DLS 125 Installation instructions

FlexxPump 125 (24 V)
Original Operating Manual
Valid for products with the article number:
135-125-100
135-125-210

Masthead / Copyright
This documentation is protected by copyright.
All rights for layout and corporate design reserved by © DLS Schmiersysteme GmbH 2017.
All rights for contents and texts reserved by DLS Schmiersysteme GmbH 2017. All rights
including photomechanical reproduction, copying and distribution by special processes (for
example data processing, data media and data networks), even in part, reserved by DLS
Schmiersysteme GmbH. The original language is German; all other language versions are
translations of this.
Expressly subject to content and technical changes without prior notice.
Manufacturer: DLS Schmiersysteme GmbH
Gewerbering 5
D-82140 Olching
Phone: [phone]
Fax: [phone]
email: [email protected]
www.DLS-Schmiersysteme.de

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Contents
1. SAFETY ............................................................................................... 6
1.1 About this operating manual ................................................................. 6
1.2 Use for the intended purpose................................................................ 6
1.3 User specication.................................................................................. 6
1.4 Handling lubricants................................................................................ 6
1.5 Transport ............................................................................................... 6
1.6 Storage.................................................................................................. 6
1.7 Assembly............................................................................................... 7
2. SCOPE OF SUPPLY........................................................................... 8
3. PRODUCT DESCRIPTION................................................................. 9
3.1 Product overview................................................................................... 9
3.2 Functional description ......................................................................... 10
3.3 Technical data ..................................................................................... 10
4. INSTALLATION AND COMMISSIONING ....................................... 11
5. OPERATION ...................................................................................... 13
5.1 Adjustable parameters ........................................................................ 13
5.1.1 P (Pressure) .................................................................................. 13
5.1.2 t (time / runtime, cartridge emptying time)..................................... 13
5.1.3 C (Cycle / number of cycles, strokes per lubricating cycle)........... 13
5.1.4 Pu (Puls mode) ............................................................................. 13
5.1.5 U (cartridge size)........................................................................... 14
5.1.6 E (Error / inversion of output signals)............................................ 14
5.1.7 L (empty signal)............................................................................. 14
5.1.8 F (Feedback signal / motor running check)................................... 14
5.2 Selection of parameters t and C.......................................................... 15
5.3 Menu structure .................................................................................... 16
5.4 Switching FlexxPump 125 on/o󰀨 ......................................................... 17
5.5 Changing parameters in the standard menu (Pro).............................. 18
5.6 Triggering a single lubrication process................................................ 19
5.7 Triggering the lling function ............................................................... 20
5.8 Changing parameters in the expert menu
5.9 Changing the cartridge........................................................................ 23
6. MESSAGES AND FAULTS .............................................................. 24
7. EXTERNAL CONTROL .................................................................... 25
7.1 Control signals (PIN 2) ........................................................................ 25
7.1.1 Overview of control signals ........................................................... 25
7.1.2 Signal 2sec (single pump stroke) .................................................. 26
7.1.3 Signal 3sec (two pump strokes) .................................................... 27
7.1.4 Signal 4sec (C pump strokes) ....................................................... 28
7.1.5 Signal 6sec / 12sec (lling/venting process) ................................. 29
7.1.6 Signal 10sec (acknowledge error massage) ................................. 30
7.2 Output signals (PIN 4)......................................................................... 31
7.2.1 Overviews of output signals .......................................................... 31
7.2.2 Errror E1 (empty) .......................................................................... 31
7.2.3 Error E2 (no cartridge) .................................................................. 32
7.2.4 Transition from error E1 to error E2 .............................................. 33
7.2.5 Erorr E3......................................................................................... 33
7.2.6 Erorr E7 overpressure................................................................... 34
8. DISPOSAL......................................................................................... 35
9. DECLARATION OF CONFORMITY ................................................ 36

