widos MINIPLAST 2 / T-Piece 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
http://www.widos.de email: [e-mail]
Headquarters: D-71254 Ditzingen-Heimerdingen County court Stuttgart HRB 200973 Managing Director: Jürgen Dommer
Working Instructions
Translation
Heating Element Butt Welding Machine
WIDOS MINIPLAST 2
Keep for further use!

Kunststoffschweißtechnik
Product Identification
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 2 of 42
Model: Heating element butt welding machine
Type: WIDOS MINIPLAST 2
Serial number / year: see type plate
Customer entries
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: ++49 (0) 71 52 99 39 - 0
Telefax: ++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: ++49 371 / 8 15 73 - 0 Phone: [phone]
Fax: ++49 371 / 8 15 73 - 20

Kunststoffschweißtechnik
Introduction
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 3 of 42
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.
14.04.2014 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
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 4 of 42
1. DESCRIPTION OF THE PRODUCT ....................................................................6
1.1. Usage and purpose-oriented use........................................................................................6
1.2. Overview................................................................................................................................6
1.3. Safety measures ...................................................................................................................7
1.4. Conformity.............................................................................................................................7
1.5. Designation of the product..................................................................................................7
1.5.1 Technical data ....................................................................................................................7
1.6. Equipment and accessories:...............................................................................................8
2. SAFETY RULES ..................................................................................................9
2.1. Explanation of the Symbols and Indications.....................................................................9
2.2. Obligations of the Owner.....................................................................................................9
2.3. Obligations of the worker ..................................................................................................10
2.4. Measures of organisation ..................................................................................................10
2.5. Instructions for the staff ....................................................................................................10
2.6. Structural modifications on the machine.........................................................................10
2.7. Cleaning the machine.........................................................................................................10
2.8. Danger while handling the machine .................................................................................11
2.9. Dangers caused by electric energy ..................................................................................11
2.10. Specific dangers.................................................................................................................11
2.10.1 Danger of being burnt by heating element, reception box and welding area..................11
2.10.2 Danger of stumbling over electric wires ...........................................................................11
2.10.3 Danger of cutting / squeezing / catching clothes..............................................................12
2.10.4 Risk of injury by noises.....................................................................................................12
2.11. Warranty and liability..........................................................................................................12
3. FUNCTIONAL DESCRIPTION...........................................................................13
4. OPERATING AND INDICATING ELEMENTS ...................................................14
4.1. Elements on the basic machine / table support ..............................................................14
4.2. Elements at Heating Element and Planer.........................................................................15
4.3. Elements at the Electric Planer (optional)........................................................................16
5. STARTING AND OPERATING ..........................................................................17
5.1. Starting.................................................................................................................................17
5.1.1 Exchanging the Reduction Inserts....................................................................................18
5.2. Welding Process.................................................................................................................18
6. WELDING TABLES ...........................................................................................21
7. MAINTENANCE AND REPAIR..........................................................................25
7.1. General.................................................................................................................................25

Kunststoffschweißtechnik
Contents
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 5 of 42
7.2. Clamping Elements.............................................................................................................25
7.3. Planer...................................................................................................................................25
7.4. Storage.................................................................................................................................25
7.5. Disposal...............................................................................................................................25
8. TRANSPORT.....................................................................................................26
9. WIRING DIAGRAMS..........................................................................................27
10. SPARE PARTS LIST .........................................................................................28
10.1. Basic machine with clamping devices and reduction inserts .......................................28
10.2. Table support ......................................................................................................................30
10.3. Clamping devices for fittings ............................................................................................32
10.4. Manual planer 4504220.....................................................................................................34
10.5. Electric planer (optional)....................................................................................................36
10.6. Heating element..................................................................................................................38
10.7. Protective box .....................................................................................................................40
11. DECLARATION OF CONFORMITY ..................................................................42

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
http://www.widos.de email: [e-mail]
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 6 of 42
1. Description of the 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 MINIPLAST 2 has been designed for heating element butt welding of pipes
and fittings out of PE, PP and PVDF with a diameter range of Ø = 20 - 110 mm.
The machine is kept small so that it can easily be used in the pipe system.
For moulded narrow bends and fittings, special small basic clamping devices are available.
All use going beyond is not purpose-oriented.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Also part of the purpose-oriented use is
respecting all the indications of the working instructions and
performing the inspection and maintenance works.
1.2. Overview
No. Denomination
1 Basic machine
2 Table support
3 Heating element
4 Electric planer (optional)
5 Clamping devices for fittings (optional)
6 Manual planer
1
2
3
5
4
6

