widos ESI 4000 User manual

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Working Instructions
Translation
WIDOS ESI 4000
Keep for further use!

Kunststoffschweißtechnik
Product Identification
18.07.2013 Working Instructions WIDOS ESI 4000 Page 2 of 37
Type: WIDOS ESI 4000
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
W. Dommer Söhne GmbH
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
Telephone: [phone] / 99 39 - 0
Telefax: +49 (0) 71 52 / 99 39 - 40
E-mail: [email protected]
Subsidiaries
WIDOS
WIDOS GmbH W. Dommer AG
An der Wiesenmühle 15 St. Gallerstr. 93
D-09224 Grüna / Sachsen CH-9201 Gossau
Phone: +49 (0) 3 71 / 8 15 73 - 0 Phone: [phone]
Fax: +49 (0) 3 71 / 8 15 73 - 20

Kunststoffschweißtechnik
Introduction
18.07.2013 Working Instructions WIDOS ESI 4000 Page 3 of 37
Purpose of the document
These working instructions give you information about all important questions which refer to
the construction and the safe working of your machine.
Just as we are, you are obliged to engage in these working instructions, as well.
Not only to run your machine economically but also to avoid damages and injuries.
Should questions arise, contact our advisers in the factory or in our subsidiary companies.
We will help you with pleasure.
According to our interest 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.
18.07.2013 WIDOS
W. Dommer Söhne GmbH
Einsteinstraße 5
D-71254 Ditzingen-Heimerdingen
All rights reserved
Reprinting only allowed with permission of the corporation.
Any changes subject to technical innovations.

Kunststoffschweißtechnik
Contens
18.07.2013 Working Instructions WIDOS ESI 4000 Page 4 of 37
1. PRODUCT DESCRIPTION.............................................................................................. 6
1.1. Application and intended use..............................................................................................6
1.2. Safety measures ...................................................................................................................6
1.3. Conformity.............................................................................................................................6
1.4. Designation of product.........................................................................................................6
1.5. Technical data.......................................................................................................................7
1.6. Equipment..............................................................................................................................7
1.7. Wear parts .............................................................................................................................7
2. SAFETY RULES.............................................................................................................. 8
2.1. Explication of the different symbols...................................................................................8
2.2. Obligations of the operator..................................................................................................8
2.3. Obligations of the worker ....................................................................................................8
2.4. Structural modifications on the device ..............................................................................9
2.5. Dangers by electrical energy...............................................................................................9
2.6. Danger of stumbling over the connecting line ..................................................................9
2.7. Danger of combustion at the socket...................................................................................9
2.8. Danger by toxic vapors........................................................................................................9
2.9. Warranty and liability..........................................................................................................10
3. FUNCTIONAL DESCRIPTION ...................................................................................... 11
4. INDICATING AND OPERATING ELEMENTS .............................................................. 12
4.1. Overview device..................................................................................................................12
4.2. Welding device....................................................................................................................13
4.3. Control panel.......................................................................................................................14
5. STARTING AND OPERATING...................................................................................... 15
5.1. Security advice....................................................................................................................15
5.1.1. How to work while using a generator ...............................................................................15
5.1.2. How to work with an extension cable...............................................................................16
5.2. Accessories for data read in / out.....................................................................................16
5.2.1. Authorization card.............................................................................................................16
5.2.2. Bar code reading pen.......................................................................................................16
5.2.3. SD – card and reading device..........................................................................................16
5.2.4. USB card reader...............................................................................................................17
5.3. Pipes and sockets...............................................................................................................17
5.4. How to switch on the machine..........................................................................................18
5.5. How to weld with the ESI 4000..........................................................................................19
5.6. How to weld without fitting bar code................................................................................22
5.7. Error messages...................................................................................................................24

