widos MINIPLAST 2 / T-Piece, Working Instructions Translation

Page 1: ...tzingen Heimerdingen Fax 49 0 7152 9939 40 http www widos de email info 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 MINIPLAST 2 Keep for further use ...

Page 2: ...nventory 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 41 0 79 4...

Page 3: ...ice 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 Du...

Page 4: ...g 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 DESCRIPTIO...

Page 5: ... 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 ...

Page 6: ...t 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 u...

Page 7: ...ignated by a sign at 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 General 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 mm Emissions Noises exceeding 80 dB A m...

Page 8: ...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 in...

Page 9: ...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 indicatio...

Page 10: ...nmental 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 sta...

Page 11: ... has to be checked regularly Loose connections and damaged cables have to be replaced immediately The heating element has to be protected from rain and dropping water if need be use a welding tent According to VDE 0100 the use on construction sites is only allowed with a power distributor with a FI safety switch 2 10 Specific dangers 2 10 1 Danger of being burnt by heating element reception box an...

Page 12: ... 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 ope...

Page 13: ...ement is inserted and the pipes are pressed against the heating element under defined adjusting pressure This process is called adjusting After the prescribed bead height being reached pressure is reduced the heating time begins The function of this time is to heat up the pipe ends After expiration of the heating time the slides are opened the heating element is removed quickly and the pipes are d...

Page 14: ...e support No Denomination Function 7 Tightening nut Tightening of the pipes 8 Upper guide bar Guidance for the slide 9 Scale Display of the applied welding force max 60 kp displayed 10 Handwheel Opening closing the slides application of the adjusting force 11 Star grip for basic machine Attaching the basic machine at the table support 12 Spindle Advance of the slide 13 Lower guide bar Guidance for...

Page 15: ...rature for the heating element 19 Control lamp green There are three different states Out signalizes that the heating element is not heated up at the moment or that it cools down Blinking the temperature of the heating element is maintained by a pulse position ratio On signalizes that the heating element is heated up at the moment and has not yet reached the desired temperature 20 Ratchet Turning ...

Page 16: ... be pushed for planing The planer has to be switched off after each planing process 23 Locking knob Keeps the on off button in position ON 24 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 an...

Page 17: ...and DVGW In situations of danger for persons and the machine the mains plug has to be unplugged immediately After completion of the welding work and during breaks the machine has to be switched off Further take care that no unauthorized person has access Protect the machine from wetness and humidity According to VDE 0100 the use on construction sites is only allowed with a power distributor with a...

Page 18: ...ng clamping device 5 2 Welding process T h e re s p e c tiv e ly v a lid w e ld in g p re s c rip tio n s I S O C E N D V S a r e t o b e b a s ic a lly fo llo w e d Do wear safety gloves as protection against burning A stop watch must be available for recording the actual times for heating up and cooling A welding table must be available from which the parameters for the pipe dimensions to be wel...

Page 19: ...orce Insert the electric planer optional between the ends of the workpieces lock it by turning the star grip at the guide rod Switch on planer at the on off button and keep it switched on with the locking knob Plane the pipes with low force For releasing the locking knob push shortly the button Planing should be carried out until a revolving cutting has been formed on both sides Open slide again r...

Page 20: ... 10 of the adjustment force The heating time starts now Press the stop watch and compare the actual time with the nominal time taken from the table After expiration of the heating time open the slide remove the heating element as quickly as possible put it into the heat protection box and close the slide smoothly The maximum time frame for this process is predetermined by the value for the change ...

Page 21: ...OS 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 info widos de 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 21 of 42 6 Welding tables ...

Page 22: ...lar heat up max time welding cool diameter wall force bead time change to reach force down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s 20 1 9 11 2 0 5 20 4 4 2 2 20 2 3 9 2 0 5 23 4 4 2 2 20 2 8 7 4 3 0 5 28 4 4 3 3 25 2 3 11 3 0 5 23 4 4 3 2 25 2 8 9 3 0 5 28 4 4 3 3 25 3 5 6 4 0 5 35 5 5 4 4 32 1 8 17 3 0 5 20 4 4 3 2 32 1 9 17 3 0 5 20 4 4 3 2 32 2 4 13 6 4 0 5 24 ...

Page 23: ...x time welding cool diameter wall force bead time change to reach force down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 50 1 8 33 5 0 5 20 4 4 5 2 50 2 0 26 5 0 5 20 4 4 5 2 50 2 4 21 6 0 5 24 4 ...

Page 24: ...ead time change to reach force down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 75 1 9 41 7 0 5 20 4 4 7 2 75 2 3 33 8 0 5 23 4 4 8 2 75 2 9 26 10 0 5 29 4 4 10 3 75 3 6 21 13 0 5 36 5 5 13 5 75 4...

