widos 7000 WM 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
WIDOS 7000 WM
with SP control unit, additional cylinder and T-90 / 60 / 45
Keep for further use!

Ku nst sto ffschwei ßtec hni k
Product identification
25.11.11 orking Instructions IDOS 7000 M page 2 of 98
Model: orkshop machine
Type: WIDOS 7000 WM
Serial no: / Year of construction: see type label
Customer‘s entries
Inventory no.:
Location:
Order of Spare Parts and Sales Service:
Manufacturer’s address WIDOS
. Dommer Söhne GmbH
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
Phone: [phone] / 99 39 - 0
Fax: [phone] / 99 39 - 40
Subsidiaries
WIDOS
IDOS GmbH . Dommer Söhne AG
An der iesenmühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH – 9201 Gossau
Phone: ++49 (0) 3 71 / 8 15 73 - 0 Phone: ++41 (0) 71 / 388 89 79
Fax: ++49 (0) 3 71 / 8 15 73 - 20 Fax: ++41 (0) 71 / 388 89 73

Ku nst sto ffschwei ßtec hni k
Introduction
25.11.11 orking Instructions IDOS 7000 M page 3 of 98
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.
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 might appear in practical
experience.
Thank you.
Structure of the working instructions
This manual is arranged in chapters which belong to the different using phases of the machine.
Therefore the searched information can be easily found.
11/25/2011 WIDOS
. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes are subject to technical innovations.

Ku nst sto ffschwei ßtec hni k
Contents
25.11.11 orking Instructions IDOS 7000 M page 4 of 98
1. DESCRIPTION OF PRODUCT ......................................................................................... 7
1.1. pplication and intended use...................................................................................... 7
1.2. Safety measures............................................................................................................. 7
1.3. Conformity....................................................................................................................... 7
1.4. Designation of product ................................................................................................. 8
1.4.1. Technical data ............................................................................................................ 8
1.4.1.1. IDOS 7000 General data ............................................................................... 8
1.4.1.2. Basic frame / table ............................................................................................. 8
1.4.1.3. Heating element................................................................................................. 8
1.4.1.4. Planer.................................................................................................................. 9
1.4.1.5. Hydraulic aggregate .......................................................................................... 9
1.5. Wear parts........................................................................................................................ 9
1.6. Tools and accessories .................................................................................................. 9
1.7. Equipment...................................................................................................................... 10
2. S FETY RULES............................................................................................................... 11
2.1. Explanation of the symbols and indications .......................................................... 11
2.2. Obligations of the owner ............................................................................................ 12
2.3. Obligations of the user................................................................................................ 12
2.4. Measure of organization ............................................................................................. 12
2.5. Information about safety precautions...................................................................... 12
2.6. Instructions for the staff ............................................................................................. 12
2.7. Dangers while handling the machine....................................................................... 13
2.8. Specific dangers........................................................................................................... 13
2.8.1. Danger of stumbling over electric wires ................................................................. 13
2.8.2. Danger of drawing-in of clothes by the planer ....................................................... 13
2.8.3. Risk of injury by noise .............................................................................................. 14
2.8.4. Danger of combustion by heating element and welding area .............................. 14
2.8.5. Danger of crushing................................................................................................... 14
2.9. Structural modifications on the machine ................................................................ 14
2.10. Warranty and liability................................................................................................... 15
3. FUNCTION L DESCRIPTION........................................................................................ 16
4. OPER TING ND INDIC TING ELEMENTS .............................................................. 17
4.1. Machine overview......................................................................................................... 17
4.2. Operator console.......................................................................................................... 17
4.2.1. Operator panel.......................................................................................................... 18
4.2.2. Switch cupboard....................................................................................................... 20
4.3. Service unit and pneumatic valves........................................................................... 20
4.3.1. Service unit ............................................................................................................... 21
4.4. Hydraulic aggregate..................................................................................................... 21
4.5. Horizontal adjustment (mismatch compensation)................................................. 22
4.6. dditional cylinder....................................................................................................... 22
4.7. Clamping tool................................................................................................................ 23

