widos MAXIPLAST, Working Instructions Translation

Page 1: ... 200973 Managing directors Jürgen Dommer Dr Kai Dombrowski Working Instructions Working Instructions Working Instructions Working Instructions Translation Translation Translation Translation Heating element butt welding machine Heating element butt welding machine Heating element butt welding machine Heating element butt welding machine WIDOS MAXIPLAST WIDOS MAXIPLAST WIDOS MAXIPLAST WIDOS MAXIPLA...

Page 2: ...Inserts of customer Inventory no Place of working Order of spare parts and sales service Order of spare parts and sales service Order of spare parts and sales service Order of spare parts and sales service Address of manufacturer WIDOS Address of manufacturer WIDOS Address of manufacturer WIDOS Address of manufacturer WIDOS Wilhelm Dommer Söhne GmbH Einsteinstr 5 D 71254 Ditzingen Phone 49 7152 99...

Page 3: ...ubsidiary 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 Design of the working instruction Design of the working instruction Design of the working instruction This manual is arrang...

Page 4: ...tural modifications on the machine 11 Structural modifications on the machine 11 Structural modifications on the machine 11 Structural modifications on the machine 11 2 8 2 8 2 8 2 8 Danger while handling the machine 12 Danger while handling the machine 12 Danger while handling the machine 12 Danger while handling the machine 12 2 9 2 9 2 9 2 9 Danger caused by electrical energy 12 Danger caused b...

Page 5: ...sal 27 Disposal 27 8 8 8 8 TRANSPORT 28 TRANSPORT 28 TRANSPORT 28 TRANSPORT 28 9 9 9 9 WIRING DIAGRAM 29 WIRING DIAGRAM 29 WIRING DIAGRAM 29 WIRING DIAGRAM 29 10 10 10 10 SPARE PARTS LIST 30 SPARE PARTS LIST 30 SPARE PARTS LIST 30 SPARE PARTS LIST 30 10 1 10 1 10 1 10 1 Basic machine 30 Basic machine 30 Basic machine 30 Basic machine 30 10 2 10 2 10 2 10 2 Planer 33 Planer 33 Planer 33 Planer 33 1...

Page 6: ...lly 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 an...

Page 7: ...Designation of product Designation of product 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 1 5 1 1 5 1 1 5 1 Technical data Technical data Technical data Technical data 1 5 1 1 WIDOS MAXIPLAST MAXIPLAST MAXIPLAST MAXIPLAST General data Material PP PE PVDF Dimensions of pipes Outside ...

Page 8: ...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 machine with table support Material frame and clamping tools Machinery steel max force 100...

Page 9: ... accessories are part of the delivery 1 set Fitting clamping tool optional 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 ...

Page 10: ...e 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...

Page 11: ...ulations 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 2 6 2 6 2 6 Instructions for the staff Instructions for the staff Ins...

Page 12: ...ables 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 2 10 2 10 2 10 Specific dangers Specific dangers Specific dangers Specific dangers 2 10 1 2 10 1 2 10 1 2 10 1 Danger of burning heating eleme...

Page 13: ...bility Warranty and liability 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 b...

Page 14: ... 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 bead up time bead up time bead up time After reaching the necessary bead height the pressure is reduce...

Page 15: ...able support No No No No Denomination Denomination Denomination Denomination Function Function Function 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 Sca...

Page 16: ...ction 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 out out out If the desired temperature is lower than the actual temperature the heating heating element cools down to the desired temperature b...

Page 17: ...the planer Nr Benennung Nr Benennung Nr Benennung Nr Benennung Funktion Funktion Funktion 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 st...

Page 18: ...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 in...

Page 19: ...rotect 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 no...

Page 20: ...t 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 ...

Page 21: ...h and compare the actual time with the nominal time taken from the table After expiration of the heating up time open slide remove heating element as quickly as possible put it into the heat protective box and close the slide smoothly The maximum time limit for this purpose is predetermined by the value for the change over time taken from the table Press the stop watch when the welding pressure ha...

Page 22: ...Dommer Söhne D 71254 Ditzingen Fax 49 7152 9939 40 GmbH E mail info widos de Webside www widos de 16 05 17 Working Instructions WIDOS MAXIPLAST Page 22 of 41 6 6 6 6 Welding record and tables Welding record and tables Welding record and tables Welding record and tables ...

Page 23: ...Welding record and tables Chapter 6 Chapter 6 Chapter 6 Chapter 6 16 05 17 Working Instructions WIDOS MAXIPLAST Page 23 of 41 ...

Page 24: ...tion All information without guarantee bead up bead up bead up bead up heat up change pressure heat up change pressure heat up change pressure heat up change pressure 0 15 PE over over over over build up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ra...

Page 25: ...eat up change pressure 0 15 PE over over over over build up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion ...

Page 26: ...ver over over over build up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine mu...

Page 27: ...er over over build up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine must be ...