Page 25: ...o reach force down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 110 2 7 41 14 0 5 27 4 4 14 3 110 3 4 33 18 0 5 34 5 5 18 4 110 4 2 26 21 0 5 42 5 5 21 6 110 5 3 21 27 1 0 53 5 5 27 7 110 6 3 17 31...

Page 26: ...e down OD s kp min s over welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 140 3 5 41 23 0 5 35 5 5 23 4 140 4 3 33 28 0 5 43 5 5 28 6 140 5 4 26 35 1 0 54 5 5 35 7 140 6 7 21 43 1 0 67 6 6 43 10 140 8 3 17 52 1 5 80 6 6...

Page 27: ... min s over welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 180 4 4 41 37 0 5 44 5 5 37 6 180 5 5 33 46 1 0 55 5 5 46 8 180 6 9 26 57 1 0 69 6 6 57 10 180 10 2 17 6 82 1 5 86 7 7 82 12 180 10 7 17 86 1 5 102 7 7 86 14 1...

Page 28: ...er welding kp time mm mm daN mm time pressure daN min s s Table for PE welding area in welding area Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up 225 5 5 41 57 1 0 55 5 5 57 8 225 6 9 33 71 1 0 69 6 6 71 10 225 8 6 26 88 1 5 86 7 7 88 12 225 10 8 21 110 1 5 108 8 8 110 15 225 12 8 17 6 128 2 0 128 8 8 128 17 225 ...

Page 29: ...ng force of the support must be added P N mm bead up heat up 280 6 9 41 89 1 0 69 6 6 89 10 280 8 6 33 110 1 5 86 7 7 110 12 280 10 7 26 136 1 5 107 7 7 136 14 280 13 4 21 169 2 0 134 8 9 169 18 280 15 9 17 6 198 2 0 159 9 10 198 20 280 16 6 17 207 2 0 166 9 10 207 21 280 20 6 13 6 252 2 5 206 10 12 252 26 280 25 4 11 305 2 5 254 12 14 305 31 280 31 3 9 367 3 0 313 14 16 367 38 280 38 3 7 4 437 3 ...

Page 30: ...0 3 4 6 2 0 5 115 5 6 2 4 20 4 1 5 3 0 5 128 5 6 3 5 25 2 3 11 2 0 5 95 4 5 2 2 25 3 5 7 4 3 0 5 117 5 6 3 4 25 4 2 6 3 0 5 130 5 6 3 6 25 5 1 5 4 0 5 145 5 6 4 7 32 1 8 17 6 2 0 5 90 4 5 2 2 32 2 9 11 3 0 5 106 4 5 3 3 32 4 4 7 4 4 0 5 133 5 6 4 6 32 5 4 6 5 0 5 149 5 6 5 8 32 6 5 5 6 0 5 167 6 7 6 11 40 1 8 26 3 0 5 90 4 5 3 2 40 2 3 17 6 3 0 5 95 4 5 3 2 40 3 7 11 5 0 5 121 5 6 5 5 40 5 5 7 4 6...

Page 31: ...the support must be added Table for PP The standard value for heating element temperature is 210 C 10 C The smaller the pipe wall the higher the temperature 50 1 8 33 3 0 5 90 4 5 3 2 50 2 0 26 4 0 5 90 4 5 4 2 50 2 9 17 6 5 0 5 106 4 5 5 3 50 4 6 11 7 0 5 137 5 6 7 6 50 6 9 7 4 10 0 5 173 6 7 10 12 50 8 3 6 11 1 0 193 6 8 11 14 50 10 1 5 13 1 0 218 7 9 13 17 63 1 8 41 4 0 5 90 4 5 4 2 63 2 0 33 4...

Page 32: ...standard value for heating element temperature is 210 C 10 C The smaller the pipe wall the higher the temperature 90 2 2 41 7 0 5 94 4 5 7 2 90 2 8 33 8 0 5 104 4 5 8 3 90 3 5 26 10 0 5 117 5 6 10 4 90 5 1 17 6 14 0 5 145 5 6 14 7 90 8 2 11 22 1 0 192 6 8 22 14 90 12 3 7 4 31 1 0 249 7 11 31 20 90 15 0 6 36 1 0 281 8 14 36 24 90 18 1 5 41 1 0 319 9 16 41 29 110 2 7 41 10 0 5 103 4 5 10 3 110 3 4 3...

