widos 5500 CNC 3.0 Working Instructions
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widos 5500 CNC 3.0 Working Instructions

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 5500 CNC 3.0
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Einsteinstr. 5
Website: http://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
Kunststoffschweißtechnik

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  • Page 1 +49 (0) 71 52 99 39 - 40 Website: http://www.widos.de Email: info@widos.de Kunststoffschweißtechnik Working Instructions Translation Heating Element Butt Welding Machine with CNC Control Unit WIDOS 5500 CNC 3.0 Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer...
  • Page 2 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 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 2 of 78...
  • Page 3 Due to this structure, the searched information can be easily found.  19.09.2011 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. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 3 of 78...

  • Page 4: Table Of Contents

    Elements on the CNC 3.0 Control Unit 4.2. EMERGENCY-Stop Push Button 4.3. Separating device for heating element 4.4. Elements on the heating element and the planer STARTING AND OPERATING 5.1. Safety Indications 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 4 of 78...
  • Page 5 Maintenance, Inspection and Repair 7.7. Saving the Welding Data 7.8. Error signals 7.9. Possible defects and their elimination 7.10. Fuse for Overload Safety Device / Printer Plug Box 7.11. Disposal TRANSPORT 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 5 of 78...
  • Page 6 WIRING AND HYDRAULIC DIAGRAMS 10. SPARE PARTS LIST 10.1. Basic Machine 10.2. CNC Control Unit 10.3. Planer 10.4. Heating Element 10.5. Reception box 10.6. Automatic heating element (option) 11. DECLARATION OF CONFORMITY 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 6 of 78...

  • Page 7: Description Of The Product

    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...

  • Page 8: Machine Overview

    Control unit Heating element Planer Reception box 1.5. Structure of the CNC 3.0 control unit Denomination Display Operating fields Barcode reader Pipe data card or general legitimacy card SD-card 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 8 of 78...

  • Page 9: Designation Of The Product

    - Avoid humidity, if necessary use a welding tent - Avoid strong sun rays influence - Protect from wind, shut the pipe ends. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 9 of 78...

  • Page 10: Basic Frame

    Alternating current motor Power: 1.1 kW Voltage: 400 V (± 10 %) Current: 2.8 A Frequency: 50 Hz (± 10 %) Driving speed appr. 140 Weight: appr. 54 kg 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 10 of 78...

  • Page 11: Reception Box

    Following optional accessories are available on request: - Pipe data card - Program WICON for reading out the data (possibility of displaying included in SD-card) - Gas legitimacy card - Automatic heating element 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 11 of 78...

  • Page 12: Safety Rules

    • It is a help for using all the functions on your machine in an optimal way and helps you to make the job easier. The regulations for the prevention of accidents are valid (UVV). 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 12 of 78...

  • Page 13: 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. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 13 of 78...

  • Page 14: Dangers While Handling The Machine

    Kunststoffschweißtechnik 2.7. Dangers while handling the machine The heating element butt welding machine WIDOS 5500 CNC 3.0 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 15: Danger Of Being Burnt By Heating Element And Welding Area

    • 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! 19.09.11...

  • Page 16: 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 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 16 of 78...

  • Page 17: Functional Description

    3. Functional Description The WIDOS CNC 3.0 control unit performs a butt welding process with the plastic welding machine WIDOS 5500 after entering the type of material, the pipe diameter and the pipe wall thickness. The welding processes are recorded and can be printed out in a short or a long version over the parallel interface, or be saved on a PCMCIA card or be transmitted over the serial interface e.g.

  • Page 18: Operating And Indicating Elements

    Mains connection cable for the control unit EMERGENCY-Stop push button Bar code reader Connection for bar code reader Connection for the travel sensor Plug box with safety stirrup for heating element Connections for hydraulic hoses 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 18 of 78...

  • Page 19: 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). 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 19 of 78...

  • Page 20: Elements On The Heating Element And The Planer

    (Planer) 5) on the CNC control unit. Locking device - Locking the planer into basic machine by planning, unlock it by pulling the ball knob in direction of arrow 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 20 of 78...

  • Page 21: Starting And Operating

    (e.g. technical pure alcool or pipe 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 22: Replacing The Reduction Inserts

    Small reduction insert, centered (for pipes) Shown here: Small reduction insert, flush to the inside (for bends, T-pieces) 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 22 of 78...

  • Page 23: 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. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 23 of 78...

  • Page 24: 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. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 24 of 78...

  • Page 25: Description Of The Display

    (4) Optionally, a ISO-legitimacy card can be supplied. It is of white colour and gives the legitimation to operate all functions (including special functions). • Protect the cards from wetness and dirtiness. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 25 of 78...

  • Page 26: Sd-Card And Drive

    • 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! 5.7.3.

  • Page 27: Switching The Cnc 3.0 On

    Display: WIDOS 5500 CNC The type of the machine is displayed line: Current date and time 22.11.2002 10:10 „ B a s i c m e n u “ 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 27 of 78...

  • Page 28: Programming And Welding With Gas Legitimacy Card

    • Read in the pipe data card or the general legitimacy card or the ISO legitimacy card with the barcode reader for setting the parameters and changing pipe data 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 28 of 78...

