widos 5500 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH 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 5500
Keep for further use !

Kunststoffschweißtechnik
Product Identification
17.02.14 Working Instructions WIDOS 5500 Page 2 of 48
Model: Heating element butt welding machine
Type: WIDOS 5500
Serial number, year of construction: see type lable
INSERTS OF CUSTOMER
inventory-no.:
place of working:
Order of Spare Parts and After Sales Service:
Address of Manufacturer WIDOS
W. Dommer Söhne GmbH
Einsteinstrasse 5
D-71254 Ditzingen-Heimerdingen
Phone: ++49 7152 / 99 39 - 0
Fax: ++49 7152 / 99 39 - 40
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: [phone]
Fax: ++49 371 / 8 15 73 - 20

Kunststoffschweißtechnik
Introduction
17.02.14 Working Instructions WIDOS 5500 Page 3 of 48
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 this working instruction, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our advisers in the factory or in our subsidiary companies. We
will help you with pleasure.
According to our interest to make our products and working instructions continuously better,
we kindly ask you to inform us about problems and defects which occur in exercise.
Thank you.
Design of the Working Instructions
This manual is arranged in chapters, which belong to the different using phases of the
machine. Therefore the searched informations can be found easily.
17.02.2014 WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved
Reprinting only allowed with permission of the corporation.

Kunststoffschweißtechnik
Contents
17.02.14 Working Instructions WIDOS 5500 Page 4 of 48
1. DESCRIPTION OF PRODUCT........................................................................................ 6
1.1. Usage and purpose-oriented use............................................................................................6
1.2. Machine overview......................................................................................................................6
1.3. Safety measures........................................................................................................................7
1.4. Conformity .................................................................................................................................7
1.5. Designation of the Product ......................................................................................................7
1.5.1 Technical Data....................................................................................................................7
1.5.1.1 WIDOS 5500 General Data .....................................................................................7
1.5.1.2 Hydraulic aggregate...................................................................................................8
1.5.1.3 Heating element.........................................................................................................8
1.5.1.4 Planer.........................................................................................................................9
1.5.1.5 Basic frame ................................................................................................................9
1.5.1.6 Protection box ............................................................................................................9
1.6. Accessories:..............................................................................................................................9
2. SAFETY RULES............................................................................................................ 10
2.1. Explanation of the symbols and indikations........................................................................10
2.2. Obligation of the owner..........................................................................................................11
2.3. Obligation of the worker.........................................................................................................11
2.4. Measures of organisation.......................................................................................................11
2.5. Information about safety precautions...................................................................................11
2.6. Instructions for the staff.........................................................................................................11
2.7. Dangers while handling the machine....................................................................................12
2.8. Maintenance, inspection and repair......................................................................................12
2.9. Dangers caused by electrical energy....................................................................................12
2.10.Dangers caused by the hydraulics........................................................................................12
2.11.Special dangers.......................................................................................................................13
2.11.1 Danger of catching clothes by the planer.....................................................................13
2.11.2 Danger of being burnt by heating element, reception box and welding area ..............13
2.11.3 Danger of stumbling over electric / hydraulic wires .....................................................13
2.11.4 Risk of injury by noises ................................................................................................13
2.11.5 Danger of squeezing by clamping devices and guideways .........................................14
2.12.Structural modifications on the machine .............................................................................14
2.13.Cleaning the machine.............................................................................................................14
2.14.Warranty and liability..............................................................................................................14
3. FUNCTIONAL DESCRIPTION ...................................................................................... 15
4. OPERATING AND INDICATING ELEMENTS .............................................................. 16
4.1. Elements on the Aggregate....................................................................................................16
4.2. Elements on the Side of the Aggregate................................................................................17
4.3. Separating Device for Heating Element................................................................................17
4.4. Elements at the Heating Element and the Planer ................................................................18

