Walther Systemtechnik WDV-01, WDV-02, WDV-04, WDV-03 Assembly & Instruction Manual

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 1 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

Assembly Instructions

Dosing Valves

Article Numbers: WDV-01 Dosing volume 0.001 – 0.020 cm³
WDV-02 Dosing volume 0.010 – 0.200 cm³
WDV-03 Dosing volume 0.100 – 2.000 cm³
WDV-04 Dosing volume 1.000 – 6.000 cm³

WDV-01

WDV-02

WALTHER-Dosing Valve

0.001 – 0.020 cm³
(1 – 20 mm³)

WALTHER-Dosing Valve

0.010 – 0.200 cm³
(10 – 200 mm³)

WDV-03

WDV-04

WALTHER-Dosing Valve

0.100 – 2.000 cm³
(100 – 2000 mm³)

WALTHER-Dosing Valve

1.000 – 6.000 cm³

(1000 – 6000 mm³)

NOTE

Please read these Assembly Instructions carefully before first using the device and strictly
adhere to the instructions!

This device may only be worked with and worked on by persons who are familiar with the
Assembly Instructions and the current regulations for industrial safety and accident
prevention.

Always keep this translation of the “Original Assembly Instructions“ at the device!

The manual has to be available anytime!

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 2 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

Table of Contents

Page

EC DECLARATION OF INCORPORATION ....................................................................................................................... 4

1 INTRODUCTION ................................................................................................................................................. 5

1.1 TARGET GROUP OF THE ASSEMBLY INSTRUCTIONS ............................................................................................................ 5

1.2 LIST OF SIGNS AND SYMBOLS ....................................................................................................................................... 5

2 SAFETY............................................................................................................................................................... 5

2.1 GENERAL INFORMATION ............................................................................................................................................. 5

2.2 DANGERS FROM RESIDUAL ENERGIES ............................................................................................................................. 5

2.3 WARRANTY AND LIABILITY ........................................................................................................................................... 5

2.4 CORRECT USE ........................................................................................................................................................... 6

2.5 INCORRECT USE ........................................................................................................................................................ 6

2.6 QUALIFICATION OF PERSONNEL .................................................................................................................................... 6

3 TRANSPORT ....................................................................................................................................................... 7

3.1 PACKAGING .............................................................................................................................................................. 7

3.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 7

4 DESCRIPTION OF FUNCTION .............................................................................................................................. 7

4.1 DESIGNATED USE OF THE INCOMPLETE DEVICE ................................................................................................................ 7

4.2 TYPE LABEL OF THE INCOMPLETE DEVICE ........................................................................................................................ 7

4.3 FUNCTIONAL PRINCIPLE .............................................................................................................................................. 8

4.4 STEPS IN THE DOSING PROCESS WITH THE WDV .............................................................................................................. 9

4.5 TECHNICAL DATA ..................................................................................................................................................... 11

5 INITIAL START-UP ............................................................................................................................................. 12

5.1 MOUNTING AND INSTALLATION .................................................................................................................................. 12

5.2 ADJUSTING THE INCOMPLETE DEVICE .......................................................................................................................... 12

6 OPERATION ..................................................................................................................................................... 13

6.1 GENERAL INFORMATION ........................................................................................................................................... 13

6.2 OPERATING ELEMENTS ............................................................................................................................................. 13

6.3 ADJUSTING THE DOSED QUANTITY .............................................................................................................................. 13

7 TAKING OUT OF SERVICE ................................................................................................................................. 14

7.1 SHORT INTERRUPTION .............................................................................................................................................. 14

7.2 LONG-TERM INTERRUPTION ....................................................................................................................................... 14

7.3 SHUTDOWN OF DEVICE ............................................................................................................................................. 14

8 MAINTENANCE AND REPAIR ............................................................................................................................ 15

8.1 GENERAL INFORMATION ........................................................................................................................................... 15

8.2 ROUTINE TASKS ....................................................................................................................................................... 15

8.3 CLEANING .............................................................................................................................................................. 15

8.4 SPARE PARTS .......................................................................................................................................................... 15