Page 33: ... heating element temperature is 210 C 10 C The smaller the pipe wall the higher the temperature 140 3 5 41 16 0 5 117 5 6 16 4 140 4 3 33 19 0 5 131 5 6 19 6 140 5 4 26 23 0 5 149 5 6 23 8 140 8 0 17 6 34 1 0 189 6 8 34 14 140 12 7 11 51 1 0 254 7 12 51 21 140 19 2 7 4 73 1 5 332 9 17 73 30 140 23 3 6 86 1 5 373 10 20 86 36 140 28 1 5 99 2 0 416 12 24 99 43 160 4 0 41 20 0 5 126 5 6 20 5 160 4 9 3...

Page 34: ... support must be added Table for PP The standard value for heating element temperature is 210 C 10 C The smaller the pipe wall the higher the temperature 200 4 9 41 31 0 5 141 5 6 31 7 200 6 2 33 38 0 5 162 6 7 38 10 200 7 7 26 47 1 0 185 6 8 47 13 200 11 4 17 6 68 1 0 237 7 11 68 19 200 18 2 11 104 1 0 320 9 16 104 29 200 27 4 7 4 149 2 0 411 11 23 149 42 200 33 2 6 174 2 0 456 13 29 174 50 225 5...

Page 35: ... must be added Table for PP The standard value for heating element temperature is 210 C 10 C The smaller the pipe wall the higher the temperature 280 6 9 41 60 0 5 173 6 7 60 12 280 8 6 33 74 1 0 197 6 8 74 15 280 10 7 26 91 1 0 227 7 10 91 18 280 15 9 17 6 132 1 0 292 8 14 132 26 280 25 4 11 204 1 5 394 11 22 204 39 280 38 3 7 4 291 2 5 493 14 33 291 57 315 7 7 41 75 1 0 185 6 8 75 13 315 9 7 33 ...

Page 36: ...ter wall force bead time to reach force down OD s kp min s welding kp time mm mm daN mm pressure daN min s 20 1 9 2 0 5 59 3 2 4 5 25 1 9 2 0 5 59 3 2 4 5 32 2 4 3 0 5 64 3 3 5 0 40 2 4 3 0 5 64 3 3 5 0 50 3 0 5 0 5 70 4 5 5 5 63 2 0 4 0 5 60 3 4 4 5 63 3 0 6 0 5 70 4 6 5 5 63 3 8 8 0 5 78 4 8 6 5 75 2 3 6 0 5 63 3 6 5 0 75 3 6 9 0 5 76 4 9 6 5 75 4 5 10 0 5 85 5 10 7 5 90 2 8 8 0 5 68 4 8 5 5 90 ...

Page 37: ...full bead up welding cool down time 0 10 PVDF pressure pressure in welding area 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 in welding area heat up P N mm max over change time change over time s 180 5 5 31 0 5 95 5 31 8 5 180 8 6 47 0 8 126 6 47 12 5 20...

Page 38: ...r For machines with a specially high usage percentage the testing cycle should be shortened The works should be performed at the WIDOS GmbH company or by an authorized partner 7 2 Clamping elements For a long service life clean and grease regularly the threaded spindles and the joint parts which are used for clamping the pipes 7 3 Planer Do not lay the planer on its blades Check the blades of the ...

Page 39: ... box and the basic machine are placed into the bottom of the sheet steel carrying case the protective box with its handle must be standing in the center of the case Place the planer in a way that it is located below the rails for the reducer inserts Place the heating element with cable and the temperature control in a way that is still located below the rail for the reducer inserts Please place co...

Page 40: ...OS 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 info widos de 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 27 of 42 9 Wiring diagram ...

Page 41: ... Heimerdingen Fax 49 0 7152 9939 40 http www widos de email info widos de 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 28 of 42 10 Spare parts list 10 1 Basic machine with clamping devices and reduction inserts 1 2 3 4 5 7 8 13 14 15 16 18 9 10 12 19 17 20 21 22 23 24 25 26 27 28 29 31 32 33 34 35 ...

Page 42: ...50109 18 Counter bracket 1 450103 19 Trapezoidal nut 1 450105 20 Clamping nut 2 450705 21 Disc 2 4507052 22 Eye bolt BM 8x45 DIN 444 2 0444H045 23 Straight pin 8 M6x26 DIN 6325 2 6325H026 24 Pipe clamp upper part 2 450701 25 Washer M 6 DIN125 4 0125F 26 Hexagon head screw M 6x16 DIN 933 4 0933F016 27 Ball bushing 1 LKH1630 28 Upper guide bar 1 450112 29 Pan head screw 2 450706 30 Straight pin 4 M ...

Page 43: ...Kunststoffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 30 of 42 10 2 Table support 1 2 3 4 5 6 ...

