widos 4002 S WI CNC User manual

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
Headquarters: D-71254 Ditzingen Country court Stuttgart HRB 200973 Managing directors: Jürgen Dommer, Dr. Kai Dombrowski
Working Instructions
Translation
Heating element butt welding machine
WIDOS 4002 S WI CNC®
Keep for further use!

Identification of product
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Model: Workshop machine
Type: WIDOS 4002 S WI-CNC®
Serial number, year of construction: see type plate
Customer entries
Inventory-no.:
Location:
Order of spare parts and after sales service:
Manufacturer’s address WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstr. 5
D -71254 Ditzingen
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]

Introduction
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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 advisers in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest in making our products and working instructions continuously better, we kindly ask
you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
The working instructions are arranged in chapters, which belong to the different using phases of the
machine.
Therefore the searched information can be found easily.
11/14/2016 WIDOS
Wilhelm Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen
All rights reserved.
Reprinting only allowed with permission of the corporation.
Any changes are subject to technical innovations.

Contents
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1.DESCRIPTION OF PRODUCT .......................................................................... 7
1.1.Usage and purpose-oriented use ............................................................................................... 7
1.2.Safety measures........................................................................................................................ 7
1.3.Conformity................................................................................................................................. 7
1.4.Marking of the product .............................................................................................................. 8
1.4.1.Technical data .................................................................................................................... 8
1.4.1.1.WIDOS 4002 S WI-CNC General data .............................................................................. 8
1.4.1.2.Basic machine.................................................................................................................. 8
1.4.1.3.Heating element ............................................................................................................... 9
1.4.1.4.Planer.............................................................................................................................. 9
1.4.1.5.3-zone heating element (optional)....................................................................................... 9
1.5.Tools and accessories............................................................................................................... 9
2.SAFETY RULES .............................................................................................. 10
2.1.Explanation of the different symbols ........................................................................................ 10
2.2.Obligations of the owner.......................................................................................................... 11
2.3.Obligations of the worker......................................................................................................... 11
2.4.Measures of organization ........................................................................................................ 11
2.5.Information about safety precautions ...................................................................................... 11
2.6.Instructions for the staff .......................................................................................................... 11
2.7.Maintenance and inspection, repair ........................................................................................ 12
2.8.Dangers while handling the machine ....................................................................................... 12
2.9.Dangers due to electrical energy............................................................................................. 12
2.10.Dangers due to the pneumatic ................................................................................................. 12
2.11.Special dangers ...................................................................................................................... 13
2.11.1.Danger of combustion at the heating element and at the welding area ................................... 13
2.11.2.Danger of crushing by clamping tools and guide rods ........................................................... 13
2.11.3.Danger of catching clothes by the planer............................................................................. 13
2.11.4.Danger of stumbling over pneumatic and electric cables ...................................................... 13
2.11.5.Risk of injury by noise ........................................................................................................ 13
2.12.Warranty and liability .............................................................................................................. 14
3.DESCRIPTION OF PROCESS ........................................................................ 15
4.OPERATING AND INDICATING ELEMENTS ............................................... 16
4.1.Elements on the front side ....................................................................................................... 16
4.2.Elements on the right side ....................................................................................................... 17
4.2.1.Main switch...................................................................................................................... 17
4.2.2.Service unit ...................................................................................................................... 17
4.3.Pneumatic components on the machine................................................................................... 18