Ku nst sto ffschwei ßtec hni k
Contents
25.11.11 orking Instructions IDOS 7000 M page 5 of 98
4.7.1. How to mount clamping tools on the machine table.............................................. 24
4.7.2. Clamping tools for straight pipes............................................................................. 25
4.7.3. How to swivel clamping tools for angles and bends.............................................. 25
4.7.4. How to adjust clamping tools................................................................................... 26
4.8. Reducer inserts ............................................................................................................ 26
4.9. Clamping tools for T–piece 90° ................................................................................. 27
4.10. Clamping tool for T-piece 45° .................................................................................... 28
4.11. Clamping tool for T-piece 60° .................................................................................... 31
4.12. How to clamp pipes in the T–tools ........................................................................... 34
5. ST RTING ND OPER TING ....................................................................................... 35
5.1. Safety indications......................................................................................................... 35
5.2. Starting........................................................................................................................... 35
5.3. How to adjust the heating element temperature.................................................... 36
5.4. SD card and drive......................................................................................................... 37
5.5. USB card reader ........................................................................................................... 37
5.6. How to switch on the SP .......................................................................................... 38
5.7. How to set the machine type...................................................................................... 39
5.8. How to set language, time and date ......................................................................... 41
5.9. How to set the pipe data ............................................................................................. 42
6. WELDING PROCESS...................................................................................................... 44
6.1. How to insert and clamp the pipes ........................................................................... 44
6.2. Welding process with SP 600.................................................................................. 45
6.2.1. Drag pressure measurement................................................................................... 45
6.2.2. Dimension ................................................................................................................. 46
6.2.3. Planing....................................................................................................................... 47
6.2.4. Compensation of mismatch..................................................................................... 47
6.2.5. Bead up ..................................................................................................................... 48
6.2.6. Heating up................................................................................................................. 48
6.2.7. Change over ............................................................................................................. 49
6.2.8. Pressure ramp .......................................................................................................... 49
6.2.9. Joining / Cooling ....................................................................................................... 49
6.2.10. Completion of welding.............................................................................................. 50
6.2.11. Signification of error codes...................................................................................... 50
6.2.12. How to copy internal data on SD card and deleting internal data (RAM)............ 51
6.2.13. How to read out the welding data ........................................................................... 52
6.3. Welding process without SP 600............................................................................ 52
6.3.1. Drag pressure measurement................................................................................... 52
6.3.2. How to plane pipes................................................................................................... 52
6.3.3. How to compensate misalignment .......................................................................... 52
6.3.4. Aligning...................................................................................................................... 53
6.3.5. Heating ...................................................................................................................... 53
6.3.6. Change over ............................................................................................................. 53

Ku nst sto ffschwei ßtec hni k
Contents
25.11.11 orking Instructions IDOS 7000 M page 6 of 98
6.3.7. Joining ....................................................................................................................... 53
6.3.8. End of welding .......................................................................................................... 53
6.3.9. Factors for the welding of angle and T-piece......................................................... 54
6.4. Formulas for the welding of segmented bends...................................................... 54
6.5. How to prepare the pipes for T–pieces .................................................................... 55
7. DI GNOSIS PROGR M ................................................................................................. 56
8. WELDING LOGS ND T BLES.................................................................................... 58
9. EQUIPMENT C RE / M INTEN NCE / REP IR ........................................................ 65
9.1. Maintenance and care ................................................................................................. 65
9.2. Clamping elements ...................................................................................................... 65
9.3. Transport ....................................................................................................................... 66
9.4. Planer.............................................................................................................................. 66
9.5. Service unit.................................................................................................................... 66
9.6. How to check the hydraulic oil level / refilling........................................................ 67
9.7. How to clean the machine .......................................................................................... 67
9.8. Disposal ......................................................................................................................... 67
10. WIRING DI GR MS........................................................................................................ 68
11. DECL R TION OF CONFORMITY............................................................................... 98

