DLS FlexxPump 1500 User manual

User Guide
FlexxPump 1500 / 2000
(24 VDC power supply)

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Content
Welcome
04
Preface and General Information
04
Warning
04
Scope of Supply
04
Labeling
05
Overview
05
General safety details
06
Use in accordance with guide
06
Extent of warranty
06
General safety information
07
Transport and storage
09
Installation instruction
09
FlexxPump 1500 basics
10
Definitions
10
Control Panel
10
Identification pump units and outlets
11
Grease pouch/bellow
11
How it works
12
Basic operation
12
Start: Visual display
14
Mode: Time control
14
Run – back pressure control – preventive check on a lubrication point
15
Pro program, menu – content
16
Pro program, PIN code protected
16
Enter Pin
16
Input break time and cycle
17
Acceptable Design
18
ESC – Return to the previous display mode
19

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CLr – Clear – delete error messages and delete filling cycles
19
FIL – Filling – de airing the pump, for example – start up, prefilling tubes…
20
Change PIN
21
Change Feedback (Pump function control)
21
Change operating mode: Time control / pulse control
22
Mode: Pulse control
23
Pro program, menu – content
23
Pro program, PIN code protected
23
Enter PIN
24
CLr – Clear – delete error messages and delete filling cycles
24
FIL – Filling – de airing the pump, for example – start up, prefilling tubes…
25
Change PIN
26
Change Feedback (Pump function control)
26
Change operating mode: Time control / pulse control
27
ESC – return to the previous display mode
28
Pulse signals to activate the outlets
28
Acceptable Design
31
Connector PIN assignment, connection to FlexxPump 1500
32
Error messages, faults
32
System Error
34
Master PIN
34
Service: FlexxPump 1500 – readout of the device memory
35
Service: FlexxPump 1500 – replacement of grease pouch
36
Service: FlexxPump 1500 – filling via grease nipple
39
General recommendations
39
Mounting FlexxPump 1500
39
Technical data FlexxPump 1500
40
Disposal
40
Accessories
40

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Welcome
Thank you very much for deciding to use our FlexxPump 1500. Make sure that you familiarize yourself with the user guide
of this unit and the accessories supplied with this unit. This manual contains important safety information.
Preface and General Information
The FlexxPump 1500 is an extraordinary compact lubrication pump for oil and grease up to NLGI 2. The pump requires
24 VDC power supply. The lubricant reservoir (1500 cm³) is in the bellow cartridge /pouch. Supply pressure is up to 70
bar (1,000 psi). The FlexxPump 1500 is available with up to 10 outlets and is therefore the best solution for applications
with limited lubrication points.
Warning
The pumpisdesigned foruse innormal industrialenvironments,inside oroutside,but isnot suitable for mountingon mobile
equipment such as trucks. Only use original FlexxPump 1500 cartridge bellows and original spare parts. Unoriginal spare
parts can damage the FlexxPump 1500.
Please take note of the safety information, intended use and first start up.
Scope of supply
Standard scope of supply FlexxPump 1500:
-lubrication pump FlexxPump 1500
-tube connectors attached to the outlets, suitable for 6 x 4 flexible tube or 8x5 flexible tube
-user guide
Upon customer request we can supply:
-Grease filled below cartridge, connecting cables, mounting accessories

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Labeling
FlexxPump 1500 is marked with a label (including serial number and CE-symbol).
Manufacturer:
Serial number
DLS Schmiersysteme GmbH
CE – symbol
Gewerbering 5, 82140 Olching, Germany
Tel.: [phone], Fax: [phone]
Email: [e-mail],
Website: www.DLS-schmiersysteme.de
Overview
The setup of your FlexxPump 1500 is easy. This user manual will learn you the basic operation and adjustments.
Ventilation lock ( with
integrated programming)
Cover for bellow
control panel
Outlets
Connection M12x1
Important remark: unused outlets must remain open to avoid damage to the pump!

