widos MINIPLAST 2 / T-Piece User manual

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
Working Instructions
Translation
Heating Element-Butt Welding Machine
WIDOS MINIPLAST 2 / T-Piece
Keep for further use!

Identification of Product
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 2 of 34
Type: WIDOS MINIPLAST 2 / T-Piece
Serial number / year: see type plate
Customer entries
Inventory-No.:
Location:
Address of manufacturer WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
Phone: [phone]
Fax: [phone]

Introduction
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 3 of 34
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 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.
Therefore the searched information can be easily found.
06.05.2019 WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes prior to technical innovations.

Contents
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 4 of 34
1.DESCRIPTION OF PRODUCT ............................................................................................... 6
1.1.Application and prescribed use ................................................................................................6
1.2.Overview..................................................................................................................................6
1.3.Dangers while handling the machine ........................................................................................7
1.4.Conformity................................................................................................................................7
1.5.Marking of the product .............................................................................................................7
1.5.1Technical data ......................................................................................................................7
1.5.1.1WIDOS MINIPLAST 2 / T-Piece General data ...................................................................7
1.5.1.2Heating element................................................................................................................8
1.5.1.3Planer ..............................................................................................................................8
1.5.1.4Basic machine with table support .......................................................................................8
1.5.1.5Electric planer (optional)....................................................................................................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........................................................................................................ 11
2.3.Obligations of the worker ...................................................................................................... 11
2.4.Measures of organisation...................................................................................................... 11
2.5.Information about safety precautions .................................................................................... 11
2.6.Instructions for the staff ........................................................................................................ 11
2.7.Dangers while handling the machine ..................................................................................... 12
2.8.Specific dangers ................................................................................................................... 12
2.8.1Danger of combustion by heating element and welding area .................................................. 12
2.8.2Danger of stumbling over electric wires................................................................................ 12
2.8.3Danger of cutting and catching clothes by the planer............................................................. 13
2.9.Structural modifications on the machine ............................................................................... 13
2.10.Warranty and liability ............................................................................................................ 13
3.DESCRIPTION OF THE WELDING PROCESS....................................................................... 14
4.OPERATING AND INDICATING ELEMENTS ....................................................................... 15
4.1.Elements on the basic frame / table support .......................................................................... 15
4.2.Elements on the heating element and the planer.................................................................... 16
4.3.Elements at the electric planer (optional) ....................................................................... 17
4.4.Clamping tools....................................................................................................................... 18
4.4.1Height adjustment for right clamping tool.............................................................................. 18
4.4.2Cross adjustment for left clamping tool ................................................................................. 18
5.STARTING AND OPERATING ............................................................................................ 19
5.1.Starting ................................................................................................................................. 19

Contents
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 5 of 34
5.2.Changing the reduction inserts.............................................................................................. 20
5.3.Welding process ................................................................................................................... 20
5.4.Welding process for T-pieces................................................................................................ 23
6.FABRICATION OF T-PIECES (90°)...................................................................................... 26
7.WELDING LOG AND TABLES ............................................................................................ 27
8.MAINTENANCE AND REPAIR ........................................................................................... 29
8.1.General ................................................................................................................................. 29
8.2.Clamping elements ................................................................................................................ 29
8.3.Planer ................................................................................................................................... 29
8.4.Storing .................................................................................................................................. 29
8.5.Cleaning the machine ............................................................................................................ 29
8.6.Disposal ................................................................................................................................ 29
9.TRANSPORT .................................................................................................................... 30
10.ELECTRIC DIAGRAM ........................................................................................................ 31
11.SPARE PARTS LIST .......................................................................................................... 33
12.DECLARATION OF CONFORMITY ...................................................................................... 34

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 6 of 47
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 MINIPLAST 2 / T-Piece is made for heating element butt welding of pipes and fittings
made out of PE, PP and PVDF with a diameter range of Ø = 20 mm - 110 mm (T- piece up to OD 90 mm).
The basic clamping tools can be swivelled up to 45° on each side for the fabrication of T- pieces and
segmented bends.
Due to the compact and small construction, the machine can be easily used in the pipe system.
For narrow bends and fittings, small basic clamping tools are available.
All use going beyond is not prescribed.
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
the respect of all the indications of the working instructions and
performing the inspection and maintenance works.
1.2. Overview
No. Denomination
1 Planer
Electic planer (optional)
2 Heating element
3 Protective box
4 Table support (optional)
5 Basic machine
4
5
1
2
3

Description of Product
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 7 of 34
1.3. Dangers while handling the machine
The machine WIDOS MINIPLAST 2 / T-Piece is constructed according to the latest state-of-the-art
and the acknowledged technical safety rules.
However, dangers for the operator or other persons standing nearby may occur.
The machine is only to be used
according to the prescription
in safety technical impeccable status
Disturbances which may affect the safety of the machine must be immediately cleared.
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. Marking of the product
The product is marked by a type plate on the basic 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 MINIPLAST 2 / T-Piece General data
Material: PP, PE, PVDF
Pipe dimension: outside-= 20 - 110 mm
Pipe dimension at T-piece: outside-= 20 - 90 mm
Sheet steel carrying case (l x w x h): 710 x 410 x 410 mm
Total weight (without packing): 30 kg
Fuse: 10 A
Wire cross section: 1,5 mm²
Environment - 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 need be use a tent
- avoid strong sun beams
- if it is windy shut the pipe ends.

