widos ASM 160 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
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 ASM 160
Keep for further use!

Kunststoffschweißtechnik
Product identification
31.01.2013 Working instructions WIDOS ASM 160 page 2 of 40
Type: WIDOS ASM 160
Serial number / year of construction: see type label
Customer entries
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 (0) 71 52 / 99 39 – 0
Fax: ++49 (0) 71 52 / 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 (0) 371 / 8 15 73 - 0 Phone: [phone]
Fax: ++49 (0) 371 / 8 15 73 - 20

Kunststoffschweißtechnik
Introduction
31.01.2013 Working instructions WIDOS ASM 160 page 3 of 40
Purpose of the document
These working instructions give you information about all important questions which refer to
the construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our service team in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest to continuously improve our products and working instructions, we
kindly ask you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters which belong to the different using phases of the machine.
Due to this structure, the searched information can be easily found.
31.01.2013 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.

Kunststoffschweißtechnik
Contents
31.01.2013 Working instructions WIDOS ASM 160 page 4 of 40
1. DESCRIPTION OF THE PRODUCT .............................................................................. 6
1.1. Usage and purpose-oriented use........................................................................................6
1.2. Safety measures ...................................................................................................................6
1.3. Conformity.............................................................................................................................6
1.4. Designation of the product..................................................................................................7
1.4.1. Technical data ................................................................................................................7
1.4.1.1. WIDOS ASM 160 General data................................................................................7
1.4.1.2. Heating element flexible ............................................................................................7
1.4.1.3. Drilling machine .........................................................................................................7
1.5. Tools and accessories .........................................................................................................8
1.6. Wear parts .............................................................................................................................8
2. SAFETY RULES ............................................................................................................ 9
2.1. Explanation of the symbols and indications......................................................................9
2.2. Obligations of the owner....................................................................................................10
2.3. Obligations of the worker ..................................................................................................10
2.4. Measure of organisation ....................................................................................................10
2.5. Information about safety precautions ..............................................................................10
2.6. Instructions for the staff ....................................................................................................10
2.7. Dangers while handling the machine ...............................................................................11
2.8. Specific dangers .................................................................................................................11
2.8.1. Danger of stumbling over electric wires .......................................................................11
2.8.2. Danger of combustion by heating element and welding area......................................11
2.8.3. Danger of crushing.......................................................................................................12
2.8.4. Danger of cutting and drawing-in by drilling machine ..................................................12
2.8.5. Danger of injury by chips / remaining pieces / noise ...................................................12
2.9. Structural modifications on the machine.........................................................................12
2.10. How to clean the machine..................................................................................................13
2.11. Warranty and liability..........................................................................................................13
3. FUNCTIONAL DESCRIPTION..................................................................................... 14
4. OPERATING AND INDICATING ELEMENTS ............................................................. 15
4.1. Machine overview ...............................................................................................................15
4.1.1. Heating element flexible...............................................................................................16
4.1.1.1. How to set the heating element temperature...........................................................16
4.2. Drilling machine..................................................................................................................18
4.2.1. How to fix the drilling machine in the clamping tool .....................................................19
4.2.2. How to adjust the drill diameter....................................................................................20
4.3. Spring clamping..................................................................................................................21
4.4. Clamping tool for branch pipe / drill.................................................................................21
5. STARTING AND OPERATING .................................................................................... 22

Kunststoffschweißtechnik
Contents
31.01.2013 Working instructions WIDOS ASM 160 page 5 of 40
5.1. Starting.................................................................................................................................22
5.2. Drilling and welding process.............................................................................................23
6. WELDING TABLES ..................................................................................................... 25
7. MAINTENANCE / STORAGE / TRANSPORT ............................................................. 29
7.1. General.................................................................................................................................29
7.2. Clamping element...............................................................................................................29
7.3. How to clean the machine..................................................................................................29
7.4. How to change the knife ....................................................................................................29
7.5. Transport .............................................................................................................................30
7.6. Disposal...............................................................................................................................30
8. ELECTRIC DIAGRAM.................................................................................................. 31
9. SPARE PARTS LIST ................................................................................................... 32
9.1. Basic machine.....................................................................................................................32
9.2. Drilling machine..................................................................................................................34
9.3. Control device.....................................................................................................................36
9.4. Heating element flexibel for ASM 160...............................................................................38
10. DECLARATION OF CONFORMITY ............................................................................ 40

