger of injuring the eyes by hydraulic oil squirting out.
• Da aged hydraulic hoses have to be i ediately replaced.
• Make a visual inspection of the hydraulic hoses before each work beginning.
• The hydraulic oil is inedible !

Kunststoffschweißtechnik
Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 14 of 45
2.11. Speci ic dangers
2.11.1 Danger o catching clothes by the planer
You can cut yourself or even get bones broken
• Only wear clothes tight to the boddy.
• Do not wear rings or jewellery during 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.
• Switch on the planer only for use. If the planing pressure is too high, there is the danger
that the planer tills and falls out of the achine during planing. For that reason do not press
the pipe ends stronger than necessary against the planer. If necessary, hold the planer
fir ly.
2.11.2 Danger o being burnt by heating element, reception box and
welding area
You can burn yourself, infla able aterials can be ignited!
The heating ele ent is heated up to ore than 250°C!
• Do not touch the surface of the heating ele ent.
• Do not leave the heating ele ent unsupervised.
• Take enough safety distance to infla able aterials.
• Do wear safety gloves.
• Allways put the heating ele ent into the heat reception box after and before use.
• Transport the heating ele ent at the handle only.
2.11.3 Danger o Stumbling over electric / hydraulic wires
• Make sure that no person has to step over the wires.
• Lay the wires in such a way that the danger is kept to a ini u .
2.11.4 Danger o squeezing by clamping devices and guideways
There is a danger of serious injuries: On the one hand between the inner
cla ping devices and on the other hand between the outer cla ping device and
the end of the guideway.
• Do not stand or put hands or foot between cla ped pipe ends.
• Do not stand or put hands between the inner cla ping devices with not yet cla ped pipes.
• Do not block opening and closing of the achine slides.

Kunststoffschweißtechnik
Safety rules Chapter 2
30.06.11 Working Instructions WIDOS 5100 Page 15 of 45
2.11.5 Risk o injury by noises
Noises exceeding 80 dB (A) ay occur; during planing it is obligatory to wear ear
protection!
2.12. Structural modi ications on the machine
• No odifications, extensions or reconstructions ay be ade on the achine without
per ission of the anufacturer.
• Machine parts wich are not in a perfect condition are to be replaced i ediately.
• Only use original WIDOS spare and wear parts.
• In case of purchase orders please always state the machine number!
2.13. Cleaning the machine
• The used aterials and tissues are to be handled properly and disposed of properly,
especially:
• when cleaning with solvents
• when lubricating with oil and grease.
2.14. Guarantee and liability
Funda entally our "General Sales and Delivery Conditions" are valid.
They are at the owner‘s disposal latest when signing the contract.
Guarantee and liability de ands referring to personal injuries or da ages on objects are
excluded if they are caused by one or several of the following reasons:
• not using the achine according to the prescriptions.
• inexpert transport, ounting, starting , operating and aintenance of the achine.
• running the achine with defective or not orderly ounted safety appliances.
• ignoring the infor ation given in this anual.
• structural odifications on the achine without per ission.
• unsatisfactory checkings of parts of the achine, which are worn out.
• unsatisfactory checking of parts of the achine, wich are worn out
• repairs perfor ed in an inexpert way.
• in case of catastrophes and force ajeure.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 16 of 45
3. Functional description
Basically, the international and national standard speci ications are to be
ul illed.
The plastic pipes are cla ped in the cla ping devices.
Then the front side of the pipes are cut plane and parallel by eans of the planer, and
issalign ent of the pipes is checked.
The cleaned and heated heating ele ent is inserted and the pipes are pressed against the
heating ele ent under defined adjusting pressure. This operation is called "adjusting".
After the prescribed bead height is reached, pressure is reduced, the heating time
begins. The function of this ti e is to heat up the pipe ends..
After expiration of the heating ti e, the slides are opened, the heating ele ent is
re oved quickly and the pipes are driven together again. The ti e gap fro the re oval of
the heating ele ent to joining the pipes is called change-over time.
The pipes are joined with the prescribed welding pressure and then cool down under
pressure (cooling time).
The weld joint can be uncla ped, the welding process is finished.
Heating ele ent heats the pipes
up to welding te perature
Finished weld joint with
internal and external bead

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 17 of 45
4. Operating and indicating elements
4.1. Elements on the aggregate
No. Denomination Function
7 Pressure gauge Digital display of the hydraulic pressure
8 Valve lever Opening/closing the slide. There are 4 different positions:
- to the le t side: slide closes
- in the middle (usual position): the pressure is
currently achieved is kept (also by eans of the
hydraulic accu ulator)
- slightly to the right side (position pressureless): a
possibly existing pressure is released without oving
the slide. Due to the hydraulic accu ulator it takes
about 10 s until the pressure is co pletely released.
- to the right side: slide opens
9 Adjusting screw for
pressure relief valve
- For the li itation of the hydraulic pressure to the
desired value
10 Hydraulic connection for
closing
- Non-dropping quick-action hose coupling
11 Hydraulic connection for
opening
- Non-dropping quick-action hose coupling
12 Screw with oil level stick - Checking the oil-level
- Filling in oil
7
8
10
11
9
12
Mains cable
230V / 50HZ
power supply
for hydraulic
aggregate
Label
„opening/
closing“
Indicating label
setting the
pressure relief
valve

