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
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
All rights reserved
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
1.
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
2.
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
3.
Functional description 17
4.
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
5.
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
6.
Diagnosis program 43
7.
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
8.
Transport 51
9.
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
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
6
9
10
8
8
7
1
2
5
4
3
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
Table of contents
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