widos 7511 User manual

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [email protected] Website: www.widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer, Dr. Kai Dombrowski
Working instructions
Translation
Heating element socket welding machine
WIDOS 7511
Keep for further use!

Product identification
19.05.15 Working instructions WIDOS 7511 Page 2 von 39
Model: Heating element socket welding machine
Type: WIDOS 7511
Serial nummer / year of construction: see type lable
Customer entries
Inventory No.:
Location:
Order of spare parts and sales service:
Address of manufacturer WIDOS
W. Dommer Söhne GmbH
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
Phone: [phone]
Fax: [phone]
Internet: www.widos.de
E-mail: [e-mail]

Introduction
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Purpose of the document
These working instructions give you information about all important questions which refer to the construction
and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our advisers in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest in making our products and working instructions continuously better, we kindly ask
you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
The working instructions are arranged in chapters, which belong to the different using phases of the
machine.
Therefore the searched information can be found easily.
19.05.2015 WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved.
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

Contents
19.05.15 Working instructions WIDOS 7511 Page 4 of 39
1. DESCRIPTION OF PRODUCT....................................................................................................... 6
1.1. Usage and purpose-oriented use ................................................................................................................... 6
1.2. Safety measures .............................................................................................................................................. 6
1.3. Conformity ........................................................................................................................................................ 6
1.4. Designation of the product.............................................................................................................................. 7
1.4.1. Technical data ............................................................................................................................................................. 7
1.4.1.1. WIDOS 7511 General data .................................................................................................................. 7
1.4.1.2. Heating element.................................................................................................................................... 7
1.5. Equipment and accessories ............................................................................................................................ 8
2. SAFETY RULES ............................................................................................................................ 9
2.1. Explanation of the different symbols .............................................................................................................. 9
2.2. Obligations of the owner ............................................................................................................................... 10
2.3. Obligations of the worker.............................................................................................................................. 10
2.4. Measure of organisation ............................................................................................................................... 10
2.5. Information about safety precautions .......................................................................................................... 10
2.6. Instructions for the staff................................................................................................................................ 10
2.7. Dangers while handling the machine........................................................................................................... 11
2.8. Dangers caused by electric energy ............................................................................................................. 11
2.9. Special dangers ............................................................................................................................................. 11
2.9.1. Danger of stumbling over electric cables ............................................................................................................. 11
2.9.2. Danger of burning at heating element and welding area................................................................................... 11
2.9.3. Danger of squeezing by clamping tool and guideways ...................................................................................... 12
2.10. Structural modifications on the machine..................................................................................................... 12
2.11. Warranty and liability .................................................................................................................................... 12
3. FUNCTIONAL DESCRIPTION .................................................................................................... 13
4. OPERATING AND INDICATING ELEMENTS ............................................................................ 14
4.1. Elements at the front ..................................................................................................................................... 14
4.2. Elements on the heating element ................................................................................................................. 15
4.2.1. How to mount the heating spigot and socket ....................................................................................................... 16
4.3. Accessore pipe champferer (optional)......................................................................................................... 16
4.4. Clamping tool left for pipe ............................................................................................................................. 17
4.5. Clamping tool for fitting ................................................................................................................................. 17
5. STARTING AND OPERATING ................................................................................................... 18
5.1. Starting ........................................................................................................................................................... 18
5.2. Surrounding conditions ................................................................................................................................. 19

