widos 4900 CNC 3.5 Working Instructions Translation
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widos 4900 CNC 3.5 Working Instructions Translation

Heating element butt welding machine with cnc control unit
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WIDOS
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen
Working Instructions
Heating element butt welding machine
WIDOS 4900 CNC 3.5
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Einsteinstr. 5
Website: www.widos.de
Translation
with CNC control unit
Keep for further use!
Phone +49 (0) 71 52 99 39 - 0
Fax
+49 (0) 71 52 99 39 - 40
Email: info@widos.de
Ku nst sto ffschweißtec hni k

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  • Page 1 Email: info@widos.de Ku nst sto ffschweißtec hni k Working Instructions Translation Heating element butt welding machine with CNC control unit WIDOS 4900 CNC 3.5 Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer...
  • Page 2 Telefon: ++49 (0) 3 71 / 8 15 73 - 0 Telefon: ++41 (0) 71 / 388 89 79 Telefax: ++49 (0) 3 71 / 8 15 73 - 20 Telefax: ++41 (0) 71 / 388 89 73 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 2 of 68...
  • Page 3 Due to this structure, the searched informations can be easily found.  02.08.2011 WIDOS W. 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. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 3 of 68...

  • Page 4: Table Of Contents

    Starting and operating 5.1. Safety indications 5.2. Replacing the reduction inserts 5.2.1. Using small and large reduction inserts 5.3. Automatic heating element (Optional) 5.4. Connection with the basic machine 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 4 of 68...
  • Page 5 Possible defects and their elimination Transport Wiring diagrams Spare parts list 10.1. CNC contol unit 3.5 10.2. Basic machine 10.3. Planer 10.4. Heating element 10.5. Reception box Declaration of conformity 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 5 of 68...

  • Page 6: Description Of The Product

    1. Description of the product 1.1. Usage and purpose-oriented Use The WIDOS 4900 CNC 3.5 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 = 90 mm up to OD = 315 mm in the way as described below.

  • Page 7: Machine Overview

    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. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 7 of 68...

  • Page 8: Technical Data

    230V (± 10 %) Current: 10.8 A Frequency: 50 Hz Outside-Ø: 320 mm Surface: nonstick-coated Attached elements: - Control lamps - Cable with multiple pole plug Weight: appr. 6 kg 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 8 of 68...

  • Page 9: Planer

    - SD-card (64 MB memory capacity) Following optional accessories are available on request: - Program WICON for reading out the data (possibility of displaying included in SD-card) - Automatic heating element 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 9 of 68...

  • Page 10: Safety Rules

    T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) . 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 10 of 68...

  • Page 11: Obligations Of The Owner

    • Only skilled and trained persons are allowed to work at the machine. • A person who is being trained may only work at the machine under supervision of an experienced person. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 11 of 68...

  • Page 12: Dangers While Handling The Machine

    Ku nst sto ffschweißtec hni k 2.7. Dangers while handling the machine The heating element butt welding machine WIDOS 4900 CNC 3.5 is constructed according to the latest technical standard and the acknowledged technical safety rules. However, dangers for the operator or other persons standing nearby may occur. Also material damages are possible.

  • Page 13: Danger Of Catching Clothes By The Planer

    (see chapter 2.5). Machine parts which are not in a perfect condition are to be replaced immediately. • Only use original WIDOS spare and wear parts. • • In case of purchase orders please always state the machine and version number ! 02.08.2011...

  • Page 14: Warranty And Liability

    • structural modifications on the machine without permission • unsatisfactory checking of parts of the machine, which are worn out • repairs performed in an inexpert way • In case of catastrophes and force majeure 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 14 of 68...

  • Page 15: Functional Description

    3. Functional description The WIDOS CNC 3.5 control unit performs a butt welding process with the plastic welding machine WIDOS 4900 after entering the type of material, the pipe diameter and the pipe wall thickness. The welding processes are recorded and can be saved on a SD-card.

  • Page 16: Operating And Indicating Elements

    Mains connection cable for the control unit EMERGENCY-Stop push button Plug box with safety stirrup for heating element Connection for the travel sensor Plug for planer Connections for hydraulic hoses 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 16 of 68...

  • Page 17: Emergency-Stop Push Button

    When inserting the heating element take care that it lies in the zone of the throat of the tear- off bar (see arrow). 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 17 of 68...

  • Page 18: Elements On Heating Element And Planer

    - During the planing process, the planer has to be switched on at the (Planer) switch and its corresponding lock button. The planing process is operated by the CNC control. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 18 of 68...

  • Page 19: Starting And Operating

    (e.g. technical pure alcool or cleaning tissues which are available at the WIDOS company). The anti-adhesive coating of the heating element must remain undamaged in the working area.

  • Page 20: Replacing The Reduction Inserts

    Small reduction insert, centered (for pipes) Shown here: Small reduction insert, flush to the inside (for bends, T-pieces) 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 20 of 68...

