DLS DLS-47 Series User manual

User manual
DLS-47x
DLS-47x-2C

Page 2 of 35
User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
Translation
With deliveries into the member states of the EU, the operating
manual has to be translated in the language of the user’s
country.
In case of any discrepancy in the translated text, the original
operating manual (German) is the reference to be used for
clarication or the manufacturer to be contacted.
Copyright
Distribution and copying of this document as well as utilization
and information on its content are prohibited, unless expressly
permitted. Violation of this stipulation leads to payment of
indemnication.
All rights reserved.

Content
1. Important note on this operating manual 5
1.1 Users 5
1.2 Obligation for reading 5
1.3 In case of questions 5
1.4 Operating manual 5
1.4.1 Validity 5
1.4.2 Content and purpose 5
1.4.3 Site 5
1.4.4 Meaning of the safety instructions and signs 6
2. Identication 7
2.1 Product brand and type designation 7
2.2 Product version 7
2.3 Product designation 7
2.4 Conformity 7
3. Product decription 8
3.1 Purpose 8
3.2 Limitation of use 8
3.3 Environmental conditions 8
3.4 Intended use 9
3.5 Technical data 9
3.5.1 Components 9
3.5.2 Dimensions (in mm) 10
3.5.3 Technical data 12
4. Functional description 14
4.1 Drive 14
4.2 Operation 14
4.3 Outlets 15
4.4 Function monitoring 15
4.5 Level monitoring 15
4.6 Reservoir cartridge control 15
4.7 „Smart 2 Cycle“ version 16
4.8 Overpressure shut-off (only S2C version) 16
4.9 Level prewarning (only S2C version) 16
4.10 Temperature monitoring (only S2C version) 16
5. Safety instructions 17
5.1 Fundamental rule 17
5.2 Required users’ skills 17
5.3 Safety facilities 17
5.4 Accident prevention 17
5.5 Residual risk 18
5.6 Incorrect applications 18
5.7 General safety regulations and duties 18
5.8 Exclusion of liability 19
6. Transportation, installation, commissioning and shut-down transport 19
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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511

6.1 Transportation 19
6.2 Unpacking 19
6.3 Installation 19
6.4 Power supply and powering-up 20
6.5 Commissioning 22
6.5.1 Assistance with initial lling (reservoir variants 380, 250 and 125) 22
6.5.2 Proposed technical modications and conversions 23
6.5.2.1 Assembly of the reservoir types 380, 250, 125 23
6.5.2.2 Assembly of the reservoir DIN 1284 23
6.5.2.3 Assembly of the reservoirs Lube-Shuttle / System Reiner 23
6.5.2.4 Foreign reservoir 24
6.5.2.5 Mounting of the non-return valve cartridges 24
6.5.2.6 Closing an outlet 24
6.5.2.7 Conversion from conical grease nipple to sealing nipple „B“ 25
6.5.2.8 Conversion from conical grease nipple to locking coupling „C“ 26
6.6 Shutdown 27
7. Operation 28
7.1 Exemplary actuation for standard operating mode 28
7.2 Exemplary actuation for dual-cycle lubrication operating mode 29
7.3 Troubleshooting, fault remedy 31
7.2 Relling the reservoir 31
7.3 Switching off 32
8. Cleaning, servicing, fault remedy, and repair 32
8.1 Cleaning 32
8.2 Servicing 32
8.3 Inspection chart 33
8.4 Repair 33
8.5 Accessories 33
9. Return to factory 34
10. Disposal 34
11. Note on the REACH regulation (1907/2006) 34
12. Declaration of conformity 35
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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
1. Important note on this operating manual
This operating manual is part of the machine and has to be accessible to the operators and main-
tenance staff at any time. The safety instructions in the operating manual must be observed. If the
machine is sold, the operating manual has to be included in the delivery.
In addition to this operation manual, always be careful to observe the laws and regulations being
applicable in the country of use.
1.1 Users
1.4 Operating manual
This operating manual is directed to technically qualied users, who were trained and instructed for the
operation of this machine.
1.2 Obligation for reading
As user and operator of the machine, you are obliged reading and understanding this operating manual,
and in particular, the chapter „Safety regulations“. It is your safety! In case of questions and doubt, please
contact DLS Schmiersysteme GmbH.
1.3 In case of questions
DLS Schmiersysteme GmbH will support you in case of questions you cannot solve by consulting this
operation manual. If such case arises, complete your question with a precise description of the situation.
1.4.1 Validity
This operating manual refers to the series type of the machines DLS-47x/-2C.
If sections of the operating manual refer to certain designs only, then special refer-ence is made to this.
1.4.2 Content and purpose
This operation manual contains the relevant information for the commissioning, operation and mainte-
nance of the pump unit. It is designed to help you in using the pump unit properly, efciently and safely.
1.4.3 Site
The operating manual has always to be available for the users at the workplace.