Kunststoffschweißtechnik
Contens
18.07.2013 Working Instructions WIDOS ESI 4000 Page 5 of 37
5.8. Enter parameters ................................................................................................................24
5.9. How to change the language.............................................................................................25
5.10. How to change date and time............................................................................................27
5.11. How to change authorization.............................................................................................28
5.12. Traceability–how to activate information and pipe length.............................................29
5.13. How to ask for project name prior to each welding........................................................30
5.14. How to delete the memory.................................................................................................31
5.15. Welding data management ................................................................................................32
5.16. Possible defects and their elimination.............................................................................32
5.17. Short instruction.................................................................................................................32
6. MAINTENANCE / STORING / TRANSPORT................................................................ 33
6.1. Cleaning and care...............................................................................................................33
6.2. Transport and storing.........................................................................................................33
6.3. Waste management ............................................................................................................33
7. SPARE PARTS LIST..................................................................................................... 34
8. DECLARATION OF CONFORMITY.............................................................................. 37

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
18.07.2013 Working Instructions WIDOS ESI 4000 Page 6 of 37
1. Product description
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. Application and intended use
The WIDOS ESI 4000 was especially designed for the use on building sites in order to weld
PE and PP pipes with all common socket types on the spot.
Any other use exceeding this is to be considered non-intended.
For damages resulting from it, the manufacturer cannot be held liable.
The risk is exclusively on the user’s side.
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
being in the surrounding 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
advices must be necessary adhered to.
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 made very carefully.
1.4. Designation of product
The product is designated by two signs at the frame.
The type-labels are fixed on the control unit and on the basic machine.
They contain the type of the machine, the serial number, and the year of construction.

Kunststoffschweißtechnik
Product description Chapter 1
18.07.2013 Working Instructions WIDOS ESI 4000 Page 7 of 37
1.5. Technical data
Weight: 12 kg
Voltage: 230 V
Power: 3.2 kW
Current: 16 A
Frequency: 50 Hz
Size: (WxHxD) 370 x 370 x 260 mm
Length connecting cable: 4 m
Length welding cable: 4 m
Material of base frame: Niro
Packing crate (wood, optional):
Size: (WxHxD) 410 x 450 x 330 mm
Weight: 6.4 kg
Packing case (aluminium, optional):
Size: (WxHxD) 400 x 400 x 300 mm
Weight: 4,5 kg
1.6. Equipment
Piece Denomination / Function
1 General authorization card
1 User authorization card
1 Initialization card (optional)
1 Bar code reading pen
2 each Adaptor for Ø 4.7
2 each Adaptor flat (optional)
1 SD-card
1 USB card reader
1.7. Wear parts
Piece Denomination Part-no.
2 Adaptor for Ø 4.7 HWAR001
2 Adaptor flat (optional) HWAF001
Order numbers and individual parts can be inquired from company WIDOS.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
18.07.2013 Working Instructions WIDOS ESI 4000 Page 8 of 37
2.Safety rules
A basic premise for working safely and without disturbances is the knowledge of the basic
safety signs and rules.
These working instructions provide you with the most important information to safely run the
device and the safety information has to be respected by all persons working with the device.
2.1. Explication of the different symbols
The working instructions contain the following signs for certain situations:
This symbol indicates a possibly dangerous situation.
The disrespect of it may result in injuries or damages on device parts.
This symbol gives important indications for the proper use of the device.
The disrespect of this indication may lead to malfunctions and damages on
the machine or on parts in the surrounding.
This symbol indicates a possibly dangerous situation due to hot surfaces.
The disrespect of these indications may lead to heavy burns, respectively to
ignition or even fire.
This symbol indicates a possible danger due to toxic vapors.
The disrespect of it may lead to hygienic damages.
This symbol means a possible danger of injury by spillings.
It is obligatory to wear safety glasses”
The regulations for the prevention of accidents are valid (UVV).
2.2. Obligations of the operator
The owner is obliged to only let persons work at the device who
know about basic safety and accident prevention rules and who are instructed in the
handling of the device
the worker also must have read and understood the safety chapter of this manual and
certify this by his signature.
The safety-conscious working of the staff has to be checked in regular intervals.
2.3. Obligations of the worker
Before working at the machine, all persons in charge of it oblige themselves:
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 understood well.
to inform themselves about the functions of the device before using it.

