widos 4600 CNC 3.5 User manual

Ku nst sto ffschweißtechn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
Heating Element Butt elding Machine
with CNC Control Unit
WIDOS 4600 CNC 3.5
Keep for further use!

Ku nst sto ffschwei ßtec hn i k
Product identification
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 2 of 72
Model: Heating element butt welding machine
with CNC control unit
Type: IDOS 4600 CNC 3.5
Serial number, year of construction: see nameplate
Customer entries
Inventory No.:
Location:
Order of s are arts and after sales service:
Address of manufacturer IDOS
ilhelm Dommer Söhne GmbH
Einsteinstrasse 5
D-71254 Ditzingen-Heimerdingen
Phone: ++49 7152 / 99 39 - 0
Fax: ++49 7152 / 99 39 - 40
Address of the subsidiary companies:
WIDOS
IDOS GmbH ilhelm Dommer Söhne AG
An der iesenmühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH-9201 Gossau
Phone: ++49 371 / 8 15 73 - 0 Phone:++41 71 / 3 88 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 3 88 89 73

Ku nst sto ffschwei ßtec hn i k
Introduction
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 3 of 72
Pur ose of the document
These working instructions give you information about all important questions which refer to
the construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our service team in the factory or in our subsidiary companies.
e will help you with pleasure.
According to our interest to continuously improve our products and working instructions, we
kindly ask you to inform us about problems and defects which occur in exercise.
Thank you.
Structure of the working instructions
This manual is arranged in chapters, which belong to the different using phases of the
machine.
Due to this structure, the searched information can be easily found.
 WIDOS 01.2001
. 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.

Ku nst sto ffschwei ßtec hn i k
Contents
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 4 of 72
1. DESCRIPTION OF THE PRODUCT..................................................................................... 6
1.1 Usage and ur ose-oriented use ....................................................................................6
1.2 Safety measures...............................................................................................................6
1.3 Conformity........................................................................................................................6
1.4 Machine overview.............................................................................................................7
1.5 Structure of the CNC 3.5 control unit ..............................................................................7
1.6 Designation of the roduct ..............................................................................................7
1.6.1 Technical data................................................................................................................8
1.6.1.1 WIDOS CNC 3.5 General data...........................................................................8
1.6.1.2 Basic frame............................................................................................................8
1.6.1.3 Heating element.....................................................................................................8
1.6.1.4 Planer....................................................................................................................9
1.6.1.5 Automatic heating element (optional) .....................................................................9
1.6.1.6 Reception box for automatic heating element (optional)..........................................9
1.7 Equi ment and accessories ............................................................................................9
2. SAFETY RULES................................................................................................................... 10
2.1 Ex lanation of the sSymbols and indications...............................................................10
2.2 Obligations of the owner................................................................................................11
2.3 Obligations of the worker...............................................................................................11
2.4 Measures of organisation ..............................................................................................11
2.5 Information about safety recautions ...........................................................................11
2.6 Instructions for the staff ................................................................................................11
2.7 Dangers while handling the machine ............................................................................12
2.8 S ecific dangers.............................................................................................................12
2.8.1 Danger of stumbling over hydraulic and electric wires...................................................12
2.8.2 Danger of catching clothes by the planer ......................................................................13
2.8.3 Danger of combustion by heating element and welding area.........................................13
2.8.4 Danger of squeezing by clamping devices and guideways............................................13
2.9 Structural modifications on the machine ......................................................................13
2.10 Warranty and liability .....................................................................................................14
3. FUNCTIONAL DESCRIPTION............................................................................................ 15
4. OPERATING AND INDICATING ELEMENTS .................................................................. 16
4.1 Elements on the CNC 3.5 control unit ...........................................................................16
4.2 EMERGENCY-Sto ush button....................................................................................17
4.3 Elements on laner and heating element......................................................................17
4.4 Se arating device for heating element..........................................................................18
5. STARTING AND OPERATING ........................................................................................... 19
5.1 Safety indications...........................................................................................................19
5.2 Re lacing the reduction inserts.....................................................................................20
5.2.1 Using narrow and large reduction inserts......................................................................20
5.3 Automatic heating element (o tional) ...........................................................................21
5.4 Connection with the basic machine ..............................................................................22

