DLS FlexxPump 125 B User manual

User Manual
FlexxPump 125 Battery
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S

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I. Revision history & imprint
I.I Revision history
The present user manual is the original user manual.
This user manual is only valid for
Product:
Product designation: FlexxPump 125 B
Product revision: ---
User manual:
date of creation: 12.2020
revision of the user manual: 1
This document is protected by copyright.
All rights for layout, content, texts and corporate design are reserved by DLS
Schmiersysteme GmbH, © 2019.
All rights, including those of photomechanical reproduction, duplication and distribution
by means of special processes (e.g. data processing, data carriers and data networks),
even in part and/or in extracts, are reserved by DLS Schmiersysteme GmbH.
The content and technical specications are subject to change without notice.
I.II Imprint of the manufacturer, distribution and service
Adress: DLS Schmiersysteme GmbH
Gewerbering 5
D-82140 Olching
Tel: +49 - (0)8142 - 650 69-0
Fax: +49 - (0)8142 - 650 69-29
E-Mail: [email protected]
Internet: www.DLS-Schmiersysteme.de
Personally liable company: DLS Schmiersysteme GmbH
Registered ofce of the company: Olching
Handelsregister München
HRB 156604
USt.-idNr.: DE128578324
Managing director: Reiner Hochholzer
Helmut Feicht

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I. Revision history & imprint 02
I.I Revision history 02
I.II Imprint of the manufacturer, distribution and service 02
I.III Table of contents 03
1. General information about this manual 05
1.1 Signal words 05
1.2 Warning symbols 06
1.3 Structure of the safety instructions 06
1.4 Symbols for information 06
2. Safety 07
2.1 EC/EU Directive 07
2.2 Hazards 07
2.3 Staff 07
2.4 Reasonably predictable misuse 07
2.5 Usage for the intended purpose 08
2.6 Warranty and Liabilty 08
2.7 General safety instructions 09
3. Description of function 10
3.1 General information 10
3.2 Nameplate and designation 11
3.3 Scope of delivery 11
3.4 Technical data 12
4. Transport and storage 13
4.1 Packaging 13
4.2 Transport 13
4.3 Storage 13
5. Mounting 14
5.1 Preparations 14
5.2 Assembly 14
5.3 Commissioning 17
6. Operation and settings 18
6.1 General information 18
I.III Table of contents
Chapter Content Page

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6.2 Factory settings 19
6.2.1 Default settings operating mode Hour-Mode -h- 19
6.2.2 Default setting operating mode Empty-Time-Mode Et 20
6.3 Menu and LCD messages 21
6.3.1 LCD 24
6.3.2 Actions with the activation and programming key 27
6.3.3 Switching on and off 29
6.3.4 INF-Menu operating mode Hour-Mode -h- 30
6.3.5 INF-Menu operating mode Empty-Time-Mode Et 31
6.3.6 SET-Menu 32
6.3.7 RUN-Menu 34
6.3.8 PRO-Menu operating mode Hour-Mode -h- 35
6.3.9 PRO-Menu operating mode Empty-Time-Mode Et 38
6.3.10 FIL-Menu 40
6.4 Error codes 41
7. Maintenance and disposal 42
7.1 Maintenance schedule 42
7.1.1 Visual check 43
7.1.2 Cleaning 43
7.1.3 Recommissioning after maintenance 43
7.2 Cartridge and battery change 44
7.3 Disposal 47
8. Released accessories 48
8.1 Lubricants 50
8.2 Tube lengths 50
9. Appendix 51
9.1 Dimension sheet and installation dimensions 51
9.2 EC/EU Declaration of conformity 52
9.3 Spare parts 53
Chapter Content Page