  • Page 29: Setting The Pipe Data

    Display of the heating element temperature calculated line: PE80 225 20.5 206° according to the prescriptions of the DVS button <Start>: back to basic menu Display: Basic menu WIDOS 5500 CNC line: 22.11.2002 10:10 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 29 of 78...

  • Page 30: Welding Process

    Enter and display the number of joint 0000 button <+> and <->: select numbers button <Enter>: cursor jumps for 1 position to the right button <Start>: confirm 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 30 of 78...
  • Page 31 Sledge closes line: Pressure systems is calibrated calibrating after a few seconds, the display changes Display: Sledge opens opening machine line: after a few seconds, the display changes 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 31 of 78...
  • Page 32 If the misalignment is too high, re-adjust the pipe ends in the basic clamping devices and repeat the planing process. Display: opening machine line: after a few seconds, the display changes 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 32 of 78...
  • Page 33 Display: line: after a few seconds, the display changes Display: Remaining pressure build-up time (sec) ramp Tf= 000s line: Ps=000 Pi=000 P =0.0 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 33 of 78...
  • Page 34 OK Welding completed, unclamp the pipes button <Start>: back to basic menu Display: Basic menu WIDOS 5500 CNC line: Current date and time 22.11.2002 10:10 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 34 of 78...

  • Page 35: Welding Process With Traceability

    2. line: +000.00 mm Enter the length of the last (read in) barcode pipe 1 up to the joint by buttons <+ / - / Enter> Press button <Start> 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 35 of 78...

  • Page 36: Error Messages

    Make sure not to go over this quantity (in the display the error message "memory full“ appears) because otherwise the first stored welding will be over- written. If necessary, read the welding data out in time. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 36 of 78...

  • Page 37: More Adjustemends

    <+> and <->: change the date button <Enter>: confirm press several times button <Start> or after a short while appears automatically: Display: Basic menu WIDOS 5500 CNC 2. line: 22.11.2000 10:10 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 37 of 78...

  • Page 38: Setting The Language

    Basic menu WIDOS 5500 CNC 2. line: Current date and time 22.11.2000 10:10 next menu by pressing button <Enter> Display: copy 2. line: next menu by pressing button <Start> 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 38 of 78...

  • Page 39: Setting Of Shortened Cooling Time

    Current date and time 22.11.2000 10:10 next menu by pressing button <Enter> Display: copy 2. line: next menu by pressing button <Start> Display: Diag Clk WICON Param 2. line: 10:10 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 39 of 78...

  • Page 40: Administration Of The Welding Data

    WIDOS 5500 CNC 2. line: 09:43 03.05.2007 next menu by pressing <Enter> button Display: copy 2. line: By pressing <+> the data from the internal memory is transferred to the SD-card. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 40 of 78...

  • Page 41: Storing Data On The Sd - Card

    Display: WIDOS 5500 CNC Basic menu 2. line: Current date and time 22.11.2000 10:10 next menu by pressing <Enter> button Display: copy 2. line: button <+> for menu "storing" 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 41 of 78...
  • Page 42 Display: Data is stored on the SD-card SD-card 0000 2. line: press button <Start> until the basic menu appears Display: Basic menu WIDOS 5500 CNC 2. line: 22.11.2000 10:10 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 42 of 78...

  • Page 43: Diagnosis Program

    - The required pressure build-up time which was calculated by the 0016 programmed welding parameters is displayed - The required cooling time which was calculated by the programmed 0017 welding parameters is displayed 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 43 of 78...
  • Page 44 • 0010 Environmental temperature • 0011 Pressure (4-20 mA) A self-test of the machine and the control unit is performed. 0044 Press button <-> for complete the dignosis program 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 44 of 78...

  • Page 45: Equipment Care / Maintenance / Repair

    • The oil level may not be over the upper mark because otherwise there is the risk of inondation. • After completion of the works, close the tank cover again tightly and close the front plate. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 45 of 78...

  • Page 46: 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). 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 46 of 78...

  • Page 47: 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 48: Error Signals

    Internal memory is empty memory memory full ! Internal memory is full (more Copy internal memory onto SD- than 400 weldings stored) card and then delete it 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 48 of 78...

  • Page 49: Possible Defects And Their Elimination

    - Clean barcode, repeat read in - Reading pen defective - Manually enter digits of the barcode: simultaneously press all three buttons <+ / - / Enter>, afterwards manually entert the digits. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 49 of 78...

  • Page 50: Fuse For Overload Safety Device / Printer Plug Box

    At the end of their life time, the machine and the wear parts have to be disposed of properly and non-polluting, and in accordance with the national laws of waste disposal. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 50 of 78...

  • Page 51: 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 piston and sealings may occur. 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 51 of 78...