Kunststoffschweißtechnik
Contents
17.02.14 Working Instructions WIDOS 5500 Page 5 of 48
5. STARTING AND OPERATING...................................................................................... 19
5.1. Safety Indications....................................................................................................................19
5.2. Connection of Hydraulic Aggregate with Basic Machine...................................................20
5.3. Replacing the Reduction Inserts...........................................................................................20
5.3.1 Using Small and Large Reduction Inserts........................................................................20
5.4. Setting the Heating Element Temperature ...........................................................................21
5.5. Welding Process .....................................................................................................................22
6. WELDING LOG AND TABLES ..................................................................................... 24
7. MAINTENANCE AND REPAIR ..................................................................................... 29
7.1. Maintenance and Inspection, Repair.....................................................................................29
7.2. Clamping Elements.................................................................................................................29
7.3. Planer........................................................................................................................................29
7.4. Storage.....................................................................................................................................29
7.5. Used Hydraulic Oil ..................................................................................................................29
7.6. Checking the Hydraulic Oil Level ..........................................................................................30
7.7. Venting the hydraulic cylinder...............................................................................................30
7.8. Disposal ...................................................................................................................................31
8. TRANSPORT................................................................................................................. 32
9. ELECTRIC AND HYDRAULIC DIAGRAMS.................................................................. 33
10. SPARE PARTS LIST..................................................................................................... 37
10.1.Basic Machine .........................................................................................................................37
10.2.Planer........................................................................................................................................39
10.3.Hydraulic Aggregat.................................................................................................................41
10.4.Heating Element......................................................................................................................44
10.5.Reception Box.........................................................................................................................46
11. DECLARATION OF CONFORMITY.............................................................................. 48

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH website: www.widos.de Email: [e-mail]
17.02.14 Working Instructions WIDOS 5500 Page 6 of 48
1. Description of product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS 5500 has been designed for heating element butt welding of pipes and fittings out
of PE, PP and PVDF with a diameter range of Ø = 200 - 500.
(Standard diameters : 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 / 500)
It is a machine for construction sites and particularly designed for the usage on-site, as well as
in the workshop.
For this reason, the frame is kept small so that it can be used even under difficult conditions
(e.g. ditch).
All use going beyond is not purpose-oriented.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Also part of the purpose oriented use is
respecting all the indications of the working instructions and
performing the inspection and maintenance works.
1.2. Machine overview
1Hydraulic aggregat
2Heating element
3Planer
4Protective box
5 Basic machine with clamping devices
1 5
2
3
4

Kunststoffschweißtechnik
Description of Product Chapter 1
17.02.14 Working Instructions WIDOS 5500 Page 7 of 48
1.3. 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.
1.4. 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.
1.5. Designation of the Product
The product is designated by two type labels which are attached at the aggregate and at the
basic machine.
They contain the type, the serial number and the year of construction of the machine.
1.5.1 Technical Data
1.5.1.1 WIDOS 5500 General Data
Material which can be welded: PP, PEHD, PE 100
Pipe diameter range: outside = 200 - 500
Box for transport machine (LxWxH):
Weight:
Box for transport insert (LxWxH):
Weight:
appr. 1390 x 1340 x 1250 mm
appr. 109 kg
appr. 1520 x 600 x 340 mm
appr. 26 kg
Weight (without boxes): 280 kg
Wire cross section: 1,5 mm²
Fuse: 16 A
Emissions - Noises 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 no toxicant damp arises.

Kunststoffschweißtechnik
Description of Product Chapter 1
17.02.14 Working Instructions WIDOS 5500 Page 8 of 48
Ambient conditions in the welding area: -take care for cleanness (no dust at the
welding area)
-If secured by an appropriate measurement
that allowed conditions for welding are
indicated, it is possible to work in any
outside temperature condition as far as the
welder is not constrained in its manual skill.
-avoid humidity, if necessary use a welding
tent
-avoid strong sun rays influence
- protect from wind, shut the pipe ends
1.5.1.2 Hydraulic aggregate
Power: 0,56 Watt
Voltage: 230 V (+-10%)
Current: 4,7 A
Frequency: 50 Hz
Displacement of phase: appr.18°
Tank appr. 1 L
International Protection IP 54
Electromotor and pump:
Speed: 2720 rpm
Max. working pressure of pump: about 130 bar
Working pressure, adjustable: 0-130 bar
Volum velocity : 3,5 L/min
Weight : appr. 23 kg
1.5.1.3 Heating element
Power: 5,8 kW
Voltage: 400V (+-10%)
Current: 14,5 A (+-10%)
Frequency: 50 Hz
: 564 mm
Surface: nonstick-coated
Attached elements: - Electric temperature control
- Signal lamp
- Connecting cable with plug
Weight: appr. 24,5 kg