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1. General information about this manual
This user manual contains all necessary information to use FlexxPump 125 in the
battery version safely and as intended. In the event that supplementary sheets are
attached to these instructions, the information and data contained in the supplementary
sheets are valid and replace the corresponding information in this user manual. Any
contradictory information contained in this user manual thus becomes invalid.
If you have any questions regarding special applications, please contact DLS
Schmiersysteme GmbH (chapter I.II).
The actual and factual operator must ensure and guarantee that these instructions,
including any supplementary sheets, have been read and understood by all persons
responsible for the installation, operation or maintenance of the FlexxPump 125 B.
Therefore, keep these instructions in a suitable place, ideally in an easily accessible
place, in the surrounding area of the FlexxPump 125 B.
Inform your colleagues who work in the local area of the machine about safety
instructions so that nobody gets hurt.
This manual was written in German, all other language versions are translations of this
manual.
1.1 Signal words
The following signal words are used in this manual to draw your attention to possible
dangers, prohibitions and other important information:
DANGER This signal word points you to an immediate and threatening risk of
serious injury or death.
WARNING This signal word indicates a potentially imminent danger which can
result in serious injury or even death.
CAUTION This signal word indicates a potentially imminent danger that can
result in minor to severe injuries.
NOTICE This signal word indicates a potentially imminent danger which can
result in damage to property.
INFORMATION This signal word refers to practical application tips or particularly
important information when using the FlexxPump 125 B.

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General warning
sign
Electricity hazard Flammable
material
1.2 Warning symbols
The following warning symbols are used in this user manual to alert you to hazards,
prohibitions and important information:
1.3 Structure of the safety instructions
The safety instructions in this user manual are structured according to the following
system:
CAUTION
The text explains the consequences of disregarding the
reference.
§The text shows what to do as an instruction.
1.4 Symbols for information
The following information symbols are used in the text and instructions in this manual:
Requests you to take action
ÜShows the consequences of an action
Additional information about the action

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2. Safety
All persons working with the FlexxPump 125 B must follow these operating instructions,
in particular the safety instructions and the rules and regulations applicable at the place
of use. Generally applicable legal regulations and other rules as well as the relevant
rules and regulations for accident prevention (e.g. Personal Protective Equipment
(PPE)) and environmental protection must be observed.
2.1 EC/EU Directive
Within the scope of the EC/EU Directive, (re)commissioning of a machine on which the
FlexxPump 125 B has been installed and/or tted is prohibited until it has been clearly
established that the machine complies with the provisions of the applicable Directive.
An EC/EU declaration of conformity for the FlexxPump 125 B can be found in the
appendix (chapter 9.2).
2.2 Hazards
In order to avoid danger to the user or damage to the machine on which the FlexxPump
125 B is used, the FlexxPump 125 B may only be used for its intended purpose
(chapter 2.5) and in a technically safe condition.
Always inform yourself about the general safety instructions (chapter 2.7) before
starting to work.
2.3 Staff
Only qualied staff who has read and understood this manual may work with the
FlexxPump 125 B. Local and/or company regulations apply accordingly.
2.4 Reasonably predictable misuse
Any use of the FlexxPump 125 B which exceeds the maximum permissible technical
data is generally considered to be improper and therefore prohibited.

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2.5 Usage for the intended purpose
The following points must be observed for the intended purpose of using the
FlexxPump 125 B:
+ The FlexxPump 125 B is exclusively approved for industrial use.
+ The FlexxPump 125 B may be used exclusively in accordance with the technical
data (chapter 3.4).
+ Unauthorized structural alterations to the FlexxPump 125 B are not permitted.
+ Read the user manual and act accordingly.
+ During operation of the FlexxPump 125 B, a visual inspection of the FlexxPump
125 B as well as of the lubrication point must be carried out regularly. Any anomalies
must be eliminated immediately and the cause rectied.
+ Relling the cartridge is not permitted.
+ The FlexxPump 125 B may not be opened or disassembled.
+ Only lubricants approved by the manufacturer may be used.
+ Relevant regulations and rules on work safety, accident prevention and environmen-
tal protection must be observed.
+ Work and activities with and on the FlexxPump 125 B are only permitted with appro-
priate authorisation (chapter 2.3).
All other uses than the aforementioned intended usage or the disregard of one of the
above points shall be deemed improper usage. In this case no liability and/or warranty
is assumed.
2.6 Warranty and Liabilty
If the following items are disregarded, all warranty and liability claims for personal injury
and/or damage to property are excluded:
+ Non-observance of the instructions for transport and storage;
+ misuse;
+ Improper or unperformed maintenance or repair work;
+ Improper assembly / disassembly or improper operation;
+ Operation of the FlexxPump 125 B with defective protective devices and devices;
+ Operation of the FlexxPump 125 B without lubricant;
+ Operation of the FlexxPump 125 B with non-approved lubricant;
+ Operation of heavily contaminated FlexxPump 125 B;
+ Modications or alterations which may be carried out without the written permission of
DLS Schmiersysteme GmbH have taken place;
+ Opening and/or partial or complete disassembly of the FlexxPump 125 B.