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
www.widos.de email: [e-mail]
31.01.2013 Working instructions WIDOS ASM 160 page 6 of 40
1. Description of the product
The chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS ASM 160 has been designed for heating element butt welding of pipes out of
PE, PP, branch pipes with a diameter range of OD = 50 – 160 mm and main pipes from OD
110 mm (the maximum diameter of branch pipe = 2/3 of the main pipe).
All use going beyond is not purpose-oriented.
The machine is only to be used in a technically perfect condition, as well as purpose- oriented,
safety- and danger-conscious in compliance with the working instructions and the relevant
safety regulations (especially the regulations for the prevention of accidents).
The described plastic welding machine may only be operated, maintained and repaired by
persons who are trained and informed about the dangers.
The manufacturer is not responsible for any damages caused by inexpert handling or
operation.
For personal injuries, material and immaterial damages resulting herefrom, only the user is
responsible!
Also part of the purpose-oriented use is:
respecting all the indications of the working instructions and
performing the inspection and maintenance works.
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
regulations must be necessarily adhered to.
1.3. Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.

Kunststoffschweißtechnik
Description of product Chapter 1
31.01.2013 Working instructions WIDOS ASM 160 page 7 of 40
1.4. Designation of the product
The product is marked by a type-label at the basic frame.
It contains the type, the serial number and the year of construction of the machine.
1.4.1. Technical data
1.4.1.1. WIDOS ASM 160 General data
Dimensions of branch pipes Outside-Ø = 50 – 160 mm (optional)
Material: PP, PE 80, PE 100
Fuse protection: 16 A
Emissions: - Noises exceeding 80 dB (A) may occur; during drilling it is
obligatory to wear ear protection!
- When using the named plastic materials and when welding
within the temperature range up to 260 °C no toxicant
damp arises.
Environment: - Take care for cleanness (no dust at the welding area)
- Do not weld below 5 °C, if necessary preheat
- Avoid humidity, if necessary use a welding tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends
1.4.1.2. Heating element flexible with control unit
Heating area: 240 x 300 mm
Power: 2250 Watt
Current: 10 A (± 10 %)
Voltage: 230 V (± 10 %)
Frequency: 50 Hz
Fuse protection: 16 A
Surface: PTFE foil
Interface heating element / control unit: 10-pole plug socket
Attached elements: - electronic temperature control
- on / off switch with red illuminated
- connecting cable with plug
1.4.1.3. Drilling machine
Power: 950 W
Current: 3,5 A (± 10 %)
Voltage: 230 V (± 10 %)
Frequency: 50 Hz
Attached elements: - Connecting cable with plug

Kunststoffschweißtechnik
Description of product Chapter 1
31.01.2013 Working instructions WIDOS ASM 160 page 8 of 40
1.5. Tools and accessories
Unit Denomination
1 set each Clamping insert for branch pipe with OD 125 / OD 160 mm or OD 2“ / 3“ / 4“
/ 5“ IPS (option)
1 Heating element flexible
1 Heating element control for heating element flexible
1 Drill with 1 center drill and 4 knife holder inclusive circular knives
1 Clamping belt, 1,5 m long
1 Torx – screw driver T 15
1 each Allen key with T-grip size 3 / 4
1.6. Wear parts
Unit/
machine Denomination Article no.:
3 Circular knife RCT 10T3MO-PL 2164117/4
1 Cutting insert SCGT 09T304FN-ALU AK10 on request
1 Center drill Ø 10 6184427
4 Flat-head screw 3,5 x 8 with Torx-drive on request
1 Heating element, flexible HASM160EKP
1 PTFE foil 6185459
For article-nos. and single parts please contact the company WIDOS.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
www.widos.de email: [e-mail]
31.01.13 Working instructions WIDOS ASM 160 page 9 of 40
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety advises and rules.
These working instructions contain the most important indications to run the machine safely.
The safety indications are to be followed by all persons working on the machine.
2.1. Explanation of the symbols and indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possibly danger for the life and the health of persons.
The disrespect of these indications may have heavy consequences for the
health.
This symbol means a possible dangerous situation.
The disrespect of these indications may cause slight injuries or damages on
goods.
This symbol means a possible dangerous situation by moving parts of the
machine
The disrespect of these indications may cause severe 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 danger of injury by drilling chips.
It is obligatory to wear safety glasses.
This symbol means a possible risk of injury by noises exceeding 80 dB (A).
It is obligatory to wear ear protection.
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
31.01.13 Working instructions WIDOS ASM 160 page 10 of 40
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.

