Widos 4900 CNC 3.0 User manual

Kunststoffschweißtechnik

WIDOS Einsteinstr. 5 Phone +49 (0) 71 52 99 39 - 0

. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 99 39 - 40

ebsite: http://www.widos.de Email: [email protected]e

Headquarters: D-71254 Ditzingen-Heimerdingen Country court Ludwigsburg HRB 973 Managing directors: Armin and Dieter Dommer

Working Instructions

Heating element butt welding machine

with CNC control unit

IDOS 4900 CNC 3.0

Keep for further use !

Kunststoffschweißtechnik

Product identification

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 2 of 76

Model: Heating element butt welding machine

with CNC control unit

Type: IDOS 4900 CNC 3.0

Serial number, year of construction: see type lable

Customer Entries

Inventory-no.:

Place of working:

Order of spare parts and sales ser ice

Address of Manufacturer WIDOS

. Dommer Söhne GmbH

Einsteinstr. 5

D -71254 Ditzingen-Heimerdingen

Phone: ++49 7152 / 99 39 - 0

Fax: ++49 7152 / 99 39 - 40

Address of the Subsidiary Companies:

IDOS GmbH IDOS AG

An der iesenmühle 15 Auwisstrasse 35

D-09224 Grüna / Sachsen CH-8493 Saland

Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 52 / 3 86 32 32

Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 52 / 3 86 29 78

Kunststoffschweißtechnik

Introduction

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 3 of 76

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.

e 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 informations can be easily found.

22.11.2005 WIDOS

. Dommer Söhne GmbH

Einsteinstraße 5

D-71254 Ditzingen-Heimerdingen

Reprinting only allowed with permission of the corporation.

Any changes prior to technical innovations.

Kunststoffschweißtechnik

Contents

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 4 of 76

Description of the product 7

1.1.

Usage and purpose-oriented Use 7

1.2.

Safety measures 7

1.3.

Conformity 7

1.4.

Machine o er iew 8

1.5.

Structure of the CNC 3.0 control unit 8

1.6.

Designation of the product 9

1.6.1.

Technical data 9

1.6.1.1.

WIDOS CNC 3.0 general data 9

1.6.1.2.

Basic frame 9

1.6.1.3.

Heating element 10

1.6.1.4.

Planer 10

1.6.1.5.

Automatic heating element (optional) 10

1.6.1.6.

Reception box for automatic heating element (optional) 10

1.7.

Emergency power supply (Optional) 11

1.8.

Equipment and accessories 11

Safety rules 12

2.1.

Explanation of the symbols and indications 12

2.2.

Obligations of the owner 13

2.3.

Obligations of the worker 13

2.4.

Measures of organisation 13

2.5.

Information about safety precautions 13

2.6.

Instructions for the staff 13

2.7.

Dangers while handling the machine 14

2.8.

Specific dangers 14

2.8.1.

Danger of stumbling over hydraulic and electric wires 14

2.8.2.

Danger of catching clothes by the planer 15

2.8.3.

Danger of being burnt by Heating Element and elding Area 15

2.8.4.

Danger of squeezing by clamping devices and guideways 15

2.9.

Structural modifications on the machine 15

2.10.

Warranty and liability 16

Functional description 17

Operating and indicating elements 18

4.1.

Elements on the CNC 3.0 control unit 18

4.2.

EMERGENCY-stop push button 19

4.3.

Separating de ice for heating element 19

4.4.

Elements on Heating Element / Planer 20

Starting and operating 21

5.1.

Safety indications 21

Kunststoffschweißtechnik

Contents

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 5 of 76

5.2.

Replacing the reduction inserts 22

5.2.1.

Using Small and large reduction inserts 22

5.3.

Automatic heating element (Optional) 23

5.4.

Connection with the basic machine 24

5.5.

Operation with emergency power supply 24

5.6.

Description of the display 25

5.7.

Accessories for reading the data in and out 25

5.7.1.

Legitimacy Cards 25

5.7.2.

PCMCIA 26

5.7.3.

Barcode 26

5.8.

Switching the CNC 3.0 on 26

5.9.

Programming and Welding with Gas Legitimacy Card 27

5.10.

Programming and Welding with General Legitimacy Card 28

5.10.1.

Setting the Pipe Data 28

5.11.

Welding process 29

5.11.1.

elding process with traceability according to ISO 33

5.12.

Error messages 34

5.13.

Administration of the welding data 34

5.13.1.

Printing the welding data from the internal memory (RAM) 34

5.13.2.

Storing the data on the PCMCIA card 36

5.13.3.

Printing the welding data from the PCMCIA 37

5.13.4.

Setting the time and the date 38

5.14.

Reading out the welding data o er a serial interface 39

5.15.

