widos MAXIPLAST User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen County court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating element butt welding machine
WIDOS MAXIPLAST
Keep for further use!

Kunststoffschweißtechnik
Product identification
01.07.13 Working instructions WIDOS MAXIPLAST Page 2 of 39
Type: WIDOS MAXIPLAST
Serial number / year: see type plate
Inserts of customer
Inventory-no.:
Place of working:
Order of spare parts and sales service:
Address of manufacturer WIDOS
W. Dommer Söhne GmbH
Einsteinstr. 5
D -71254 Ditzingen-Heimerdingen
Phone: [phone] - 0
Telefax: [phone] - 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: [phone] - 0 Phone: [phone]
Fax: [phone] - 20

Kunststoffschweißtechnik
Introduction
01.07.13 Working instructions WIDOS MAXIPLAST Page 3 of 39
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 during operation.
Thank you.
Design of the working instruction
This manual is arranged in chapters which belong to the different using phases of the
machine.
Therefore the searched information can be found easily.
01.07.2013 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
01.07.13 Working Instructions WIDOS MAXIPLAST Page 4 of 39
1. DESCRIPTION OF PRODUCT........................................................................................ 6
1.1. Application and prescribed use ..........................................................................................6
1.2. Safety measures ...................................................................................................................6
1.3. Conformity.............................................................................................................................6
1.4. Overview................................................................................................................................7
1.5. Designation of product.........................................................................................................7
1.5.1 Technical data ....................................................................................................................7
1.5.1.1 WIDOS MAXIPLAST General data ........................................................................7
1.5.1.2 Heating element.........................................................................................................8
1.5.1.3 Planer.........................................................................................................................8
1.5.1.4 Basic nachine with table support ...............................................................................8
1.6. Equipment and accessories:...............................................................................................9
2. SAFETY RULES............................................................................................................ 10
2.1. Explanation of the different symbols................................................................................10
2.2. Obligations of the owner....................................................................................................10
2.3. Obligations of the user.......................................................................................................11
2.4. Measure of organisation ....................................................................................................11
2.5. Information about safety precautions ..............................................................................11
2.6. Instructions for the staff ....................................................................................................11
2.7. Structural modifications on the machine.........................................................................11
2.8. Danger while handling the machine .................................................................................12
2.9. Danger caused by electrical energy .................................................................................12
2.10. Specific dangers.................................................................................................................12
2.10.1 Danger of burning / heating element, protective box, welding area.................................12
2.10.2 Danger by stumbling over electric wires...........................................................................12
2.10.3 Danger by cutting / squeezing / catching .........................................................................13
2.11. Warranty and liability..........................................................................................................13
3. DESCRIPTION OF THE WELDING PROCESS............................................................ 14
4. ELEMENTS FOR OPERATING THE MACHINE........................................................... 15
4.1. Elements on the basic machine / table support ..............................................................15
4.2. Elements at the heating element.......................................................................................16
4.3. Element at the planer..........................................................................................................17
5. STARTING AND OPERATING...................................................................................... 18
5.1. Starting.................................................................................................................................18
5.1.1 Change of the reduction inserts .......................................................................................18
5.2. Welding process .................................................................................................................19
6. WELDING RECORD AND TABLES ............................................................................. 22
7. MAINTENANCE INSTRUCTIONS................................................................................. 27

Kunststoffschweißtechnik
Contents
01.07.13 Working Instructions WIDOS MAXIPLAST Page 5 of 39
7.1. General.................................................................................................................................27
7.2. Clamping elements.............................................................................................................27
7.3. Planer...................................................................................................................................27
7.4. Storing..................................................................................................................................27
7.5. Cleaning of the machine ....................................................................................................27
7.6. Disposal...............................................................................................................................27
8. TRANSPORT................................................................................................................. 28
9. WIRING DIAGRAM........................................................................................................ 29
10. SPARE PARTS LIST................................................................................................. 30
10.1. Basic machine.....................................................................................................................30
10.2. Planer...................................................................................................................................33
10.3. Heating element..................................................................................................................35
10.4. Protective box .....................................................................................................................37
11. DECLARATION OF CONFORMITY.......................................................................... 39

