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Summary of Contents for wiwa DOSYS M
- Page 1 Operation Manual DOSYS M MV 1:0,03 MV 1:1 MV 2:1 Type: MV 10:1 MV 1:0.03 MV 1:1 MV 2:1 MV 10:1 Serial No.: 2dom_BA_en_B0550055 ✓(2023/09/04)
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Page 2: Ec Declaration Of Conformity
EC declaration of conformity in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC, as amended by 2009 / 127 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany... -
Page 3: Eu Declaration Of Conformity
EU declaration of conformity in accordance with ATEX Directives The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany hereby declares that the machine DOSYS M type with serial no. conforms with the provisions of Directive 2014 / 34 / EU. -
Page 5: Table Of Contents
Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ......2.2 Safety notes ....... 2.2.1 Working pressure . - Page 6 Contents 4 Transport, installation, and assembly 4.1 Transport ....... . 32 4.2 Installation site .
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Page 7: Foreword
If questions should arise, we would be happy to assist you. We wish you excellent working results with your unit WIWA Wilhelm Wagner GmbH & Co. KG Copyright © 2025 WIWA The copyright to this operation manual belongs to WIWA Wilhelm Wagner GmbH &... -
Page 8: Safety
We recommend that the unit operator have this confirmed in writing. 2.1 Explanation of symbols Safety notes warn of potential accident risks and describe the measures required for accident prevention. In the WIWA operation manuals, safety notes are high- lighted and labeled as follows: DANGER... - Page 9 Safety General risk of accident Risk of explosion due to explosive atmosphere Risk of explosion due to explosive substances Risk of accident due to electricity or electrostatic charge Warning about the risk of crushing Warning of corrosive substances Risk of injuries due to rotating unit parts Risk of burning due to hot surfaces Risk of freezing due to cold surfaces The first line of the safety instructions indicates the personal protective equipment...
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Page 10: Safety Notes
Safety Wear protective gloves Signals an instruction to wear protective gloves in order to prevent injuries due to aggressive chemicals, burns when processing heated materials, or freezing due to contact with very cold surfaces. Wear safety shoes Signals an instruction to wear safety shoes, in order to prevent foot injuries due to falling, toppling or rolling objects, as well as slipping on slippery floors. -
Page 11: Working Pressure
Never spray solvents or materials containing solvents into narrow-mouthed cans or drums with a bung opening! Only use electrically conductive material hoses. All original material hoses from WIWA are conductive and designed for our devices. Only use electrically conductive accessories/accessory parts. WARNING Dirty machines can become electrostatically charged. -
Page 12: Risks Due To Rams
Safety 2.2.3 Risks due to rams WARNING During the lifting movement of the rams, fingers, hands or other body parts may be crushed by moving parts. Do not reach between the follower plate/cover and material drum, traverse, and cylinder cover of the pneumatic cylinder or the clamping piece and cylinder cover of the pneumatic cylinder. -
Page 13: Explosion Protection
Precise information on the lifting weight can be found in section 8 on page 54. 2.2.4 Explosion protection The following short designations are used in the instructions of WIWA: Ex protection: Explosion protection Ex area: potentially explosive or non-explosion protected area... -
Page 14: Health Risks
Safety 2.2.5 Health risks CAUTION Depending on the materials being processed, solvent vapors may arise, which could cause damage to health and property. Make sure the workplace is sufficiently ventilated and aired. Always observe the safety data sheets and processing instructions of the material manufacturer. -
Page 15: Safety Signs
Safety Lubricate threaded connections during assembly. 2.3 Safety signs The safety signs attached on the unit indicate possible hazard points and must be observed. The symbolism on the safety signs corresponds to the labeling of the safety notes described in section 2.1 on page 2. The safety signs may not be removed from the unit. -
Page 16: Safety Valves
Safety Check list on the pressureless unit: Seal on the safety valves OK? Safety valves free of external damage? Function of the compressed air shut-off valves OK? Ground cable free of damage? Is the ground cable connected to the unit and OK at the circuit board? Protective cover present and closed? Check list on the pressurized unit: Function of the safety valves OK? (For function test, see section 2.4.1 on page... -
Page 17: Emergency Stop Button
Safety WARNING If the maximum permissible air inlet pressure is exceeded, parts may rupture. The consequences may be personal injuries and property damage. Never operate the unit without safety valves or with defective safety valves! If it is necessary to replace a safety valve, please refer to the machine card for the order number. -
Page 18: Compressed Air Shut-Off Valves