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2.7 General safety instructions
The following safety instructions are given for the FlexxPump 125 B:
DANGER
Damaged or incorrect electrical connections or unauthorized
live components lead to serious injuries or even death.
§ Have all electrical connection work carried out by qualied
personnel only.
§Replace damaged cables or plugs immediately.
NOTICE
Loose or overloaded screw connections can cause damage to
the FlexxPump 125 B.
§Mount and check all screw connections with the permissible
torques specied for this purpose. Use a calibrated torque
wrench.
WARNING
Lubricants are ammable.
§ In case of re, do not use a water jet to extinguish the re.
§ In case of re, use only suitable extinguishing agents such as
powder, foam and carbon dioxide.
§Observe the relevant safety instructions of the lubricant manu-
facturer on the safety data sheet of the lubricant used.
CAUTION
Lubricants can cause skin irritations.
§Avoid direct skin contact.
NOTICE
Lubricants can contaminate soil and water.
§Use and dispose lubricants properly.

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3. Description of function
3.1 General information
Nr. Description
0 FlexxPump 125 B
1 LCD
2 Operation pad (for actions with the activation and programming key)
3 Activation and programming key
4 Lubricant outlet / M16 male thread for bottom mounting
5 M5 female thread for bottom mounting
6 Battery compartment
7 Serial number of the FlexxPump 125 B
8 M5 female thread for rear mounting
9 Cartridge sensor
10 Lubricant inlet with thread for cartridge
11 Nameplate with designation and CE mark and serial number
10
9
8
7
6
Fig. 1: Overview FlexxPump 125 B
2
1
4
5
3
0
The FlexxPump 125 B is designed as an extremely compact double piston pump
for autonomous operation with grease or oil as lubricant. The two pistons run force-
controlled and counter-rotating. They are united into one outlet. The outlet is secured
by an integrated non-return valve. Approx. 0.15 cm³ of lubricant is pumped during each
dispensing operation; multiple dispensers can be set one after the other.
The LCD on the front panel displays the various operating states; further information
(empty cartridge, error) can be read.
The present FlexxPump1 as battery version has no electrical interface. The supplied
activation and programming key can be used to adjust the operating mode and the
quantity of lubricant pumped per time to supply the lubrication point with the ideal
quantity of lubricant.
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3.2 Nameplate and designation
The nameplate of the FlexxPump 125 B is visibly attached to the side of the pump
itself. There the CE mark and the serial number of the FlexxPump 125 B are visible.
Refer to chapter 3, Fig. 1 for the location of the nameplate and serial number.
3.3 Scope of delivery
The FlexxPump 125 B is available in several different versions. They differ in the
number of accessories supplied.
All versions of the FlexxPump 125 B are prelled with a neutral, food-grade (H1)
lubricant (approx. 3 cm³), which can be mixed with the lubricants approved by DLS
Schmiersysteme GmbH, to simplify the initial commissioning. The manufacturer's
designation is F02.
Further data and documentation on the lubricant F02 are available on request from
DLS Schmiersysteme GmbH or at www.dls-schmiersysteme.de.

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3.4 Technical data
Housing
Dimensions without cartridge width x height x
depth
83 x 82 x 85 mm
Dimensions with catridge 83 x 152 x 85
Weight (without cartridge) appx. 350 g
Mounting options backside: female thread M5 (2x)
bottom: female thread M5 (1x)
bottom: male thread M16 (1x)
max. torque mounting 3 Nm
Mounting position upright
Material housing PA 6.6 GF30 / POM
Material outlet stainless steel
Operating temperature -10 ... +60 °C
Lubricant and hydraulic
Volume cartridge 125 ml
Lubricant characteristics grease until NLGI class 2
Number of outlets 1
Hydraulic connection directly or via PA-tube
Number of lubrication points 1
max. pressure 35 bar
Grease delivery per stroke 0.16 (-5%) cm³
Electrics
Display LCD
Operating voltage 4.5 V
Protection - A
Protection class IP 54