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
01.07.13 Working Instructions WIDOS MAXIPLAST 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. Application and prescribed use
The WIDOS MAXIPLAST is made for heating element butt welding of pipes and fittings out of
PE, PP and PVDF with a diameter range of Ø = 50 - 160.
The machine is kept small so that it can easily be used in the pipe system.
The clamping of the pipes is managed by steel clamping tools.
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 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
the respect of all the indications of the working instructions and
the performing of the inspection and maintenance works.
1.2. Safety measures
In case of wrong use, wrong operation or wrong maintenance the machine itself or products
being in the surrounding can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thouroughly read and the corresponding
safety advices must necessarilly be 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
01.07.13 Working Instructions WIDOS MAXIPLAST Page 7 of 39
1.4. Overview
No. Denomination
1 Heating element
2 Basic machine
3 Planer
4 Protective box
5 Table support
1.5. Designation of product
The product is designated by a sign at the frame.
It contains the type of the machine, the serial number and the year of construction.
1.5.1 Technical data
1.5.1.1 WIDOS MAXIPLAST General data
Material: PP, PE, PVDF,
Dimensions of pipes: Outside-= 50 - 160 mm
Transport box (LxBxH): 630 x 505 x 562 mm
Weight (without packing): 45 kg
Weight transportbox appr. 14 kg
Fuse: 16 A
Wire cross section: 1,5 mm²
1
2
3
4
5

Kunststoffschweißtechnik
Description of product Chapter 1
01.07.13 Working Instructions WIDOS MAXIPLAST Page 8 of 39
Emissions: - The sound intensity level is below 70 dB (A)
- When using the named pipe materials and
when welding below 260 °C no toxicant damp
arises.
Environment - Keep the workshop clean (especially 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
- avoid strong sun beams
- if it is windy shut the pipe endings.
1.5.1.2 Heating element
Power: 800 Watt
Voltage: 230 V (10 %)
Current: 3,5 A (10 %)
Frequency: 50 Hz
Outside-: 200 mm
surface: anti-stick coated
Elements: - electric temperature control
- control lamp
- connecting cable with plug
Weight: appr. 3,9 kg
1.5.1.3 Planer
Power: 950 Watt
Voltage: 230 V (10 %)
Current: 3,5 A (10 %)
Frequency: 50 Hz
Weight: appr. 9,3 kg
1.5.1.4 Basic nachine with table support
Material frame and clamping tools: Machinery steel
max. force 1000 N
See spare parts list chapter 10, for order-numbers and single parts, when ordering, please state the
machine number!

Kunststoffschweißtechnik
Description of product Chapter 1
01.07.13 Working Instructions WIDOS MAXIPLAST Page 9 of 39
1.6. Equipment and accessories:
Following accessories are part of the delivery:
1 Allan key with T-grip size 3 for screwing in / out the reduction inserts
1 Allan key with T-grip size 4 for tightening the optional clamping jaws for
fittings
1 Allan key tilted size 5 for tightening the pipe support
1 Torx-screwdriver T10
Screws for reduction inserts, flat-head screws for reduction inserts, flat-
head screws for mounting the optional clamping jaws for fittings

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
01.07.13 Working Instructions WIDOS MAXIPLAST Page 10 of 39
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 different symbols
In the working instructions the 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 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).
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
the workers also must 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.

Kunststoffschweißtechnik
Safety rules Chapter 2
01.07.13 Working Instructions WIDOS MAXIPLAST Page 11 of 39
2.3. Obligations of the user
All persons who are to work at the machine are obliged:
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, before working.
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 by a third person, 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.
2.7. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer (look chapter 2.11. In cases of non-compliance, any
guarantee and liabilitydemands 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
01.07.13 Working Instructions WIDOS MAXIPLAST Page 12 of 39
2.8. Danger while handling the machine
The machine WIDOS MAXIPLAST is constructed according to the actual technical standards
and the acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby may occur.
Also damages to the machine itself or to other things 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 immediately cleared.
2.9. Danger caused by electrical energy
Only skilled qualified workers are allowed to work at electrical features.
The electrical equipment of the machine has to be regularly checked.
Loose connections and damaged cables have to be replaced immediately.
The heating element need to be protected from rain and dropping water,
eventually put up welding tent.
The use on construction sites is only allowed according VDE 0100 over a
power distributor with a FI-safety switch.
2.10. Specific dangers
2.10.1 Danger of burning / heating element, protective box, welding
area
You may burn parts of your body and material may also be ignited!
The heating element is heated up to over 200° C!
Do not leave the heating element unattended.
Take enough safety distance to materials which may be ignited.
Do wear safety gloves.
Always put the heating element back into its box before and after usage.
Only transport the heating element at the holder, do not touch the surfaces of
the heating element.
2.10.2 Danger by stumbling over electric wires
Make sure that no person must step over the wires.