Serial Printer (optional) 41

5.16.

Function of the emergency power supply (Optional) 42

Diagnosis program 43

Equipment care / maintenance / repair 45

7.1.

Storage 45

7.2.

Cleaning the machine 45

7.3.

Clamping elements 45

7.4.

Checking the hydraulic oil le el 45

7.5.

Venting the hydraulic cylinders 46

7.6.

Maintenance, inspection and repair 47

7.7.

Sa ing the Welding Data 47

7.8.

Data Interface Connection 47

7.9.

Error Signals 48

7.10.

Possible Defects and their Elimination 49

7.11.

Fuse for o erload safety de ice / printer plug box 50

7.12.

Accumulator for emergency power supply (Optional) 50

Kunststoffschweißtechnik

Contents

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 6 of 76

Transport 51

Wiring Diagrams 52

10.

Spare Parts List 65

10.1.

CNC Contol Unit 3.0 65

10.2.

Basic Machine 67

10.3.

Planer 70

10.4.

Heating Element 72

10.5.

Reception Box 74

11.

Declaration of conformity 76

Kunststoffschweißtechnik

WIDOS Einsteinstr. 5 Phone +49 (0) 71 52 99 39 - 0

. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 99 39 - 40

ebsite: http://www.widos.de Email: [email protected]e

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 7 of 76

1. Description of the product

1.1. Usage and purpose-oriented Use

The WIDOS 4900 CNC 3.0 has been designed only for heating element butt welding of pipes

and fittings made out of the materials PE, PP, and PVDF with their diameter

range going from OD

min

=90mm up to OD

max

=315mm in the way as described below.

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!

The control unit is reliable in the use when it is used according to the prescriptions in

connection with a welding machine designed by IDOS.

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. 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 thoroughly read and the corresponding safety

regulations must be necessarily 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 the product Chapter 1

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 8 of 76

1.4. Machine o er iew

No. Denomination

1 Basic machine

2 Control unit

3 Reception box

4 Planer

5 Heating element

1.5. Structure of the CNC 3.0 control unit

No. Denomination

6 Display

7 Operating field

8 Pipe data card or general legitimacy card

9 PCMCIA card

10 Barcode reader

Kunststoffschweißtechnik

Description of the product Chapter 1

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 9 of 76

1.6. Designation of the product

The product is designated by type labels.

The type labels are attached at the control unit, at the heating element, at the planer and at

the basic machine.

They contain the type, the serial number and the year of construction of the machine.

1.6.1. Technical data

All important technical data of each single component are listed. This allows a quick

information about working capacity and structure.

1.6.1.1. WIDOS CNC 3.0 general data

eight (without transport box):

Dimensions (l x w x h):

40.5 kg

appr. 630x430x510 (mm)

Power: 650 att

Voltage: 110 V (± 10%)

hole current: 30 A

Frequency: 60 Hz

Phase shift: ca. 18°

Control voltage: 5 V

Insulation system: IP 44

Hydraulic oil tank: appr. 1 l

Electro motor and pump:

Power: 350 att

Driving speed (t/min): 1380

Max. working pressure of the pump: 110 bar

orking pressure: 100 bar

Volume flow: 1.9 l/min.

1.6.1.2. Basic frame

Material of frame: Construction steel

Material of clamping devices: Aluminium

eight: 48 kg

Ø of cylinder / Ø of cylinder piston: 40 / 35

Stroke length of cylinder: 150 mm

Max. force (per cylinder): (F=P*A) 2945 N

Kunststoffschweißtechnik

Description of the product Chapter 1

22.11.2005 orking Instructions IDOS 4900 CNC 3.0 (110 V) Page 10 of 76

1.6.1.3. Heating element

Power: 2.5 k

Voltage: 110V (± 10 %)

Current: 20,5 A

Frequency: 60 Hz

Outside-Ø: 320 mm

Surface: nonstick-coated

Attached elements: - Control lamps

- Cable with multiple pole plug

eight: appr. 6 kg

1.6.1.4. Planer

Engine: Monophase-alternating current motor

Power: 1050 att

Voltage: 110 V (± 10 %)

Current: 9,54 A

Frequency: 60 Hz (± 10 %)

Driving speed n2 of the planer appr. 60

eight: appr. 14 kg

1.6.1.5. Automatic heating element (optional)

Power: 2.1 K

Voltage: 110 V (± 10 %)

Current: 19.1 A (± 10 %)

Frequency: 60 Hz

Outside-∅: 320 mm

Surface: nonstick-coated

Attached elements: - Control lamps

- Cable with multiple pole plug

eight: appr. 17 kg

1.6.1.6. Reception box for automatic heating element (optional)

eight: appr. 6 kg

See spare parts list (chapter 10) for order numbers and single parts

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