widos 6100 CNC 3.0 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 welding machine
with CNC control unit
WIDOS 6100 CNC 3.0
Keep for further use!

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Product identification
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 2 of 76
Model: Heating element butt welding machine with
CNC control unit
Type: IDOS 6100 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 ser ice:
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 / 388 89 79
Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73

Ku nst sto ffschwei ßtec hni k
Introduction
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 3 of 76
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.
27.10.2011 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.

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Contents
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 4 of 76
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 o er iew 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. Planer 10
1.6.1.5. Reception box 10
1.7. Emergency power supply (optional) 11
1.8. Equipment and accessories: 11
2. SAFETY RULES 12
2.1. Explanation of the symbols and indications 12
2.2. Obligations of the owner 12
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 13
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
2.9. Structural modifications on the machine 15
2.10. Warranty and liability 15
3. FUNCTIONAL DESCRIPTION 16
4. OPERATING AND INDICATING ELEMENTS 17
4.1. Elements on the CNC 3.0 control unit 17
4.2. EMERGENCY-stop push button 18
4.3. Separating de ice for heating element 18
4.4. Elements on the heating element and the planer 19
4.5. Lift-off de ice (optional) 20
4.5.1. Mounting of the machine 20
4.5.2. Mounting the lift-off device 20

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Contents
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 5 of 76
4.5.3. Transport 20
5. STARTING AND OPERATING 21
5.1. Safety indications 21
5.2. Replacing the reduction inserts 22
5.2.1. Using small reduction inserts 22
5.3. Connection with the basic machine 23
5.4. Operation with Emergency Power Supply 23
5.5. Description of the Display 24
5.6. Accessories for Reading the Data in and out 24
5.6.1. Legitimacy Cards 24
5.6.2. SD – card and drive 25
5.6.3. Barcode 25
5.6.4. Read-out ICON with USB card reader (optional) 25
5.7. Switching the CNC 3.0 on 26
5.8. Programming and welding with gas legitimacy card 27
5.9. Programming and welding with general legitimacy card or ISO legitimacy card 27
5.9.1. Setting the pipe data 28
5.10. Welding process 29
5.10.1. elding process with traceability 33
5.11. Error messages 34
5.12. More adjustemends 35
5.12.1. Setting the time and the date 35
5.12.2. Setting the language 36
5.12.3. Setting information of traceability and lenght of pipe 36
5.12.4. Setting of shortened cooling time 37
5.13. Administration of the welding data 38
5.13.1. Copying internal data onto SD-card and deleting them (RAM) 38
5.13.2. Storing data on the SD - card 39
5.14. Function of the emergency power supply (optional) 40
6. DIAGNOSIS PROGRAM 41
7. EQUIPMENT CARE / MAINTENANCE / REPAIR 43
7.1. Storage 43
7.2. Cleaning the machine 43
7.3. Clamping elements 43
7.4. Checking the hydraulic oil le el 43
7.5. Venting the hydraulic cylinders 44
7.6. Maintenance, inspection and repair 45
7.7. Sa ing the welding data 45
7.8. Error signals 46

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Contents
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 6 of 76
7.9. Possible defects and their elimination 47
7.10. Accumulator for emergency power supply (optional) 48
7.11. Fuse for o erload safety de ice / printer plug box 48
7.12. Disposal 48
8. TRANSPORT 49
9. WIRING AND HYDRAULIC DIAGRAMS 50
10. SPARE PARTS LIST 64
10.1. Basic machine 64
10.2. CNC control unit 66
10.3. Planer 68
10.4. Heating element 70
10.5. Reception box 72
10.6. Lift off de ice (optional) 74
11. DECLARATION OF CONFORMITY 76

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WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 7 of 76
1. Description of the product
1.1. Usage and purpose-oriented use
The WIDOS 6100 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
= 355 mm up
to OD
max
= 630 mm (standar diameters: 355 / 400 / 450 / 500 / 560 / 630 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.

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Description of product Chapter 1
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 8 of 76
1.4. Machine o er iew
No. Denomination
1 Basic machine
2 Control unit
3 Lift off device (optional)
4 Heating element
5 Planer
6 Reception box
1.5. Structure of the CNC 3.0 control unit
No. Denomination
7 Display
8 Operating fields
9 Barcode reader
10 Pipe data card or general legitimacy card
11 SD card
2
6
5
4
3
1
7
10
9
11
8

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Description of product Chapter 1
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 9 of 76
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):
450 kg
appr. 630x430x510 (mm)
Covering: 16 A
Voltage: 400 V (± 10%)
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 CEE - motor protective plug 16 A
Power of emergency set: 6.5 kVA / 400 V/3~
Emissions - Noises exceeding 80 dB (A) may occur; during planing it
is obligatory to wear ear protection!
- hen using the named pipe materials and when welding
below 260°C no toxicant damp arises
Ambient conditions in the welding
area
- take care for cleanness (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
Electro motor and pump:
Power: 0,56 k
Current: 4,7 A
Driving speed: 2720 rpm
Max. working pressure of the
pump:
110 bar
orking pressure: 100 bar
Volume flow: 3,5 l/min.

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Description of product Chapter 1
27.10.2011 orking Instructions IDOS 6100 CNC 3.0 Page 10 of 76
1.6.1.2. Basic frame
Material frame: Construction steel
Material clamping inserts: Aluminium
eight: appr. 226 kg
Cylinder-Ø: 60 mm
Piston rod-Ø: 50 mm
Stroke length of cylinder: 300 mm
Max. force: (F=P*A) 17,30 kN (at 100 bar)
Velocity os piston rod: 3,4 cm/s
1.6.1.3. Heating element
Power: 6,0 k
Voltage: 400 V (± 10 %)
Current: 15 A
Frequency: 50 Hz
Outside-Ø: 684 mm
Surface: nonstick-coated
Attached elements: - electronic temperature control
- control lamps
- cable with 16 pole plug
eight: appr. 36 kg
1.6.1.4. Planer
Motor: Alternating current motor
Power: 1.1 k
Voltage: 400 V (± 10 %)
Current: 3,5 A
Frequency: 50 Hz (± 10 %)
Driving speed appr. 140
eight: appr. 103 kg
Attached elements: - cable with plug CEE 16A
- locking device
1.6.1.5. Reception box
Dimensions: 870 x 610 x 740 mm
eight: appr. 62 kg
See spare parts list for order numbers and single parts