Kunststoffschweißtechnik
Safety rules Chapter 2
31.01.13 Working instructions WIDOS ASM 160 page 11 of 40
2.7. Dangers while handling the machine
The machine WIDOS ASM 160 is constructed according to the latest technical standard and
the acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby may occur. Also
material damages are possible.
The machine may only be used
according to the purpose-oriented use
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be cleared immediately.
Only skilled persons are allowed to work at electrical appliances.
The electrical equipment of the machine has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
Protect the heating element and drilling machine from rain and dropping water.
According to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
2.8. Specific dangers
2.8.1. Danger of stumbling over electric wires
Make sure that no person has to step over the wires of the heating element and the drilling
machine.
2.8.2. Danger of combustion by heating element and welding area
You can burn yourself, inflammable materials can be ignited.
The heating element temperature is heated up to more than 250° C!
Do not leave the heating element unattended.
Hinge resp. place the heating element on a fireproof mat before and after the welding.
Do not touch the surfaces of the heating element.
Take enough safety distance to inflammable materials.
Do wear safety gloves.
When cleaning the hot heating element with detergents (e.g. with PE cleaner) there is the
danger of inflammation. For this reason take care that the inflammation point is above the
actual temperature of the heating element. Do not bring any fire sources (e.g. cigarettes)
close thereto.

Kunststoffschweißtechnik
Safety rules Chapter 2
31.01.13 Working instructions WIDOS ASM 160 page 12 of 40
2.8.3. Danger of crushing
Heavy injuries can result from crushing:
By swivelling of drilling machine into / out of machine.
Make sure that no body part is between machine and drill.
By lifting of drilling machine.
Make sure that no body part is between basic machine and drilling machine.
Do not touch the guide rods of basic machine. Shift drilling machine only if
shifting way is clear.
If the hoses are insufficiently clamped.
Check clamping before drilling.
By transporting the machine
Lock the drilling machine against unintentional swiveling.
2.8.4. Danger of cutting and drawing-in by drilling machine
You may encounter cutting injuries and even fractures!
Wear tight-fitting clothes.
Do not wear rings or jewelry during work.
If necessary wear snood-type cap.
Keep away others from the drilling area.
Do not reach between drill and clamped pipe ends.
Make sure that the drill does not draw-in any clothes.
Special care is to be taken during the transport of the machine, if necessary
detach drill head and transport separately.
2.8.5. Danger of injury by chips / remaining pieces / noise
Do wear safety glasses during drilling!
Never remove chips if the drilling machine is running.
Do wear an ear protection during drilling!
2.9. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer. In cases of non-compliance, any guarantee and liability
demands expire.
Machine parts which are not in a perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
In case of purchase orders please always state the machine number and version
number!

Kunststoffschweißtechnik
Safety rules Chapter 2
31.01.13 Working instructions WIDOS ASM 160 page 13 of 40
2.10. How to clean the machine
The used materials and tissues are to be handled and disposed of properly, especially:
when cleaning with solvents
when lubricating with oil and grease
2.11. Warranty and liability
Fundamentally our „General Sales and Delivery Conditions“ are valid.
They are at the owner's disposal latest when signing the contract.
Warranty and liability demands referring to personal injuries or damages on objects are
excluded if they are caused by one or several of the following reasons:
Not using the machine according to the prescriptions.
Inexpert transport, starting and operation of the machine and maintenance.
Ignoring the information given in this manual.
Structural changes on the machine without permission.
Unsatisfactory checking of parts of the machine which are worn out.
Repairs performed in an inexpert way.
In case of catastrophes and force majeure.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
www.widos.de email: [e-mail]
31.01.2013 Working instructions WIDOS ASM 160 page 14 of 40
3. Functional description
Basically, the international and national process guidelines are to be followed.
The machine is placed on the main pipe and clamped by the tension belt.
The clamping tool is opened.
The drilling machine is swivelled over the main pipe, clamped into the clamping tool and the
spring is locked.
Now the hole is drilled into the main pipe, afterwards the clamping tool is released, the drilling
machine is swivelled back and the spring unlocked.
The branch pipe is placed into the clamping tool, aligned to the main pipe and then clamped.
Put the flexible heating element onto the hole of main pipe and the pipes are pressed against
the heating element under defined adjusting force.
This process is called „adjusting“.
The applied force can be read on the scale mounted at the machine.
After the prescribed bead height being reached, force is reduced, the heating time begins.
The function of this time is to heat up the pipe ends.
After expiration of the heating time, the 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 force and then cool down under force (cooling
time).
The welded joint can be unclamped, the welding process is finished.
Completed welding joint with
in- and outside bead
Heating element flexible
Heating element heats the pipes
up to welding temperature
Branch pipe
Main pipe

