Widos 5500 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 Stuttgart HRB 200973 Managing director: Jürgen Dommer

Working Instructions

Translation

Heating Element Butt elding Machine

with CNC Control Unit

WIDOS 5500 CNC 3.0

Keep for further use!

Kunststoffschweißtechnik

Product Identification

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 2 of 78

Model: Heating element butt welding machine

with CNC control unit

Type: IDOS 5500 CNC 3.0

Serial number, year of construction: see type lable

Customer entries

Inventory-No.:

Place of working:

Order of spare parts and after sales service

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

WIDOS

IDOS GmbH . Dommer Söhne AG

An der iesenmühle 15 St. Gallerstr. 93

D-09224 Grüna / Sachsen CH-9201 Gossau

Phone: ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 3 88 89 79

Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 3 88 89 73

Kunststoffschweißtechnik

Introduction

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 3 of 78

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 information can be easily found.

19.09.2011 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

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 4 of 78

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 overview 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.

IDOS CNC 3.0 General data 9

1.6.1.2.

Basic frame 10

1.6.1.3.

Heating element 10

1.6.1.4.

Automatic heating element (optional) 10

1.6.1.5.

Planer 10

1.6.1.6.

Reception box 11

1.7.

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 14

2.8.3.

Danger of being burnt by heating element and welding area 15

2.8.4.

Danger of Squeezing by clamping devices and guideways 15

2.8.5.

Risk of injury by noises 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 device for heating element 19

4.4.

Elements on the heating element and the planer 20

STARTING AND OPERATING 21

5.1.

Safety Indications 21

Kunststoffschweißtechnik

Contents

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 5 of 78

5.2.

Replacing the Reduction Inserts 22

5.2.1.

Using Small and Large Reduction Inserts 22

5.3.

Connection with the Basic Machine 23

5.4.

Operation with Emergency Power Supply 23

5.5.

Automatic Heating Element (optional) 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.

SD-card and drive 26

5.7.3.

Barcode 26

5.7.4.

Read out ICON with USB card reader (option) 26

5.8.

Switching the CNC 3.0 on 27

5.9.

Programming and welding with gas legitimacy card 28

5.10.

Programming and welding with general legitimacy card or ISO legitimacy card 28

5.10.1.

Setting the Pipe Data 29

5.11.

Welding Process 30

5.11.1.

elding process with traceability 35

5.12.

Error Messages 36

5.13.

Administration of the Welding Data 36

5.14.

More adjustemends 37

5.14.1.

Setting the time and the date 37

5.14.2.

Setting the language 38

5.14.3.

Setting information of traceability and lenght of pipe 38

5.14.4.

Setting of shortened cooling time 39

5.15.

Administration of the welding data 40

5.15.1.

Copying internal data onto SD-card and deleting them (RAM) 40

5.15.2.

Storing data on the SD - card 41

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 Level 45

7.5.

Venting the Hydraulic Cylinders 46

7.6.

Maintenance, Inspection and Repair 47

7.7.

Saving the Welding Data 47

7.8.

Error signals 48

7.9.

Possible defects and their elimination 49

7.10.

Fuse for Overload Safety Device / Printer Plug Box 50

7.11.

Disposal 50

TRANSPORT 51

Kunststoffschweißtechnik

Contents

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 6 of 78

WIRING AND HYDRAULIC DIAGRAMS 52

10.

SPARE PARTS LIST 65

10.1.

Basic Machine 65

10.2.

CNC Control Unit 67

10.3.

Planer 69

10.4.

Heating Element 71

10.5.

Reception box 73

10.6.

Automatic heating element (option) 75

11.

DECLARATION OF CONFORMITY 78

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

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 7 of 78

1. Description of the product

1.1. Usage and purpose-oriented use

The WIDOS 5500 CNC 3.0 has been designed only for heating element butt welding of pipes

and fittings made out of PE, PP, PVDF with their diameter range going from OD

min

= 200 mm

up to OD

max

= 500 mm

(standard diameters: 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 / 500 mm.)

All use of this control 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 Product Chapter 1

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 8 of 78

1.4. Machine overview

No. Denomination

1 Basic machine

2 Control unit

3 Heating element

4 Planer

5 Reception box

1.5. Structure of the CNC 3.0 control unit

No. Denomination

6 Display

7 Operating fields

8 Barcode reader

9 Pipe data card or general legitimacy card

10 SD-card

Kunststoffschweißtechnik

Description of Product Chapter 1

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 9 of 78

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. IDOS CNC 3.0 General data

eight (without transport box):

Dimensions (l x w x h):

40.5 kg

appr. 630x430x510 (mm)

Power: 560 att

Voltage: 400 V (± 10%)

Current: 4,7 A

Frequency: 50 Hz

Phase shift: appr. 18°

Control voltage: 5 V

Insulation system: IP 44

Hydraulic oil tank: appr. 1 l

Attached elements: Connection cable with motor protective plug 16 A

Power of emergency set: 6.5 kVA / 400 V/3~

Electro motor and pump:

Driving speed (t/min): 2720

Max. working pressure of the pump: 110 bar

orking pressure: 100 bar

Volume flow: 3,5 l/min.

Emissions - The sound intensity level while using the

planer can be higer than 85 dB (A).

- hen using the named pipe materials and

when welding below 260 °C / 500 °F no

toxicant damp arises.

Environmental conditions at the

welding area:

- 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 necessary use a welding

tent

- Avoid strong sun rays influence

- Protect from wind, shut the pipe ends.

Kunststoffschweißtechnik

Description of Product Chapter 1

19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 10 of 78

1.6.1.2. Basic frame

Material frame: Construction steel

Material clamping inserts: Aluminium

eight: appr. 165.5 kg

Cylinder-Ø: 50 mm

Piston rod-Ø: 40 mm

Stroke length of cylinder: 300 mm

Max. force: (F=P*A) 14,14 kN (at 100 bar)

Velocity of piston rod: 4,1 cm/s

1.6.1.3. Heating element

Power: 5.9 k

Voltage: 400 V (± 10 %)

Current: 14.9 A

Frequency: 50 Hz

Outside-Ø: 564 mm

Surface: nonstick-coated

Attached elements: - electronic temperature control

- control lamps

- cable with 16 pole plug

eight: appr. 24.5 kg

1.6.1.4. Automatic heating element (optional)

Power: 5.9 k

Voltage: 400 V (± 10%)

Current: 14.9 A (± 10%)

Frequency: 50 Hz

Outside-∅: 564 mm

Surface: nonstick-coated

Attached elements: cable with 16 pole plug

eight: appr. 57.5 kg

1.6.1.5. Planer

Motor: Alternating current motor

Power: 1.1 k

Voltage: 400 V (± 10 %)

Current: 2.8 A

Frequency: 50 Hz (± 10 %)

Driving speed appr. 140

eight: appr. 54 kg

Table of contents

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual

widos 5500 CNC 3.0 User manual

Popular Welding System manuals by other brands