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General safety details
Everybody who is involved with the installation, start-up, maintenance and operation of the FlexxPump 1500 must read
these instructions carefully!
Use in accordance with guide
•The FlexxPump 1500 is only allowed for industrial use.
•The FlexxPump 1500 may only be put into service, if it is integrated or attached to
another machine and will be operated together with that machine.
•The FlexxPump 1500 may only be used according to the technical data (see chapter
“technical data”)
•Unauthorized structural changes at the FlexxPump 1500 are not permitted. We do
not assume liability for damages of persons or machines which result from that.
•
•Other uses or uses beyond those described above cannot be considered to be in
•Accordance with the regulations.
Extent of warranty
Warranties concerning operating safety, reliability and capacity, are only granted under the following conditions:
Assembly, installation, maintenance and repair are only carried out through trained specialist. Hazardous hot or cold
machine parts must be shielded to prevent touching.
•The FlexxPump must be used according to the instructions in the technical operating manual
•The rated technical data must not be exceeded in any case.
•Retrofitting and repair work on the FlexxPump may only be done by TriboServ or trained agents.
Attention
!

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General safety information
Basic information, which must be followed during service, operation and maintenance, are listed as follows.
It is absolutely essential that the end user reads the operator’s manual / user guide before installation and start up.
In addition to this, it must be permanently available at the site.
IMPORTANT
Please pay attention, to the safety instructions in this chapter as well as special security cautions that are mentioned
throughout the user guide.
This symbol warns of electrical voltage.
Safety instructions which, if not complied with, may endanger persons, are marked
Specifically with the general hazard symbol.
this heading is used if inaccurate compliance or non-compliance with the
Operating Instruction or specified work procedures etc. may result in damage.
Points out special information
Instructions attached directlyto the machine, must be strictly followed and maintained in completely readable condition!
Qualification and training of the personnel
The operation, maintenance, service and installation personnel must have appropriate
qualifications for this work. Responsibility and supervision of the personnel must be clearly
defined by the end user / operator. If the personnel do not have the necessary knowledge, they
must be trained and instructed. The operator must ensure that the personnel have completely
understood the contents of the user information.
Non-observance of the safety information can be dangerous
Not observing the safety information can lead to danger for people, environment and machines.
Not observing the safety information can mean the loss of any or all damage claims. In special
cases, non-observance can, for example, lead to the following dangers:
•Failure of important plant functions.
•Failure of prescribed methods of maintenance and preventive maintenance.
•Endangering people due to electrical, mechanical and chemical effects.
•Endangering the environment due to leaks of dangerous materials.
Attention
Remark !

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Safety information for operators/operating staff
•Hot or cold machine parts are hazardous and must be protected from touching. The protection
on "moving or rotating parts" must not be removed.
•In case of dangerous lubricant leaks media proper disposal not endangering environment or
people must be ensured.
•Legal Regulation must be observed and complied.
•Eliminate any danger due to electrical power.
Safety information for maintenance, inspection and assembly work
•All maintenance, inspection and installationwork may only be carried outby trained specialists
who have been informed appropriately by studying the user information closely.
•All work must only be carried out when machine is shut down and while wearing appropriate
protective clothing. Always comply with the procedures for shutting the machine down that are
described in the operating manual. All the safety and protective equipment must be replaced
immediately after completing work. Environmentally hazardous substances that endanger the
environment must be disposed in accordance with local regulations. Secure the system during
maintenance and repair work, against intentional or unintentional operation. Dispose of used
lubricants in accordance with the safety data sheets of the lubricant manufacturer.
Alterations and manufacture of spare parts without authority
Rebuilding or altering the FlexxPump 1500 are only allowed after consultation with the
manufacturer. Original spare parts and accessories authorized by the manufacturer are for safety
purposes. Using other parts results in loss of liability for claims resulting out of this. For
components, retrofitted by the operator, DLS Schmiersysteme does not assume guarantee nor
claims for damages.
Prohibited methods of operation
OperationalsecurityoftheFlexxPump1500isonlyguaranteedifitisoperatedinaccordancewiththeoperatinginstructions.
The limit values stated in the technical data must not be exceeded under any circumstances.
General risk reference
All components of the system are designed in accordance with the prevailing regulations of the
construction of technical machines, in regards to operational safety and accident prevention.
Operation outside of these constraints can lead to dangers for the user respectively third persons
or other technical facilities. The FlexxPump therefore may fulfil only in technically fault-free
condition its intended use. This may only be carried out under compliance of the safety
regulations and the attention of the operator's manual. Therefore please regularlyinspect the
pump and its attachments for possible damage or leaks