Safety 2.4.4 Compressed air shut-off valves The compressed air shut-off valve on the maintenance unit interrupts the air supply to the entire machine. Furthermore, the machine is equipped with additional compressed air shut- off valves, with which it is possible to interrupt the air supply to individual components, such as e. -
Page 19: Protective Cover
Safety A rupture disc is installed in the screw connection on the rear side of the mixer block. Rupture discs are pressure protection with a disposable membrane. If the permissible material pressure is clearly exceeded, the membrane bursts and the material escapes into the connected collecting vessel. -
Page 20: Operating And Maintenance Personnel
Safety The grounding points on this machine are labeled with the symbol shown on the left. 2.5 Operating and maintenance personnel 2.5.1 Obligations of the owner The owner: is responsible for training the operating and maintenance personnel, must instruct the operating and maintenance personnel on correct handling of the unit, and on wearing the correct work clothing and protective equipment, must make work aids, such as lifting gear for transporting the unit or container, available to the operating and maintenance personnel,... -
Page 21: Personal Protective Equipment
Safety Children, young persons under the age of 16 and untrained personnel may not operate this unit. 2.5.4 Personal protective equipment Wear protective clothing Always wear the protective clothing stipulated for your working environment (e.g. anti-static protective clothing in potentially explosive areas) and also observe the recommendations in the safety data sheet of the material manufacturer. -
Page 22: Spare Parts
2.6.1 Spare parts When maintaining and repairing the unit, only original spare parts from WIWA may be used. If spare parts are used, that have not been produced or supplied by WIWA, all warranty claims and liability shall be excluded. 2.6.2 Accessories If you use original accessories from WIWA that are designed for the working pressure, their suitability for use in our units is guaranteed. -
Page 23: Leakage
Safety 2.7.3 Leakage WARNING In case of leakage, material may escape under very high pressure and cause serious personal injuries and property damage. Immediately shut down the unit and relieve the pressure. Tighten threaded connections and replace defective parts (must be performed by trained personnel). -
Page 24: Description
Description 3 Description The DOSYS M is a dual component conveying and filling system with a fixed mixing ratio, which ensures accurate and consistent proportioning. Mixed and ready-to-process material can be filled directly at the static mixer. The technical data for your unit can be found on the machine card enclosed or on the type plate. -
Page 25: Contruction
Description 3.3 Contruction 3.3.1 Design with mixing ratio 1:1 Fig. 8: Design of the unit with mixing ratio 1:1 Description Mixing unit section 3.6 on page 27 Static mixer section 3.6 on page 27 Proportioning unit section 3.6 on page 27 Proportioning panel section 3.4 on page 23 Compressed air shut-off valve... -
Page 26: Design With Mixing Ratio 1:0.03
Description 3.3.2 Design with mixing ratio 1:0.03 Fig. 9: Design of the unit with mixing ratio 1:0.03 Description Mixing unit section 3.6 on page 27 Static mixer section 3.6 on page 27 Proportioning unit section 3.6 on page 27 Proportioning panel section 3.4 on page 23 Compressed air shut-off valve section 2.4.4 on page 12... -
Page 27: Design With Mixing Ratio 2:1
Description 3.3.3 Design with mixing ratio 2:1 Fig. 10: Design of the unit with mixing ratio 2:1 Description Mixing unit section 3.6 on page 27 Static mixer section 3.6 on page 27 Proportioning unit section 3.6 on page 27 Proportioning panel section 3.4 on page 23 Console, adjustable Compressed air shut-off valve... -
Page 28: Design With Mixing Ratio 10:1
Description 3.3.4 Design with mixing ratio 10:1 Fig. 11: Design of the unit with mixing ratio 10:1 Description Mixing unit section 3.6 on page 27 Static mixer section 3.6 on page 27 Proportioning unit section 3.6 on page 27 Proportioning panel section 3.4 on page 23 Cartridge filling device section 3.7.2 on page 30... -
Page 29: Operating Panel
Description 3.4 Operating panel Most of the control elements and displays for the machine are located on the operating panel. Fig. 12: Operating panel Description Optical display for component B container empty message – If the minimum fill level has been reached in the container, a green pin is pressed out Component B feed pump pressure display Optical display for component A container empty message –... -
Page 30: Extrusion Units
Description 3.5 Extrusion units Extrusion units are generally used for the material feed for components A and B. The sizes for this are customer-specific, depending on the properties of the processing materials and the required mixing ratio. Various equipment can be used to feed the material. - Page 31 Description Description Venting ball valve of the feed pump Fluid pump of the feed pump Compressed air connection for the ventilation of the material drum Shut-off valve for venting the material drum Follower plate Traverse of the ram Pneumatic cylinder of the ram Holder for lashing strap Connection for container ventilation on the follower plate Drum stop...