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Safety
1. Safety
1.1 About This Operating Manual
Thank you for choosing the FlexxPump 125 from DLS Schmiersysteme GmbH.
This operating manual is part of the product. Read it through carefully before all work
with and on the device. It must be kept on hand at all times at the device or in a place the
operator can access quickly at any time. The owner must ensure that the operating manual
is kept for the entire life cycle of the device and is passed on with the device.
1.2 Use for the Intended Purpose
Observe the following points for use of the FlexxPump 125 for the intended purpose:
• The FlexxPump 125 is only approved for industrial use.
• The FlexxPump 125 may only be used in accordance with the technical data (see 3.3
Technical Data).
• Unauthorized constructional modications to the FlexxPump 125 are prohibited unless they
have been approved in writing by DLS Schmiersysteme GmbH.
• Read and follow the instructions in the operating manual.
• The FlexxPump 125 and the lubricating point must be subjected to regular visual inspec-
tions during operation of FlexxPump 125. Any irregularities ust be remedied immediately!
• Only use the lubricants that have been approved by DLS Schmiersysteme GmbH.
• Observe work safety and accident prevention regulations.
• Only carry out work with and on the FlexxPump 125 with the appropriate authorization, see
1.3 User Specication.
All other types of use or disregard of one of these points shall be considered as not for the
intended purpose. DLS Schmiersysteme GmbH will accept no liability and/or provide any
warranty in this case.
1.3 User Specication
The device may only be operatied by trained persons who have read the operating manuel
and act accordingly. The operating personnel must be authorized by the owner.
Assembly, connection, maintenance and repairs may only be carried out by technical person-
nel authorized by the owner.
1.4 Handling Lubrications
Leaking or surplus lubricant must be collected and disposed of according to the lubricant
manufacturer´s safety data sheets and local regulations.
1.5 Transport
Do not throw the Flexxpump 125 or subject it to heavy impact during transport.
1.6 Storage
Store the FlexxPump 125 in a cool, dry place.

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Safety
1.7 Assembly
Have the FlexxPump 125 connected only by a trained electrician.
Pay attention to the appropriate torques and assembly dimensions during assembly, see 3.3
Technical Data.

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Scope of Supply
2. Scope of Supply
Standard scope of supply
• FlexxPump 125
• This operating manual
• Quickstart Guide for quick starting with factory settings
The scope of supply may include optional accessories.
Individual customer parameters may have been pre-set at the factory at the customer’s
request.

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Product Description
3. Product Description
3.1 Product Overview
SET
6
1
2
3
4
5
7
8
9
10
1 LCD
2 Field of activity
3 Lubricant feed
4 Type plate
5 M5 thread for rear mounting
6 Sensor probe for cartridge
7 M12x1-connection
8 Magnetic pin
9 Hydraulic connection / outlet
10 M5 thread for mounting from below

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Product Description
3.2 Functional Description
The FlexxPump 125 has a double piston pump. The two pistons run in opposite directions
whereby one piston sucks in the lubricant respectively whilst the other one pumps the
quantity sucked in by the previous stroke to the outlet. 0.15 cm³ of lubricant is pumped per
displacement or metering cycle. The FlexxPump 125 is controlled by an external controller
(PLC) in the factory settings. Alternatively, the time and frequency of the lubrication and the
lubricant quantity per lubrication process can be dened by the parameters t and C.
The operating state and error messages are displayed on the LCD. In addition, statuses and
errors can be read out and interpreted by the external controller.
3.3 Technical Data
Housing
Dimensions with 125 ml cartridge (W x H x D) 83 x 152 x 83 mm
Dimensions with 250 ml cartridge (W x H x D) 83 x 190 x 83 mm
Weight (without lubricant) approx. 350 g
Assembly possibilities Rear 2x M5
Bottom 1x M5 and/or G1/4“
Torque M5 3 Nm
Installation position any, preferably vertical
Permissible operating temperature -20 °C ... +70 °C
Material PA 6.6 GF 30 / POM
Lubricant
Cartridge lling volume 125 cm³ / 250 cm³
Lubricating medium Grease up to NLGI class 3, solid parts possible
Hydraulic data
Number of outlets 1
Outlet thread G1/4" and M6
Number of lubricating points up to 4 in connection with splitter
up to 14 in connection with progressive distributor
Hydaulic connection direct or by additional hose connection to PA hose
Max. pressure 12 or 50 bar (adjustable)
Dosing volume/stroke 0,15 cm³
Number of pump strokes per
cartridge
approx. 830 (at 125 cm³) / approx. 1,666 (at 250
cm³)
Electrical data
Display LCD
Operating voltage 24 V (20V...28V)DC (external)
Current consumptio Imax < 300 mA
no-load current < 25 mA
Fusing 750 mA, slow-blow
Connecting plug M12x1
Protection class IP 54

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Installation and Commissioning
4. Installation and Commissioning
1. Unscrew the cartridge cap.
2. Screw the cartridge onto the Flexx-
Pump 125
3. Mount the FlexxPump 125 in the
desired position (see 3.3 Technical
Data for assembly data).
4. Connect the controller cable.
SET
A
A
B
B
5. Hold the magnetic pin
against the area of activity
A) Until "On" appears.
6. Remove the magnetic pin (B).
SET
A
B
7x
A
B
40x
1 MAX
7. Hold the magnetic pin against the
area of activity unitl "FIL" appears.
Ventings starts
8. Remove the magnetic pin (B) and put
it back into the holder

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Installation and Commissioning
9. Connect the lubricating line.
10. OPTIONAL:
Fill the lubrication line see step 7.