Ku nst sto ffschwei ßtec hn i k
Contents
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 5 of 72
5.5 O eration with emergency ower su ly .....................................................................22
5.6 Descri tion of the dis lay..............................................................................................23
5.7 SD – card and drive........................................................................................................23
5.8 Read-out WICON with USB card reader ........................................................................24
5.9 Switching the CNC 3.5 on ..............................................................................................24
5.10 Programming and welding.............................................................................................25
5.10.1 Setting the pipe data ....................................................................................................26
5.11 Welding rocess.............................................................................................................27
5.11.1 elding process with traceability..................................................................................31
5.12 Error messages..............................................................................................................33
5.13 Administration of the welding data ...............................................................................33
5.13.1 Copying internal data onto SD-card and deleting them (RAM) ......................................33
5.13.2 Storing data on the SD - card .......................................................................................34
5.14 More adjustemends........................................................................................................35
5.14.1 Setting the time and the date........................................................................................35
5.14.2 Setting the language ....................................................................................................36
5.14.3 Setting information of traceability and lenght of pipe .....................................................37
5.14.4 Setting of shortened cooling time..................................................................................38
6. DIAGNOSIS PROGRAM ..................................................................................................... 39
7. EQUIPMENT CARE / MAINTENANCE / REPAIR ............................................................ 41
7.1 Storage ...........................................................................................................................41
7.2 Cleaning the machine.....................................................................................................41
7.3 Clam ing elements.........................................................................................................41
7.4 Checking the hydraulic oil level ....................................................................................41
7.5 Venting the hydraulic cylinders.....................................................................................42
7.6 Maintenance, ins ection and re air ..............................................................................43
7.7 Saving the welding data.................................................................................................43
7.8 Fuse for overload safety device ....................................................................................43
7.9 Error signals...................................................................................................................44
7.10 Possible defects and their elimination ..........................................................................45
8. TRANSPORT........................................................................................................................ 46
9. ELECTRIC AND HYDRAULIC DIAGRAMS...................................................................... 47
10. SPARE PARTS LIST ........................................................................................................... 57
10.1 CNC control unit 3.5 .......................................................................................................57
10.2 Basic machine ................................................................................................................59
10.3 Planer..............................................................................................................................62
10.4 Heating element..............................................................................................................65
10.5 Rece tion box ................................................................................................................67
10.6 Automatic heating element (o tion) ..............................................................................69
11. DECLARATION OF CONFORMITY................................................................................... 72

Ku nst sto ffschwei ßtec hn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 6 of 72
1. Descri tion of the roduct
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 ur ose-oriented use
The WIDOS 4600 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
OD
min
= 75 mm up to OD
max
= 250 mm in the way as described below.
All use of this machine going beyond is not ur ose oriented.
The machine is only to be used in a technically perfect condition, as well as purpose oriented,
safety- and danger-conscious in compliance with the working instructions and the relevant
safety regulations (especially the regulations for the prevention of accidents).
The described plastic welding machine may only be operated, maintained and repaired by
persons who are trained and informed about the dangers.
The manufacturer is not responsible for any damages caused by inexpert handling or
operation.
For personal injuries, material and immaterial damages resulting herefrom, only the user is
responsible!
The control unit is reliable in the use when it is used according to the prescriptions in
connection with a welding machine designed by IDOS.
Also part of the purpose oriented use is
• respecting all the indications of the working instructions and
• performing the inspection and maintenance works.
1.2 Safety measures
In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby can be damaged or destroyed.
Persons being in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
regulations must be necessarily adhered to.
1.3 Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.

Ku nst sto ffschwei ßtec hn i k
Description of the product Cha ter 1
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 7 of 72
1.4 Machine overview
No. Name
1 Basic machine
2 Control unit
3 Heating element
4 Planer
5 Reception box
1.5 Structure of the CNC 3.5 control unit
No. Name
6 Display
7 Operation field
8 SD - card
1.6 Designation of the roduct
The product is designated by type labels.
The type labels are attached at the control unit, at the heating element, at the planer and at the
basic machine.
They contain the type, the serial number and the year of construction of the machine.
1
2
5
4
3
6
8
7