8.5 CUSTOMER SERVICE / SUPPORT .................................................................................................................................. 16

9 TROUBLESHOOTING ........................................................................................................................................ 16

9.1 GENERAL INFORMATION ........................................................................................................................................... 16

10 APPENDIX ........................................................................................................................................................ 17

10.1 DIMENSIONED DRAWING – DOSING VALVE WDV-01 ................................................................................................ 17

10.1.1 Spare Part Drawing – Dosing Valve WDV-01 ........................................................................................ 18

10.1.2 Spare Part List Dosing Valve WDV-01 up to batch no. 013078 ............................................................. 19

10.1.3 Spare Part List Dosing Valve WDV-01 from batch no. 018633 .............................................................. 20

10.1.4 Wear Part Kits ...................................................................................................................................... 20

10.2 DIMENSIONED DRAWING DOSING VALVE WDV-02 ................................................................................................... 21

10.2.1 Spare Part Drawing Dosing Valve WDV-02 ........................................................................................... 22

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 3 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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10.2.2 Spare Part List Dosing Valve WDV-02 up to batch no. 014696 ............................................................. 23

10.2.3 Spare Part List Dosing Valve WDV-02 from batch no. 018322 ............................................................. 24

10.2.4 Wear Part Kits ...................................................................................................................................... 24

10.3 DIMENSIONED DRAWING DOSING VALVE WDV-03 ................................................................................................... 25

10.3.1 Spare Part Drawing Dosing Valve WDV-03 ........................................................................................... 26

10.3.2 Spare Part List Dosing Valve WDV-03 up to batch no. 011386 ............................................................ 27

10.3.3 Spare Part List Dosing Valve WDV-03 from batch no. 016056 ............................................................. 28

10.3.4 Wear Part Kits ...................................................................................................................................... 28

10.4 DIMENSIONED DRAWING DOSING VALVE WDV-04 ................................................................................................... 29

10.4.1 Spart Part Drawing Dosing Valve WDV-04 ........................................................................................... 30

10.4.2 Spare Part List Dosing Valve WDV-04 up to batch no. 011387 ............................................................ 31

10.4.3 Spare Part List Dosing Valve WDV-04 from batch no. 023000 ............................................................. 32

10.4.4 Wear Part Kits ...................................................................................................................................... 32

10.5 ACCESSORIES ..................................................................................................................................................... 33

10.5.1 Data Sheet – Dosing Piston Sensor (Article No. WDV-DS) .................................................................... 34

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 4 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

EC Declaration of Incorporation

in accordance with EU Machinery Directive 2006/42/EU, dated 17 May 2006, Appendix II B

We herewith confirm that the below mentioned incomplete device meets the basic requirements for safety
and health as stated in EU Machinery Directive 2006/42/EU for its design and construction as well as for the
configuration released by us on the market. This machine component will not be operated before it has been
determined that the incomplete system where the machine component will be installed also meets the
requirements of the Directive (2006/42/EG).

Manufacturer

Walther Systemtechnik GmbH
Hockenheimer Straße 3
D- 76726 Germersheim

Description

Dosing Valves, Article No. WDV-01 bis 04

We also declare the conformity with other, product-relevant directives/guidelines:

Mach. Direct. 2006/42/EU App. I, Clause: 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.3.2, 1.3.3,

1.3.4, 1.5.9
EMC- Directive 2014/30/EU, dated 26. February 2014

Applied harmonized standards, in particular:

DIN EN ISO 12100 Safety of Machinery – General Design Principles –

Risk Assessment and Risk Reduction (ISO
12100:2010)

In addition, we also confirm that the special documentation according to Appendix VII Part B has
been prepared.

The manufacturer, respectively his authorized representative obligates himself to submit this documentation
to the market surveillance authorities, if requested.

This EC Declaration of Incorporation becomes invalid if the incomplete device will be altered or changed
without consent of Walther Systemtechnik GmbH.