Kunststoffschweißtechnik
Safety rules Chapter 2
01.07.13 Working Instructions WIDOS MAXIPLAST Page 13 of 39
2.10.3 Danger by cutting / squeezing / catching
Always put the planer back into its box before and after usage.
Only transport the planer at the holder and do not touch surfaces.
Do not grip between clamped pipe endings.
Make sure that your clothing is not seized into the planer.
2.11. Warranty and liability
Fundamentally our "general sales and delivery conditions" are in force.
The buyer received them before making the contract.
Guarantee and liability demands referring 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 prescription.
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 this manual.
Structural changes on the machine without permission.
Unsatisfactory checkings of parts of the machine, which are worn out.
Unprofessionally performed repairs.
In case of catastrophes and acts of God.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
01.07.13 Working Instructions WIDOS MAXIPLAST Page 14 of 39
3. Description of the welding process
Basically the international and national guidelines are to be
followed.
The plastic pipes are clamped by means of the clamping tools.
Then the front of the pipes are planed. As soon as the pipes are parallel and the pipe deviation
is smaller than 0,1x pipe thickness, the welding can begin.
Now the clamping tool with the pipes must be moved forward against the heating element until
a certain pressure is achieved. Now the pipes are heated up and a circular bead arises.
This happens during the bead-up time.
After reaching the necessary bead-height, the pressure is reduced, and this is the beginning of
the heat-up time, this time is used to heat-up the pipe ends.
After heat-up time the support must be moved backward and the heating element must be
removed as quickly as possible and the pipes driven together again.
The time between moving backward of the support and moving forward again after the heating
element is taken out ist called change-over time.
The pipes are fitted together according to the prescribed welding pressure and now the pipe
cools down under pressure (cool-down time).
The welded pipes can be unclamped, the welding process is finished
heating element
heats-up the pipes
welded pipe with internal
and external bead

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
01.07.13 Working Instructions WIDOS MAXIPLAST Page 15 of 39
4. Elements for operating the machine
4.1. Elements on the basic machine / table support
No. Denomination Function
1 Tightening nut - tightening of the pipes
2 Lever for horizontal offset (2x) - by loosening the levers the clamping tool can
be moved upwards and downwards on the
wedge
3 Clamping lever (4x) - adjustment of the angle
4 Guide bar above - guidance for the support
5 Star grip - fixing the support
6 Scale - display of the actual welding force
- max. 120 kp
7 Handwheel - Driving the support forward / backward
- application of the bead-up force
8 Star grip for basic machine - tightening the basic machine at the table
support.
9 Spindle - advance for support
10 Guide bar below - guidance for the support
- fixing the planer
- rest for the heating element
1
4
3
2
5
6
7
8
9
10

Kunststoffschweißtechnik
Elements for operating the machine Chapter 4
01.07.13 Working Instructions WIDOS MAXIPLAST Page 16 of 39
4.2. Elements at the heating element
No. Denomination Function
1 Switch on / off with lamp - comes on as soon as the heating element has
been connected to he aggregate and the switch
has been switched „on“.
2 control knob with slot - setting temperature at heating element
3 control lamp green - there are three statuses:
out: If the desired temperature is lower
than the actual temperature the heating
heating element cools-down to the desired
temperature.
blinking: The adjusted temperature is maintained.
on: The heating element is heated up because
it has not reached the desired temperature.
3
2
1

Kunststoffschweißtechnik
Elements for operating the machine Chapter 4
01.07.13 Working Instructions WIDOS MAXIPLAST Page 17 of 39
4.3. Element at the planer
Nr. Benennung Funktion
1 Switch on / off for planer - The planer can be switched on via the switch and
the associated adjustment knob.
- The planer has to be switched off before and
after use.
2 Locking with protection switch - protection against unintentional running.
- locking the planer, thus avoiding a falling out.
- planer can only start when switch is pressed.
1
2