Ku nst sto ffschwei ßtec hn i k
Description of the product Cha ter 1
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 8 of 72
1.6.1 Technical data
All important technical data of each single component are listed. This allows a quick
information about working capacity and structure.
1.6.1.1 WIDOS CNC 3.5 General data
eight (without transport box):
Dimensions (l x w x h):
40.5 kg
appr. 630x430x510 (mm)
Power: 370 att
Voltage: 230 V (± 10%)
Current: 3,0 A
Frequency: 50 Hz
Phase shift: appr. 18°
Control voltage: 5 V
Insulation system: IP 44
Hydraulic oil tank: appr. 1 l
Power of emergency set: 4.0 kVA / 230 V/1~
Electro motor and pump:
Driving speed (t/min): 1340
Max. working pressure of pump: 120 bar
orking pressure: 100 bar
Volume flow: 1.9 l/min.
1.6.1.2 Basic frame
Material of frame: Construction steel
Material of clamping shells: Aluminium
eight: 44 kg
∅ of cylinder / ∅ of piston rod: 35 / 30 mm
Stroke length of cylinder: 150 mm
Max. force: (F=PxA) 5100 N (at 100 bar)
Velocity of piston rod: 6,2 cm/s
1.6.1.3 Heating element
Power: 1.5 k
Voltage: 230V (± 10 %)
Current: 6.5 A
Frequency: 50 Hz
Outer ∅: 320 mm
Surface: nonstick-coated
Attached elements: - Control lamps
- Connecting cable with multiple pole plug
eight: appr. 6 kg

Ku nst sto ffschwei ßtec hn i k
Description of the product Cha ter 1
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 9 of 72
1.6.1.4 Planer
Motor: Monophase-alternating current motor
Power: 1050 att
Voltage: 230 V (± 10 %)
Current: 3.8 A
Frequency: 50 Hz (± 10 %)
Driving speed n2 of the planer (t/min) appr. 60
eight: appr. 14 kg
1.6.1.5 Automatic heating element (optional)
Power: 1.5 K
Voltage: 230 V (± 10 %)
Current: 6.5 A (± 10 %)
Frequency: 50 Hz
Outer ∅: 320 mm
Surface: nonstick-coated
Attached elements: - Control lamps
- Connecting cable with multiple pole plug
eight: appr. 17 kg
1.6.1.6 Reception box for automatic heating element (optional)
eight: appr. 6 kg
See s are arts list (cha ter 10) for order numbers and single arts
1.7 Equi ment and accessories
Following accessories are part of the delivery:
1 x - Key for front plate / hydraulic system
1 x - SD - card (64 MB memory capacity)
1 Tool bag for 10 parts
je 1 Allan key angle size 5 / 6 / 8
je 1 Allan key with T grip size 4 / 5
1 Socket spanner size 27
1 Torx screw driver T10
Following optional accessories are available on request:
- Program ICON for reading out the data (possibility of displaying included in SD-card)
- Automatic heating element

Ku nst sto ffschwei ßtec hn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 10 of 72
2. Safety rules
The base for the safe handling and the fault-free operation of this machine is the knowledge of
the basic safety indications and rules.
• These working instructions contain the most important indications to run the machine
safely.
• The safety indications are to be followed by all persons working on the machine.
2.1 Ex lanation of the sSymbols and indications
In the working instructions, following denominations and signs are used for dangers:
This symbol means a possible danger for the life and the health of persons.
• The disrespect of these indications may have heavy consequences for the
health.
This symbol means a possible dangerous situation.
• The disrespect of these indications may cause light injuries or damages on
goods.
This symbol means a possible dangerous situation due to hot surfaces.
• The disrespect 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 crushings of parts of
the body resp. damages of parts of the machine.
This symbol gives important indications for the proper use of the machine.
• The disrespect of these indications may conduct to malfunctions and
damages on the machine or on goods in the surrounding.
Under this symbol you get user tips and particularly useful information.
• It is a help for using all the functions on your machine in an optimal way and
helps you to make the job easier.
T h e r e g u l a ti o n s f o r th e r e v e n t i on o f a c c i d en t s a r e v a l i d ( U VV) .

Ku nst sto ffschwei ßtec hn i k
Safety rules Cha ter 2
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 11 of 72
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 organisation
• 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 recautions
• 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.

Ku nst sto ffschwei ßtec hn i k
Safety rules Cha ter 2
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 12 of 72
2.7 Dangers while handling the machine
The heating element butt welding machine WIDOS 4600 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.
The machine should only be used
• According to the purpose oriented usage;
• In safety technical impeccable status.
Disturbances which may affect the safety of the machine must be cleared immediately.
Only skilled persons are allowed to work at electrical appliances.
• The electrical equipment of the machine has to be checked regularly.
Loose connections and damaged cables have to be replaced immediately.
• All electric tools (heating element, planer, basic machine with clamps and control unit)
have to be protected from rain and dropping water (if need be use a welding tent).
• According to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
• Replace damaged front foil at the control unit in order to avoid water coming in.
System parts and pressure hoses should be depressurized before beginning of
any repair works.
There is a danger of injuring the eyes by hydraulic oil squirting out. The hydraulic
oil can be hot !
• Damaged hydraulic hoses have to be immediately replaced.
• Make a visual inspection of the hydraulic hoses before each work beginning.
• The hydraulic oil is inedible !
• The hydraulic oil has to be handled and disposed of ro erly.
2.8 S ecific dangers
2.8.1 Danger of stumbling over hydraulic and electric wires
Make sure that nobody has to step over the cables.
Make sure that the cables lay in such a way that the danger is maintained in a
minimum. Do not squeeze, buckle, etc. the cables. Avoid the hydraulic cables
from being heated up (increase of pressure !).