Kunststoffschweißtechnik
Description of Product Chapter 1
17.02.14 Working Instructions WIDOS 5500 Page 9 of 48
1.5.1.4 Planer
Motor: Three-phase alternating current motor
Power: 1.1 kW
Voltage: 400 V (+-10%)
Nominal current 3,5 A
Frequency: 50 Hz (+-10%)
Speed of motor: appr. 140 rpm
Gear: Gear transmission ratio: appr. 0,5
Speed of planer: appr. 60 – 100 rpm
Atached elements: -On/off switch
-Connecting cable with plug
Weight: appr. 100 kg
1.5.1.5 Basic frame
Reduction inserts, pipe supports Optional dimensions
Material frame: structural steel
Material reduction inserts: aluminium
Weight: 120 kg
Cylinder-Ø: 50 mm
Piston rod-Ø: 40 mm
Length of stroke of cylinder: 200 mm
Max.force (F=P*A) 14140 N (at p= 100 bar)
Velocity of piston rod: 4,1 cm/s
1.5.1.6 Protection box
Weight protection box: appr. 30 kg
See spare parts list for article numbers and single parts
1.6. Accessories:
1 Tool bag for 10 parts
1 each Allan key angulate, size 3 / 6 / 10
1 each Allan key with T-grip, size 4 / 5 / 7 (for reduction inserts and adapter piece)
1 Socket spanner size 27
1 Torx srew driver T10
optional Different reduction inserts; roller stands for the pipes;
transformator 42V

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH website: www.widos.de Email: [e-mail]
17.02.14 Working Instructions WIDOS 5500 Page 10 of 48
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety indications and rules.
These working instructions contain the most important indications to run the machine
safely.
The safety indications are to be followed by all persons working on the machine.
2.1. Explanation of the symbols and indikations
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possibly danger for the life and the health of persons.
The disrespect of these indications may have heavy consequences for the
health.
This symbol means a possible dangerous situation.
The disrespect of these indications may cause slight injuries or damages on
goods.
This symbol means a possible dangerous situation by moving parts of the
machine.
The disrespect of these indications may cause heavy crushings of parts of the
body resp. damages of parts of the machine.
This symbol means a possible dangerous situation due to hot surfaces.
The disrespect of these indications may conduct to heavy burns, respectively
to self-ignition or even fire.
This symbol means a possible risk of injury by noises 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.
The regulations for the prevention of accidents are valid (UVV).

Kunststoffschweißtechnik
Safety Rules Chapter 2
17.02.14 Working Instructions WIDOS 5500 Page 11 of 48
2.2. Obligation 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. Obligation of the worker
All persons who are to work at the machine are obliged before working:
to follow the basic safety and accident protection rules.
to have read and understood the safety chapter and the warnings in this manual and to
confirm by their signature that they have well understood them.
to inform themselves about the functions of the machine before using it.
2.4. Measures of 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 effort.
In addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
All safety and danger indications on the machine have to be in a clear readable condition.
Every time the machine changes hands or is being rent to third persons, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
Only skilled and trained persons are allowed to work at the machine.
It must be clearly defined who is responsible for transport, mounting and dismounting,
starting the operation, setting and tooling, operation, maintenance and inspection, repair
and dismounting.
A person who is being trained may only work at the machine under supervision of an
experienced person.

Kunststoffschweißtechnik
Safety Rules Chapter 2
17.02.14 Working Instructions WIDOS 5500 Page 12 of 48
2.7. Dangers while handling the machine
The machine WIDOS 5500 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 must only be used:
according to the prescription
in safety technical impeccable status
Disturbances, which may affect the safety of the machine must be cleared immediately.
2.8. Maintenance, inspection and repair
All maintenance and repair works have to be basically performed with the
machine in off position.
During this the machine has to be secured against unauthorized switching on.
Prescribed maintenance and inspection works should be performed in time. The
DVS gives the advice of inspection works after 1 year.
For machines with a specially high usage percentage the testing cycle should be
shortened .
The works should be performed at the WIDOS GmbH company or by an
authorized partner.
2.9. Dangers caused by electrical energy
Only skilled persons are allowed to work at electrical appliances!
The electrical equipment of the machine has to be checked regularly. Loose
connections and damaged cables have to be replaced immediately.
If works at alive parts are necessary, a second person has to assist who can
disconnect the machine from the mains if necessary.
All electric tools (heating element, planer and aggregate) have to be protected
from 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 hydraulics
System parts and pressure hoses should be made pressureless before beginning
of any repair works. Even if the machine is switched off, pressure may be in the
hydraulic accumulator!
There is a danger of injuring the eyes by hydraulic oil squirting out.
Damaged hydraulic hoses have to be immediately replaced.
Make a visual inspection of the hydraulic hoses before each work beginning.
The hydraulic oil is inedible !