Description of Product
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 8 of 34
Emissions: - Noise 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 (500 °F)no toxicant damp
arises.
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 50 - 60 Hz
Outside-: 145 mm 145 mm
Surface: antisticking coated
Mounted elements: - electronic temperature control
- control lamp
- connecting cable with plug
Weight: approx. 2 kg
1.5.1.3 Planer
Weight: approx. 2 kg
1.5.1.4 Basic machine with table support
Material frame and clamping tools: Aluminium
max. force 600 N
1.5.1.5 Electric planer (optional)
Power: 550 W 840 W
Voltage: 230 V (10 %) 120 V (10 %)
Current: 2,4 A 7,0 A
Frequency: 50 Hz 50-60 Hz
Weight: on request on request
See spare parts list for order-numbers and single parts, when ordering, please state the machine number !

Description of Product
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 9 of 34
1.6. Equipment and accessories:
Following accessories are part of the first delivery:
1 Ring / fork key size 10
1 each curved Allan key size 3; 4
1 Torx-screw driver T10
screws for reduction inserts, flat-head screws for reduction inserts, flat-head
screws for optional fitting clamping tools
option Stub end holder

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Stück Page 10 of 47
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 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
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 11 of 34
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. Measures of organisation
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
The working instructions have to be permanently kept at the place of use of the machine.
They are to be at the operator's disposal at any time and without 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, setting, tooling, operation, maintenance, inspection and repair.
A person who is being trained may only work at the machine under supervision of an experienced
person.

Safety Rules Chapter: 2
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 12 of 34
2.7. Dangers while handling the machine
The machine WIDOS Miniplast 2 / T-piece 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 FI-safety switch.
2.8. Specific dangers
2.8.1 Danger of combustion by heating element and welding area
You can burn yourself, inflammable materials can be ignited!
The heating element is heated up to more that 250° C (482 °F)!
Do not leave the heating element unsupervised.
Do not touch the surfaces of the heating element.
Take enough safety distance to inflammable materials.
Do wear safety gloves.
Make sure that no person is in the swinging area of the heating element.
When cleaning the hot heating element with detergents (e.g. with PE cleaner) 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.
2.8.2 Danger of stumbling over electric wires
Make sure that no person must step over the wires of heating element and planer.

Safety Rules Chapter: 2
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 13 of 34
2.8.3 Danger of cutting and catching clothes by the planer
You can cut yourself or even get bones broken.
Only wear clothes tight to the body.
Do not wear rings or jewellery during the work.
If necessary, wear a hair-net.
Do not touch the faces of the planer.
Take care that no person is standing in the swivelling area of the planer.
Take care that the planer does not catch your clothes.
2.9. Structural modifications on the machine
No modifications, extensions or reconstructions may be made on the machine without permission
of the manufacturer.
Machine parts that are not in perfect condition are to be replaced immediately.
Only use original WIDOS spare and wear parts.
2.10.Warranty and liability
Fundamentally our "General Sales and Delivery Conditions" are valid.
They are at the owner's disposal latest when signing the contract.
Guarantee and liability demands referring to personal injuries or damages on objects are
excluded if they are caused by one or several of the following reasons:
not using the machine according to the prescriptions
inexpert transport, mounting, starting, operating, and maintenance of the machine
ignoring the information given in this manual
structural modifications on the machine without permission
unsatisfactory checking of parts of the machine which are worn out
repairs performed in an inexpert way
in case of catastrophes and force majeure.

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 14 of 34
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 by means of the planer and the pipe mismatch is checked.
Now the heating element is moved in and the pipes are pressed against the heating element under
defined adjustment pressure. This process is called adjusting.
After the prescribed bead height being reached the pressure is reduced and the heat up time begins.
During this period the pipe ends are heated up.
After completion of the heat up time the support moves apart, the heating element should be removed
as fast as possible and the pipes are moved together again. The time period between the removal of
the heating element and the closing of the pipes is called change over time.
The pipes are joined with the prescribed welding pressure and then cool down under pressure
(cooling time).
The welding joint can be unclamped, the welding process is finished.
Heating element heats up
the pipe ends onto
welding temperature
welded pipe with internal and
external bead