Ku nst sto ffschwei ßtec hni k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
25.11.11 orking Instructions IDOS 7000 M page 7 of 98
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. pplication and intended use
The WIDOS 7000 is a workshop machine for the heating element butt welding of pipes and
fittings out of PE and PP from OD = 200 mm to OD = 630 / 800 mm.
(The standard diameter for clamping inserts: OD = 200 / 225 / 250 / 280 / 315 / 355 / 400 / 450
/ 500 / 560 / 630 / 710 / 800 mm).
The right-hand clamping tool is axially displaceable by means of a thread spindle for the
compensation of diameter tolerances.
The machine is (optionally) equipped with a SPA control unit.
For the fabrication of segmented bends and fittings, both clamping tools are swiveling up to
15° each.
The machine can weld T-pieces with (optional) T – clamping tools 45° / 60° and 90°; with
OD = 315 mm up to OD = 630 mm.
ny other use of this machine is non-intended.
The machine is only to be used in a technically perfect condition as well as intended, safety-
and danger-conscious in compliance with the working instructions and the relevant safety
regulations (especially the regulations for the prevention of accidents).
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 purpose oriented use is
• the respect of all the indications of the working instructions and
• performing the inspection and maintenance work.
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 in the endangered area may be injured.
Therefore these working instructions have to be thoroughly read and the corresponding safety
regulations must necessarily be observed.
1.3. Conformity
The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the European standard specifications.
The development, manufacturing and mounting of the machine were executed very carefully.

Ku nst sto ffschwei ßtec hni k
Description of product Chapter 1
25.11.11 orking Instructions IDOS 7000 M page 8 of 98
1.4. Designation of product
The product is designated by a type label.
It contains the type of the machine, the serial number and the year of construction.
1.4.1. Technical data
All important technical data of the individual components is listed.
The data provides quick information on the capability and construction.
1.4.1.1. IDOS 7000 General data
Material: PE, PP
Tube dimensions: Outer-∅ = 200 mm – 630 / 800 mm
Emissions • Noise exceeding 80 dB (A) may occur; during planing it
is obligatory to wear ear protection!
• In case of use of the prescribed plastic materials and if
the work is performed inside 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 point)
• Prevent from moisture influence
• 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.
eight (without accessories): appr. 3200 kg
Dimension (w x d x h): appr. 2150 x 3650 x 2900 mm (without operator control,
high = clamping tools open)
Feeding 28 k / 400 V / 50 Hz
Connecting plug CEE 63 A
1.4.1.2. Basic frame / table
Material basic frame: Construction steel
Ø of cylinder- / Ø of piston rod: 50 / 32 mm
max. force (F = P*A): 11,6 kN (at 100 bar)
Additional Ø of cylinder- / Ø of piston rod: 32 / 20 mm
max. force include additional cylinder (F = P*A): 16,5 kN (at 100 bar)
max. working pressure: 160 bar
1.4.1.3. Heating element
Power: 21,6 k
Voltage: 400 V (± 10%)
Current: 94 A / Phase
Frequency: 50 Hz (± 10%)
Surface: anti-stick coating