Contents
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4.4.Socket at the machine (at the front)......................................................................................... 19
4.5.Elements at the heating element .............................................................................................. 19
5.STARTING AND OPERATING ...................................................................... 20
5.1.Starting ................................................................................................................................... 20
5.2.Separating claws..................................................................................................................... 20
5.3.Description of the display ........................................................................................................ 21
5.3.1.Emergency-stop ................................................................................................................ 21
5.4.Buttons on the touch screen .............................................................................................. 22
5.4.1.Small symbol buttons ......................................................................................................... 22
5.4.2.Large symbol buttons......................................................................................................... 23
5.5.Accessories for reading data in and out (option)...................................................................... 24
5.5.1.Legitimacy cards ............................................................................................................... 24
5.5.2.Bar code scanner.............................................................................................................. 24
5.5.3.SD card and drive.............................................................................................................. 24
5.5.4.Read out WICON with USB flash drive................................................................................. 25
5.6.Switching the WI – CNC®1.1 / 1.3 on ................................................................................. 26
5.6.1.Select machine type with digital way-measuring device ....................................................... 27
5.6.2.Define dimension............................................................................................................... 29
5.6.3.Specialties for welding standard >LAB< .............................................................................. 31
5.6.4.How to enter further settings like traceability, ½ cooling time or RAM > USB........................... 35
5.6.4.1.How to set date, time, buzzer and language....................................................................... 36
5.7.Welding with the WI–CNC®1.1 - 1.3 ................................................................................... 38
5.7.1.Copy internal data onto SD card and delete internal data (RAM) ............................................ 50
5.8.Setting the welding angle ........................................................................................................ 52
5.8.1.Welding of T-piece 90°....................................................................................................... 52
5.8.2.Drillings at the table........................................................................................................... 53
6.EQUIPMENT CARE / MAINTENANCE / REPAIR ......................................... 54
6.1.Maintenance and inspection, repair................................................................................... 54
6.2.How to clean the operator panel (touch screen) .............................................................. 54
6.3.Fuses in the switch cabinet ..................................................................................................... 55
6.4.Safety switch and end switch at tghe machine ........................................................................ 55
6.5.Clamping elements .................................................................................................................. 56
6.6.Planer ..................................................................................................................................... 56
6.7.Storage.................................................................................................................................. 56
6.8.Disposal ................................................................................................................................ 56
7.TRANSPORT .................................................................................................. 57
7.1.WI-CNC®1.1 / 1.3..................................................................................................................... 57
7.2.4002 S CNC .............................................................................................................................. 57

Contents
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8.ELECTRIC AND PNEUMATIC DIAGRAMS .................................................. 58
8.1.Pneumatic diagram.............................................................................................................. 58
8.2.Electric diagrams for 4002 S WI-CNC®............................................................................... 59
9.SPARE PARTS LIST ...................................................................................... 85
9.1.Basic machine......................................................................................................................... 85
9.2.Clamping tool .......................................................................................................................... 89
9.3.Planer ..................................................................................................................................... 90
9.4.Heating element ...................................................................................................................... 92
9.5.3-zone heating element (variant).............................................................................................. 93
9.6.Heating element holder ........................................................................................................... 94
9.7.Beam for one-sided planing..................................................................................................... 95
10.DECLARATION OF CONFORMITY .............................................................. 103

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
14.11.2016 Working instructions WIDOS 4002 S WI CNC Page 7 of 103
1. Description of product
This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.
1.1. Usage and purpose-oriented use
The WIDOS 4002 S WI-CNC is a workshop machine and especially designed for the heating element butt
welding of plastic pipes and fittings from Ø = 90 up to 315 mm (Standard-: 90 / 110 / 125 / 140 / 160 / 180 / 200 /
225 / 250 / 280 / 315 mm).
The machine is screwed tightly on a steel pipe frame in the correct working height and has a movable
machine slide (left-hand) and 2 (optional 4) clamping tools. For the compensation of diameter tolerances, the
right table half is movable crosswise to the working direction.
For the fabrication of segmented bends, both clamping tools are swiveling up to 15° each.
All use going beyond is not prescribed.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.
Also part of the appropriate usage are
following all indications of the working instructions and
performing the inspection and maintenance works.
1.2. Safety measures
At incorrect usage of the machine, incorrect operation or incorrect maintenance, the machine itself or
products being around can be damaged or destroyed.
Persons in the dangerous zone may be injured.
For that reason, these working instructions have to be read thoroughly and the according safety rules have
absolutely to be followed.
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.