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Transport and storage
Use suitable lifting gear for transport.
Do not throw or expose the FlexxPump 1500 to strong shock loads.
Store the FlexxPump 1500 in a cool and dry place to avoid corrosion of the system’s individual parts.
Pay attention to the current safety- and accident prevention instructions during the transport. Wear
suitable protection equipment if necessary!
Installation instruction
The following conditionshave to be satisfied during the installation of this FlexxPump 1500, thus it
can be assembled, with other parts, to a complete machine without affecting the safety and health
of humans:
The housing of the FlexxPump 1500 should not be exposed to direct sunlight and / or
radiant heat preventingthe formation of condensation.
Electrical connection
•Have the electric power supply connected only by a trained electrician!
•Connection and wiring of the electric components should be done by an expert trained in this
field.
•Check that the voltage requirements correspond to the existing power supply voltage!
Maintenance / repair
•Disconnect the voltage feed, before starting with maintenance or repair.
•Maintenance and repair work may only be done with the system shut down.
•Check the surface temperature of 50 °C, due to danger of burning by radiantheat. Always
wear heat-resistance gloves! Protect the system from activation during maintenance and
repair work!

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FlexxPump 1500 basics
Definitions
Lubrication pump designed for applicationswith minimal amounts of lubricant:
oDepending on the configuration FlexxPump 1500 is available with up to 5 pumpunits (P1, P2, P3, P4, P5), each
with 2 outlets.
o1 pump unit is the housing for 2 piston pumps. 1 pump unit is dispensing equal quantities from both outlets.
oMinimum quantity lubrication means the controlled and efficient supply of a lubrication point with selected, high
performance lubricants
oRun = back pressure control – preventive check on a lubrication point: The measurement of the back pressure is
done during the dispensing pumping process and the result will beshown on the display. The displayed value is
a first orientation over the pressure range.
Control panel
Pumpunit P1 … P5: display green LED
Error messages (ALARM): display red LED

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Identification pump units and outlets
Grease pouch / bellow
Each active pump body (P1, P2, P3, P4, P5)
is indicated by a green LED on the control
panel.
Each active outlet is displayed during a
function with a number (1 or 2) on the
control panel.

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How it works
After connecting and activating FlexxPump 1500, the piston pumpstarts to work andpumps the lubricantin small quantities
to the outlets. The integrated microprocessor controls the function. Delivery rates and pause time between the lubrication
intervals can be individually set.
The FlexxPump 1500 uses a four-pin socketto connect a M12X1 plug allowing communication with the machine controller.
An external 24 VDC power supply is used to switch ON and OFF (voltage 24 VDC -5% / +10%), supplied to PIN 1). When
voltage is supplied the lubrication pump is in operating condition. If there are no errors (Pump OK) the input voltage will be
transferred to the output signal (PIN 4) indicating all is OK. Once the voltage supply to PIN 1 is stopped (switched OFF),
thepumprestsandsavesthecurrentoperatingconditionsinmemory.Whenthepumpisturnedbackonthesavedoperating
conditions will be continued. PIN 4 relays the operating condition.
Basic operation
All changes to the settings are made with the programming key (ventilation lock). Open the ventilation lock (turn clockwise
to OPEN) and remove the cover. The nose of the cover is your operating / programming key. If there are no desired
changes to the settings, please set your operating / programming key back at its place and close the ventilation lock (turn
counter clockwise to CLOSE).
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period,the device automatically returns to the previous display mode.

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Start: Menu

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Start: Visual display
Apply operating voltage
Softwareversion: n01 … n99
Operating mode
Operating mode
Pulse control
Next see mode time control or pulse control.
Mode: time control
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
On: Operating mode – time control
run: Run = back pressure control – preventive check on a lubrication point: The measurement of the back pressure is
done during the dispensing pumping process and the result will be shown on the display. The displayed value is
a first orientation over the pressure range.
Pro: Other functions, PIN code protected
ESC: Key to leave and return to the main menu

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run – back pressure control – preventive check on a lubrication point
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
Select pump unit via SELECT, indicated by
a green LED on the control panel.
Confirmation via ENTER, result shown on
the display, repeat with ENTER possible,
outlets of one pumpunit are dispensing
lubricant alternately.
Select other pump unit or timeout: leave the
menu

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Pro program, menu – content
a) Enter PIN
b) Input delivery rates and pause time for every pumpunit
c) ESC: Return to the previous display mode
d) CLr: Clear - delete error messages and delete filling cycles
e) FIL: Filling - de airing the pump, for example – start up, prefilling tubes …
f) Change PIN
g) Change Feedback – Pump function control
h) Change operating mode: Time control / pulse control
Pro programm, PIN code protect
Selection of other menu items with PIN entry possible-
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
Enter PIN, factory setting PIN: 000 (Master PIN see service)
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period,the device automatically returns to the previous display mode.