Ku nst sto ffschwei ßtec hni k
Description of product Chapter 1
25.11.11 orking Instructions IDOS 7000 M page 9 of 98
1.4.1.4. Planer
Motor: Three-phase motor
Power: 2,2 k
Voltage: 400 V (± 10%)
Current: 5,4 A
Frequency: 50 Hz (± 10%)
Speed planer disc: ca. 7,5 U/min
1.4.1.5. Hydraulic aggregate
Power: 3,0 k
Voltage: 400 V (± 10 %)
Current: 6,8 A
Frequency: 50 Hz
Driving speed: 1450 (rpm)
max. working pressure of the pump: 160 bar
Flow velocity for moving: 25 l / min
Hydraulic oil tank: ca. 170 l
1.5. Wear parts
Pieces: Name: Order no.:
12 Blade 170 mm MES170
72 Flat-head screw M 3x8 with Torx drive 0965C008TX
1 Temperature probe PT 1000 H09082
1 Heating plate (OD 630 T / OD 800 – 15°) 1475701
12 Heating cartridge Ø 16 x 1115 mm / 400 V 1800 on request
1 l Hydraulic oil HLDP35
1.6. Tools and accessories
The following tools and accessories are part of the original delivery:
Pieces: Name:
1 Key for switch cupboard
ttention! Hand over the key to authorized personnel only.
1 Fork wrench size 24
1 Ratchet tightener with nut size 24
each 1 Hexagon socket screw key size 30, 46
each 1 Allan key with T-grip size 6 / 7 / 8 / 10
1 Face spanner 4 mm, for center bolt
1 Torx-screw driver TX10

Ku nst sto ffschwei ßtec hni k
Description of product Chapter 1
25.11.11 orking Instructions IDOS 7000 M page 10 of 98
1.7. Equipment
The following (optionally) accessories are part of the original delivery:
Pieces: Name:
1 set Clamping tool 15° / 22° with OD 630 / 800 mm
4
8
Reduction insert OD 710 in clamping tool OD 800 mm
Pan-head screw M 12 x 50 DIN 912
4
8
Reduction insert OD 630 in clamping tool OD 800 mm
Pan-head screw M 12 x 90 DIN 912
4
8
Reduction insert OD 560 in reduction insert / clamping tool OD 630 mm
Pan-head screw M 12 x 40 DIN 912
4
8
Reduction insert OD 500 in reduction insert / clamping tool OD 630 mm
Pan-head screw M 12 x 40 DIN 912
4
8
Reduction insert OD 450 in reduction insert / clamping tool OD 500 mm
Pan-head screw M 10 x 35 DIN 912
4
8
Reduction insert OD 400 in reduction insert / clamping tool OD 500 mm
Pan-head screw M 10 x 35 DIN 912
4
8
Reduction insert OD 355 in reduction insert / clamping tool OD 500 mm
Pan-head screw M 10 x 80 DIN 912
4
8
Reduction insert OD 315 in reduction insert / clamping tool OD 500 mm
Pan-head screw M 10 x 80 DIN 912
1 set T-piece clamping tool 90° with OD 630 mm
6
12
T-piece reduction insert for OD 560 in T–piece clamping tool OD 630 mm
Pan-head screw M 12 x 40 DIN 912
6
12
T-piece reduction insert for OD 500 in T-piece clamping tool OD 630 mm
Pan-head screw M 12 x 70 DIN 912
6
12
T-piece reduction insert for OD 450 in T-piece clamping tool OD 630 mm
Pan-head screw M 12 x 100 DIN 912
6
12
T-piece reduction insert for OD 400 in T-piece clamping tool OD 630 mm
Pan-head screw M 12 x 120 DIN 912
3
6
T-piece reduction insert for OD 355 in T-piece reduction insert OD 400 mm
Pan-head screw M 10 x 25 DIN 912
3
6
T-piece reduction insert for OD 315 in T-piece reduction insert OD 400 mm
Pan-head screw M 10 x 45 DIN 912
1 set T-piece clamping tool 45° / 60° with OD 630 mm
4
8
T-piece reduction insert 45°/60° for OD 560 in T-piece clamping tool 45°/60°,
OD 630 mm
Pan-head screw M 12 x 40 DIN 912
4
8
T-piece reduction insert 45°/60° for OD 500 in T-piece clamping tool 45°/60°,
OD 630 mm
Pan-head screw M 12 x 70 DIN 912
4
8
T-piece reduction insert 45°/60° for OD 450 in T-piece clamping tool 45°/60°,
OD 630 mm
Pan-head screw M 12 x 100 DIN 912
4
8
T-piece reduction insert 45°/60° for OD 400 in T-piece clamping tool 45°/60°,
OD 630 mm
Cylinder head screw M 12 x 120 DIN 912
4
8
T-piece reduction insert 45°/60° for OD 355 in T-piece reduction insert 45°/60°,
OD 400 mm
Pan-head screw M 10 x 25 DIN 912
4
6
T-piece reduction insert 45°/60° for OD 315 in T-piece reduction insert 45°/60°,
OD 400 mm
Pan-head screw M 10 x 45 DIN 912
Order numbers and spare parts can be ordered at company WIDOS.

