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

Description of product Chapter 1
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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).