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Operation
5. Operation
The FlexxPump 125 is operated with the enclosed magnetic pin and/or an external
controller depending on the mode (time or pulse mode). The FlexxPump 125 is delivered
ready for operation and dosing is controlled by an external controller in the factory settings.
However, the individual control parameters can be changed later.
5.1 Adjustable Parametersr
Parameter Designation Permissible
values Factory Change to
P Maximum pressur [bar] 12 / 50 50 Expert menu
t Cartridge emptying time
[months]
1 ... 36 6
Standard menu
and Expert menu
C Number of cycles [0,15 cm³/
stroke]
1 / 2 / ... / 10 2
Pu Puls mode 0 / 1 1
U Cartridge size[x 10 cm³] 12 / 25 12
Expert menu
E Output signal inversion 0 / 1 0
L Empty signal 0 / 1 / 2 2
F Feedback signal 0 / 1 1
5.1.1. P (Pressure)
The parameter P indicates the maximum counter-pressure. It can be set to 12 bar or 50 bar.
The maximum pressure must be reduced depending on the used system and connected
lines (e.g. hoses). If the set maximum pressure is exceeded, the FlexxPump 125 goes into
fault status and stops the current lubricating cycle. The LCD displays a message which is
output to the external controller.
No further pumping cycle takes place until the message is acknowledged.
5.1.2. t (time / runtime, cartridge epmtying time)
The parameter t can only be set if the parameter Pu0 is set. With parameter Pu1, the
emptying time is controlled externally by a controller.
The parameter t indicates the time in which the cartridge is to be emptied. The emptying time
can be set within a range from 1 to 36 months.
See 5.2 Selection of Parameters t and C for further information.
5.1.3. C (Cycle / number of cycles, strokes per lubricating cycle)
The parameter C indicates how many dosing processes per lubricating cycle are performed
or how much lubricant is fed. 1 to 10 dosing processes can be set. Four dosing processes of
0.15 cm³ each are dosed at a value of C4.
5.1.4. Pu (Pulse mode)
The parameter Pu indicates in which mode the FlexxPump 125 is working. In Pu1, the
dosing is controlled by an external controller. In Pu0, the dosing is controlled by the
parameter t.

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Operation
5.1.5. U (cartridge size)
The parameter U indicates which cartridge size is used. U12 stands for cartridge size 125
cm³, U25 for cartridge size 250 cm³.
5.1.6. E (Error / inversion of output signals)
The parameter E indicates whether the signal images are generated inversely to an external
controller for empty, error message and feedback (motor running check). See 7.2 Output
Signals (PIN 4) for further information.
5.1.7. L (empty signal)
The parameter L indicates how the signal image for the empty message is output to an
external controller. The parameter depends on parameter E.
Only the L values L0 (low level signal) and L2 (square wave signal) are possible for the
setting E0 (factory setting).
Only the L values L1 (high level signal) and L2 (square wave signal) are possible for the
setting E1.
5.1.8. F (Feedback signal / motor running check)
The parameter F indicates whether a signal is output to an external controller during a
pumping process (motor running). The parameter depends on parameter E.
For the setting E0 (factory setting), the FlexxPump 125 sends a low-level signal to an
external controller during the pumping process, the pumping process cannot be detected in
the controller.
For the setting E1, the FlexxPump 125 sends a high-level signal to an external controller
during the pumping process, the pumping process is registered.

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Operation
5.2 Selection of Parameters t and C
Note
The emptying time t can only be set in the FlexxPump 125 if it not controlled by an external
controller (Pu0).
Emptying time t for 125 cm³ cartridge (U12)
t (months) 1 3 6 10 12 15 20 24 30 36
Lubricant quantity
per month [cm³]
125 41,6 20,8 12,5 10,4 8,3 6,3 5,2 4,2 3,5
Emptying time t for 250 cm³ cartridge (U25)
t (months) 1 3 6 10 12 15 20 24 30 36
Lubricant quantity
per month [cm³]
250 83,3 41,6 25 20,8 16,7 12,5 10,4 8,3 6,9
Values for t are examples, values from 1 to 36 can be set.
Number of cycles C, strokes per cycle
C 12345678910
Lubricant quantity
per cycle [cm³]
0,15 0,30 0,45 0,60 0,75 0,90 1,05 1,20 1,35 1,50
The emptying time t determines over what period of time the total quantity of lubricant per
cartridge is fed. It also determines accordingly how much lubricant per month is fed.
The number of cycles C indicates how many strokes per lubrication are performed and
therefore how much lubricant is fed per lubrication.
The time between two lubrications (pause time) can be determined using the following
formula: TPause = t / H x C .
With t in hours and H as the total number of strokes per cartridge (830, for cartridge 125 cm³)
as well as a lubricant quantity of 0.60 cm³ (C4) over 6 months gives the following pause time
as an example:
TPause = 6 x 3600 h / 830 x 4 = 104 h .
This gives a lubricating cycle for the above determined parameters t and C of
104 hours. 0.60 cm³ of lubricant is fed every 104 hours over a period of six months.