Kunststoffschweißtechnik
Safety Rules Chapter 2
17.02.14 Working Instructions WIDOS 5500 Page 13 of 48
2.11. Special dangers
2.11.1 Danger of catching clothes by the planer
You can cut yourself or even get bones broken !
Only wear clothes tight to the body.
Do not wear rings or jewellery during the work.
If necessary, wear a hair-net.
Always put the planer back into the reception box after and before each use.
Transport the planer at the handle only. Do not touch the surfaces.
Switch the planer on only for usage.
If the planing pressure is too high, there is the danger that the planer tilts during planing.
For that reason do not press the pipe ends stronger than necessary against the planer. If
necessary, hold the planer firmly.
2.11.2 Danger of being burnt by heating element, reception box 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 touch the surfaces of the heating element.
Do not leave the heating element unsupervised.
Take enough safety distance to inflammable materials.
Do wear safety gloves.
Always put the heating element back into the reception box after and before each use.
Transport the heating element at the handle only.
2.11.3 Danger of 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 minimum.
2.11.4 Risk of injury by noises
Noises exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!

Kunststoffschweißtechnik
Safety Rules Chapter 2
17.02.14 Working Instructions WIDOS 5500 Page 14 of 48
2.11.5 Danger of squeezing by clamping devices and guideways
There is a danger of serious injuries: on the one hand between the inner
clamping devices and on the other hand between the outer clamping device and
the end of the guideway.
Do not stand or put hands between clamped pipe ends.
Do not stand or put hands between the inner clamping tools with not yet clamped pipes.
Do not block opening and closing of the machine slides.
2.12. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
Machine parts which are not in a perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
In case of purchase orders please always state the machine number !
2.13. 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
2.14. Warranty and liability
Fundamentally our "General Sales and Delivery Conditions" are valid.
They are at the owner's disposal latest when signing the contract.
Guarantee and liability demands referring to personal injuries or damages on objects are
excluded if they are caused by one or several of the following reasons:
not using the machine according to the prescriptions
inexpert transport, mounting, starting, operating, and maintenance of the machine
running the machine with defective or not orderly mounted safety appliances
ignoring the information given in this manual
structural modifications on the machine without permission
unsatisfactory checking of parts of the machine, which are worn out
repairs performed in an inexpert way
In case of catastrophes and force majeure

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH website: www.widos.de Email: [e-mail]
17.02.14 Working Instructions WIDOS 5500 Page 15 of 48
3. Functional description
Basically, the international and national process guidelines are to be followed!
The plastic pipes are clamped in the clamping devices. Then the front sides of the pipes are
cut plane and parallel by means of the planer and the misalignment of the pipes is checked.
The cleaned and heated heating element is inserted and the pipes are pressed against the
heating element under defined adjusting pressure. This process is called "adjusting".
After the prescribed bead height being reached, pressure is reduced, the heating time begins.
The function of this time is to heat up the pipe ends.
After expiration of the heating time, the slides are opened, the heating element is removed
quickly and the pipes are driven together again. The time gap from the removal of the heating
element to joining the pipes is called change over time.
The pipes are joined under prescribed welding pressure and then cool down under pressure
(cooling time).
The welded joint can be unclamped, the welding process is finished.
Heating element heats the pipes
up to welding temperature
Finished welding with
internal and external bead

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH website: www.widos.de Email: [e-mail]
17.02.14 Working Instructions WIDOS 5500 Page 16 of 48
4. Operating and Indicating Elements
4.1. Elements on the Aggregate
No. Name Function
1 Screw with oil dipstick - checking the oil level
- oil filler neck
2 Hydraulic connection for
opening the slides
- Non-dropping quick-acting coupling
3 Hydraulic connection for
closing the slides
- Non-dropping quick-acting coupling
4 Setting screw for pressure
relief valve
- Limitation of the pressure to the desired value.
5 Valve lever Opening the slides. There are 4 different positions:
- to the left side: slides close.
- in the middle (usual position): the pressure which is
currently achieved is kept (also by means of the
built-in hydraulic accumulator)
- slightly to the right side (position pressureless): a
possibly existing pressure is released without moving
the slides. Due to the hydraulic accumu-lator, it takes
about 10 s until the pressure is completely released.
- to the right side: slides open
6 Pressure gauge Digital display of the hydraulic pressure
Planer and heating element have to be connected to a power distributor for building sites
(400 Volt).
6
5
2
3
1
4
Label „opening / closing „
Indicating label setting the
pressure relief valve