Description of product Chapter 1
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1.4. Marking of the product
The product is marked by a type-plate at the basic machine.
It contains the machine type, the serial number and the year of construction.
1.4.1. Technical data
All important technical data of the singular components are mentioned.
This allows a quickly information about the capacity and the structure.
1.4.1.1. WIDOS 4002 S WI-CNC General data
Material: PP; PE, PVC, C-PVC, PVDF,
Pipe dimension: Outside-= 90 - 315
Voltage: 230 V / 3 Ph
Frequency: 50 Hz /60 Hz
Power: 5,8 kVA
Wires cross section: 1,5 mm²
Max. working pressure: 8 bar
Weight, without reducer inserts
and packing):
325 kg
Dimensions: (width x depth x
height)
1000 x 1500 x 1300 mm
1000 x 1600 x 1400 mm (with conversion kit)
Emissions - The sound pressure level during planing is below 80 dB (A)
- In case of use of the prescribed plastics and if the work is
performed within the temperature range up to 260 °C / 500 °F, no
toxic fumes will be generated.
Environmental conditions in the
welding area
- Be aware of cleanliness (no dust at the welding spot)
- If secured by appropriate measures that allowed conditions for
welding are indicated, it is possible – insofar as the welder is not
handicapped in his skills - to work at any outside.
- protect from moisture influence
- avoid strong sun radiation
- protect from strong wind
- attention when swiveling out the heating element
1.4.1.2. Basic machine
Frame material: Construction steel
Servo motor:
Power: 2,89 kW
Voltage: 230 V (10 %)
Amperage: 6,3 A
Frequency: 50 Hz / 60 Hz
Type of protection: IP 55
Engine revolution: 4000 (U/min)
Driving torque: max. 8,2 Nm

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1.4.1.3. Heating element
Power: 3,5 kW
Voltage: 230 V (10 %) / 3 Ph
Amperage per phase: 15,2 A (10 %)
Frequency: 50 Hz / 60 Hz
Surface: anti-stick coated
1.4.1.4. Planer
Motor: Three-phase universal motor
Power: 0,37 kW
Voltage: 230 V (10 %) / 3 Ph
Amperage: 1,02 A
Frequency: 50 Hz / 60 Hz (10 %)
1.4.1.5. 3-zone heating element (optional)
Power: 3,8 kW
Voltage: 230 V (10 %) / 3 Ph
Amperage per phase: 16,6 A (10 %)
Frequency: 50 Hz / 60 Hz
Surface: anti-stick coated
1.5. Tools and accessories
The following tools and accessories are part of the first delivery:
1 Key for switch cabinet
1 Ring/fork wrench size SW 19
1 Tubular hexagon box wrench size 27
each 1 Allen key with T-grip size 4; 5; 6
each 1 Allen key bent size 3; 6; 7; 8
Order numbers and singular components on request at the WIDOS company.
The following optional accessories are available on request:
- Program WICON for reading out the data (possibility of displaying included in USB stick)

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
14.11.2016 Working instructions WIDOS 4002 S WI CNC Page 10 of 103
2. Safety rules
The basic condition for the safety conscious handling and the fault free operation of this machine is the
knowledge of the basic safety advises and rules.
These working instructions contain the most important indications for running the machine according to
the safety regulations.
The safety indications need to be followed by all persons working on the machine.
2.1. Explanation of the different symbols
The following denominations and symbols indicating dangers are used in the working instructions:
This symbol signifies a possible endangering for the life and the health of persons.
Not following these indications may conduct to severe consequences for health.
This symbol means a potential dangerous situation.
Not following these indications may conduct to slight injuries or damages on goods.
This symbol means a possible dangerous situation due to hot surfaces.
The non-respect of these indications may conduct to heavy burns, respectively to self-
ignition or even fire.
This symbol means a possible dangerous situation by moving parts of the machine
The disrespect of these indications may cause heavy crushing of parts of the body resp.
damages of parts of the machine.
This symbol means a possible risk of injury by noises exceeding 80 dB (A).
Ear protection is obligatory
This symbol gives the most important indications for the appropriate handling of the
machine.
Not following these indications may conduct to disturbances and damages on the
machine or items in the surrounding.
Under this symbol you will get tips and particularly important information.
This shall help you to use all functions of the machine in an optimal way and makes the
work easier for you.
The accident prevention measures are valid (UVV).

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2.2. Obligations of the owner
The owner is obliged only to let persons work at the machine, who
know about basic safety and accident prevention rules and are instructed in the handling of the machine,
as well as who
have read and understood the safety chapter of this manual and certify this by their signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
All persons who are to work at the machine are obliged before working:
To follow the basic safety and accident protection rules;
To have read and understood the safety chapter and the warnings in this manual and to confirm by their
signature that they have well understood them;
To inform themselves about the functions of the machine before using it.
2.4. Measures of organization
All equipment required for personal safety is to be provided by the owner.
All available safety equipment is to be inspected regularly.
2.5. Information about safety precautions
The working instructions have to be permanently kept at the place of use of the machine.
They are to be at the operator's disposal at any time and without effort.
In addition to the manual, the common valid and the local accident protection rules and
regulations for the environmental protection must be available and followed.
All safety and danger indications on the machine have to be in a clear readable condition.
Every time the machine changes hands or is being rent to third persons, the working instructions are to be
sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
It must be clearly defined who is responsible for transport, mounting and dismounting, starting the
operation, setting and tooling, operation, maintenance and inspection, repair and dismounting.
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.