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
www.widos.de email: [e-mail]
31.01.2013 Working instructions WIDOS ASM 160 page 15 of 40
4. Operating and indicating elements
4.1. Machine overview
No. Denomination Function
1 Hand wheel - to open / shut the machine.
- Application of the adjusting force and of the
jointing force.
2 Scale - Display of the applied welding force
- max. display: 150 kp
3 Clamping lever - spring clamping during drilling
4 Lock - swivelled in, during drilling
- swivelled out, during welding
5 Heating element flexible - to heat up the pipes
6 Control for heating element - electric power supply and controlling
7 Star screw - to lock the support
8 Star screw and clamping plate - to level the drill head angular in the clamping tool
9 Clamping tool - to insert the branch pipe
- to insert the drill
10 Clamping nut - to clamp the branch pipe
11 Handle at drilling machine - to move the drilling machine up and down
- to swivel the drilling machine in and out
12 Drilling machine with drill plate - to drill the hole into main pipe
- Can be swivelled in and out of the machine
13 Prism - Support for the machine onto the main pipe
14 Clamping belt - to fasten the machine onto the main pipe
1
2
6
3
5
7
8
11
10
12
13
9
14
4

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
31.01.13 Working instructions WIDOS ASM 160 page 16 of 40
4.1.1. Heating element flexible
4.1.1.1. How to set the heating element temperature
Display = Display of the actual value
Push shortly the button P (1), the display shows <SP>,
change desired value with buttons ▲(3) ▼(2).
Push shortly the button P (1), actual temperature is
displayed again (or automatic change after 30s).
During heating up to desired value, the control lamp K2 (4)
is on, having reached the desired temperature, the control
lamp K2 (4) is blinking.
4.2. Working with the heating element
Learn how to weld from the existing working instructions.
Make sure that the plastic film within the welding area is clean, free of grease and
undamaged.
If necessary clean the plastic film prior to each welding e.g. by PE cleaning agent or WIDOS
pipe cleaning cloths.
Replace a damaged plastic film immediately.
Heating range
Grip
Grip
Heating element connecting cable
Controller connecting cable
with plug 230 V
Plug 10-pole
On / off switch; as soon as the heating
element is switched on, it is heated up
and the control lamp illuminates
Temperature regulator
Control device

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
31.01.13 Working instructions WIDOS ASM 160 page 17 of 40
In case you want to hinge the heated
heating element, do not hinge it
horizontally but e.g. suspend it from one
corner of the heating element handle thus
reducing the emitting heat upwards to the
handle.

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
31.01.13 Working instructions WIDOS ASM 160 page 18 of 40
4.3. Drilling machine
No. Denomination Function
23 Fixing - Fixing to clamp into the clamping tool
- retainer for drill plate
24 Guard - to protect against contact with the running drill plate
25 Grip with button - to start drill, when drilling machine is switched on
26 Switch - to switch drilling machine on / off
27 Connecting cable - Connect with energy supply 230 V
28 Drill plate - Retainer for drill and knife holder
29 Drill - to drill the center drilling into the main pipe
30 Knife plate - to fasten the knife holder, can be adjusted continuously
31 Scale - to adjust the drilling diameter
32 Knife holder with knife - to fasten the circular knife
30
31
32
29
28
(11)
15
17
18
(10)
16
19
(8)

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
31.01.13 Working instructions WIDOS ASM 160 page 19 of 40
4.3.1. How to fix the drilling machine in the clamping tool
Photo shows drill fixed into clamping tool.
In order to fix the drilling machine hoist it with grip of drilling and swivel it above the pipe.
Open the clamping tool.
Hoist the drilling machinewith its fixing into clamping tool.
Close the clamping tool and clamp the clamping tool fractionally.
Mount the clamp plate between the top of clamping tool and the star screw.
Pick up the star screw as far as the fixing with its top is against the collar of clamping tool.
Then tighten the clamping nut.
So a fractionally cant is out of question.
Clamping tool
Fixing (15) clamp into clamping tool
Clamping nut
Klemmplatte
Star screw
Fixing
Grip of drilling

Kunststoffschweißtechnik
Operating and indicating elements Chapter 4
31.01.13 Working instructions WIDOS ASM 160 page 20 of 40
4.3.2. How to adjust the drill diameter
For drillings larger than 60 mm.
You must carry out the adjustment of the drilling
diameter steadily on all four knife plates:
Detach the four pan-head screws of a knife
plate.
Shift the knife plate onto scale until the
desired diameter is displayed, read it at the
outer edge of knife plate (pointer of reading).
Fix the knife plate in this position with pan-
head screws.
For drillings of 60 mm and smaller.
You must remove the four knife plates as well
as the center drill for drilling with 60 mm and
smaller.
Detach the three fixing screws and remove
the guard plate downwards.
Detach the pan-head screws on the knife
plates and remove all four knife plates
including the slot nuts.
Detach both threaded pins and remove the
center drill.
Put the optionally plastic drill into the center
and secure it with the threaded pins.
Install the guard plate back again.
Fixing screw
Guard for drill
Grub screw
Plastic drill (option)
Pan-head screw
Pointer of reading
Scale