Authorized representative for Technical Documentation:

Stefan Hirl, Hockenheimer Straße 3, D- 76726 Germersheim

Germersheim, 09 August 2016
(Place, Date) (Stefan Hirl, Management)

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 5 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

1 Introduction

1.1 Target Group of the Assembly Instructions

 Operating Personnel
 Maintenance Personnel

1.2 List of Signs and Symbols

Symbols are used to identify hazards and certain practices. Symbols are also used in the assembly
instructions. The below symbols for hazards and information describe circumstances which can result in
damages to persons, objects and environment if not observed.

The following terms and symbols are used in the assembly instructions to identify hazards:

DANGER

Describes a potentially dangerous situation.
Death, grievous bodily harm or severe material damage WILL occur if the respective
measures of precaution have not been taken.

WARNING

Describes a potentially dangerous situation.
Death, grievous bodily harm or severe material damage MAY occur if the respective
measures of precaution have not been taken.

CAUTION

Describes a potentially dangerous situation.
Slight injuries CAN occur if the respective measures of precaution have not been taken.
This signal word is also used to describe possible property damages.

IMPORTANT

Indicates tips for usage and other particularly useful information.

No dangerous situation.

2 Safety

2.1 General Information

The construction of this incomplete device is according to the latest technology and is absolutely reliable.
The individual components as well as the complete device are continuously checked by our quality man­agement.

2.2 Dangers from Residual Energies

Please instruct the operating personnel on the respective measures to be taken against the occurrence of
mechanical, hydraulic, pneumatic and electric / electronic residual energies.

2.3 Warranty and Liability

According to the conditions laid down by the German Engineering Federation (VDMA), Walther Systemtech­nik GmbH has a guarantee of 12 months under normal European operating conditions on its own parts
(spare parts are excluded); or according to the conditions of the manufacturer.

This guarantee can only be granted by Walther Systemtechnik GmbH, if:

 the user has thorough knowledge of the content of these assembly instructions;
 the user follows the instructions and notes contained in these assembly instructions;
 the user does not rebuild or make changes on parts of the (incomplete) device without prior consent

of WST Systemtechnik GmbH.

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 6 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

2.4 Correct Use

CAUTION

This device will not be operated under other than the described conditions.
It has solely been designed for the dosing of media in accordance with the detailed
information of this operating manual. Any other type of use or beyond is considered as
not intended. The manufacturer cannot be made liable for damages resulting from such
incorrect use

Correct use of the device also includes:

 Observing and adhering to all operating instruction s stated in this manual.

 Adherence to inspection and maintenance tasks.

2.5 Incorrect Use

The manufacturer cannot be made liable for damages resulting from such incorrect use; incorrect use
includes among others:

 Processing aggressive media (such as acids, alkaline, cleaning agents, chemicals etc.) or media

which have not been approved in writing by the manufacturer;

 Using corrosive and / or curable materials;
 Operating the device with insufficient knowledge about the operation, maintenance and care of the

device.

 Making changes, extensions or alterations on the device that may hamper its safety without the prior

consent of Walther Systemtechnik GmbH.

 Operating the device with defective safety installations or not properly attached or malfunctioning

safety devices.

 Handling the device while energized

2.6 Qualification of Personnel

Only trained and instructed personnel may conduct work on the equipment.
The responsibilities of the personnel for assembly work, operation, repair work or maintenance work must be
clearly assigned to individuals!

Persons in training may work with the equipment only under supervision of an experienced person.

Personnel

Task

Instructed
Personnel

Personnel with Technical
Qualification

Specialist

Supervisor

Packaging, Transport

X

-

-

-

Commissioning

X

X

-

Operation

X

-

Troubleshooting, general

X

X

-

Troubleshooting
mechanical

-

X

-

-

Troubleshooting electrical

-

-

X

-

Setting up

-

X

-

-

Maintenance

-

X

-

-

Repair

-

X

X

-

Taking out of service,
Storage

-

X

X

-

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 7 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

3 Transport

3.1 Packaging

The type of packaging depends on the individual mode of shipping. If not separately contracted, the
packaging is in accordance with the rules and regulations of Walther Systemtechnik GmbH. This rule is in
accordance with the Federal Association for Packaging HPE.