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2.7. Maintenance and inspection, repair
All maintenance and repair work are to be basically performed with the machine in off-
position.
During this, the machine has to be secured against unintended switching on.
Prescribed maintenance and inspection work have to be performed in time.
The DVS recommends inspection work after 1 year.
For machines with a specially high usage percentage, the inspection cycle should be
shortened.
The work must be performed at the WIDOS GmbH company or by an authorized partner.
2.8. Dangers while handling the machine
The machine WIDOS 4002 S WI-CNC 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.
The machine may only be used in safety-technical impeccable status.
Disturbances which may affect the safety of the machine must be cleared immediately.
2.9. Dangers due to electrical energy
Works on the electric parts may only be performed by skilled workers.
The electric equipment of the machine is to be checked regularly.
Loose connections and damaged cables are to be replaced immediately.
If works on conductive parts are necessary, a second person is required who may switch the power off in
case of emergency.
The machine is to be protected from rain and dropping water.
2.10. Dangers due to the pneumatic
Pressure lines have to be depressurized before any kind of repair.
There is a particular danger for the eyes due to compressed air emerging suddenly.
Replace defective pneumatic hoses immediately.
Make a visual inspection of the pneumatic lines before beginning to weld.

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2.11. Special dangers
2.11.1. Danger of combustion at the heating element and at the welding area
You may burn parts of the body and inflammable materials may ignite!
The heating element is heated up to a temperature of more than 200° C / 392 °F!
Do not touch the surface of the heating element.
Do not leave the heating element unattended.
Keep enough safety distance to inflammable materials.
Do wear safety gloves.
Switch off the heating element after use.
2.11.2. Danger of crushing by clamping tools and guide rods
Heavy injuries by squeezing may occur between the two inner clamping tools.
Do not put hands between the clamped pipe ends.
Do not put hands or step between the inner clamping tools with pipes not yet clamped.
Do not touch the guide bar of the support.
Do not stop at opening or closing the machine.
2.11.3. Danger of catching clothes by the planer
You can cut yourself or even get bones broken!
Do wear clothes tight to the body.
Do not touch the face of the planer.
2.11.4. Danger of stumbling over pneumatic and electric cables
Take care that no person has to step over cables.
Lay the cables in such a manner that the danger is minimized.
2.11.5. Risk of injury by noise
Noise exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!

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2.12. Warranty and liability
Basically, our "General Terms of sale and delivery“ are valid.
They are at the owner’s disposal latest at conclusion of the contract.
Guarantee an liability demands referring to personal injuries or damages on objects are excluded if they are
caused by one or several of the following reasons:
Not using the machine according to the prescriptions.
Unsuitable transport, mounting, starting, operating and maintenance of the machine.
Operating the machine without or with not correctly fixed safety devices.
Not following the indications of the working instructions.
Unauthorized structural modifications on the machine.
Unsatisfactory inspection of machine parts which are subject to wearing.
Unsatisfactory performed repairs.
In case of catastrophes through action of an external body or actions of God.

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
14.11.2016 Working instructions WIDOS 4002 S WI CNC Page 15 of 103
3. Description of process
Basically, the international and national process guidelines are to be
followed!
At first, the clamping tools are mounted on the slide.
For welding angles and bends, the clamping tools can be turned on both sides.
The plastic pipes are clamped by means of the clamping tools.
Then the front sides of the pipes are planed parallel and the misalignment of the pipes is checked.
Now the heating element is swiveled in and the pipes are pressed against the heating element under defined
adjusting pressure (this process is called "bead up time").
After the prescribed bead height being reached, pressure is reduced, the heat up time begins.
The function of this time is to heat the pipe ends up to welding temperature.
After expiration of the heat up time, the slide is opened, the heating element is removed quickly and the
pipes are closed again hydraulically.
The time gap from the removal of the heating element to joining the pipes is called change over time.
The pipes are joined under prescribed welding pressure and then cool down under pressure (cooling time).
The welded joint can be unclamped, the welding process is finished.
welded pipe with
internal and
external bead
Heating element heats
the pipes up to welding
temperature.

