widos 5500 CNC 3.0 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: http://www.widos.de Email: [email protected]e
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 5500 CNC 3.0
Keep for further use!

Kunststoffschweißtechnik
Product Identification
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 2 of 78
Model: Heating element butt welding machine
with CNC control unit
Type: IDOS 5500 CNC 3.0
Serial number, year of construction: see type lable
Customer entries
Inventory-No.:
Place of working:
Order of spare parts and after sales service
Address of manufacturer WIDOS
. Dommer Söhne GmbH
Einsteinstr. 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 . 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

Kunststoffschweißtechnik
Introduction
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 3 of 78
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 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.
19.09.2011 WIDOS
. 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.

Kunststoffschweißtechnik
Contents
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 4 of 78
1. DESCRIPTION OF THE PRODUCT 7
1.1. Usage and purpose-oriented use 7
1.2. Safety measures 7
1.3. Conformity 7
1.4. Machine overview 8
1.5. Structure of the CNC 3.0 control unit 8
1.6. Designation of the product 9
1.6.1. Technical data 9
1.6.1.1. IDOS CNC 3.0 General data 9
1.6.1.2. Basic frame 10
1.6.1.3. Heating element 10
1.6.1.4. Automatic heating element (optional) 10
1.6.1.5. Planer 10
1.6.1.6. Reception box 11
1.7. Equipment and accessories 11
2. SAFETY RULES 12
2.1. Explanation of the symbols and indications 12
2.2. Obligations of the owner 13
2.3. Obligations of the worker 13
2.4. Measures of organisation 13
2.5. Information about safety precautions 13
2.6. Instructions for the staff 13
2.7. Dangers while handling the machine 14
2.8. Specific dangers 14
2.8.1. Danger of stumbling over hydraulic and electric wires 14
2.8.2. Danger of catching clothes by the planer 14
2.8.3. Danger of being burnt by heating element and welding area 15
2.8.4. Danger of Squeezing by clamping devices and guideways 15
2.8.5. Risk of injury by noises 15
2.9. Structural modifications on the machine 15
2.10. Warranty and liability 16
3. FUNCTIONAL DESCRIPTION 17
4. OPERATING AND INDICATING ELEMENTS 18
4.1. Elements on the CNC 3.0 Control Unit 18
4.2. EMERGENCY-Stop Push Button 19
4.3. Separating device for heating element 19
4.4. Elements on the heating element and the planer 20
5. STARTING AND OPERATING 21
5.1. Safety Indications 21

Kunststoffschweißtechnik
Contents
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 5 of 78
5.2. Replacing the Reduction Inserts 22
5.2.1. Using Small and Large Reduction Inserts 22
5.3. Connection with the Basic Machine 23
5.4. Operation with Emergency Power Supply 23
5.5. Automatic Heating Element (optional) 24
5.6. Description of the Display 25
5.7. Accessories for Reading the Data in and out 25
5.7.1. Legitimacy Cards 25
5.7.2. SD-card and drive 26
5.7.3. Barcode 26
5.7.4. Read out ICON with USB card reader (option) 26
5.8. Switching the CNC 3.0 on 27
5.9. Programming and welding with gas legitimacy card 28
5.10. Programming and welding with general legitimacy card or ISO legitimacy card 28
5.10.1. Setting the Pipe Data 29
5.11. Welding Process 30
5.11.1. elding process with traceability 35
5.12. Error Messages 36
5.13. Administration of the Welding Data 36
5.14. More adjustemends 37
5.14.1. Setting the time and the date 37
5.14.2. Setting the language 38
5.14.3. Setting information of traceability and lenght of pipe 38
5.14.4. Setting of shortened cooling time 39
5.15. Administration of the welding data 40
5.15.1. Copying internal data onto SD-card and deleting them (RAM) 40
5.15.2. Storing data on the SD - card 41
6. DIAGNOSIS PROGRAM 43
7. EQUIPMENT CARE / MAINTENANCE / REPAIR 45
7.1. Storage 45
7.2. Cleaning the Machine 45
7.3. Clamping Elements 45
7.4. Checking the Hydraulic Oil Level 45
7.5. Venting the Hydraulic Cylinders 46
7.6. Maintenance, Inspection and Repair 47
7.7. Saving the Welding Data 47
7.8. Error signals 48
7.9. Possible defects and their elimination 49
7.10. Fuse for Overload Safety Device / Printer Plug Box 50
7.11. Disposal 50
8. TRANSPORT 51