Page 28: ...ver build up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine must be added to ...

Page 29: ... up build up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine must be added to the indic...

Page 30: ...uild up build up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine must be added to the indicated ...

Page 31: ...ild up build up pressure in welding area Tdesired temperature 0 01 in welding area time pipe SDR bead up circular heat up max force welding special wall degree force bead time change ramp force cooling s kp height over time time kp 15 C 15 25 C 25 C time Table for PE Table for PE Table for PE Table for PE The individual motion force of each welding machine must be added to the indicated bead up an...

Page 32: ...reach force down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s Table for PP Table for PP Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up he...

Page 33: ...or heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added s s 40 40 40 40 1 8 26 3 0 5 90 4 5 3 2 40 40 40...

Page 34: ...m time pressure daN min s s Table for PP Table for PP Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding ...

Page 35: ...or PP Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding force the moving force of the support must be ad...

Page 36: ...P Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added ...

Page 37: ...P Table for PP Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding force the moving force of the support m...

Page 38: ...daN mm time pressure daN min s s Table for PP Table for PP Table for PP Table for PP The standard value for heating element temperature is 210 C 10 C The smaller smaller smaller smaller the pipe wall the higher higher higher higher the temperature welding area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the wel...

Page 39: ...ing area in welding area P N mm bead up bead up bead up bead up heat up heat up heat up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added s s 280 280 280 280 6 9 41 60 0 5 173 6 7 60 12 280 280 280 280 8 6 33 74 1 0 197 6 8 74 15 280 280 280 280 10 7 26 91 1 0 227 7 10 91 18 280 280 280 280 15 9 17 6 132 1 0 292 8 14 132 26 280 280...

Page 40: ...rature heat up heat up heat up heat up P N mm over over over over change change change change time time time time Tdesired temperature time pipe pipe bead up circular heat up time welding cool diameter wall force bead time to reach force down OD s kp min s welding kp time mm mm daN mm pressure daN min s change over time s in welding area max s 20 20 20 20 1 9 2 0 5 59 3 2 4 5 25 25 25 25 1 9 2 0 5...

Page 41: ...o reach full reach full reach full reach full bead up bead up bead up bead up welding welding welding welding cool down time cool down time cool down time cool down time 0 10 PVDF pressure pressure pressure pressure pressure in welding area Tdesired temperature heat up heat up heat up heat up P N mm over over over over change change change change time time time time Tdesired temperature time pipe ...

Page 42: ...le should be shortened The works should be performed at the WIDOS GmbH company or by an authorized partner Only use WIDOS spare parts when executing repairs 7 2 7 2 7 2 7 2 Clamping elements Clamping elements Clamping elements Clamping elements For a long service life clean and grease regularly the treaded spindles and the joint parts which are used for clamping the pipes 7 3 7 3 7 3 7 3 Planer Pl...

Page 43: ...ine with care Make sure that the box is closed correctly The machine is transported by means of a transport box out of steel The single elements are placed within the steel transport box The steel transport box contains a rectangular insert for the planer The basic machine and the table support are put at the side of the planer Insert heating element with cable and temperature control in such a wa...

Page 44: ...9 7152 9939 0 Wilhelm Dommer Söhne D 71254 Ditzingen Fax 49 7152 9939 40 GmbH E mail info widos de Webside www widos de 16 05 17 Working Instructions WIDOS MAXIPLAST Page 29 of 41 9 9 9 9 Wiring diagram Wiring diagram Wiring diagram Wiring diagram ...

Page 45: ...l info widos de Webside www widos de 16 05 17 Working Instructions WIDOS MAXIPLAST Page 30 of 41 10 10 10 10 Spare parts list Spare parts list Spare parts list Spare parts list 10 1 10 1 10 1 10 1 Basic machine Basic machine Basic machine Basic machine 7 32 41 6 43 34 49 10 2 3 30 13 31 48 4 9 52 54 56 57 53 35 51 5 29 33 39 30 ...

Page 46: ...Spare parts list Chapter 10 Chapter 10 Chapter 10 Chapter 10 16 05 17 Working Instructions WIDOS MAXIPLAST Page 31 von 41 16 17 44 25 26 27 28 47 19 20 40 15 14 36 50 37 38 18 40 42 21 24 45 46 22 23 ...

Page 47: ... 454706 20 Lower part of the axial alignment 1 454707 21 Clamp strip 1 454709 22 Rivet 4 4547131 23 Permaglid bushing 4 on request 24 Center bolt 2 454708 25 Knurled screw 2 161109 26 Threaded rod 2 160108 27 Washer M12 DIN 125 2 0125L 28 Rivet 2 160111 29 Ball bushing 2 LKH3050 30 Permaglid bushing 4 PAP2020 31 Hand wheel tilting 1 BH125 32 Thrust ball bearing 1 L51104 33 Clamping lever GN300 1 4...