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Operation
5.3 Menu Structure
The  gure below shows the complete menu structure of the FlexxPump 125.
Action by user, LED  ashes red
once
FlexxPump 125 is ready for
operation but not switched on
Sequence / reaction in the menu FlexxPump 125 is in operation
LED in LCD  ashes green
FlexxPump 125 is waiting
for a signal from the external
controller
LED in LCD  ashes red Perform single manual dosing
Display in the LCD  ashes 2x Programming
Firmware information Expert menu
Programming (Standard menu)
Expert menu
MAX1
MAX1MAX2MAX1MAX2MAX1
3x 7x

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Operation
5.4 Switching FlexxPump 125 On/O󰀨
3x
Switching on
1. Hold the magnetic pin against the area of activity.
The LED ashes red three times.
2. Remove the magnetic pin when ON is displayed.
3. The rmware information and settings for emptying time (t) and number of cycles (C)
are displayed.
On ashes twice in the LCD.
The green LED ashes, the FlexxPump 125 is in operation
The FlexxPump 125 feeds lubricant according to the presettings for t and C. If the LCD
displays PAU, the FlexxPump 125 receives no signal from an external controller.
Switching o󰀨
1. Hold the magnetic pin against the area of activity.
The LED ashes red and run, On, OFF are displayed one after another in the
LCD.
2. Remove the magnetic pin when OFF is displayed. OFF ashes twice in the LCD.
The FlexxPump 125 is switched o󰀨.

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Operation
5.5 Changing Parameters in the Standard Menu (Pro)
The following parameters can be set in the Standard menu:
• Pulse mode Pu
• Emptying time t
• Number of cycles C
A description of the individual parameters can be found in chapter 5.1 Adjustable
Parameters.
Note
The emptying time t can only be set in the FlexxPump 125 if it not controlled by an external
controller (Pu0).
Changing parameters
9FlexxPump 125 in operation (PAU / On)
1. Hold the magnetic pin against the area of activity.
The LED ashes red and run, On, OFF, On, Pro are displayed one after another in the
LCD.
2. Remove the magnetic pin when Pro is displayed.
The display shows the parameters Pu, t and C one after another (depending on the
FlexxPump 125 type).
3. Hold the magnetic pin against the eld of activity for the parameter to be set.
The value for the parameter is counted up in the LCD and starts again from the begin-
ning after the highest value.
4. Remove the magnetic pin from the eld of activity at the desired value.
The set value ashes twice.
The next parameter is displayed in the LCD.
The FlexxPump 125 starts operating again automatically after the last parameter.

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Operation
5.6 Triggering a Single Lubrication Process
You can trigger a single lubrication process with the FlexxPump 125 at any time during
operation.
MAX1
9FlexxPump 125 in operation (PAU / On)
1. Hold the magnetic pin against the area of activity.
The LED ashes red.
2. Remove the magnetic pin when run is displayed.
The FlexxPump 125 performs a single lubrication process.
The LCD displayed the approximate counter-pressure and the pumping pump piston.
The FlexxPump 125 starts operating again automatically at the end of the lubrication
process.

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Operation
5.7 Triggering the Filling Funktion
You can trigger the lling function of the FlexxPump 125 for lling or venting. The FlexxPump
125 then performs 40 pumping processes automatically with a total lubricant quantity of 6
cm³.
You can abort the lling function again manually.
MAX1 MAX2 MAX1 MAX2MAX1
9FlexxPump 125 in operation (PAU / On)
1. Hold the magnetic pin against the area of activity.
The LED ashes red and run, On, OFF, On, Pro, FIL are displayed one after another
in the LCD.
2. Remove the magnetic pin when FIL is displayed.
The FlexxPump 125 starts the lling process.
The LCD displayed the approximate counter-pressure and the pumping pump piston.
The FlexxPump 125 starts operating again automatically at the end of the lubrication
process.
Aborting the lling process
1. Hold the magnetic pin against the eld of activity during the lling function.
The LCD shows CLr.
2. Remove the magnetic pin.
The lling function is aborted.
The FlexxPump 125 starts operating again automatically.