Ku nst sto ffschwei ßtec hn i k
Safety rules Cha ter 2
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 13 of 72
2.8.2 Danger of catching clothes by the laner
You can cut yourself or even get bones broken !
For some machines the planer may shortly turn when switching the machine on !
• Only wear clothes tight to the body.
• Do not wear rings or jewellery during the work.
• If necessary wear a hair-net.
• Always put the planer back into the reception box after and before each use.
• Only transport the planer at the handle. Do not touch the surfaces.
2.8.3 Danger of combustion by heating element and welding area
You can burn parts of your body and inflammable materials can also be ignited !
The heating element is heated up to more than 200°C !
• Do not touch the surfaces of the heating element.
• Do not leave the heating element unsupervised.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
• Always put the heating element back into the reception box after and before each use.
• Only transport the heating element at the handle.
2.8.4 Danger of squeezing by clam ing devices and guideways
There is a danger of serious injuries: on the one hand between the inner
clamping devices and on the other hand between the outer clamping device and
the end of the guideway.
• Do not stand or put hands between clamped pipe ends.
• Do not stand or put hands between the inner clamping tools with not yet clamped pipes.
• Do not block opening and closing of the machine sledge.
2.9 Structural modifications on the machine
• No modifications, extensions or reconstructions may be made on the machine without
permission of the manufacturer. In case of non-compliance, any claims to warranty or
liability are excluded.
• Machine parts which are not in a perfect condition are to be replaced immediately.
• Only use original IDOS spare and wear parts.
• In case of purchase orders please always state the machine and version number !

Ku nst sto ffschwei ßtec hn i k
Safety rules Cha ter 2
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 14 of 72
2.10 Warranty and liability
Fundamentally our "General Sales and Delivery Conditions" are valid.
They are at the owner's disposal latest when signing the contract.
Guarantee and 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;
• Inexpert building-up, starting, operating, maintenance and transport of the machine;
• Running the machine with defective or not orderly mounted safety appliances;
• Ignoring the information given in this manual;
• 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.

Ku nst sto ffschwei ßtec hn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 15 of 72
3. Functional descri tion
The IDOS CNC 3.5 control unit performs a butt welding process with the plastic welding
machine IDOS 4600 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.
The corresponding pipe data are entered manually through the operation field.
Welding with the IDOS 4600 CNC 3.5 works as follows:
The plastic pipes are clamped by means of the clamping devices (basic machine) and the pipe
ends are cut plane and parallel by means of the planer.
As soon as the pipes are plane (i.e. a circulating cutting has been produced) and parallel and
the misalignment is smaller than 0,1 X pipe wall thickness you can start welding.
The heating element has to be cleaned and checked before insertion and the desired
temperature prescribed by the DVS must have been reached.
The clamped pipes drive under pressure in direction of the heating element and are heated up
under the defined adjustment pressure (adjusting), the duration of the adjustment is called
adjusting time.
During the adjustment the bead prescribed by the DVS is performed.
After reaching the prescribed bead height, the control unit automatically switches into the
heating time.
During the heating time the basic machine is in a depressurized state and the pipe ends are
heated.
After expiration of the heating time, the sledges move apart and the heating element should be
removed as fast as possible.
The time period between the removal of the heating element and the closing of the pipes is
called change over time.
After the maximum time prescribed by the DVS, the pipe ends are driven together and a
continuous welding pressure is built up.
The pipe then cools down under the prescribed welding pressure (cooling time).
After completion of the cooling time, the pressure on the pipe is automatically released and the
welded pipe can be unclamped.
The welding process is completed.
Heating element heats the pipes
up to welding temperature
Finished welded joint with
internal and external bead

Ku nst sto ffschwei ßtec hn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 16 of 72
4. O erating and indicating elements
4.1 Elements on the CNC 3.5 control unit
No. Name
1 Operation field with display
2 Reading unit for SD - card
3 Main switch
4 Outside temperature sensor
5 Plug box (fuse protection 1 A)
6 Mains connection cable for the control unit
7 EMERGENCY-Stop push button
8 Plug box with safety stirrup for heating element
9 Connection for the travel sensor
10 Plug for planer
11 Connections for hydraulic hoses
1
2
3
4
5
6
7
10
8
9
11