Kunststoffschweißtechnik
Operating an Indicating Elements Chapter 4
17.02.14 Working Instructions WIDOS 5500 Page 17 of 48
4.2. Elements on the Side of the Aggregate
No. Denomination Function
7 Plug socket 230 V / 50 Hz Possibility for connecting
8 Plug socket 230 V / 50 Hz Possibility for connecting
9 Mains cable 230 V / 50Hz Power supply
4.3. Separating Device for Heating Element
There is a tear-off bar mounted between the
movable and the fixed clamping shells on the
basic machine. It prevents the heating element
from sticking to the heated-up pipe ends.
When inserting the heating element take care
that it lies in the zone of the throat of the tear-off
bar (see arrow).
7
8
9

Kunststoffschweißtechnik
Operating an Indicating Elements Chapter 4
17.02.14 Working Instructions WIDOS 5500 Page 18 of 48
4.4. Elements at the Heating Element and the Planer
No. Name Function
10 Locking device - Locking the planer into basic machine by planing
11 On/off switch for planer - For switching on/off the planer.
- Switch off the planer after use.
12 Lifting screw - For lifting/inserting the heating element / planer with the
lift-off device.
13 Lever - For holding the planer when lifting / removing.
- Lever can be screwed off.
14 Thermostat - For setting the required temperature.
15 Display of temperature -Digital display of set heating element temperature. Three
different displays are possible.
-For meaning of the displays please refer to chapter 5.4,
Setting the Heating Element Temperature
16 Grip - For holding the heating element when lifting / removing.
11
12
10
15
14
12
16
13

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 7152 9939 - 0
D-71254 Ditzingen-Heimerdingen Fax ++49 7152 9939 - 40
W. Dommer Söhne GmbH website: www.widos.de Email: [e-mail]
17.02.14 Working Instructions WIDOS 5500 Page 19 of 48
5. Starting and Operating
The instructions of this chapter are supposed to initiate in the operation of the machine and
lead during the appropriate starting of the machine.
This includes:
- the safe operation of the machine
- using all the possible options of the machine
- economic operation of the machine
5.1. Safety Indications
The machine may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and
DVGW.
In situations of danger for persons and the machine, the mains plug has to be
unplugged immediately.
In case of power failure, there may still be pressure in the hydraulic system.
Therefore release pressure if need be.
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.
Check the oil level of the hydraulic system before each starting of the control unit
in order to avoid damages on the pump. The oil level must be between the two
marks at the oil dipstick.
If necessary, add hydraulic oil of the quality HLPD 32.
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 fibre-free paper and a cleaning agent (e.g. PE cleaner or pipe
cleaning tissues which are available at the WIDOS company).
The anti-adhesive coating of the heating element must remain undamaged in the
working area.
Take care that all hydraulic and electric connections are connected.
Make sure that pump and planer are connected in a way that they turn in right-
hand direction.
Connect planer and heating element to a power distributor for building sites with 400 V.
Take into account the surrounding conditions:
-The welding may not be performed under direct sun rays influence.
-Use a welding umbrella if necessary.
If the surrounding temperature is under 5°C / 41°F, measures have to be taken:
-Use a welding tent or preheat the pipe ends if necessary.
In addition, take measures against rain, wind and dust.

Kunststoffschweißtechnik
Starting and Operating Chapter 5
17.02.14 Working Instructions WIDOS 5500 Page 20 of 48
5.2. Connection of Hydraulic Aggregate with Basic Machine
Connect the aggregate to the mains supply (230 V/50 Hz).
Put the hydraulic hoses of the basic machine into the quick-acting couplings of the hydraulic
aggregate.
Lay the hydraulic and electric wires carefully (danger of stumbling)
5.3. Replacing the Reduction Inserts
Unscrew the mounted reduction inserts by means of the provided Allan key.
Screw the reduction inserts with the corresponding diameter into the clamping devices.
Pipes with OD 550 have to be clamped in the basic clamping devices.
If necessary (e.g. for T-pieces) the outer fixed clamping device can be dismantled by
unscrewing the three hexagon socket screws.
Dismantling of the outer fixed clamping device
5.3.1 Using Small and Large Reduction Inserts
Small Reduction Inserts:
Pipe fittings often have only a short straight surface area on which they can be clamped.
Fittings mostly need to be clamped in the inner clamping devices with the small reduction
inserts.
When fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can
also be used flush to the inside or to the outside.