Ku nst sto ffschwei ßtec hni k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
25.11.11 orking Instructions IDOS 7000 M page 11 of 98
2. Safety rules
The base for a safe handling and the fault-free operation of this machine is the knowledge of
the basic safety advises and rules.
The safety instructions of this chapter represent the general part. Specially instructions are
closed by the according activity.
• 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. Explanation of the symbols and indications
In the working instructions the following denominations and signs are used for dangers:
This symbol means a possibly 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 slight 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 crushing of parts of the
body resp. damages of parts of the machine.
This symbol means a possible risk of injury by noise exceeding 80 dB(A).
• Ear protection is obligatory
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 t i o n s f o r th e p re v e n t i on o f a c c i d en t s a r e v a li d ( U VV ) .

Ku nst sto ffschwei ßtec hni k
Safety rules Chapter 2
25.11.11 orking Instructions IDOS 7000 M page 12 of 98
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
• the workers also must 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 user
All persons who are to work at the machine are obliged:
• 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, before working.
2.4. Measure 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 much 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 by a third person, the working
instructions are to be sent along with and their importance is to be emphasized.
2.6. Instructions for the staff
•
••
• Only skilled and trained persons are allowed to work at the machine.
•
••
• It must be clearly defined who is responsible for transport, mounting and dismounting, and
starting the operation.
•
••
• A person who is being trained may only work at the machine under supervision of an
experienced person.

Ku nst sto ffschwei ßtec hni k
Safety rules Chapter 2
25.11.11 orking Instructions IDOS 7000 M page 13 of 98
2.7. Dangers while handling the machine
The machine WIDOS 7000 M 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
• according to the purpose-oriented use
• 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.
• Protect the heating element and planer from rain and dropping water.
System sections which have to be opened in case of repair work have to be
depressurized before starting to repair.
There is a danger of hurting your eyes because of a sudden flow compressed air
resp. squirting hydraulic oil. The hydraulic oil can be hot!
• Damaged hydraulic / pneumatic hoses have to be immediately replaced.
• Before starting to work make a visual examination of the hydraulic / pneumatic lines.
• The hydraulic oil is brackish!
• The hydraulic oil is to be handled and disposed of in appropriate manner.
2.8. Specific dangers
2.8.1. Danger of stumbling over electric wires
Pay attention that nobody has to step over the lines.
Favorably pass the lines in order that the danger is minimized. Do not squeeze
and kink the lines or anything likewise. Avoid the heating-up of hydraulic lines
(rise in pressure!).
2.8.2. Danger of drawing-in of clothes by the planer
You can carry away cut injuries up to fractures!
ith some machines there is a short rubbing of the planer by activating the
machine although the planer is not switched on!
• Do wear formfitting clothes.
• Do not wear any rings or jewelry during work.
• If necessary wear a snood-type cap.
• Take care that no person is standing in the swiveling area of the planer.
• Only remove chips with the planer standing still.