  • Page 52: Wiring And Hydraulic 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: http://www.widos.de Email: info@widos.de Kunststoffschweißtechnik 9. Wiring and Hydraulic Diagrams 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 52 of 78...
  • Page 53 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 53 of 78...
  • Page 54 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 54 of 78...
  • Page 55 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik Rear Panel Adapter X7 CNC 3.0 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 55 of 78...
  • Page 56 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 56 of 78...
  • Page 57 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 57 of 78...
  • Page 58 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik Rear Panel X 12 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 58 of 78...
  • Page 59 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 59 of 78...
  • Page 60 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 60 of 78...
  • Page 61 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 61 of 78...
  • Page 62 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 62 of 78...
  • Page 63 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 63 of 78...
  • Page 64 Wiring and Hydraulic Diagrams Chapter 9 Kunststoffschweißtechnik Mounting Plate 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 64 of 78...

  • Page 65: Spare Parts List

    29 / 36 52 - 53 54 - 55 37 - 39 59 - 60 40 - 42 43 - 46 47 - 49 50 - 51 61 - 62 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 65 of 78...
  • Page 66 Spare Parts List Chapter 10 Kunststoffschweißtechnik Basic unit WIDOS 5500 CNC 3.0 Pos. Name Piece Order no. Outer clamp, fixed 390101 Inner clamp, fixed 390102 Inner clamp, movable 390103 Outer clamp, movable 390104 Upper clamp 390105 Thread insert M10 GEW-M10...
  • Page 67 Spare Parts List Chapter 10 Kunststoffschweißtechnik Basic unit WIDOS 5500 CNC 3.0 Pos. Name Piece Order no. Hexagon -head screw M 8x12 DIN 933 0933H010 Washer M8 DIN 125 0125H Filter V092114 Holder for filter 093119 Washer M8 DIN 125...

  • Page 68: Cnc Control Unit

    Spare Parts List Chapter 10 Kunststoffschweißtechnik 10.2. CNC Control Unit 9 - 10 • 3 - 6 21 - 22 15 - 16 17 - 19 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 67 of 78...
  • Page 69 Spare Parts List Chapter 10 Kunststoffschweißtechnik CNC-control unit WIDOS 5500 CNC 3.0 Pos. Name Piece Order no. Flat head screw M 3x16 DIN 965 0965C016 Outside temperature sensor KTY 10 EE0404 Carrying frame 105010 Pan head screw M 8x40 DIN 912...

  • Page 70: Planer

    7 / 8 9 - 10 11 - 19 20 - 25 26 - 27 4 - 6 32 - 37 29 / 30 38 - 40 43 - 45 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 69 of 78...
  • Page 71 0125J Lock nut M10 DIN 985 0985J Knife MES120 Knife MES085 Flat head screw M 3x8 DIN 965 0965C008TX Locking for planer complete 082420 Torx screw driver T10 ZT10 19.09.2011 Working Instructions WIDOS 5500 CNC 3.0 Page 70 of 78...

  • Page 72: Heating Element

    Spare Parts List Chapter 10 Kunststoffschweißtechnik 10.4. Heating Element 2 - 6 7 - 9 8 - 10 16 - 17 25 - 28 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 71 of 78...
  • Page 73 Spare Parts List Chapter 10 Kunststoffschweißtechnik Heating element WIDOS 5500 CNC 3.0 Pos. Name Piece Order no. Heating element H 5500 230 V H5500E Heating plate, new HP5500E Heating plate in exchange HPT550E Washer 0715091 Handle 071508 Axis for grip...

  • Page 74: Reception Box

    Spare Parts List Chapter 10 Kunststoffschweißtechnik 10.5. Reception box 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 73 of 78...
  • Page 75 Spare Parts List Chapter 10 Kunststoffschweißtechnik Reception box WIDOS 5500 CNC 3.0 Pos. Name Piece Order no. Reception box 390520 Heat absorbing steel sheet 3905201 Blind rivet 4x10 DIN 7337 7337D010 Fitting cap 40 x 30 x 2 J0203 Lifting screw M16 DIN 580 0580P 19.09.2011...

  • Page 76: Automatic Heating Element (Option)

    9 / 10 / 12 13 - 18 41 - 44 19 - 22 46 - 48 49 - 51 53 - 55 59 - 60 56 - 58 62 / 63 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 75 of 78...
  • Page 77 Spare Parts List Chapter 10 Kunststoffschweißtechnik 71 / 72 74 / 75 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 76 of 78...
  • Page 78 Spare Parts List Chapter 10 Kunststoffschweißtechnik Automatic heating element 5500 CNC 3.0 (option) Pos. Name Piece Order no. Cover plate with ring nut 3975301 Pan head screw M 8 x 20 DIN 912 0912H020 Frame for heating element 397530 Pneumatic cushion on request Wire cable with eye Ø4 x 800...
  • Page 79 Spare Parts List Chapter 10 Kunststoffschweißtechnik Automatic heating element 5500 CNC 3.0 (option) Pos. Name Piece Order no. Heating cartridge Ø10 x 100; 230V; 160W; AL 1110 on request Heating cartridge Ø10 x 190; 230V; 300W; AL 1110 on request...

  • Page 80: 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 19.09.2011 Martin Dommer (Technical director) 19.09.11 Working Instructions WIDOS 5500 CNC 3.0 Page 78 of 78...

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