Kunststoffschweißtechnik
Safety rules Chapter 2
18.07.2013 Working Instructions WIDOS ESI 4000 Page 9 of 37
2.4. Structural modifications on the device
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!
2.5. Dangers by electrical energy
Only skilled persons are allowed to work at electric appliances.
The electric equipment of the machine has to be regularly checked.
Loose connections and damaged cables have to be immediately replaced.
The device has to be protected against humidity.
Only qualified WIDOS personnel resp. authorized service partners are allowed
to open the device.
2.6. Danger of stumbling over the connecting line
Pay attention that nobody has to step over the connecting lines (230 V).
2.7. Danger of combustion at the socket
You may burn parts of your body, inflammable materials may ignite! The socket
may get hot!
Do not leave the device unattended.
Do not touch the welded socket before the cooling time has elapsed.
Wear protective gloves.
Wear safety glasses.
Keep sufficient safety distance to inflammable materials.
2.8. Danger by toxic vapors
In unfavorable circumstances, toxic vapors may escape during the welding
process.
Care for good ventilation during welding in closed locations.
Keep sufficient space between machine and the welded joint.

Kunststoffschweißtechnik
Safety rules Chapter 2
18.07.2013 Working Instructions WIDOS ESI 4000 Page 10 of 37
2.9. 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.
Warranty 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 safety 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.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
18.07.2013 Working Instructions WIDOS ESI 4000 Page 11 of 37
3. Functional description
The socket welding machine ESI 4000 carries out an electric socket welding process in which
pipes are welded to a fitting.
The prepared pipes are fed into the socket and then aligned and clamped in the clamping tool.
The contacts are plugged to the socket.
The sockets are furnished with a bar code, it will be read in with the bar code reading pen or
manually entered at the machine.
The welding process is started, the welding joint is heated (Heating up), and afterwards the
machine automatically shifts.
The welded pipe cools down without tension. (Cooling down)
The welded pipe can be unclamped, the welding process is completed.

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
18.07.2013 Working Instructions WIDOS ESI 4000 Page 12 of 37
4.Indicating and operating elements
4.1. Overview device
Transport case
Support device with
securing straps
(optional)
Bar code reading pen
Safety bag for bar
code reading pen
Welding device
Bag for adaptors and
authorization cards
Connection plug

Kunststoffschweißtechnik
Indicating and operating elements Chapter 4
18.07.2013 Working Instructions WIDOS ESI 4000 Page 13 of 37
4.2. Welding device
No. Denomination / Function
1 Device holder with handle
2 Control panel with display and buttons (chapter 4.3)
3 Bar code reading pen to authorize and read in the socket codes (here pouched
in the safety bag)
4 Plug with connector for adaptors, connection to socket
5 Holder for coiling the cables
6 ON/OFF switch
7 SD-card drive
8 Adaptor, for fitting connection Ø 4,8 mm
9 Adaptor, for fitting connection flat (optional)
1
2
5
6
7
3
4
8
9

Kunststoffschweißtechnik
Indicating and operating elements Chapter 4
18.07.2013 Working Instructions WIDOS ESI 4000 Page 14 of 37
4.3. Control panel
No. Denomination / Function
15 Display, indicates working steps and status messages, several values can be
indicated at once.
16 <+> / <-> - buttons, for manually entering socket code number / parameter
17 <Stop> - button, aborts the welding process
18 <Start> - button: starts the welding process
- Confirms the entered parameters
15
16
17
18