Contents
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5.3. Welding process ............................................................................................................................................ 19
6. WELDING LOG AND TABLES ................................................................................................... 22
6.1. Table for PP.................................................................................................................................................... 22
6.2. Table for PVDF ............................................................................................................................................... 22
6.3. Table for PEHD ............................................................................................................................................... 23
6.4. Table für PB (Polybutene) ............................................................................................................................. 23
6.5. Welding log .................................................................................................................................................... 24
7. MAINTENANCE / STORAGE / TRANSPORT ............................................................................ 25
7.1. Maintenance .................................................................................................................................................. 25
7.2. Storage ........................................................................................................................................................... 25
7.3. Transport ........................................................................................................................................................ 25
7.4. Cleaning the machine .................................................................................................................................... 25
7.5. Setting the mismatch compensation ............................................................................................................ 26
7.6. Disposal .......................................................................................................................................................... 26
8. ELECTRIC DIAGRAMS...............................................................................................................27
8.1. Electric diagram for machine with 230 V...................................................................................................... 27
8.2. Electric diagram for machine with 110 V...................................................................................................... 28
9. SPARE PARTS LIST................................................................................................................... 29
9.1. Basic machine................................................................................................................................................ 29
9.2. Prism clamping tool for pipes ....................................................................................................................... 31
9.3. Prism clamping tool for fitting with support................................................................................................. 33
9.4. Heating element............................................................................................................................................. 35
9.5. Spigot and socket .......................................................................................................................................... 37
10. DECLARATION OF CONFORMITY............................................................................................. 39

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [email protected] Website: www.widos.de
19.05.15 Working instructions WIDOS 7511 Page 6 of 39
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 7511 is exclusively designed for the heating element socket welding of pipes and fittings out of
PE, PP and PVDF with an outside diameter range from 20 mm to 75 mm.
At heating element socket welding, pipe and fitting are welded overlapping.
The heated tool is adjusted to the size of the fitting in a way that a joining pressure is built up at joining.
The motion for socket welding is controlled by means of a transport wheel and a toothed rack.
All use of this machine going beyond is not purpose oriented.
The machine is only to be used in a technically perfect condition, as well as purpose oriented, safety- and
danger-conscious in compliance with the working instructions and the relevant safety regulations (especially
the regulations for the prevention of accidents).
The described plastic welding machine may only be operated, maintained and repaired by persons trained
and informed about the dangers.
The manufacturer is not responsible for any damages caused by inexpert handling or operation.
For personal injuries, material and immaterial damages resulting herefrom, only the user is responsible!
Prescribed use also means:
following all indications in these working instructions and
performing the inspection and maintenance works.
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products standing near
by 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 advices must
be necessarily adhered to.
1.3. Conformity
The machine corresponds in its construction to the valid recommendations of the European Community as
well as to the European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.

Description of product Chapter 1
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1.4. Designation of the product
The product is designated by a type lable at basic machine and heating element.
The lables contain the type of the machine, the serial number and the year of construction.
1.4.1. Technical data
1.4.1.1. WIDOS 7511 General data
Material: PP, PE, PVDF, PB
Pipe diameter range: OD = 20 - 75 mm (2” IPS)
Transport box (l x w x h): 670 x 500 x 350 mm
Total weight: 23 kg
Protection: 16 A
Emissions: - When using the named pipe materials and when welding below
260° C or 500° F no toxic damp arises.
Ambient conditions: - Keep the workshop clean (especially the welding area must be
clean)
- 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 put up a tent
- Avoid strong sun beams
- If it is windy shut the pipe endings
1.4.1.2. Heating element
Power: 630 Watt 1000 Watt
Voltage: 230 V (10%) 110 V (10%)
Current: 2,7 A (10%) 5,4 A (10%)
Wire cross section: 1,5 mm² 1,5 mm²
Frequency: 50 Hz 60 Hz
Attached elements: - electronic temperature control
- control lamp
- connecting cable with plug
Weight: approx. 2 kg

Description of product Chapter 1
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1.5. Equipment and accessories
The following accessories are part of the first delivery:
Pieces Denomination
1 Allan key tilted, size 5 (screw in / out the clamping elements)
1 Allan key with T-grip, size 6
1 set Gripping tools for fitting Ø 29 – 52 mm and Ø 50 – 95 mm
(1 set already mounted)
1 set Gripping tools for pipes Ø 29 – 52 mm and Ø 40 – 75 mm
(1 set already mounted)
Heating spigots and sockets, according to order