Ku nst sto ffschwei ßtec hni k
Safety rules Chapter 2
25.11.11 orking Instructions IDOS 7000 M page 14 of 98
2.8.3. Risk of injury by noise
Noise exceeding 80 dB (A) may occur; during planing it is obligatory to wear ear
protection!
• Ear protection is obligatory during drilling / planing!
2.8.4. Danger of combustion by heating element and welding area
You can burn yourself, inflammable materials can be ignited.
The heating element temperature is heated up to more than 250 °C / 482 °F!
• Do not leave the machine with heated heating element unsupervised.
• Do not touch the surfaces of the heating element.
• Take enough safety distance to inflammable materials.
• Do wear safety gloves.
2.8.5. Danger of crushing
Heavy injuries can result from crushing:
• upon opening / closing the clamping tools.
• upon driving in and out the planer and heating element.
• upon opening / closing the slides.
• upon mounting the reducer inserts.
• Do not touch in-between clamped pipes.
• Do not touch into the clamping and swiveling area.
• Do not stand or touch in-between the machine slides during welding.
• In case of working inside the machine, the mains plug always has to be switched off and
secured against unauthorized activation.
• Special attention with the rear area when driving back the planer.
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 disrespect the warranty or liability will expire.
• Machine parts which are not in a perfect condition are to be immediately replaced.
• Only use original WIDOS spare and wear parts.
• In case of purchase orders please always indicate the machine number!

Ku nst sto ffschwei ßtec hni k
Safety rules Chapter 2
25.11.11 orking Instructions IDOS 7000 M page 15 of 98
2.10. Warranty and liability
Our „General Sales and Delivery Conditions“ are principally valid.
They are at the owner's disposal at the latest when signing the contract.
arranty and liability demands referring to damages of persons or objects are suspended if
they are caused by one or several of the following reasons:
• not using the machine according to the prescriptions
• improper transport, building-up, starting and operating the machine and maintenance
• operating the machine with defective or improperly installed security measures
• ignoring the information given in this manual
• structural changes at the machine without permission
• unsatisfactory checking of machine parts which are worn out
• repairs performed in an inexpert way
• catastrophes by external influence and Acts of God.

Ku nst sto ffschwei ßtec hni k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
25.11.11 orking Instructions IDOS 7000 M page 16 of 98
3. Functional description
l l i n te r n a t i on al a n d n a t i on al p r o c e s s g u i d el i n e s a r e t o b e b a s i c a l l y
f ol l ow e d !
The plastic pipes are clamped by means of corresponding clamping tools.
In order to weld angles and bends, you may turn the clamping tools on both sides.
Insert the plastic pipes and clamp them by means of the clamping tools.
If necessary stabilize the pipes by means of roller stands or pipe supports.
Afterwards, the planer is driven into the machine and the front sides of the pipes are planed in
parallel by means of the planer, and the pipe displacement is checked. The planer is then
driven back to its basic position.
Subsequently, the heating element is placed between the pipes. The pipes are pressed
against the heating element with the defined adjusting pressure, this process is called
adjustment.
After reaching the prescribed bead height, the pressure is reduced and this induces the
heating-up time. This period serves for heating the pipe ends.
After the heating-up, the machine slides are driven apart, the heating element is quickly driven
out and the pipes are again pressed together.
The period from driving out the heating element until closing the pipes is called change-over
time.
The pipes are joined with the required welding pressure and cool down under pressure
afterwards. This is called the cooling down time.
Subsequently, the welded connection can be unclamped, the welding process is completed.
Heating element heats
the pipes up to welding
temperature
Completed welding joint
with in- and outside bead

Ku nst sto ffschwei ßtec hni k
WIDOS Einsteinstr. 5 Phone [phone] - 0
. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax [phone] - 40
ebsite: www.widos.de Email: [e-mail]
25.11.11 orking Instructions IDOS 7000 M page 17 of 98
4. Operating and indicating elements
4.1. Machine overview
4.2. Operator console
Switch cabinet
SD card drive
Main switch
Type label
Guide roller
Guide roller, lockable
Operator panel
Additional cylinder
Heating element
Planer
Left clamping tool
Hydraulic
Pneumatic
Left table
Holder for additional cylinder
Adjusting screw
Right clamping tool
Right table
Operator
console
Right horizontal adjustment
Protective cover
Heat sink