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
14.11.2016 Working instructions WIDOS 4002 S WI CNC Page 16 of 103
4. Operating and indicating elements
4.1. Elements on the front side
No. Denomination
1 Heating element
2 Planer
3 Protective enclosure
4 Support angle and pipe bracket (option)
5 Switch cabinet with fuses etc.
6 Clamping tools
7 WI CNC with emergency-stop and USB connection
8 Heating element handle, here placed at the safety switch
9 Swinging WI-CNC with emergency-stop and USB connection (NEW replacing no. 7)
1
2
3
4
6
7
8
5

Operating and indicating elements Chapter 4
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4.2. Elements on the right side
No. Denomination
10 Main switch
11 Electric connecting cable
12 Service unit with pressure gauge (pneumatic)
13 Plug for compressed air hose, connection with local compressed air supply (not
included in delivery)
14 Manual outlet for condensed water
4.2.1. Main switch
You activate and shut the machine off with the main switch.
Shut the machine off during all work within the machine and
secure the machine against unintentional activation.
4.2.2. Service unit
The service unit (LFR-1/8-D-7-MINI) adjusts the incoming compressed air to the set working pressure and
compensates fluctuations in pressure. It frees the compressed air of dirt and condensation water. The use
with any other fluid (liquid or gas) is a misapplication.
Adjusting the regulator:
Slowly pressurize the complete system.
Pull the pressure setting button upwards (away from the housing).
Turn the pressure setting button until the desired pressure is shown on the manometer. The input
pressure must be at least 1 bar higher than the output pressure.
Press the pressure setting button downwards (towards the housing) to secure it against unintentional
turning.
14
10
13
12
11

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4.3. Pneumatic components on the machine
Nr. Benennung
15 QM21 Pneumatic valve for: heating element move out of machine
Nr. Benennung
16 BG21 Safety switch „release handle heating element“
15
Safety switch inactive
Safety switch active
(by heating element handle)
16

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4.4. Socket at the machine (at the front)
Nr. Benennung
17 XZ20 Heating element socket
4.5. Elements at the heating element
Standard heating element 3–zone heating element (optional)
There are 3 different states:
illuminating: only interrupted by short switch-off pulses: the heating element is being heated up, the
desired temperature is not yet reached. The desired and the actual temperature are displayed alternating
on the display of the control
blinking: the temperature of the heating element is maintained by a pulse-position ratio.
off: the desired temperature has been exceeded, the heating element is cooled automatically onto desired
temperature, or the heating element is switched off.
Control lamp green
17

WIDOS Einsteinstr. 5 Phone [phone]
Wilhelm Dommer Söhne D-71254 Ditzingen Fax [phone]
GmbH info @ widos.de Internet: www.widos.de
14.11.2016 Working instructions WIDOS 4002 S WI CNC Page 20 of 103
5. Starting and operating
The indications of this chapter are supposed to instruct you in the operation of the machine and to lead you
during the skilled starting of the machine.
This includes:
the safe operation of the machine
using all possibilities
economic operation of the machine
5.1. Starting
The machine may only be operated by skilled and authorized persons.
A plastic welder exam according to DVS and DVGW can be taken for the qualification.
In dangerous situations for man, workpiece or machine immediately push the emergency-
stop or shut the machine off at the main switch.
Connect the mains plug with the local mains supply 400V / 3 Ph / 6,1 kVA / 50 Hz, right-handed rotary field.
Necessarily arrange the machine horizontally.
Plug the service unit at the right machine side to the local compressed air supply (6 – 8 bar) by means of an
compressed air hose.
After switching on the machine, check the phase-sequence. For that purpose switch on the
planer (with diagnosis no. 0003) and check if it is turning in the right direction, otherwise
change direction by changing the phases.
5.2. Separating claws
Take care that the separating bracket of the
heating element is swinging between both
separating claws.
Separating claw (basic machine)
Separating bracket (heating element)