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
1.4.4 Meaning of the safety instructions and signs
Safety instructions
The pictograms and signal words for safety instructions, precautions and notes have the following mea-
ning in this operating manual:
Danger! Directly imminent danger, which may lead to severe body injuries.
Warning! Possibly imminent situation, which may lead to severe body injuries.
Caution! Possibly imminent situation, which may lead to light body injuries.
Caution! Warning of material damage.
Note! Possibly damaging situation, in which the product or an object in its environment
could be damaged.
Important! Notes on use as well as other useful information, which facilitate the use of the
product according to its intended technical purpose.
Danger! Directly imminent danger by electric power, which may lead to severe body injuries.

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
2. Identication
Piston pump unit of the manufacturer DLS Schmiersysteme GmbH
Produkttyp: DLS-47x // DLS-47x-2C
2.1 Product brand and type designation
Version from year of construction 2022
2.2 Product version
The type plate is mounted on the side of the pump body and contains the following details:
Typ (DLS-474)
No. <order number> (z. B. 2022010101)
Year of construction
2.3 Product designation
The pump unit complies with the requirements of the EC directive (2006/42/EC).
The pump unit complies with the requirements of the UKCA Safety Regulations 2008 No. 1597.
As for the declaration of conformity, see chapter 11.
2.4 Conformity
*For better understanding, the designation DLS-47x/-2C is used for both pump variants

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3. Product decription
3.1 Purpose
The pump unit DLS-47x/-2C is designed for the delivery of lube oils as of 150 mm²/s or for
the delivery of lube greases from NLGI class 000 up to NLGI class 2 exclusively. Different
viscosity classes are possible, but this requires careful verifycation. Therefore, please contact
DLS Schmiersysteme GmbH if you wish to operate the unit with lubricants other than those
described above.
3.2 Limitation of use
The range of use of the components of the pump unit is limited as follows:
Temperature range: -20 … +60 °C
Permitted discharge pressure: max. 70 bar
The device can also be used at lower temperatures, but this requires careful verication in combination
with the desired medium. Therefore, please contact DLS Schmiersysteme GmbH if you wish to operate
the device in a temperature range other than that described above.
Depending on the version, these limits of use may be restricted further. Such further restrictions are
dealt with in this operation manual later on. Besides, the unit’s area of application is determined by the
medium to be delivered. Hence, when determining the area of application, you also need to refer to the
technical data sheets for the medium to be used.
3.3 Environmental conditions
Unit operation in an aggressive atmosphere (solvent vapours, acids, lyes, saltwater mist, etc.)
may cause damage and/or corrosion of components and thus, failure of the installation as
well as hazards by escaping lubricant!
Ambient temperature range
lower limit temperature: - 20 °C
upper limit temperature: + 60 °C
relative humidity: max. 70%
Noise level: <70 dB(A)
Physical environment
Use of the installation above 1000 m sea level after consultation with the manufacturer only.

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3.4 Intended use
The unit is exclusively to be used for the supply of lubricating oils or greases in central lubricating instal-
lations. The intended use includes as well:
• Considering the safety instructions as well as safety regulations in this operating manual, and
• complying with the service and maintenance instructions in this operating manual.
Any other use or use beyond the intended one may result in severe damages of persons and
objects.
Any supply of gases, liqueed gases, gases liqueed under pressure, vapours and uids, whose
steam pressure exceeds the normal atmospheric one (1013 hPA) by more than 0,5 bar with the ad-
missible maximum temperature, highly ammable or explosive media as well as the supply of food
are interdict.
Important! Please consider the safety data sheets of the used sub-stances!
3.5 Technical data
3.5.1 Components
The unit consists of up to three assemblies the different versions of which may vary:
• Pump body with drive, function monitoring and level monitoring
• Reservoir
• Non-return valve cartridges (outlets)
The unit is designed for the direct lubrication of up to six lubrication points. Use the ow dividers to dis-
tribute the lubricant.
The unit is expressly not intended to supply a distribution system, especially not with main and secondary
distributors.
Due to the low ow rate, the use of the shortest possible lubricant lines is strongly recommended in or-
der to avoid ageing of the lubricant in the lines.