Ku nst sto ffschwei ßtec hni k
Operating and indicating elements Chapter 4
25.11.11 orking Instructions IDOS 7000 M page 18 of 98
4.2.1. Operator panel
No. Denomination Function
1 Display (Option) - to display the necessary parameters (for welding and
programming).
- Two values can be displayed at the same time.
2 Buttons for operation
(Option)
- Drag pressure measurement;
- to set the pipe data and project number;
- to set the type of the machine;
- to print the welding data;
- Diagnosis menu;
- to reset to the previous item of the menu
3 Turning switch 0 / I - to switch the heating element on <I> and <0> off
4 Temperature regulator - to set the heating temperature
5 Joystick heating element - Heating element out of machine
- Heating element into machine
6 Joystick Planer - Planer out of machine
- Planer into machine
- Planer rotate (planing pipes)
7 Joystick (cylinder 1) left
clamping tool - To open left clamping tool
- To close left clamping tool
- To clamp left clamping tool (option)
- To release left clamping tool (option)
8 Joystick (cylinder 2)
clamping tool (option) - To open clamping tool
- To close clamping tool
- To clamp clamping tool (option)
- To release clamping tool (option)
1
2
3
4
5
7
8
11
12
14
13
15
16
17
9
10
6

Ku nst sto ffschwei ßtec hni k
Operating and indicating elements Chapter 4
25.11.11 orking Instructions IDOS 7000 M page 19 of 98
No. Denomination Function
9 Joystick (cylinder 4) right
clamping tool - To open right clamping tool
- To close right clamping tool
- To clamp right clamping tool (option)
- To release right clamping tool (option)
10 Joystick (cylinder 3)
clamping tool (Option) - To open clamping tool
- To close clamping tool
- To clamp clamping tool (option)
- To release clamping tool (option)
11 Pressure gauge - Pressure indication [bar]
12 Pressure controller - Adjust bead-up pressure (Reading: on pressure gauge)
13 Joystick tables - To close tables for bead-up
- To open tables
- To close tables for joining / cooling
- To close tables for planing
14 Pressure controller - Adjust welding pressure (Reading: on pressure gauge)
15 Pressure controller - Adjust planing pressure (Reading: on pressure gauge)
16 Switch: change over
limitation - on: change over limitation , switch illuminates
- off: change over limitation , switch extinguishes
17 Button: pressure release - for heat-up, after reaching revolving bead-up height
- to unclamp welding piece at the end of the welding
process
- to relieve pressure limitedly on preset value only
upon activation of <joystick 12> 




 Example: In case you intend to carry out welding with two different cooling pressures,
you may:
- use the aligning pressure as first cooling pressure, for this purpose you must put the
<joystick 12> on: after the change-over.
- You must put the <joystick 12> on for a minor (preset) cooling pressure and
simultaneously press .

Ku nst sto ffschwei ßtec hni k
Operating and indicating elements Chapter 4
25.11.11 orking Instructions IDOS 7000 M page 20 of 98
4.2.2. Switch cupboard
No. Denomination Function
F1 Circuit breaker motor 3 x B16A
F20 Circuit breaker heating element 3 x B40A
F2 Circuit breaker control K10A
F10 Protective motor switch hydraulic pump 7 – 10A
F40 Protective motor switch planer 2,8 – 4A
Q10 Contactor hydraulic pump
Q40 Contactor planer
G40 Soft starting planer
T3 Switching power supply 24V
4.3. Service unit and pneumatic valves
Service unit: Pneumatic valves:
F1 / F20 / F2 / F10 / F40 / Q10 / Q40 / G40 / T3
Activating valve
manual
Pressure regulator
valve with manometer
Manual discharge for
condensed water
Plug-in connectors
for closing / opening
cylinder
Connection for
compressed air hose
M41, Planer out of machine
M42, Planer into machine
M21, Heating element out of machine
M22, Heating element into machine
M46, Planer unlock
M16; Stopper table