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Page 32: Pressure Vessel
Description The fill level in each material drum is monitored with a sensor on the rear side of one of the two pneumatic cylin- ders. As soon as the set minimum quantity has been reached, the sensor triggers a container empty message. A green pin is then pressed out in the optical display for the container empty mes- sage of the respective component on... -
Page 33: Proportioning And Mixing Unit
Description To fill the container, the cover screw connection must be released. After the filling, the pressure vessel is closed again and pressurized. The processing material is pressed out of the pressure vessel into the proportioning cylinder for component B through the pressurization. As soon as the set minimum fill level in the component A container is reached, the fill level in the pressure vessel has also dropped to a minimum. -
Page 34: Description 1
Description Fig. 18: Proportioning and mixing unit for model Fig. 19: Proportioning and mixing unit for model with mixing unit 1:1 with mixing unit 1:1 Fig. 20: Proportioning and mixing unit for model Fig. 21: Proportioning and mixing unit for model with mixing unit 2:1 with mixing unit 10:1 Designation... -
Page 35: Optional Expansions And Accessories
The following list contains just some of the most common accessories and expan- sions. The detailed accessory catalog can be found at www.wiwa.de. For further informa- tion and order numbers, you can also contact a WIWA dealer or WIWA customer service. Original Operation Manual ✓(2023/09/04), Status: 2024/09/11... -
Page 36: Console
Description 3.7.1 Console A height adjustable console can op- tionally be installed on the operating panel. The position can be adjusted to the material drum used. The height of the console is set as follows: 1. Loosen the nuts underneath the console. -
Page 37: Foot Pedal
Description 4. Release the cartridge locking device. 5. Insert the cartridge into the cartridge holder with the opening pointing up. 6. Lock the cartridge with the cartridge locking device. 3.7.3 Foot pedal The filling process can be controlled using a foot pedal. 1. -
Page 38: Transport, Installation, And Assembly
Transport, installation, and assembly 4 Transport, installation, and assembly Only carry out the transport, installation, and assembly of the unit if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 15. The unit left the factory in faultless condition and was packaged correctly for transport. -
Page 39: Installation Site
Transport, installation, and assembly 4.2 Installation site The machine can be installed inside or outside spray booths. In order to avoid con- tamination, installation outside of the immediate spraying area is recommended. WARNING If the machine is used outdoors during a storm, a life-endangering situation may arise for the operating personnel due to lightning! Never operate a machine outdoors during a storm! The owner must ensure that the machine is equipped with suitable lightning... -
Page 40: Assembly
Transport, installation, and assembly 4.3 Assembly WARNING If untrained personnel carry out assembly work, they endanger themselves and others, as well as risking the operational safety of the unit. Electrical and electronic parts may only be installed by specialist personnel with electrical training;... -
Page 41: Compressed Air Shut-Off
Transport, installation, and assembly Operation with contaminated or moist compressed air leads to damage in the machine’s pneumatic system. Use only dried, oil-free and dust-free compressed air, which corresponds to purity class [7:5:4] according to ISO 8573-1:2010! 1. Ensure that all compressed air regulators are turned down completely and all compressed air shut-off... -
Page 42: Operation
Operation 5 Operation Only put the machine into operation if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 15. The unit must be correctly erected and fully assembled. The air inlet pressure can be found in the information on the type plate (sec- tion 8.2 on page 54). -
Page 43: Starting The Unit
Operation 4. Fill and ventilate the proportioning and mixing unit 5. Install the static mixer Always pay attention to the correct component assignment. The two components of the processing material may only come in contact with the intended machine parts: blue = standard component (A) red = hardener (B) 5.1.1 Starting the unit... -
Page 44: Filling The Pressure Vessels With Processing Material
Operation – Pull off the ventilation tube for the venting of the material drum on the follower plate. – Open the shut-off valve for the venting of the material drum on the follower plate. Set the control lever of the ram back to As soon as material is visible at the connection for the venting of the material drum, the air has escaped from the material drum. -
Page 45: Filling And Ventilating The Proportioning And Mixing Unit
Operation 5.1.4 Filling and ventilating the proportioning and mixing unit 1. Place a material collecting vessel under the material outlet of the mixing unit (without static mixer). 2. Press the “Start” button on the operating panel. The proportioning cylinders of both components are now pressed out and filled again using the feed pumps. -
Page 46: Flushing
Operation 5.4 Flushing Flushing the machine is necessary during initial commissioning so that the processing material is not influenced by the test substance with which the machine was tested for fault-free functioning in the factory, when material is changed, when work is interrupted and when decommissioning, in order to flush the processing material out of the machine before it hardens. -
Page 47: Decommissioning