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [email protected] Internet: www.widos.de
19.05.15 Working instructions WIDOS 7511 Page 9 of 39
2. Safety rules
A basic premise for working safely and without disturbances is the knowledge of the basic safety signs and
safety rules.
These working instructions provide you with the most important information to run the machine safely.
The safety information must be followed by all persons who work at the machine.
2.1. Explanation of the different symbols
The working instructions contain the following signs for certain situations:
This symbol means a possibly danger for the life and the health of persons by electrical
energy.
The disrespect of these indications may have heavy consequences for the health.
This symbol means a possible general dangerous situation.
The disrespect of these indications may cause slight injuries or damages on goods.
This symbol means a possible dangerous situation due to hot surfaces.
The disrespect of these indications may conduct to heavy burns, respectively to self-
ignition or even fire.
This symbol gives important indications for the proper use of the machine.
The disrespect of these indications may conduct to malfunctions and damages on the
machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
It is a help for using all the functions on your machine in an optimal way and helps you to
make the job easier.
The regulations for the prevention of accidents are valid (UVV).

Safety rules Chapter 2
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2.2. Obligations of the owner
The owner is obliged only to let persons work at the machine who
know about basic safety and accident prevention rules and are instructed in the handling of the machine,
as well as who
have read and understood the safety chapter of this manual and certify this by their signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged before working:
to follow the basic safety and accident protection rules.
to have read and understood the safety chapter and the warnings in this manual and to confirm by their
signature that they have well understood them.
to inform themselves about the functions of the machine before using it.
2.4. Measure of organisation
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
The working instructions have to be permanently kept at the place of use of the machine.
They are to be at the operator's disposal at any time and without much effort.
In addition to the manual, the common valid and the local accident protection rules and regulations for the
environmental protection must be available and followed.
All safety and danger indications on the machine have to be in a clear readable condition.
Every time the machine changes hands or is being rent to third persons, the working instructions are to be
sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
Only skilled and trained persons are allowed to work at the machine.
It must be clearly defined who is responsible for transport, mounting and dismounting, and starting the
operation.
A person who is being trained may only work at the machine under supervision of an experienced person.

Safety rules Chapter 2
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2.7. Dangers while handling the machine
The machine WIDOS 7511 is constructed according to the latest technical standard and the acknowledged
technical safety rules.
However, dangers for the operator or other persons standing nearby may occur. Also material damages are
possible.
The machine may only be used
according to the purpose-oriented use
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately
Only skilled persons are allowed to work at electrical appliances.
The electrical equipment of the machine has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
Protect the heating element and planer from rain and dropping water.
According to VDE 0100, the use on construction sites is only allowed with a power distributor with a RCD
(FI)-safety switch.
2.8. Dangers caused by electric energy
Only skilled persons are allowed to work at electrical appliances!
The electrical equipment of the machine has to be checked regularly. Loose connections
and damaged cables have to be replaced immediately.
If works at alive parts are necessary, a second person has to assist who can disconnect the machine from
the mains if necessary.
The heating element has 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
RCD (FI) safety switch.
2.9. Special dangers
2.9.1. Danger of stumbling over electric cables
Make sure that no person must step over the wires.
Make sure that the cables lie in such a way that the danger is maintained at a minimum.

2.9.2. Danger of burning at heating element and welding area
You can burn yourself, inflammable materials can be ignited!
The heating element reaches temperatures of more than 260° C / 500° F!
Do not touch the surface of the heating element.
Do not leave the surfaces of the heating element unattended.
Take enough safety distance to materials which may be ignited.
Do wear safety gloves.
Only swivel the heating element at the handle.