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected] Internet: www.widos.de
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 15 of 34
4. Operating and indicating elements
4.1. Elements on the basic frame / table support
No. Denomination Function
6 Screws for horizontal offset - Loosen the screws for moving forward or
backward the clamping tool
7 Hexagon screws (4x) - Setting the angle (in case of fabrication of
segmented bends)
8 Upper guide bar - Guidance of the slide
9 Spindle - Advance of slide
10 Tightening nut - Tightening of the pipes
11 Screws for vertical offset - Loosen the screws for moving up or down the
clamping tool
12 Scale - Display of the applied welding force
- max. display: 60 kp
13 Handwheel - Open / close the slide
- application of adjustment force
14 Lower guide bar - Guidance of the slide
- Fixing the planer
- Support for heating element
15 Star wheel for basic frame - Fixing the basic frame onto the table support
10
8
12
9
6
11
7
13
14
15

Operating and indicating elements Chapter: 4
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 16 of 34
4.2. Elements on the heating element and the planer
No. Denomination Function
16 On - / off switch - Switching the machine on / off
17 Knob with slot - Adjustment temperature of the heating element
18 Control lamp green - There are three different states:
off: the heating element is not being heated up
or is cooling down.
blinking: the temperature of the heating el.
is being maintained by means of a certain
pulse-position ratio.
on: the heating element is being heated up at
the moment. Desired temperature has not yet
been reached.
19 Ratchet - Turning the planer by means of the ratchet
20 Star grip screw and tin disc - Attaching the planer at the guidance bar by turning
the screw and tin disc
19
17
16
20
18

Operating and indicating elements Chapter: 4
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 17 of 34
4.3. Elements at the electric planer (optional)
No. Name Function
21 Button on/off - The button must be pushed for planing.
- The planer has to be switched off after each planing process
22 Locking knob - Keeps the on/off button in position: ON
23 Star grip screw and tin disc - Attaching the planer at the guidance bar by turning the
screw and tin disc
Be especially cautions, there ist the danger of cuttings!
Only activate the planer if it has been placed into the machine and secured by locking tin
disc and star grip screw.
21
22
23

Operating and indicating elements Chapter: 4
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 18 of 34
4.4. Clamping tools
Put the pipe into the open clamping tool, shut the clamping tool, swivel the clamping nut into the
upper clamping ring and fix the pipe by the clamping nut.
4.4.1 Height adjustment for right clamping tool
The right clamping tool may be adjusted in order to compensate the
height.
For this purpose detach the pan-head screws and shift the
clamping tool on the sloping platform (arrow) until the height is
balanced.
Afterwards necessarily tighten the pan-head screws again.Sie die
Zylinderschraube danach unbedingt wieder fest.
4.4.2 Cross adjustment for left clamping tool
The left clamping tool may be adjusted in transverse manner to the
axis in order to compensate differences.
Detach the two pan-head screws on the left side and shift the
clamping tool (arrow) until the difference is balanced.
Afterwards tighten the 2 pan-head screws again.
Clamping tool closed
Clamping tool opened
Clamping nut clamped
Clamping nut released
Bore for clamping insert
Pan-head screw for height adjustment
Pan-head screw for cross adjustment

WIDOS Einsteinstraße 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH [email protected]e Internet: www.widos.de
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 19 of 34
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
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.
Lay electric cables thoroughly (danger of stumbling) !
Works on electric devices may only be performed by electric experts.
The electric equipment of the machine has to be checked routinely. Loose connections
and damaged cables have to be removed
immediately.
The heating element is to be protected against rain and trickling water, if necessary,
use a welding tent.
According to VDE 0100, the use on construction sites is only allowed through a power
distributor with a FI-safety switch.
In dangerous situations for persons and the machine, the machine has to be unplugged
immediately.
Switch off the machine after completion of the works and during breaks.
Take care that no unauthorized person has access to the machine.
Connect the heating element to the mains (230 V / 16 A / 50 Hz) (110 V / 16 A / 50-60Hz).
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 below 5 °C (41 °F)measures should be taken:
Build up a welding tent or heat up the pipe ends if necessary.
In addition, take measures against rain, wind and dust.

Starting and operating Chapter: 5
06.05.19 Working instructions WIDOS MINIPLAST 2 / T-Piece Page 20 of 34
5.2.Changing the reduction inserts
Unscrew the in-screwed reduction inserts by means of the enclosed Allan key.
Screw on reduction inserts of the desired diameter.
For the fabrication of bends, the angle on the basic clamping tools can be set (on
each side from –45° up to +45°).
Large basic clamping tool Narrow basic clamping tool
(for fittings)
5.3. Welding process
Basically, the valid welding regulations (ISO/CEN/DVS...) are to be
observed.
There is the risk of burning parts of your body, inflammable materials can be ignited!
The heating element is heated up to more than 250° C (482 °F)!
Do not leave the heating element unattended.
Take enough safety distance to inflammable materials.
Always put the heating element back into the reception box before and after each use.
Only transport the heating element at the holder, do not touch the surface with bare
hands.
Do wear safety gloves as protection against burning !
A stop-watch should be available in order to be able to register the actual times for heating up and
cooling down.