Operation 5.6 Decommissioning 1. Close the compressed air shut-off valves at the compressed air connection underneath the operating panel and at the feed pumps, optionally on the pressure vessel. 2. Disassemble the static mixer. The static mixer is only suitable for one-time use and must be properly dis- posed after the end of use. -
Page 48: Maintenance
Maintenance and repair work on electrical parts may only be performed by specialist personnel with electrical qualifications — all other maintenance and repair work may only be done by WIWA customer service or specially trained personnel. WARNING During maintenance work, ignition sources may arise (e. -
Page 49: Regular Testing
The test certificate or a copy of this must be available at the unit’s place of use. Have repair work carried out exclusively by WIWA Service or specialist personnel in/from authorized workshops. When using the unit in EX-zones, the specialist personnel must have knowledge of ATEX. -
Page 50: Safety Valve
Maintenance Time frame Activity for further reading Prior to each commissioning Check the safety features and section 2.4 on page 9 control panels for functionality Check the release agent levels section 6.5 on page 46 Adjust the packing section 6.6.1 on page 48 and section 6.6.2 on page 49 After the first 3 working days and Adjust the packing... -
Page 51: Replacing The Safety Valve
Maintenance Description Hexagon nut Knurled nut This is how to check the function of the safety valve: Safety valves with a ” connection: 1. Increase the air inlet pressure on the completely filled machine briefly to approx. 10 % over the maximum permissible pressure according to the type plate. The safety valve must discharge! Safety valves with a ”... -
Page 52: Maintaining The Filter Regulator
(section 6.6.3 on page 49). After performing the check, add a corresponding quantity of clean release agent through the filler opening. We recommend using the release agent from WIWA (order no. 0163333). Original Operation Manual ✓(2023/09/04), Status: 2024/09/11... -
Page 53: Checking The Release Agent Level In The Feed Pumps
Maintenance 6.5.1 Checking the release agent level in the feed pumps Fig. 30: Example of adjusting cup on the feed Fig. 31: Example of adjusting cup on the feed pump 134.26 pump 37.04,5 with a mixing ratio 1:0.03 At maximum fill level, the adjusting cup is completely filled in each case. 6.5.2 Checking the release agent level in the release agent container Only for model with pressure vessel (optional). -
Page 54: Checking The Release Agent Level In The Automatic Valves
Maintenance 6.5.3 Checking the release agent level in the automatic valves Only for model with pressure vessel (optional). To protect the valve needle, there must always be release agent in the packing gland screw. Refill the release agent if necessary. Observe the separate operation manual for the automatic valves. -
Page 55: Adjusting The Packing Of The Feed Pump 37.04,5
Maintenance 3. Insert the attached pin wrench into a free bore of the adjusting cup. 4. Turn the adjusting cup to the right until resistance can be felt. Then turn it another quarter turn. 6.6.2 Adjusting the packing of the feed pump 37.04,5 1. -
Page 56: Removing The Silica Gel Filter
Maintenance 6.7.1 Removing the silica gel filter Only for model with pressure vessel (optional). If the granulate has changed color to white, it is saturated with moisture and must either be dried or replaced. Designation Locking slide Granulate container Fig. 35: Removing the silica gel filter 1. -
Page 57: Installing The Silica Gel Filter
Make sure the O-ring is seated correctly! No granulate may be stuck in the screw connection! When screwing in the double nipple use thread locker or Teflon tape. 6.7.4 Accessories for silica gel filter Designation WIWA order number Drying pellets (65 g / 0.14 lbs ) 0648622 Teflon tape 0000099 6.8 Checking the compressed air and material hoses... -
Page 58: Recommended Operating Fluids
Maintenance 6.9 Recommended operating fluids Only use original operating fluids from WIWA: Operating materials WIWA order number Release agent, yellow, standard (0.5 l) 0163333 Release agent, red, for isocyanate (0.5 l) 0640651 Locking agent (50 ml) 0000015 Lubricant (acid-free grease, 0.4 kg) -
Page 59: Eliminating Operational Faults
Eliminating operational faults 7 Eliminating operational faults Only eliminate operational faults if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 15. fault possible cause remedy After starting the unit, no mate- Material drum empty Add material rial is pressed out... -
Page 60: Technical Data
Technical data 8 Technical data You can find the technical data for your unit on the machine card enclosed, on the type plate or in the documentation for the individual components. 8.1 Machine card The machine card contains all important and safety-relevant data and information regarding your unit: precise designation and manufacturer’s data, technical data and limit values,... - Page 61 Technical data Please ensure that the data on the type plate matches the information on the machine card. If there are discrepancies, or the type plate is missing, please inform us immediately. Furthermore, some unit components have a separate type plate, such as e.g. the feed pumps.
- Page 62 Technical data Original Operation Manual ✓(2023/09/04), Status: 2024/09/11 2dom_BA_en_B0550055...
- Page 63 Headquarter and production WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestraße 1–3 35633 Lahnau Germany Phone: +49 (0)6441 609-0 Fax: +49 (0)6441 609-2450 Email: info@wiwa.de Website: www.wiwa.de WIWA subsidiary USA WIWA LLC – USA, Kanada, Lateinamerika 107 N. Main St.
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