Kunststoffschweißtechnik
WIDOS Einsteinstr. 5 Telephone [phone] / 99 39 - 0
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Telefax +49 (0) 71 52 / 99 39 - 40
E-mail: [e-mail] Internet www.widos.de
18.07.2013 Working Instructions WIDOS ESI 4000 Page 15 of 37
5. Starting and operating
The instructions of this chapter are supposed to guide you in the operation of the machine and
lead you during the appropriate starting of the machine.
This includes:
the safe operation of the machine;
using all possible options of the machine;
economic operation of the machine.
5.1. Security advice
The machine only has to be introduced and used by skilled persons. For their qualification
they can pass an exam of plastic welding according to DVS and DVGW.
In cases of danger for man and machine, immediately press the emergency switch, turn off
the main plug or pull the power plug.
Having finished the welding work and during intervals you have to turn off the machine.
Furthermore you have to control that no unauthorized person can use the machine.
The operation on building sites is only allowed via power distributor with FI security switch
according to VDE 0100.
Observe the environmental conditions:
The welding must not be carried out with direct solar radiation, if necessary erect welding
shield.
With temperatures below 5° C, measurements have to be taken:
If necessary erect welding tent or heat pipe ends.
The device ESI 4000 is connected to the local mains supply 230 V / 16 A / 50 Hz resp. to a
generator (Chapter: 5.1.1.).
5.1.1. How to work while using a generator
The nominal capacity of the generator is depending upon the size of the sockets, the
connecting circumstances, the environmental conditions, the generator type and the
adjustment traits. The nominal capacity of the generator is single-phase, 220 – 240 V / 50 – 60
Hz.
Socket size: Generator type:
< d 160 mm 3,2 kW mechanically controlled
> d 160 mm 4,0 kW mechanically controlled
5,0 kW electronically controlled
Always start the generator first, connect the device ESI 4000 with a idling voltage being
adjusted up to 230 V.
After the welding always detach the ESI 4000 first, afterwards switch off the generator.
During welding do not connect any other consumer to the generator at the same
time

Kunststoffschweißtechnik
Starting and operating Chapter 5
18.07.2013 Working Instructions WIDOS ESI 4000 Page 16 of 37
5.1.2. How to work with an extension cable
Only use extension cables that are admitted and marked with the following conductor cross-
sections:
Up to 20 m: 1,5 mm² ; Type H07RN-F
Beyond 20 m:2,5 mm² ; Type H07RN-F
The extension cable may only be used in an unfolded and straight condition!
5.2. Accessories for data read in / out
5.2.3. Authorization card
Each supplied machine normally includes a general authorization card. It authorizes to carry
out all functions (including special functions).
Moreover, a user authorization card is included. It entitles to carry out all functions except
modifications of date, time and authorization.
Optionally, an initialization card can be purchased by which the welding is started
independently from the device (e.g. in the trench).
Keep card dry and clean.
Do not fold card or expose to strong magnetic fields.
The card is not transferable.
5.2.4. Bar code reading pen
In order to read in the bar codes, equally draw the reading pen over the bar code (hold pen
vertically), the scanning is acoustically confirmed.
The reading pen is ready when the red lamp at the pen top illuminates.
Always store the pen in the bag after its use.
5.2.5. SD – card and reading device
The ESI 4000 is equipped with a drive for a SD card.
The drive memorizes the welding data in the internal memory as well as on the SD card as
soon as a card is in the drive.
Data of appr. 32000 weldings can be stored on a card with a memory of 64 MB.
The SD card has to be formatted by „FAT 16“ before use.
Insert the card with the marking to the top and cautiously into the reading device with
minor efforts.
The card can be read out with a WICON program.
Do not fold, open, overheat and wet the card!
Please only use SD cards purchased from WIDOS. We will not be liable for any
cards from other manufactures!

Kunststoffschweißtechnik
Starting and operating Chapter 5
18.07.2013 Working Instructions WIDOS ESI 4000 Page 17 of 37
5.2.6. USB card reader
You may read out the welding data onto a PC by the USB card reader.
Remove the card from the SD card drive of the ESI 4000.
Remove the rear cap and plug card
according to the image into the USB card
reader.
Remove the front cap and plug USB card
reader into the USB interface in your PC.
As soon as the USB card reader has been
plugged, it appears as removable medium
in the drive list.
Open the WIDOS folder, there you will
find:
- WICON2000 viewer for considering and
printing the welding data,
- working instructions for WICON2000
viewer as PDF file.
5.3. Pipes and sockets
The prepared pipes are fed into the socket on both sides in a flush manner, the
connection has to be tension-free.
The pipes being plugged into the socket e. g. are inserted in optional supporting devices and
firmly clamped.
Supporting device
(optional)
Pipes with socket
clamped