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
weight container
with contai-
ner 380
with contai-
ner 250
with contai-
ner 125
with DIN
1284
with Lube-
Shuttle
with System
Reiner
weight in kg ca. 1,6 ca 1,6 ca 1,6 ca 2,4 ca 2,0 ca 2,0
3.5.2 Dimensions (in mm)

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Lube-Shuttle System Reiner
DIN 1284
Container 250 Container 125
Space for
cartridge change

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3.5.3 Technical data
In its basic version, the unit comprises the pump body with DC motor. The technical data of this unit is as
follows:
• Unit: DLS-47x/-2C
• Delivery volume per stroke and outlet: 40 mm³
• Speed: ca. 6 min-1
• Number of outlets: 1 … 6
• Medium: Grease NLGI-Klasse 000 … 2
Oil 150 … 1900 mm²/s
• Temperature range: +10 … +80 °C
• Material Pump body: Aluminium anodized
galvanized steel
Sealings: FPM / NBR / HNBR
• Mounting position: vertical
• Protection class: DIN EN 60529 IP44
(only with mounted reservoir)
Motor:
• Voltage: 24 VDC
• Current consumption: max. 0,5 A
Level monitoring for reservoir 380, 250, 125:
• Voltage: 10 … 30 VUC
• Switching current: max. 0,25 A
• Switching capacity: 5 W/VA
• Switching function: NC contact at min
Function monitoring:
• Voltage: 10 … 30 VUC
• Switching current: max. 0,5 A
• Switching capacity: 10 W/VA
• Switching function: NO contact
1 signal per revolution
Reservoir cartridge control button:
• Voltage: 0,1 … 50 VUC
• Switching current: max. 0,2 A
• Switching function: NO contact
• Electrical connection of the pump: Male M12x1, 5-pin
The level monitoring of the reservoirs Lube-Shuttle, System Reiner and DIN1284 are connected separate-
ly (see also technical data of the respective reservoir variant).
If inductive or capacitive loads are connected, suitable protection circuits are to be installed! (diode,
RC-module, varistor)

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
Reservoir 380, 250, 125 with capacity 380 ml, 250 ml, 125 ml:
• Medium: Grease NLGI-Klasse 000 … 2
Oil 150 … 1900 mm²/s
• Material: Polyamid
• Weight: ca. 0,1 kg
• Mounting position: Grease: vertical
Oil: vertical
Reservoir DIN 1284
• Medium: Grease NLGI-Klasse 0 ... 2
other NLGI-classes upon request
• Material: St und Al
• Seals: NBR / FPM
• Weight without cartridge: ca. 0,9 kg
• Mounting position: vertical
Level monitoring:
• Voltage: 10 … 30 VUC
• Switching current: max. 250 mA
• Connection type: Male M8x1, 3-pin
• Protection class: DIN EN 60529 IP67
• Switching function: NC contact
• Connection diagram:
Reservoir System Lube Shuttle /
Reservoir System Reiner:
(the following piston must be at least 25 mm away from the edge of the cartridge)
• Medium: Grease NLGI-Klasse 0 ... 2
other NLGI-classes upon request
• Material: St, Al und PA
• Seals: FPM
• Weight without cartridge: ca. 0,5 kg
• Mounting position: vertical
• for cartridges: 400 or 500 g
Cartridges are not part of the scope of delivery!
Level monitoring:
• Voltage: 10 … 30 VUC
• Switching current:: max. 0,1 A
• Protection typ: DIN EN 60529 IP67
• Connection type: Cable with male M8x1, 3-pin
• Switching function: NC contact
• Connection diagram:

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
4. Functional description
4.1 Drive
The unit is driven by a DC motor, which is installed inside the pump.
4.2 Operation
The rotational movement of an electric motor 1is converted via a swash plate 2 into a lifting movement
of the delivery pistons 3and 4. In the suction position (piston 4) the medium is drawn in from the reser-
voir 5, in the pressure position (piston 3) the medium is pumped towards the outlet.
At ow the medium ows through the integrated non-return valve 6to the outlet. Lubricant lines can be
connected with the push-in tting 7. An empty reservoir 5 can be relled via the grease nipple 8.