  • Page 21: Automatic Heating Element (Optional)

    After expiration of the adjusting or heating time, the heating element is unlocked by opening the sledge and is moved automatically out of the basic machine. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 21 of 68...

  • Page 22: Connection With The Basic Machine

    The emergency power supply should be maintained periodically. For further details see the working instructions of the emergency power supply. Important: first start the emergency power supply and then the other current consuming devices. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 22 of 68...

  • Page 23: Description Of The Display

    • The card can be read out with a WICON program. • The card may not be bent, opened, overheated and become wet! Please only use SD cards purchased from WIDOS. We will not be liable for any cards from other manufactures! 02.08.2011...

  • Page 24: Read-Out Wicon With Usb Card Reader

    As soon as the USB card reader has been plugged, it appears as removable medium in the drive list. Open the WIDOS folder, there you will find: - WICON2000 viewer for considering and printing the welding data, - working instructions for WICON2000 viewer as PDF file.

  • Page 25: Programming And Welding

    Current date and time In the basic menu, following functions are possible: button <+> and <−>: moving the sledge button <Enter>: menu / setting button <Start>: welding process 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 25 of 68...

  • Page 26: Setting The Pipe Data

    Display of the heating element temperature PE80 225 20.5 206° line: calculated according to the prescriptions of the DVS button <Start>: back to basic menu WIDOS 4900 CNC Display: Basic menu 22.11.2000 10:10 line: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 26 of 68...

  • Page 27: Welding Process

    <+> and <->: select numbers button <Enter>: cursor jumps for 1 position to the right button <Start>: confirm Abort with button <C> if need be → basic menu 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 27 of 68...
  • Page 28 Display: Machine closes calibrating line: Pressure systems is calibrated after a few seconds, the display changes opening machine Display: Machine opens line: after a few seconds, the display changes 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 28 of 68...
  • Page 29 Insert the heating element in the machine and make sure that it is lying in the necking of the tear off rod, (Chapter 4.3), then press button <Start> 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 29 of 68...
  • Page 30 Remaining pressure build-up time (sec) Ps=000 Pi=000 P line: after a few seconds, the display changes cooling Tk=00:00 Display: Remaining cooling time (min and sec) Ps=000 Pi=000 P line: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 30 of 68...

  • Page 31: Welding Process With Traceability

    Select first digit with <+/-> and jump to the next digit with <Enter>. Traceability 1: Display: The pipe data is displayed RB PE80 2. line: After e few seconds, the display changes 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 31 of 68...
  • Page 32 Display: PE80 225 20.5 206° 2. line: The welding parameters are displayed next menu by pressing <Start> button Continue as described in chapter: 5.11 welding process 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 32 of 68...

  • Page 33: Error Messages

    09:43 03.05.2007 2. line: next menu by pressing <Enter> button copy Display: 2. line: By pressing <+> the data from the internal memory is transferred to the SD-card. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 33 of 68...

  • Page 34: Storing Data On The Sd - Card

    22.11.2000 10:10 2. line: Current date and time next menu by pressing <Enter> button SD-card Display: Storing the welding data on the PCMCIA 2. line: button <+> for menu "storing" 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 34 of 68...

  • Page 35: More Adjustemends

    Display: 22.11.2000 2. line: Setting the date buttons <+> and <->: change the date button <Enter>: confirm press several times button <Start> or after a short while appears automatically: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 35 of 68...

  • Page 36: Setting The Language

    <+> and <->: change the language button <Enter>: confirm press several times button <Start> or after a short while appears automatically: WIDOS 4900 CNC Display: Basic menu 22.11.2000 10:10 2. line: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 36 of 68...

  • Page 37: Setting Information Of Traceability And Lenght Of Pipe

    Wth button <+> - enter length of pipe (yes) press several times button <Start> or after a short while appears automatically: WIDOS 4900 CNC Display: Basic menu 22.11.2000 10:10 2. line: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 37 of 68...

  • Page 38: Setting Of Shortened Cooling Time

    - Load onto the workpieces only after being completely cooled down press several times button <Start> or after a short while appears automatically: WIDOS 4900 CNC Display: Basic menu 22.11.2000 10:10 2. line: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 38 of 68...

  • Page 39: Diagnosis Program

    - The required cooling time which was calculated by the programmed welding 0017 parameters is displayed - The required joining pressure which was calculated by the programmed 0018 welding parameters is displayed 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 39 of 68...
  • Page 40 - A self-test of the machine and the control unit is performed, including a weld log 0044 on SD-card. Abort with button <->. Press several times button <Start> or after a short while appears automatically. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 40 of 68...

  • Page 41: Equipment Care / Maintenance / Repair

    • The oil level may not be over the upper mark because otherwise there is the risk of inondation. • After completion ot the works, close the tank cover again and close the front plate. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 41 of 68...

  • Page 42: Venting The Hydraulic Cylinders

    If air remains in the lower cylinder, it will ascend in the upper cylinder when pressure is applied. There must always be enough oil in the tank (see chapter 7.4). 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 42 of 68...