Page 44: ...Pos Name Piece Order no 1 Basic frame 1 4501010 2 Hexagon nut M 8 DIN 934 2 0934H 3 Threaded bolt 2 450116 4 Star grip DIN 6336 KT 40 M8 K 1 on request 5 Headless pin GN 632 M8 50 1 0632H050 6 Threaded insert M 8x12 1 GEW M8 14 04 2014 Working instruction WIDOS MINIPLAST 2 Page 30 of 42 ...

Page 45: ...Kunststoffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 32 of 42 10 3 Clamping devices for fittings 1 2 3 4 5 6 7 8 9 10 10 ...

Page 46: ...12 5 Rivet 2 S0110 6 Handle 2 451714 7 Left hand clamping device for fittings 1 4508110L 8 Flat head screw M 6x12 DIN 7991 4 7991F012 9 Straight pin 4 M6x12 DIN 6325 4 6325D012 10 Gib for screwing 2 450703 Clamping insert OD 20 90 1 set 2008 Pan head screw M 4x20 DIN 912 OD 20 75 4 0912D020 Pan head screw M 4x16 DIN 912 OD 90 4 0912D016 Allan key DIN 911 B size 4 1 ZIG04 14 04 2014 Working instruc...

Page 47: ...Kunststoffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 34 of 42 10 4 Manual planer 5 4 13 1 2 12 11 6 8 18 17 9 10 16 3 14 15 19 ...

Page 48: ...ZZ 7 Washer M 3 DIN 125 4 0125C 8 Grooved taper pin 3x20 DIN 1472 2 1472C020 9 Pressure spring 1 450409 10 Ball Ø 4 5 1 L0005 11 Star grip screw 1 BG3230 12 Mechanical drive 1 ZK002 13 Planer disk left hand 1 450403 14 Bearing ring 2 450405 15 Driving plate right hand 1 450406 16 Pan head screw M 5x25 DIN 912 1 0912E025 17 Driving plate left hand 1 450407 18 Closing disc 1 450408 19 Hexagon nut M ...

Page 49: ...ffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 36 of 42 10 5 Electric planer optional 8 1 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 30 31 32 33 34 35 ...

Page 50: ... x 12 DIN 6325 4 6325D012 16 Connection flange holder side 1 450438 17 Washer M 6 DIN 125A 1 0125F 18 Pan head screw M 6x30 DIN 912 1 0912F030 19 Driving motor 230 V 1 A0550230 19 Driving motor110 V 1 A0550110 20 Planer disk leftt hand 1 450436 21 Flat head screw M 6x25 DIN 7991 2 7991F025 22 Bolt for planer disk 1 450436 23 Ball bearing 6010 RS 1 L6010ZR 24 Adapter ring 1 450437 25 Bevel gear m 1...

Page 51: ...Kunststoffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 38 of 42 10 6 Heating element 1 2 10 6 3 5 7 14 11 12 13 15 16 18 19 20 21 8 9 ...

Page 52: ...ete 110 V 1 HMINIE110 Heating plate new 110V 1 HPMINIE110 Heating plate for change 110V 1 HPTMINIE110 10 Triac with heat sink 1 H09081 11 Pan head screw M 6x45 DIN 912 2 0912F045 12 Spring washer 6 DIN 128 2 0128FF 13 Electronic control without probe GZ4 230V 1 H0918220 13 Electronic control without probe GZ4 110V 1 H0918110 14 Connection piece 1 450504 15 Pan head screw M 4x70 DIN 912 3 0912D070 ...

Page 53: ...Kunststoffschweißtechnik Spare Parts List Chapter 10 14 04 14 Working Instructions WIDOS MINIPLAST 2 Page 40 of 42 10 7 Protective box 1 2 3 7 9 4 5 10 11 12 13 14 15 6 8 ...

Page 54: ...0 5 DIN 125 4 0125J 6 Bar for distance 4 2 450521 7 Insert for heating element 1 450512 8 Protective sheet inside 1 450519 9 Protective sheet outside 1 450513 10 Bar for distance 2 4 450515 11 Bar for distance 1 4 450514 12 Threaded bolt 4 450518 13 Sleeve nut M 6 8 J0106 14 Bar for distance 3 2 450520 15 Rivet Ø 3x8 DIN 7337 10 7337C008 14 04 2014 Working instruction WIDOS MINIPLAST 2 Page 41 of ...

Page 55: ...en Heimerdingen declares under own responsibility that the product Plastic Welding Machine WIDOS MINIPLAST 2 to which this declaration refers corresponds to the following norms and norming documents 1 DIN EN ISO 12100 1 and 2 replacement for DIN EN 292 part 1 and 2 Safety of machines basic terminology general guidelines for design 2 DIN EN 60204 1 Electric equipment of industrial machines 3 DIN EN...