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Rev.: SG-20230511
4.3 Outlets
Any number of non-return valve cartridges 6or screw plugs 9 can be retrotted to outlets. If a screw
plug is used, the lubricant is pumped back into the suction line.
4.4 Function monitoring
A xed Reed contact is located in the pump housing. The rotational movement of swash plate 2is detec-
ted by a monitoring element 10. A signal is emitted at each rotation. This signal can be evaluated by an
external controller.
version: DLS-47x/-2C-2C
In standard mode (continuous actuation), the rotation time of the swash plate 2is monitored. In addition,
a signal is emitted when the rotation has been completed.
In dual-cycle mode (pulsed actuation), a pulsed signal is emitted after conveying has been completed,
depending on the lubrication circuit.
4.5 Level monitoring
The position of the follower piston 11 or the oat in the reservoir 5is monitored via a further monitoring
element 12. The signal is emitted as long as the follower piston or the oat is in the detection range of
the monitoring element. When the reservoir is relled, the empty signal disappears automatically.
With the S2C version, a pre-warning is issued in addition to the empty message.
4.6 Reservoir cartridge control
A pushbutton 13 integrated in the pump body serves as a control whether the cartridge is completely
screwed in (only for reservoirs 380, 250, 125). If the button is not actuated, an error message is genera-
ted.
Only with standard version:
The error messages „Fill level min“ and „Cartridge not screwed in“ are generated as a common NC signal
at pin 2.

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4.8 Overpressure shut-off (only S2C version)
The pump has an integrated overpressure shut-off. An integrated control system switches off the pump
at a maximum of 120 bar to prevent the maximum permissible operating pressure from being harmfully
exceeded. All pressurised parts up to the lubrication point must be dimensioned for this maximum pres-
sure.
4.9 Level prewarning (only S2C version)
With the S2C version, a pre-warning is issued in addition to the empty message. The pre-warning is auto-
matically reset when the reservoir is lled. For technical reasons, the level pre-warning is not possible for
reservoirs Lube-Shuttle, System Reiner and DIN 1284.
4.10 Temperature monitoring (only S2C version)
With the S2C version, the ambient temperature of the pump is monitored. If the pump is activated out-
side the permissible operating temperatures, an alarm is emitted, as perfect conveyance is no longer
guaranteed.
4.7 „Smart 2 Cycle“ version
In the „Smart 2 Cycle“ version, the pump has two different operating modes. The selection is made de-
pending on the actuation signal at pin 2. To operate the pump in dual-cycle mode, the corresponding
signal length of the actuation must be selected. The number of input signals corresponds to the num-
ber of doses at the respective lubrication cycle. After successful conveyance at the actuated lubrication
circuit, a specic output signal is output at pin 5.
When using a continuous signal for the control at pin 2, the pump is operated in standard operating
mode. This means that the pump conveys at all outlets as long as the actuation signal is applied. A signal
is emitted at pin 5 when delivery has taken place at all outlets. If the signal at pin 2 is removed, the pump
ends the delivery process that has been started and continues until delivery has taken place at all outlets.
Attention:
If the pump is used in dual-cycle lubrication mode, outlets 3 and 6 have to be closed and cannot
be used.