Safety rules Chapter 2
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When cleaning the hot heating element with detergents (e.g.with PE – claening agent) 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.
2.9.3. Danger of squeezing by clamping tool and guideways
There is the danger of serious injuries. On the one hand between the clamping tools and on the
other hand between the ends of the guideways and the machine slide.
Do not grip between the workpieces.
Do not touch the guideways.
2.10. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without permission of the
manufacturer. In case of disrespect, the warranty or liability will expire resp. the EC declaration of conformity
will get obsolete.
Machine parts that are not in perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
In case of purchase orders, please always note the machine and version number!
2.11. Warranty and liability
Fundamentally, our "General sales and delivery conditions" are in force.
They are at the buyer's disposal latest when signing the contract.
Guarantee and liability demands refering to damages of persons or things are excluded if they are caused by
one or several of the following reasons:
Not using the machine according to the prescriptions.
Unprofessional transport, building-up, starting, operating and maintenance of the machine.
Running the machine with defective or not properly mounted safety equipment.
Ignoring the information given in these working instructions.
Structural modifications on the machine without permission.
Unsatisfactory maintenance of parts of the machine which are worn out.
Unprofessionally performed repairs.
In case of catastrophes and acts of god.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [e-mail] Internet: www.widos.de
19.05.15 Working instructions WIDOS 7511 Page 13 of 39
3. Functional description
Basically, the international and national standard specifications are to be
fulfilled.
First insert the fitting to be welded into the clamping device up to limit stop and clamp it there.
Afterwards, carry out zero alignment.
Clamp the pipe in a way that both workpieces touch each other during zero alignment.
Open up the machine and swing the heating element between the workpieces.
Pipe and fitting can be heated up to welding temperature at the same time (heat-up time) with the help of a
socket or spigot-shaped heating element.
After swinging out the heating element (change-over time), the workpieces are joined (cooling time).
The pipe end, heating element and fitting socket are to match each other in size in such a way that a joining
pressure will build up during joining.
After expiration of the cooling time, the welded joint can be unclamped, the welding process is finished.
Principle of heating element socket welding

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [email protected] Internet: www.widos.de
19.05.15 Working instructions WIDOS 7511 Page 14 of 39
4. Operating and indicating elements
4.1. Elements at the front
No. Denomination / function
1 Clamping tool left for pipe
2 Handle for pipe clamping tool left side, clamping tool open / close
3 Stop bolt, limited the depth of insertion and the zero offset
4 Rotary handle for slides; both slides open / close (can be removed for the transport)
5 Heating element with socket on left side and spigot on right side
6 Clamping tool for fitting right side
7 Clamping lever for locking slides
8 Handle for fitting clamping tool tight side, clamping tool open / close
9 Stop washer metric / inch, for insertion depth and zero offset
10 Drawer with handle, storing accessories such as clamping tools, spigots, sockets and tool
1
2
4
5
6
7
8
9
10
3

Operating and indicating elements Chapter 4
19.05.15 Working instructions WIDOS 7511 Page 15 of 39
4.2. Elements on the heating element
No. Denomination Function
11 Grip Swiveling the heating element in / out manually
12 Fixing element Fixied the heating element in basic machine
13 Switch on/off Red light as soon as the heating element is switched on
14 Knob with slot Setting the heating element temperature
15 Control lamp green Three different states:
off: signal showing that the heating element is not heated up
at the moment or that it is cooling.
blinking: the temperature of the heating element is maintained by a
defined pulse-position ratio.
on: signal showing that the heating element is heated up at
the moment. The nominal temperature has not been
reached yet.
11
12
13
14
15

Operating and indicating elements Chapter 4
19.05.15 Working instructions WIDOS 7511 Page 16 of 39
4.2.1. How to mount the heating spigot and socket
Screw socket and spigot of the required diameter onto the heating element. Mount the heating socket on
the side of pipes (left-hand) and the heating spigot on the fitting side (right-hand).
Use the special pan-head screw, the pressure spring, washer and hexagon nut for spigots without screw
thread (according to the illustration).
4.3. Accessore pipe champferer (optional)
Pipe chamferer size 1, for 15°-chamfering the pipe end.
Heating spigot
Heating socket
Heating spigot
Heating socket

Operating and indicating elements Chapter 4
19.05.15 Working instructions WIDOS 7511 Page 17 of 39
4.4. Clamping tool left for pipe
There are two sizes of pipe clamping tool OD 20 - OD 50
mm and OD 40 - OD 75 mm.
The clamping claws of the pipe clamping tool sitting on
straight pins internally and externally.
How to change clamping claws:
Remove the flat-head screws and detach the clamping jaws. Set the clamping jaw with other size on the
straight pins and mount it with flat-head screw.
4.5. Clamping tool for fitting
There are two sizes of fitting clamping tool OD 25 -
OD 55 mm and OD 50 - OD 90 mm. The clamping jaws of
the fitting clamping tool sitting on straight pins and are
mounted with flat-head screws.
How to change clamping claws:
For changing a jaw remove the flat-head screw and detach the jaw.
Set the clamping jaw with other size on the straight pins and mount it with flat-head screw.
Marking of size
Straight pin
Flat-head screw
Straight pin
Flat-head screw
Marking type and size