3.2 Tasks before Transport

The following has to be done before transport:

 Disconnect all power lines.

The actual transport of the device and its individual parts requires special care in order to prevent damages
from external forceful impact or careless on- and off-loading. Depending on the mode of transportation,
suitable transport and load securing has to be selected. The device will be aligned and leveled by

appropriate fastening elements.

4 Description of Function

4.1 Designated Use of the Incomplete Device

Dosing valves are used for the application of a pre-defined quantity of medium on certain selected parts. A
special drive technology (pneumatic/electric) will define and control the application time. The Dosing Valves
are also suitable for use with oil.

4.2 Type Label of the Incomplete Device

The Dosing Valve is marked on the side of the
housing by an engraving that contains the
production number, the article number, the max.
operating pressure and the dosing volume.

IMPORTANT

Please indicate the product information shown on the type label when ordering spare
parts or requesting technical support.

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 8 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

4.3 Functional Principle

The pneumatic part of the dosing valve is controlled by a 5/2-way valve. This initiates the grease dosing. The
dosing pressure depends on the lubricant feed pressure (medium).

In order to obtain a high quality and repeatability of the dosing process, the complete cycle must be complet­ed. This means that the control piston must be driven from the starting position to the dosing position and
then back to the starting position.

LEGEND
Pos. Description

1 Support bracket
2 Connection for medium G 1/8“ (in the back of the support frame)
3 Connection for air ø4 mm
4 Regulating screw
5 Dosing output
6 Fastening screw

5 3 3 4 1

2

6

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Assembly Instructions – Dosing Valves WDV-0x

Page 9 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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4.4 Steps in the Dosing Process with the WDV

I Dosing lift

1. The dosing chamber is filled with medium before the actual dosing

Controlled via an external 5/2-way valve, the air piston first moves to the front end position

2. After having reached the end position, the dosing piston moves and the dosing chamber is emptied

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 10 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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II Refill lift

3. Once the dosing piston reaches the end position, the dosing piston sensor sends a signal, if
applicable. The volume has been completely dosed.

4. Controlled by the external 5/2-way valve, the air piston is moved back into the basic position.

5. Also the dosing piston will be moved hereby and the dosing chamber is refilled by in-flowing medium.
Both pistons have returned into the basic position.

6. The cycle can start again.

Rev. 1.2

Assembly Instructions – Dosing Valves WDV-0x

Page 11 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

4.5 Technical Data

WALTHER-Dosing Valve WDV-01

WALTHER-Dosing Valve WDV-02

Dosing range [cm³] / [mm³]

0.001 – 0.020
1 – 20

0.010 – 0.200

10 – 200

Weight [kg]

0.180

0.182

Material inlet [mm]

External thread G 1/8

Material outlet [mm]

Internal thread M61

Compressed air supply
[mm]

Swivel-type angles M 3 for hose 4/2

Fixture [mm]

2 x M 4

min. / max. material inlet
pressure [bar]

20 / 200

min. / max. pneumatic
operating pressure [bar]

5 / 7

1

Do not exceed the max. screw-in depth!

WALTHER-Dosing Valve WDV-03

WALTHER-Dosing Valve WDV-04

Dosing range [cm³] / [mm³]

0.100 – 2.000

100 – 2000

1.000 – 6.000

1000 – 6000

Weight [kg]

0.773

0.802

Material inlet [mm]

External thread G 1/4

Material outlet [mm]

Internal thread G 1/8

Compressed air supply
[mm]

Swivel-type angles M 3 for hose 4/2

Fixture [mm]

2 x M 4

min. / max. material inlet
pressure [bar]

20 / 160

min. / max. pneumatic
operating pressure [bar]

5 / 7

Article Number

WDV-DS

Construction type

2.9 x 16.8 x 4.5

Switching output

PNP

Switching function

NO switch

Electrical version

DC voltage

Rated operating voltage [V DC]

24

Rated normal current [mA]

100

Ambient temperature min. [C°]

-25

Ambient temperature max. [C°]

+85

Connection

cable with plug connector

Protection type according to DIN 40050

IP 67

Housing material

PA 12