Kunststoffschweißtechnik
Starting and operating Chapter 5
18.07.2013 Working Instructions WIDOS ESI 4000 Page 18 of 37
5.4. How to switch on the machine
The device ESI 4000 is connected to the local mains supply resp. distributor 230 V / 16 A / 50
Hz, completely roll out cable.
Activate <Main switch>
As soon as the power plug of the ESI 4000 is connected and the main switch activated, the
display will get bright (the processor is initialized).
Display:
2nd line:
WIDOS GmbH
Germany
After a few seconds the display changes to
Display:
2nd line:
Version 0.00.00
Serial no. 0000000
Number of software version
Serial number of device
After a few seconds the display changes to
Display:
2nd line:
000 Weldings free
0000 SD-card
Number of free disc space in memory (RAM)
Number of free disc space on SD-card
After a few seconds the display changes to
Display:
2nd line:
WIDOS ESI 4000
Please authorize
Indication of machine type
Read in the code from the general or user or ISO-welding authorization
card via the bar code reading pen, this is confirmed by a signal.
After a few seconds the display changes to
Display:
2nd line:
WIDOS ESI 4000
Welcome XXXX
Indication of machine type
Indication of general or user name
After a few seconds the display changes to
Display:
2nd line:
WIDOS ESI 4000
10.10.2011 10:10
Indication of machine type
Current date and time
„Basic menu“

Kunststoffschweißtechnik
Starting and operating Chapter 5
18.07.2013 Working Instructions WIDOS ESI 4000 Page 19 of 37
5.5. How to weld with the ESI 4000
Basically, the respectively valid welding guidelines have to be
respected (ISO / CEN / DVS ...).
Entirely roll out welding cable, plug ESI 4000 to the sockets if necessary use adaptor.
Wear safety gloves to prevent burnings.
You may be injured by spillings.
Wear safety glasses during welding.
Only insert prepared pipes (peeled) into the socket!
Only use connecting contacts that fit the socket type.
Observe a tight fit of these contacts!
Display:
2nd line:
no.0000 read in socket
R=0.000hm
Current joint number is indicated.
Current resistor is indicated.
Read in code of the socket via the bar code reading pen, this is confirmed
by a signal.
Display:
2nd line:
Error: Socket does
not fit to code
Appears if socket and pipes do not match, or if
socket still is too warm after aborting the welding
process. => This occurs unless the wires inside
the fittings have cooled down inbetween two
welding processes, and thus the actual resistance
does not match the required value.
Delete error and confirm error message with <Start> - button
Display:
2nd line:
Manu Type Diam Time
XXXX XXX 000 000
Indicates the manufacturer, socket type, socket
diameter [mm] and heating [sec]
If the bar code is to be entered manually:
Keep button <+> pressed for 4 s
Display:
2nd line:
Manually enter code
0
Manually enter the socket bar code via the buttons <+ / - / Start>, at the
end of the code number press start several times until following indication
appears
Display:
2nd line:
Manu Type Diam Time
XXXX XXX 000 000
Indicates the manufacturer, socket type, socket
diameter [mm] and heating [sec]

Kunststoffschweißtechnik
Starting and operating Chapter 5
18.07.2013 Working Instructions WIDOS ESI 4000 Page 20 of 37
Press <Start> - button
In case traceability has been confirmed with "yes", (chapter: 5.12) the display indicates:
Display:
2nd line:
Please read
trac.Code (fitting)
Either: Read in traceability 1 of the fitting via the bar code reading pen
Or: Keep button <+> pressed for 4 s, then manually enter the socket bar code
via the buttons <+ / - / Start>
Display:
2nd line:
Traceability 1:
FR PE100 50 4.5
After a few seconds the display changes to
Display:
2nd line:
Please read addit.
trac.Code 2nd pipe
Either: Read in traceability 2 of lefthand pipe with barcode reader
Or: Keep button <+> pressed for 4 s, then manually enter the 2nd socket bar
code via the buttons <+ / - / Start>
Or: skip with <Start>
Display:
2nd line:
Traceability 2:
FR PE100 50 4.5
After a few seconds the display changes to
Display:
2nd line:
Please read addit.
trac. Code 3rd pipe
Either: Read in traceability 3 of righthand pipe with barcode reader
Or: Keep button <+> pressed for 4 s, then manually enter the 3rd socket bar
code via the buttons <+ / - / Start>
Or: skip with <Start>
Display:
2nd line:
Traceability 3:
FR PE100 50 4.5
After a few seconds the display changes to