Kunststoffschweißtechnik
Operating and indicating ele ents Chapter 4
30.06.11 Working Instructions WIDOS 5100 Page 18 of 45
4.2. Elements at heating element and planer
No.
Denomination Function
14 Switch on / off for planer - Switching on the planer at the switch and the fixing knob
- The planer has to be switched off before and after use
15 Handle - For lifting the planer in the achine or in the protective
box
Control
Control la p red - There are 3 statuses:
• off: heating ele ent is not heating up or is
cooling at the o ent
• blinking: te perature of heating ele ent is
kept. (reached by a pulse-position ratio)
• on: heating ele ent is heating up at the
o ent. Desired te perature is not yet reached
Control la p green - Indication for ains connection
16
Control knob - Te perature control of heating ele ent
17 Handle - For lifting the heating ele ent in the achine or in the
protective box
4.3. Separating device or heating element
There is a tear-off bar ounted between the
ovable and the fixed cla ping shells on the
basic achine. It prevents the heating
ele ent fro sticking to the heated-up pipe
ends.
When inserting the heating ele ent take care
that it lies in the zone of the throat of the tear-
off bar (see arrow).
16
14
15
15
17

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Do er Söhne G bH D-71254 Ditzingen-Hei erdingen Fax [phone] - 40
info @ widos.de http://www.widos.de
30.06.11 Working Instructions WIDOS 5100 Page 19 of 45
5. Starting and operating
The instructions of this chapter are supposed to instruct you in the operation of the achine
and to lead you during the appropriate starting of the achine.
This includes:
• the safe operation of the achine
• using all the possibilities
• running the achine econo ically
5.1. Starting
The achine should only be operated by trained and authorized people.
For the qualification a plastic welding exa can be taken according to DVS and
DVGW.
In case of danger unplug the achine i ediately.
In case of power failure, the hydraulic syste can still be under pressure.
For this reason, release pressure when required.
After co pletion of the welding work and during breaks the achine has to be
switched off. Further be sure that no unauthorized persons have access.
Protect the achine fro wetness and oisture !
Check the oil level of the hydraulic syste before each starting of the control
unit in order to avoid da ages on the pu p. The oil level ust be between the
two arks at the oil dipstick.
If necessary, add hydraulic oil of the quality HLPD 32.
The heating ele ent surfaces ust be clean, especially non greasy, therefore
they need to be cleaned shortly before each welding or in case of dirtiness by
eans of a ibre- ree paper and a cleaning agent (e.g. PE cleaner or pipe
cleaning tissues which are available at the WIDOS co pany).
The anti-adhesive coating of the heating ele ent ust re ain unda aged
in the working area.
Clean the heating ele ent only in a cold state ⇒ danger of co bustion /
burning.
Take care that all hydraulic and electric connections are connected.
Take into consideration the environ ental conditions:
• Welding should not be carried out in direct sunlight.
• If necessary put up a welding tent.
• In case of a bient te peratures below 5°C the following easures have to be taken:
If need be, put up a welding tent and heat up the pipe ends.
• Take easures against rain, wind and dust.

Kunststoffschweißtechnik
Starting and operating Chapter 5
30.06.11 Working Instructions WIDOS 5100 Page 20 of 45
5.2. Connection hydraulic aggregate with the basic machine
• Connect the power line plug of the hydraulic aggregate to the ains (230 V/50 Hz).
• Connect the planer to the corresponding plug of the aggregate. Connect the heating
ele ent on an external plug box. Otherwise there is the danger of overloading the current
lead.
• Connect the hydraulic hoses of the basic achine to the quick-action couplings of the
hydraulic aggregate.
Lay the hydraulik and electro wires carefully! (Danger of Stu bling)
5.2.1 Exchanging the reduction inserts
• Unscrew the already ounted reduction inserts by eans of the Allan key being part of the
delivery.
• Screw on the reduction inserts with the corresponding dia eter.
For cla ping the dia eters between 200 - 315 , adapters are needed which have to be
screwed into the cla ping shells before.
Pipes with the dia eters OD 355 and OD 400 can be cla ped without these adapters,
pipes with OD 450 can be cla ped directly.
• If necessary (e.g. T-pieces), the fixed outer cla ping tool can be dis antled by
unscrewing the three hexagon socket screws.
Dis antling of the fixed outer cla ping tool
5.2.2 Using small and large reduction inserts
Small reduction inserts:
• pipe fittings often have an only short straight surface area on which they can be cla ped.
⇒ Fittings often need to be cla ped in the inner cla ping tools with narrow reduction inserts.