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen-Heimerdingen Fax [phone]
GmbH E-mail: [email protected] Internet: www.widos.de
19.05.15 Working instructions WIDOS 7511 Page 18 of 39
5. Starting and operating
The indications of this chapter are supposed to instruct you in the operation of the machine and to lead you
during the skilled starting of the machine.
This includes:
the safe operation of the machine
using all possibilities
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 danger situations for person and the machine, the mains plug has to be unplugged
immediately.
At the end of the work and during breaks, the machine has to be switched off.
Also take care that no unauthorized person has access to the machine.
Protect the machine from wetness and humidity!
According to VDE 0100, operation on building sites is only allowed with a current distributor
with RCD (FI)-security protective switch.
The socket and spigot surfaces are to be clean and, above all, free from grease. Therefore
they are to be cleaned with non-fraying paper and detergent (e.g. PE – cleaning agent or
WIDOS pipe cleansing cloths) before every welding or if they are dirty.
The nonstick coating of the socket and spigot must remain undamaged in the working area.
Take the machine out of the transport case and put the machine e.g. onto a working table.
Connect the turning handle (chapter: 4.1 no. 4) to the front of the left axis and make sure that it can move
freely without crushing your fingers.
Release the clamping lever (no. 7) and drive the tables apart by means of turning handle.
Swing the heating element to the rear.
Connect the heating element to the local power supply (230 V / 16 A / 50 Hz) / (110V / 16 A / 60 Hz).
Assemble the machine in a way that no unauthorized person may touch the swiveled out heating element,
otherwise install a barrier on site.
The machine can be operated now.

Starting and operating Chapter 5
19.05.15 Working instructions WIDOS 7511 Page 19 of 39
5.2. Surrounding conditions
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.
5.3. Welding process
The respectively valid welding prescriptions (ISO / CEN / DVS...) are to be
basically followed.
Do wear safety gloves as protection against burning!
A stop-watch is to be available in order to be able to register the actual times for heating up and cooling.
Screw the cleaned and fitting socket and spigot which are free from grease onto the heating element
(spigot right-hand / socket left-hand).
Mount the prism clamping tools for the pipe with a corresponding diameter range on the left side (chapter:
4.5).
Mount the prism clamping tool for the fitting with a corresponding diameter range on the right side. For
clamping the fitting, fitting stops are provided (chapter: 4.6).
A welding table is to be available from which you can read the parameters that are prescribed by the
welding regulations for the pipe dimension to be welded.
The heating element socket / spigot are to be clean and, above all, free from grease.
Therefore they are to be cleaned with non-fraying paper and detergent (e.g. PE cleaner) before every
welding or if they are dirty.
The nonstick coating of the heating element must remain undamaged in the working area.
In addition, the workpieces (fitting and pipe) to be welded must be clean. If need be, clean them with
detergent and non-fraying paper.
The pipe end is to be chamfered to appr. 15°.
appr. 15°
2-3 mm

Starting and operating Chapter 5
19.05.15 Working instructions WIDOS 7511 Page 20 of 39
Switch on the heating element and adjust the necessary welding temperature at the set screw at the
handle.
If the control lamp blinks, the nominal temperature has been reached and is maintained by means of a
defined pulse-pause ratio.
Put the fitting in the fitting clamping tool onto the stop.
Clamp the fitting by handle.
Turn the dial until the position “0” locks over the red spot.
Shut the machine until the dial rest against the stop bolt (upper left image) and fix this position with the
clamping lever.
Insert the chamfered pipe so that the end face is adjacent to the fitting.
Close the pipe clamping tool and clamp the pipe by handle.
Limit Stopp for fitting
Dial for pipes (here metric version displayed)
Upon resetting and for joining drive the machine
with the dial onto stop bolt (arrow).
Clamping lever