Ku nst sto ffschwei ßtec hn i k
Operating and indicating elements Cha ter 4
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 17 of 72
4.2 EMERGENCY-Sto ush button
There is an EMERGENCY-Stop push button (see chapter 4.1 / No. 9) on the CNC control unit,
for interrupting the working process if the work piece, tools or persons are endangered by the
working pressure.
• The EMERGENCY-Stop push button snaps when it is operated.
• In case the EMERGENCY-Stop push button was pushed, the system is pressure-less and
the sledge can only be moved manually.
• After elimination of the danger the EMERGENCY-Stop push button must be unlocked again
by turning it in clockwise direction and the functions of buttons <+> and <-> (open and close
the sledge) are possible again.
There is a high risk of being burnt since the heating element cools down very
slowly.
• Switch the machine off and on again over the main switch to return to the welding operation.
4.3 Elements on laner and heating element
Name Function
Safety micro switch
(Planer)
- The planer starts only when the safety micro switch is pressed.
- Locking device of the planer
On/off-switch
(Planer)
- During the planing process, the planer has to be switched on at
the switch and its corresponding lock button. The planing process
is operated by the CNC control.
Control lamp green
(Heating element)
There are 3 different states:
• lightening, 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.
On/off-switch
+ lock button
Safety micro
switch
Control lamp,
green

Ku nst sto ffschwei ßtec hn i k
Operating and indicating elements Cha ter 4
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 18 of 72
4.4 Se arating device for heating element
There is a tear-off bar mounted between the
movable and the fixed clamping shells on the
basic machine. It prevents the heating
element from sticking to the heated-up pipe
ends.
hen inserting the heating element take care
that it lies in the zone of the throat of the tear-
off bar (see arrow).

Ku nst sto ffschwei ßtec hn i k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 19 of 72
5. Starting and o erating
The instructions of this chapter are supposed to initiate in the operation of the machine and
lead during the appropriate starting of the machine.
This includes:
• The safe operation of the machine;
• Using all the possible options of the machine;
• Economic operation of the machine.
5.1 Safety indications
• The machine may only be operated by initiated and authorized persons.
For the qualification, a plastic welding exam can be taken according to DVS and DVG .
• In situations of danger for persons and the machine, the EMERGENCY-Stop push button
or the main switch have to be activated immediately.
• After completion of the welding work and during breaks the machine has to be switched
off. Further take care that no unauthorized person has access.
• According to VDE 0100, the use on construction sites is only allowed with a power
distributor with a FI-safety switch.
Check the oil level of the hydraulic system before each starting of the control unit
in order to avoid damages on the pump.
If necessary, add hydraulic oil of the quality HLPD 32
The heating element surfaces must be clean, especially non greasy, therefore
they need to be cleaned shortly before each welding or in case of dirtiness
by means of a fibre-free a er and a cleaning agent (e.g. PE – cleaning agent
or pipe cleaning tissues which are available at the IDOS company).
The anti-adhesive coating of the heating element must remain undamaged in
the working area.
Take care that all hydraulic and electric connections are connected.
Never lift or transport the basic machine
at path measuring system!
• Take into account the surrounding conditions:
The welding may not be performed under direct sun rays influence, use a welding
umbrella if necessary.
• If the surrounding temperature is under 5° C, measures have to be taken:
Use a welding tent or preheat the pipe ends if necessary.
Path measuring system

Ku nst sto ffschwei ßtec hn i k
Starting and operating Cha ter 5
21.05.12 orking Instructions IDOS 4600 CNC 3.5 Page 20 of 72
5.2 Re lacing the reduction inserts
• Unscrew the mounted reduction inserts.
• Screw the reduction inserts with the corresponding diameter into the clamping devices.
• If necessary (e.g. for T-pieces) the outer fixed clamping device can be dismantled by
unscrewing the three hexagon socket screws.
Dismantling of the outer fixed clamping device
5.2.1 Using narrow and large reduction inserts
Small Reduction Inserts:
• Pipe fittings often have only a short straight surface area on which they can be clamped.
• Fittings mostly need to be clamped in the inner clamping devices with the small reduction
inserts.
• hen fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can
also be used flush to the inside or to the outside.
R
Small reduction insert,
centered (for pipes)
Shown here:
Small reduction insert,
flush to the inside
(for bends, T-pieces)