  • Page 43: Maintenance, Inspection And Repair

    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. • The operating staff has to be informed before the starting of the maintenance works.

  • Page 44: Error Signals

    Internal memory is empty memory memory full ! Internal memory is full (more than Copy internal memory onto 300 weldings stored) SD-card and then delete it 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 44 of 68...

  • Page 45: Possible Defects And Their Elimination

    - Pipes have slipped through - Clamp pipes correctly. fast, the pump keeps on - Hydraulic bloc is leaky - Check oil leakage. working - Cylinder is leaky - Inform service-team 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 45 of 68...

  • Page 46: Transport

    Transport the planer in the reception box. If the planer is transported in the basic machine, grease the holders with PTFE- spray because otherwise damages at the piston and sealings may occur. 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 46 of 68...

  • Page 47: Wiring Diagrams

    Phone +49 (0) 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen +49 (0) 71 52 99 39 - 40 Website: www.widos.de Email: info@widos.de Ku nst sto ffschweißtec hni k 9. Wiring diagrams 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 47 of 68...
  • Page 48 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 48 of 68...
  • Page 49 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k Rear Panel Adapter X7 CNC 3.5 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 49 of 68...
  • Page 50 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 50 of 68...
  • Page 51 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 51 of 68...
  • Page 52 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k Rear Panel X 12 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 52 of 68...
  • Page 53 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 53 of 68...
  • Page 54 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 54 of 68...
  • Page 55 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k Mounting Plate 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 55 of 68...
  • Page 56 Wiring diagrams Chapter 9 Ku nst sto ffschweißtec hni k 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 56 of 68...

  • Page 57: Spare Parts List

    +49 (0) 71 52 99 39 - 40 Website: www.widos.de Email: info@widos.de Ku nst sto ffschweißtec hni k 10. Spare parts list 10.1. CNC contol unit 3.5 8 - 9 19 / 20 12 - 14 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 57 of 68...
  • Page 58 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k CNC-control unit WIDOS 4900 CNC 3.5 Pos. Name Piece Order no. Flat head screw M 3x16 DIN 965 0965C016 Outside temperature sensor EE0404 Carrying frame 105010 Pan head screw M 8x40 DIN 912...

  • Page 59: Basic Machine

    1 / 6 12 / 13 7 - 11 15 - 17 36 / 37 33 /35 25 - 31 38 - 40 21 / 23 23 / 24 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 59 of 68...
  • Page 60 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k 46 - 48 50 / 51 41 / 42 52 / 53 Illustration without rail for the travel sensor: 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 60 of 68...
  • Page 61 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k Basic machine WIDOS 4900 CNC 3.5 Pos. Name Piece Art.-No. Outer clamp, fixed 216101 Inner clamp, fixed 216102 216103 Outer clamp, movable 216104 Upper clamp 214105 Thread insert M 6...
  • Page 62 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k Basic machine WIDOS 4900 CNC 3.5 Pos. Name Piece Art.-No. Sintering filter V091114 Screwed connection GE 8 LR 1/4" VXGE8L14 Hydraulic tube 2161121 Hydraulic tube 2161131 Stop bolt 091117...

  • Page 63: Planer

    10.3. Planer 21 - 25 2 - 4 27 - 29 6 - 10 31 - 33 11 / 12 35 - 40 14 / 15 16 - 18 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 62 of 68...
  • Page 64 Chain joint KSCH38 Ball bearing L6020 Flat head screw M 8x20 DIN 7991 7991H020 Chain wheel, large (95 teeth) K38095 Cover 214404 Pan-head screw M 4x16 DIN 912 0912D016 02.08.2011 Working instructions WIDOS 4900 CNC 3.5 Page 63 of 68...

  • Page 65: Heating Element

    Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k 10.4. Heating el ment 3 - 5 6 - 8 13 / 14 17 - 21 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 64 of 68...
  • Page 66 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k Heating element WIDOS 4900 CNC 3.5 Pos. Name Piece Art.-No. Shim PTFE 211508 Control lamp, green H2105 Ring nut M 12 DIN 582 0582L Lock washer M 12 DIN 127...

  • Page 67: Reception Box

    Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k 10.5. Reception box 1 / 2 9 - 11 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 66 of 68...
  • Page 68 Spare parts list Chapter 10 Ku nst sto ffschweißtec hni k Reception box WIDOS 4900 CNC 3.5 Pos. Name Piece Art.-No. Heat absorbing steel sheet 214528 Insertion for heating element 214523 Stirrup 214527 Fitting cap Ø20x2 J5401 Spacing bolt for heating element...

  • Page 69: Declaration Of Conformity

    Safety specifications for fluid technical installations and components 5. EN 60555, EN 50082, EN 55014 Electro-magnetic resistance The technical documentation is completely available. Ditzingen-Heimerdingen, the 02.08.2011 Martin Dommer (Technical director) 02.08.2011 Working Instructions WIDOS 4900 CNC 3.5 Page 68 of 68...

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