Practical Guide
Setting up WIWA DOSYS XL correctly – constant mixing, large-scale coating
This guide shows you in a practical way how to prepare the DOSYS XL for continuous 2K delivery and bubble-free mixing – including standard values, workflow, troubleshooting, and maintenance.
Large-Area Coatings
2K Bonding & Sealing
Constant Mixing Ratio
WIWA DOSYS XL – stationary/trolley-mounted for high flow rates
Introduction: What you gain with the DOSYS XL in practice
When 2K materials are mixed by hand, the result often fluctuates – depending on daily form, user, and process discipline. The DOSYS XL is designed to reduce this variance: It was specifically developed for large-scale industrial coatings where continuous delivery performance matters, and focuses on bubble-free mixing with a constant mixing ratio.
At the same time, material extraction from large and differently sized containers ensures an economical material flow – ideal when downtimes and rework become expensive.
Product Overview: Variants, Applications, Advantages (Brief Comparison)
| Variant / Order No. | Mixing Ratio (Example) | Output per Cycle | Max. Operating Pressure | Typical Use |
|---|---|---|---|---|
| DOSYS XL 0671751 | 1:1 (Example system) | 2106 cm³ | 208 bar | Large-area, continuous, 2K bonding/sealing |
| DOSYS XL 0671752 | 1:1 (Example system) | 2106 cm³ | 270 bar | Higher pressure requirement for viscous materials |
| DOSYS XL 0671758 | 5:1 (Example system) | 1263 cm³ | 192 bar | Other mixing ratios / process windows |
Note: The DOSYS XL is modularly configurable (e.g., different delivery rates, mixing ratios, feed variants).
KPI Boxes: How to recognize a "good setup" in 3 points
KPI 1
Constant Mixing Ratio
No visible fluctuations in application over the shift length.
KPI 2
Bubble-Free Mixing
Less rework (e.g., filling/sanding) due to a clean surface.
KPI 3
Stable Flow Rate
Uniform material flow without pulsation – even with viscous media.
Pro Tip (Yellow Box): Stable application through pressure control + temperature
If your material tends to pulsate or the application "breathes," rely on clean pressure management:
Material pressure regulators can stabilize outlet pressure and compensate for pulsation – especially helpful when piston pumps are delivering.
For very high-viscosity media, a heated follower plate additionally boosts the material flow significantly (less "drag" on the system).
CTA: Select DOSYS XL directly
Choose the appropriate DOSYS XL variant – we are happy to help with mixing ratios, flow rates, and accessories.
Recommended Basic Settings (Guide Values)
The following values are guide values from typical DOSYS XL example systems. Your actual needs depend heavily on material viscosity, hose lengths, temperature, and tools (e.g., mixer/nozzle).
| Parameter | Guide Value / Starting Point | Why this helps |
|---|---|---|
| Air Inlet Pressure | up to max. 8 bar | Basis for stable flow rate (do not exceed maximum value). |
| Output per Cycle | 1263–2106 cm³ (model dependent) | Dimensions your timing / throughput planning. |
| Max. Operating Pressure | approx. 192–270 bar (model dependent) | Relevant for viscous media, long lines, restrictive mixers. |
| Material Pressure Regulation (optional) | e.g., control ranges 10–320 bar / 20–250 bar / 25–275 bar (depending on regulator) | Helps to stabilize outlet pressure and compensate for pulsation. |
Tip: If the material runs "sluggishly," check the temperature management first (e.g., heated follower plate) and only then increase the pressure.
Professional Workflow (5–7 Steps) – How to start production cleanly
- Define Variant & Mixing Ratio: Choose the sample mixing ratio (e.g., 1:1 or 5:1) and the appropriate order number for your process window.
- Prepare Containers & Feeding: Use large containers/drum feeding to minimize downtime. Ensure clean suction paths and tightness.
- Stabilize Temperature: For high-viscosity media: use follower plate/heating until a uniform material flow is achieved (do not "start cold").
- Adjust Pressure Management: Bring air supply to a stable, reproducible value (start below maximum limits). Optionally use material pressure regulators to smooth the outlet pressure.
- Bleed/Prime Material Paths: Start both components separately until no air pockets/interruptions are visible.
- Test Application + Check Mixing Pattern: Brief test application (e.g., on a test plate) – evaluate surface and reaction pattern. Only then release for series production.
- Secure Series Process: Document parameters (pressure/temperature/material batch). Check visually at fixed intervals during long shifts.
Troubleshooting: 4 Typical Problems + Quick Measures
1) Bubbles / Pores in Application
- Repeat priming/bleeding until both components run absolutely uniformly.
- Check mixers/lines for air intake (tightness, connections, suction side).
- Stabilize material temperature (high viscosity = heat rather than "more pressure").
2) Mixing Ratio Drifts / Reacts "Oddly"
- Check feeding of both components (fill level, suction, blockage, check valve).
- Verify unit configuration/mixing ratio (example system vs. project requirement).
- Keep temperature constant if viscosity fluctuates heavily (batch/environment).
3) Flow Rate Drops / "Starving"
- Check suction side: avoid cavitation, bleed/seal container properly.
- Use heating/follower plate to improve material flow (high viscosity).
- Check filters/mixers for partial blockage and clean.
4) Pulsation / Unsteady Bead
- Use/correctly dimension material pressure regulators to compensate for pulsation.
- Protect hose routing (no kinks, minimum bend radii), keep line lengths pragmatic.
- Check filter condition (system "pumps" if partially blocked).
Maintenance (5 Points) – Ensuring the DOSYS XL delivers constantly
- Filter Care: Regularly check/clean filters to ensure throughput and pressure stability.
- Check Tightness: Check suction and pressure sides for air intake/leakage (common cause of bubbles).
- Clean Mixer/Dispenser: Avoid restrictions – otherwise pressure demand increases unnecessarily.
- Check Heating Components: Monitor follower plate/heating circuits for stable temperature control (highly beneficial for viscous media).
- Document Parameters: Record "best setup" for each material/batch (pressure, temperature, tool, hose length).
FAQ (Practically Relevant)
1) Which DOSYS XL variant is the right one?
Choose based on mixing ratio, required output per cycle, and the pressure window of your material. For higher pressure requirements, the 270-bar variant is the obvious choice; other processes benefit from 192/208 bar.
2) Do I always have to increase pressure for viscous materials?
Not necessarily. Often, constant temperature management (e.g., heated follower plate) is the better lever because it improves material flow before you run the process "hard."
3) How do I get pulsation under control?
A material pressure regulator can stabilize outlet pressure and compensate for pulsation. Additionally, clean hose routing (without kinks) and well-maintained filters help.
4) Which materials typically fit the DOSYS XL?
Typical are 2K fillers (e.g., epoxy/PU/peroxide-based), adhesives, sealants, thickeners, putties, and insulation/isolating materials – especially when continuous delivery is required.
5) Can I adjust the mixing ratio and flow rate for specific projects?
Yes – the DOSYS XL is modular and can be configured in many parameters (e.g., mixing ratio, flow rate, feed variants). For optimal design, it is worth coordinating based on your material and process goal.
Conclusion
The WIWA DOSYS XL shows its strength when you need to process on a large scale and continuously: constant mixing ratio, bubble-free mixing, and stable throughput reduce rework and make your process reproducible. Start with guide values, ensure temperature and pressure management – and document your "Best Setup" for each material.