Page 48: ... 1 454101 53 Stargrip Ø40 M8x30 4 on request 54 Covering cap Ø 12 4 on request Reducer inserts OD 50 OD 140 two parts 2 set 1608 Reducer inserts large OD 50 OD 140 two parts 2 set 1618 Reducer inserts extra large OD 50 OD 140 two parts 2 set 1628 Pan head screw M5x16 DIN 912 for OD 50 125 8 0912E16X Flat head screw M5x16 DIN 7991 for OD 140 8 7991E16X 56 Pipe support OD 50 OD 160 2 0106 57 Knurled...

Page 49: ...ist Chapter 10 Chapter 10 Chapter 10 Chapter 10 16 05 17 Working Instructions WIDOS MAXIPLAST Page 33 of 41 10 2 10 2 10 2 10 2 Planer Planer Planer Planer 1 2 4 5 6 3 7 11 12 13 15 24 14 25 27 28 29 30 33 34 36 37 ...

Page 50: ...inion 1 454408 16 Spindle for pinion 1 454431 17 Ball bearing 16101 2 L16101 18 Spacer 1 454412 19 Spacer 1 454413 20 Spacer ring 1 450444 21 Washer M 10 DIN 433 1 0433J 22 Hexagon nut M10x1 DIN 934 1 0934J1 23 Washer 1 450441 24 Coupling 1 454410 25 Pan head screw M6x30 DIN 912 1 0912F030 26 Washer M6 DIN 125 1 0125F 27 Hexagon nut M6 DIN 985 1 0985F 28 Stargrip M8x40 DIN 6336 1 BG40KTK 29 Extens...

Page 51: ... Chapter 10 Chapter 10 Chapter 10 16 05 17 Working Instructions WIDOS MAXIPLAST Page 35 of 41 10 3 10 3 10 3 10 3 Heating element Heating element Heating element Heating element 15 9 4 3 6 5 1 2 19 22 12 14 16 7 8 11 17 13 18 10 ...

Page 52: ... 0125F 9 Electronic control GZ4 1 H0918220 10 Temperature probe PT 1000 1 H09082 11 Isolator piece 1 454502 12 Heating element complete 1 HMAXI Heating plate new electric 1 HPMAXI Heating plate for change electric 1 HPTMAXI 13 Heat sink with triac 1 H09081 14 Heating element holder 1 454503 15 Cylinder head screw M 4x65 DIN 912 3 0912D065 16 Gripping form 2 012505 17 Grip shell 1 450504 18 Sheet m...

Page 53: ...s list Chapter 10 Chapter 10 Chapter 10 Chapter 10 16 05 17 Working Instructions WIDOS MAXIPLAST Page 37 of 41 10 4 10 4 10 4 10 4 Protective box Protective box Protective box Protective box 3 4 10 5 6 7 9 1 2 11 ...

Page 54: ... 2 454511 2 Screw cap 35 x 35 x 1 5 6 on request 3 Screw cap Ø 18 x 2 1 on request 4 Insert for planer 1 454512 5 Insert for heating element 1 454513 6 Spacer 2 454514 7 Cylinder head screw M5x45 DIN 912 4 0912E045 8 Cap nut M5 4 1587E 9 Washer M5 DIN 125 8 0125E 10 Blind rivet S 4x8 4 7337D008 11 Screw cap 20 x 10 x 1 5 4 on request 16 05 2017 Working Instructions WIDOS MAXIPLAST Page 38 of 41 ...

Page 55: ... Instructions WIDOS MAXIPLAST Page 39 of 41 10 5 10 5 10 5 10 5 Fitting clamping tool Fitting clamping tool Fitting clamping tool Fitting clamping tool Fitting clamping tool right side Fitting clamping tool left side 1 2 3 4 5 6 8 6 8 9 10 11 12 14 13 10 12 15 16 17 18 5 4 3 2 1 ...

Page 56: ...mping tool Ø 160 1 Set 454801160 Insert for fitting clamping tool Ø 154 4 1 Set 454801154 4 7 Pan head screw M 5x12 DIN 6912 4 6912E012 8 Spring washer M 5 DIN 7980 4 7980E 9 Fitting clamping tool right side 1 454716 10 Rivet Ø 4x16 5 3 010711 11 Joint shackle outside 1 0107172 12 Straight pin Ø 4m6x16 DIN 7 1 0007D016 13 Fixing ledge 1 454717 14 Fitting clamping tool left side 1 454715 15 Joint s...

Page 57: ...C according the EC guideline EC Machinery Directive 2006 42 EC Company WIDOS GmbH Einsteinstr 5 D 71254 Ditzingen declares that the product Plastic welding machine WIDOS MAXIPLAST MAXIPLAST MAXIPLAST MAXIPLAST has been designed in compliance with the following standards 1 DIN EN ISO 12100 1 and 2 replacement for DIN EN 292 Teile 1 and 2 safety of machines general recommendations for designing mach...