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Input break (pause) time (H: TIME = time between the lubrication intervals in hours) and cycle
(C: CYCLE = lubrication quantity) for every pump unit
Input H: Time (pause time) = time between the lubrication intervals in hours (1 to 240 h are possible)
Display: possible number -> H 0 to H 99 -> after -> 100 to 240, remark: 240h = 10 days
When H. TIME = 0, it is impossible to input cycles.
Input C: CYCLE (number of cycles) = delivery rate of one period (1 to 30 are possible, 1 cycle = 0,15 cm³)
Pump unit can beturned off by setting C: CYCLE = 0
Factory setting for every pump unit: H: TIME = 4h, C: CYCLE = 1
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
Select other pump unit or timeout: leave the menu.
Important: Changes of the parameters are only applied
Select pump unit via SELECT, indicated
by a green LED on the control panel.
Confirmation via ENTER
Input pause time (H: TIME) via SELECT,
240 hours are possible, confirmation via
ENTER
Input number of cycles C: Cycle via
SELECT, 30 cycles are possible,
confirmation via ENTER

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FlexxPump 1500 is designed for minimum quantity lubrication.
The microprocessor calculates from the inputs of pause time and numer of cycles a
comparison value. If this value is too high, a reduction in the lifetime of FlexxPump
1500 is accepted consciously.
Warning: The ALARM LED flashes on the control panel and the display shows "InF" (for
information) for 10s. During this 10s, the operation of FlexxPump 1500 is blocked.
Acceptable Design
Attention: FlexxPump 1500 is designed for minimum quantity lubrication
A higher demand for lubricant at one lubricating point the outlets of different pump units can be combined externally.
Important remark: unused outlets must remain open to avoid damage to the pump!
Examples:
4 outlets supplying 1 lubrication point:
Allowedamountoflubricantfor1lubricationpoint= max.
6.000cm³ a year = 4 pouches a year for 1 lubrication
point
or
Allowedamountoflubricantfor2lubricationpoint= max.
12.000cm³ a year = 8 pouches a year for 2 lubrication
it
Attention !
1 outlet supplying 1 lubrication point:
Allowedamount of lubricant for1 lubrication point =max.
1.500cm³ a year = 1 pouch a year for 1 lubrication point
or
Allowedamount of lubricant for2 lubrication point =max.
3.000cm³ a year = 2 pouches a year for 2 lubrication
points
2 outlets supplying 1 lubrication point:
Allowedamount of lubricant for1 lubrication point =max.
3.000cm³ a year = 2 pouches a year for 1 lubrication
point
or
Allowedamount of lubricant for2 lubrication point =max.
6.000cm³ a year = 4 pouches a year for 2 lubrication
points

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ESC – Return to the previous display mode
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
CLr – Clear - delete errormessages and delete filling cycles
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmationofallchanges - touch the operating padwiththe operating/programming key.Thedisplay
flashes 2 times for confirmation.
Timeout: If no interaction takes place for aperiod, the device automatically returns to the previous displaymode.
See also error messages

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FIL – Filling - de airing the pump, for example – start up, prefilling tubes …
SELECT: Change settings - touch the operating pad with the operating / programming key
ENTER: Confirmation of all changes - touch the operating pad with the operating / programming key. The display
flashes 2 times for confirmation.
Timeout: If no interaction takes place for a period, the device automatically returns to the previous display mode.
Attention: FlexxPump 1500 lubrication pumps must be vented at initial operation. Each pump unit must be vented
separately. The operation is completed when lubricant is visible at the outlet.
Initial startup:
Select other pump unit (Pro -> PIN -> FIL) or timeout: leave the menu.
Prefillhousinginletwith50mlofsuitablelubricant(same
as content of pouch)
Attention: Low level indicator in the inlet must not be
damaged.
Then place grease pouch and start FIL function.
SELECT FIL -> ENTER
SELECT pump unit -> ENTER
Delete with CLr (Clear)
FIL means that the outlet of each pump unit is 15 times active.
Total time of FIL / pump unit: about 5 minutes
This function can also be used to pre-fill tubes.
15 cycles with 0,15cm³ = about. 2 cm³
Delete with CLr (Clear)
Attention !