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User manual DLS-47x // DLS-47x-2C
Rev.: SG-20230511
5. Safety instructions
5.1 Fundamental rule
The unit leaves the factory in faultless state and ensures high technical safety.
The unit represents the state-of-the-art as well as fulls all the current safety and health protection regu-
lations. Nevertheless, there is danger in case of maloperation or misuse:
• for body and life of the user or third parties
• for the pump unit or other user’s objects
• for efcient use of the pump unit
5.2 Required users’ skills
Persons, who operate the unit have to be authorised and trained for that job by the user. They must be
able recognising and avoiding possible dangers. This includes also knowledge on accident prevention
rules, rst aid measures and local rescue equipment.
Only skilled technicians, who have been specically trained for the product, are allowed in-
specting, maintaining and repairing
Skilled electricians are the only ones permitted intervening in the electrical installation according to
DIN VDE 1000-10.
5.3 Safety facilities
Mechanically, the unit is built intrinsically safe.
5.4 Accident prevention
For accident prevention, take the following measures:
• Prevent unauthorised persons from access to the pump unit.
• Keep foreign persons out of the danger areas and danger spots.
• Inform present foreign persons on residual hazards on a regular basis.
Get yourself informed on the residual dangers in chapter „Residual hazards“.

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5.5 Residual risk
When using the unit properly and adhering to the maintenance and repair cycles and measures prescri-
bed, there are no residual risks to persons and objects within the unit’s area.
5.6 Incorrect applications
Any usage contrary hereto or going beyond the conventional one may cause serious
personal and property damage.
Based on experience, possible inappropriate use includes, for example:
• Supply of highly ammable or explosive materials.
• Supply of media that can react with materials that are used for the manufacture of the pump unit.
• Supply of food.
5.7 General safety regulations and duties
Basically, the following safety regulations and duties are applicable to the use of the pump unit:
• The generally accepted rules for work safety need to be oserved. Besides, the basic regu-
lations and rules on work safety and accident prevention being applicable to the place of
use have to be followed.
• When using the unit inside vehicles, the generally accepted trafc law-related rules need
to be observed.
• The user is obliged to observe the regulations pertaining to the use of working applian-
ces.
• The unit must be operated in awless and clean condition only.
• It is prohibited to remove, modify, bridge or bypass any and all protection, safety or mo-
nitoring facilities.
• The unit may only be modied or changed in the areas and functions provided for this
purpose. The prescribed procedure must be followed.
• The operator should be notied of any fault or damage immediately.
• For repair, no others than original spare parts may be used.
• The operator is required to regularly check and maintain all protection, safety, and moni-
toring facilities.
• After every repair, the awless condition of the unit must be ensured by means of a test
run.

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Rev.: SG-20230511
5.8 Exclusion of liability
If any damage to persons, objects, environment and/or assets occurs due to ignoring this operating ma-
nual, either by intension or not, DLS Schmiersysteme GmbH shall not be liable and every warranty claim
will be refused. The abovementioned ts to every consequential damage, too.
6. Transportation, installation, commissioning and shut-down transport
6.1 Transportation
Transport the unit to its destination carefully and by using suitable aids.
6.2 Unpacking
Lift the unit out of its packaging carefully and put it on a stable and plane base.
Note! The unit and the components attached in accordance with the scope of delivery may
still contain residues of blue-dyed test oil.
6.3 Installation
The unit is ready for wall-mounting. It is to be secured by means of two M5 screws at the both female
threads of the pump body. The device is screwed from the rear side. For this purpose, through holes are
required on the wall surface. The mounting surface must be sufciently stable in order to be capable of
carrying the pump unit’s weight including the lled reservoir. Besides, it needs to be ensured that the
mounting surface is plane.
Drill scheme:
Alternatively, the optional mounting plate can be used. The mounting plate has through holes. The plate
can be attached to the pump body using the screws supplied. The pump can then be mounted to the
wall from the front of the unit using two M6 screws.
Drill scheme:
When using oil as the delivery medium, an installa-
tion position in which the reservoir stands vertical-
ly is preferred in order to ensure air-free delivery
of the medium.

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6.4 Power supply and powering-up
Important! Compare the specication of the local voltage supply with the indicated
technical data.
Important! Lay the mains cable that it cannot be torn off acci-dentally.
Important! Skilled electricians are the only ones permitted intervening in the electrical
installation according to DIN VDE 1000-10.
Caution! Intervening in the electric installation, there is danger of life!
Connect the unit to the voltage supply.
Check the electric connections for correct installation prior to commissioning.
The pump needs about 10 seconds to convey at all outlets, regardless
of the number of activated outlets.
The resulting electrical signal follows the pattern ton = 1 s, toff = 9 s.
If there is no signal from the function control after 15 seconds, the unit
should be switched off and checked for safety reasons.
Version Smart 2 Cycle