Kunststoffschweißtechnik
Description of Product Chapter 1
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 7 of 42
1.3. Safety measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thouroughly read and the corresponding
safety regulations must be necessarily adhered to.
1.4. Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.
1.5. Designation of the product
The product is designated by a sign at the basic frame.
It contains the type of the machine, the serial number and the year of construction.
1.5.1Technical data
1.5.1.1 WIDOS MINIPLAST 2General Data
Material: PP, PE-HD, PVDF, PE 100
Pipe diameter range: Outside = 20 - 110 mm
Sheet steel carrying case (lxwxh): 450 x 300 x 365 mm
Weight (without packing): 30 kg
Fuse: 10 A
Wire cross section: 1.5 mm²
Emissions: - Noises exceeding 80 dB (A) may occur; during
planing it is obligatory to wear ear protection!
- When using the named pipe materials and
when welding below 260 °C no toxicant damp
arises.
Ambient conditions in the welding area: - Keep the workshop clean (no dust at the
welding area)
- If secured by an appropriate measurement that
allowed conditions for welding are indicated, it
is possible to work in any outside temperature
condition as far as the welder is not
constrained in its manual skill.
- Avoid humidity, if necessary use a welding tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends

Kunststoffschweißtechnik
Description of Product Chapter 1
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 8 of 42
1.5.1.2 Heating element
Power: 500 Watt 500 Watt
Voltage: 230 V (10 %) 110 V (10 %)
Current: 2,2 A (10 %) 4,5 A (10 %)
Frequency: 50 Hz 60 Hz
Outside : 145 mm
Surface: nonstick-coated
Attached elements: - electronic temperature control
- control lamp
- connecting cable with plug
Weight: appr. 2 kg
1.5.1.3 Manual planer
Weight: appr. 2 kg
1.5.1.4 Basic machine and table support
Material frame and clamping devices: Aluminium
Max. force 600 N
1.5.1.5 Electric planer (optional)
Power: 550 W 550 W
Voltage: 230 V (10 %) 110 V (10 %)
Current: 2,4 A 5,0 A
Frequency: 50 Hz 60 Hz
Weight: on request
See spare parts list for order numbers and single parts, when ordering, please state the machine number!
1.6. Equipment and accessories:
Following tools and accessories are part of the delivery:
1 Allan key, angled size 3 for screwing in / out the reduction inserts
1 Allan key, angled size 4, for mounting the fitting clamping devices (option)
1 Annular fork wrench size 10
1 Torx screwdriver T10, for changing the knifes
8 each Pan-head screws M 4x16 / 20 DIN 912, for mounting the reduction inserts
8 Flat-head screws M 6x12 DIN 7991, for mounting the fitting clamping devices
(option)

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone ++49 (0)7152 / 9939 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0)7152 / 9939 - 40
http://www.widos.de email: [e-mail]
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 9 of 42
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety indications and rules.
These working instructions contain the most important indications to run the machine safely.
The safety indications are to be followed by all persons working on the machine.
2.1. Explanation of the symbols and indications
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 due to hot surfaces.
The disrespect of these indications may conduct to heavy burns, respectively
to self-ignition or even fire.
This symbol means a possible risk of injury by noises exceeding 80 dB (A).
Ear protection is obligatory
This symbol gives important indications for the proper use of the machine.
The disrespect of these indications may conduct to malfunctions and
damages on the machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
It is a help for using all the functions on your machine in an optimal way and
helps you to make the job easier.
The regulations for the prevention of accidents are valid (UVV).
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.

Kunststoffschweißtechnik
Safety Rules Chapter 2
14.04.14 Working Instructions WIDOS MINIPLAST 2 Page 10 of 42
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.
2.4. Measures of organisation
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
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.
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.
2.5. Instructions for the staff
Only skilled and trained persons are allowed to work at the machine.
It must be clearly defined who is responsible for transport, mounting and dismounting,
starting the operation, setting and tooling, operation, maintenance and inspection, repair
and dismounting.
A person who is being trained may only work at the machine under supervision of an
experienced person.
2.6. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer.
Machine parts which are not in a perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
2.7. Cleaning the machine
The used materials and tissues are to be handled and disposed of properly, especially:
when cleaning with solvents
when lubricating with oil and grease.