Widos 6100 CNC 3.0 User manual

Ku nst sto ffschweißtechn i k

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: www.widos.de Email: info@widos.de

Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer

Working Instructions

Translation

Heating element butt welding machine

with CNC control unit

WIDOS 6100 CNC 3.0

Keep for further use!

Ku nst sto ffschwei ßtec hni k

Product identification

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 2 of 76

Model: Heating element butt welding machine with

CNC control unit

Type: IDOS 6100 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 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

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 / 388 89 79

Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73

Ku nst sto ffschwei ßtec hni k

Introduction

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 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 information can be easily found.

27.10.2011 WIDOS

. Dommer Söhne GmbH

Einsteinstraße 5

D-71254 Ditzingen-Heimerdingen

Reprinting only allowed with permission of the corporation.

Any changes prior to technical innovations.

Ku nst sto ffschwei ßtec hni k

Contents

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 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.

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.

Planer 10

1.6.1.5.

Reception box 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 12

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 13

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

2.9.

Structural modifications on the machine 15

2.10.

Warranty and liability 15

FUNCTIONAL DESCRIPTION 16

OPERATING AND INDICATING ELEMENTS 17

4.1.

Elements on the CNC 3.0 control unit 17

4.2.

EMERGENCY-stop push button 18

4.3.

Separating de ice for heating element 18

4.4.

Elements on the heating element and the planer 19

4.5.

Lift-off de ice (optional) 20

4.5.1.

Mounting of the machine 20

4.5.2.

Mounting the lift-off device 20

Ku nst sto ffschwei ßtec hni k

Contents

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 5 of 76

4.5.3.

Transport 20

STARTING AND OPERATING 21

5.1.

Safety indications 21

5.2.

Replacing the reduction inserts 22

5.2.1.

Using small reduction inserts 22

5.3.

Connection with the basic machine 23

5.4.

Operation with Emergency Power Supply 23

5.5.

Description of the Display 24

5.6.

Accessories for Reading the Data in and out 24

5.6.1.

Legitimacy Cards 24

5.6.2.

SD – card and drive 25

5.6.3.

Barcode 25

5.6.4.

Read-out ICON with USB card reader (optional) 25

5.7.

Switching the CNC 3.0 on 26

5.8.

Programming and welding with gas legitimacy card 27

5.9.

Programming and welding with general legitimacy card or ISO legitimacy card 27

5.9.1.

Setting the pipe data 28

5.10.

Welding process 29

5.10.1.

elding process with traceability 33

5.11.

Error messages 34

5.12.

More adjustemends 35

5.12.1.

Setting the time and the date 35

5.12.2.

Setting the language 36

5.12.3.

Setting information of traceability and lenght of pipe 36

5.12.4.

Setting of shortened cooling time 37

5.13.

Administration of the welding data 38

5.13.1.

Copying internal data onto SD-card and deleting them (RAM) 38

5.13.2.

Storing data on the SD - card 39

5.14.

Function of the emergency power supply (optional) 40

DIAGNOSIS PROGRAM 41

EQUIPMENT CARE / MAINTENANCE / REPAIR 43

7.1.

Storage 43

7.2.

Cleaning the machine 43

7.3.

Clamping elements 43

7.4.

Checking the hydraulic oil le el 43

7.5.

Venting the hydraulic cylinders 44

7.6.

Maintenance, inspection and repair 45

7.7.

Sa ing the welding data 45

7.8.

Error signals 46

Ku nst sto ffschwei ßtec hni k

Contents

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 6 of 76

7.9.

Possible defects and their elimination 47

7.10.

Accumulator for emergency power supply (optional) 48

7.11.

Fuse for o erload safety de ice / printer plug box 48

7.12.

Disposal 48

TRANSPORT 49

WIRING AND HYDRAULIC DIAGRAMS 50

10.

SPARE PARTS LIST 64

10.1.

Basic machine 64

10.2.

CNC control unit 66

10.3.

Planer 68

10.4.

Heating element 70

10.5.

Reception box 72

10.6.

Lift off de ice (optional) 74

11.

DECLARATION OF CONFORMITY 76

Ku nst sto ffschwei ßtec hni k

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: www.widos.de Email: info@widos.de

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 7 of 76

1. Description of the product

1.1. Usage and purpose-oriented use

The WIDOS 6100 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

= 355 mm up

to OD

max

= 630 mm (standar diameters: 355 / 400 / 450 / 500 / 560 / 630 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.

Ku nst sto ffschwei ßtec hni k

Description of product Chapter 1

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 8 of 76

1.4. Machine o er iew

No. Denomination

1 Basic machine

2 Control unit

3 Lift off device (optional)

4 Heating element

5 Planer

6 Reception box

1.5. Structure of the CNC 3.0 control unit

No. Denomination

7 Display

8 Operating fields

9 Barcode reader

10 Pipe data card or general legitimacy card

11 SD card

Ku nst sto ffschwei ßtec hni k

Description of product Chapter 1

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 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. IDOS CNC 3.0 General data

eight (without transport box):

Dimensions (l x w x h):

450 kg

appr. 630x430x510 (mm)

Covering: 16 A

Voltage: 400 V (± 10%)

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 CEE - motor protective plug 16 A

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

Emissions - Noises exceeding 80 dB (A) may occur; during planing it

is obligatory to wear ear protection!

- hen using the named pipe materials and when welding

below 260°C no toxicant damp arises

Ambient conditions in the welding

area

- take care for cleanness (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

Electro motor and pump:

Power: 0,56 k

Current: 4,7 A

Driving speed: 2720 rpm

Max. working pressure of the

pump:

110 bar

orking pressure: 100 bar

Volume flow: 3,5 l/min.

Ku nst sto ffschwei ßtec hni k

Description of product Chapter 1

27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 10 of 76

1.6.1.2. Basic frame

Material frame: Construction steel

Material clamping inserts: Aluminium

eight: appr. 226 kg

Cylinder-Ø: 60 mm

Piston rod-Ø: 50 mm

Stroke length of cylinder: 300 mm

Max. force: (F=P*A) 17,30 kN (at 100 bar)

Velocity os piston rod: 3,4 cm/s

1.6.1.3. Heating element

Power: 6,0 k

Voltage: 400 V (± 10 %)

Current: 15 A

Frequency: 50 Hz

Outside-Ø: 684 mm

Surface: nonstick-coated

Attached elements: - electronic temperature control

- control lamps

- cable with 16 pole plug

eight: appr. 36 kg

1.6.1.4. Planer

Motor: Alternating current motor

Power: 1.1 k

Voltage: 400 V (± 10 %)

Current: 3,5 A

Frequency: 50 Hz (± 10 %)

Driving speed appr. 140

eight: appr. 103 kg

Attached elements: - cable with plug CEE 16A

- locking device

1.6.1.5. Reception box

Dimensions: 870 x 610 x 740 mm

eight: appr. 62 kg

See spare parts list for order numbers and single parts

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