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
E-mail: [e-mail] Webside: www.widos.de
01.07.13 Working Instructions WIDOS MAXIPLAST Page 18 of 39
5. Starting and operating
The instructions of this chapter are supposed to initiate in the operation of the machine and
lead during the appropriate starting of the machine.
This includes:
the safe operation of the machine
using all the possible options of the machine
economic operation of the machine
5.1. Starting
The machine should only be operated by initiated and authorized people.
For the qualification a plastic welding exam can be taken according to DVS and
DVGW.
If dangers occur unplug the machine immediately.
Switch off the machine after the work and during pauses.
Make sure that unauthorized people are kept at a distance.
Protect the machine from wetness and moisture!
For working at the building site use a current distributor with a FI-security
protective.
Lay electric cables thoroughly (danger of stumbling)!
Take care of the surrounding conditions:
-The welding should not be performed under direct sun rays influence, use a welding
umbrella if necessary.
In case of surrounding temperature under 5° C measures should be taken :
-Build up a welding tent or heat up the pipe ends if necessary.
Take measures against rain, wind and dust.
Connect the heating element to the mains supply (230 V / 50 Hz).
5.1.1 Change of the reduction inserts
Unscrew the in-screwed reduction inserts by means of the enlcosd Allan key.
Screw on reduction inserts of the desired diameter.
With respect to curves, the angle on the basic clamping tools can be set (on each side
between -15° to +15°).

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.07.13 Working Instructions WIDOS MAXIPLAST Page 19 of 39
5.2. Welding process
In principle, the valid welding regulations (ISO / CEN / DVS ...) are
to be observed.
Put on safety gloves to protect you from being burned.
A stop-watch should be available in order to be able to register the actual times for heating
up and cooling down.
A table should be available from which you can read the parameters that are prescribed by
the welding regulation for the pipe diemesion to be welded.
The heating elements are to be clean and, above all, free from grease. Therefore they are
to be cleaned with non-fraying paper and detergent (e.g. technically pure alcohol or pipe-
cleansing cloths which can be bought at the WIDOS company) before every welding or if
they are dirty.
The anti-adhesive coating of the heating element has to remain undamaged in the working
area.
Switch on heating element and set the required welding temperature on the adjustment
screw on the handle.
If the control light flashes, the nominal temperature has been reached and is held at a
constant level through a given impulse-break relationship.
Screw in reduction inserts according to the outer diameter of the pipes to be welded, if
necessary set the angle.
wide clamping tool small clamping tool

Kunststoffschweißtechnik
Starting and operating Chapter 5
01.07.13 Working Instructions WIDOS MAXIPLAST Page 20 of 39
Clamp the basic frame to the table holder, if required mount the table holder to the support
surface or insert machine without table holder directly into the pipe system.
machine working directly in the pipe system
Put the workpieces into the clamping tool, fasten clamping nuts tightly and align the
workpieces with respect to one another.
Insert the planer between the workpieces, arrest them on the guide bar by turning the star
grip. Switch on the planer and plane with little pressing force.
Planing should be carried out until a revolving cutting has been formed on both sides.
Open slide again, switch off the planer, remove it and put it into the heat protective box.
Remove the produced cuttings, thereby preventing contact with the worked surfaces.
Close slide again.
Check pipe mismatch and gap at the abutting pipe ends.
According to DVS 2207, the mismatch on the pipe outside should not exceed 0.1 x pipe wall
thickness, the admissible gap should not exceed 0.5 mm.
The mismatch compensation is effected through the stronger tightening or releasing of the
clamping nuts. In case mismatch compensation was effected, renewed planing has to be
carried out afterwards.
Take the adjustment force for the pipe dimension to be welded from the table and add the
motivity.
Open slide again somewhat.
Take the heating-up time, the maximum change-over time, the cooling-down time and the
bead height for the pipe dimension to be welded from the table.
Bring the heating element which has been cleaned and brought to its nominal
temperature between the pipes with the handle facing downwards (hang into guide bar).