Kunststoffschweißtechnik
Contents
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 6 of 78
9. WIRING AND HYDRAULIC DIAGRAMS 52
10. SPARE PARTS LIST 65
10.1. Basic Machine 65
10.2. CNC Control Unit 67
10.3. Planer 69
10.4. Heating Element 71
10.5. Reception box 73
10.6. Automatic heating element (option) 75
11. DECLARATION OF CONFORMITY 78

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: http://www.widos.de Email: [email protected]e
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 7 of 78
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
min
= 200 mm
up to OD
max
= 500 mm
(standard diameters: 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450 / 500 mm.)
All use of this control going beyond is not purpose 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.

Kunststoffschweißtechnik
Description of Product Chapter 1
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 8 of 78
1.4. Machine overview
No. Denomination
1 Basic machine
2 Control unit
3 Heating element
4 Planer
5 Reception box
1.5. Structure of the CNC 3.0 control unit
No. Denomination
6 Display
7 Operating fields
8 Barcode reader
9 Pipe data card or general legitimacy card
10 SD-card
6
9
8
10
7
4
2
1
3
5

Kunststoffschweißtechnik
Description of Product Chapter 1
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 9 of 78
1.6. Designation of the product
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.
1.6.1. 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. IDOS CNC 3.0 General data
eight (without transport box):
Dimensions (l x w x h):
40.5 kg
appr. 630x430x510 (mm)
Power: 560 att
Voltage: 400 V (± 10%)
Current: 4,7 A
Frequency: 50 Hz
Phase shift: appr. 18°
Control voltage: 5 V
Insulation system: IP 44
Hydraulic oil tank: appr. 1 l
Attached elements: Connection cable with motor protective plug 16 A
Power of emergency set: 6.5 kVA / 400 V/3~
Electro motor and pump:
Driving speed (t/min): 2720
Max. working pressure of the pump: 110 bar
orking pressure: 100 bar
Volume flow: 3,5 l/min.
Emissions - The sound intensity level while using the
planer can be higer than 85 dB (A).
- hen using the named pipe materials and
when welding below 260 °C / 500 °F no
toxicant damp arises.
Environmental conditions at the
welding area:
- Keep the workshop clean (no dust at the
welding area)
- If secured by an appropriate measurement
that allowed conditions for welding are
indicated, it is possible to work in any
outside temperature condition as far as the
welder is not constrained in its manual skill.
- Avoid humidity, if necessary use a welding
tent
- Avoid strong sun rays influence
- Protect from wind, shut the pipe ends.

Kunststoffschweißtechnik
Description of Product Chapter 1
19.09.11 orking Instructions IDOS 5500 CNC 3.0 Page 10 of 78
1.6.1.2. Basic frame
Material frame: Construction steel
Material clamping inserts: Aluminium
eight: appr. 165.5 kg
Cylinder-Ø: 50 mm
Piston rod-Ø: 40 mm
Stroke length of cylinder: 300 mm
Max. force: (F=P*A) 14,14 kN (at 100 bar)
Velocity of piston rod: 4,1 cm/s
1.6.1.3. Heating element
Power: 5.9 k
Voltage: 400 V (± 10 %)
Current: 14.9 A
Frequency: 50 Hz
Outside-Ø: 564 mm
Surface: nonstick-coated
Attached elements: - electronic temperature control
- control lamps
- cable with 16 pole plug
eight: appr. 24.5 kg
1.6.1.4. Automatic heating element (optional)
Power: 5.9 k
Voltage: 400 V (± 10%)
Current: 14.9 A (± 10%)
Frequency: 50 Hz
Outside-∅: 564 mm
Surface: nonstick-coated
Attached elements: cable with 16 pole plug
eight: appr. 57.5 kg
1.6.1.5. Planer
Motor: Alternating current motor
Power: 1.1 k
Voltage: 400 V (± 10 %)
Current: 2.8 A
Frequency: 50 Hz (± 10 %)
Driving speed appr. 140
eight: appr. 54 kg