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4. Transport and storage
4.1 Packaging
The FlexxPump 125 B is delivered in an outer packaging (cardboard box) and -
depending on the scope of delivery with a lubricant cartridge and other accessories - in
the same package. To protect them from moisture and dirt, they are also packed in PE
lms. As a preventive protective measure against the escape of the prelled lubricant
from the FlexxPump 125 B, appropriate protective caps are tted on the lubricant
supply and at the lubricant outlet.
Dispose the packaging materials at the designated disposal points in compliance with
the relevant national and company regulations.
After receiving the FlexxPump 125 B, check the delivery note for completeness and
correctness.
Any missing parts or damage must be reported immediately to the forwarding agent,
the insurance company or DLS Schmiersysteme GmbH in writing.
4.2 Transport
NOTICE
Hard shocks, e.g. due to falling or setting down too hard, can
damage the FlexxPump 125 B.
§Do not throw the FlexxPump 125 B.
Store the FlexxPump 125 B in its original packaging in a vertical position in a dry, frost-
free environment at an ambient temperature of +5°C to +30°C. The maximum storage
time in unopened condition is 2 years.
The so-called "First-In-First-Out-Principle" (FiFo) is recommended for storage logistics.
4.3 Storage

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5. Mounting
5.1 Preparations
Before starting to work, inform yourself in detail about the FlexxPump 125 B using this
user manual; in particular about the general safety instructions (section 2.7). Prepare
the installation site carefully.
NOTICE
Pressurised air can damage the seals of the FlexxPump 125 B
and can transport dirt and foreign matter into the FlexxPump
125 B or the lubricant.
§Do not use pressurised air.
§Make sure that there is no coarse dirt in the mounting area.
2. Remove the protective cap from top of
the FlexxPump 125 B.
Remove the yellow protective cap
from the top of the lubricant inlet of the
FlexxPump 125 B.
 Make sure that no dirt, water or foreign
bodies enters the lubricant inlet.
5.2 Assembly
1. Condition as delivered
The FlexxPump 125 B is delivered in a
cardboard box. Depending on the version
ordered, further accessories such as
battery, lubricant cartridge or additional tube
connection parts are included.

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3. Remove the protective cap from the
bottom of the FlexxPump 125 B.
Unscrew the yellow protective cap
counterclockwise from the bottom of the
lubricant outlet of the FlexxPump 125 B.
4. Inserting the battery
Extract the battery cable from the battery
compartment.
Connect the battery to the battery cable
using the plug.
Store the battery and the battery cable in
the battery compartment.
Make sure that the battery cable or
plug does not protrude from the battery
compartment.

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5. Unscrewing the cartridge cap.
Turn the cap on the lubricant cartridge
counterclockwise and pull it off.
Pay attention to cleanliness when
carrying out the work. It is imperative that
dirt and foreign bodies do not enter the
cartridge.
6. Mounting the lubricant cartridge
Place the full lubricant cartridge on the
FlexxPump 125 B.
Turn the lubricant cartridge clockwise onto
the FlexxPump 125 B.
The end position is reached after two
full rotations when the label of the lubricant
cartridge is aligned with the front label of the
FlexxPump 125 B.
LCD

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5.3 Commissioning
Mount the FlexxPump 125 B carefully according to the steps described in chapter 5.2.
Depending on the scope of delivery, you must also carry out the following additional
measures for the rst-time commissioning:
1. Mechanical fastening
Fix the FlexxPump 125 B mechanically through the M5 female threads or through the
M16 male thread of the FlexxPump 125 B lubricant outlet. Pay particular attention to
the maximum tightening torques permissible for the M5 female threads!
2. Check the assembly
Make sure that the FlexxPump 125 B is properly and completely assembled. In
particular, the battery must be inserted and a lubricant cartridge must be tted.
3. Power on
If you want to put the FlexxPump 125 B into operation, switch on the FlexxPump 125
B. Only if you switch on the FlexxPump 125 B, it delivers lubricant to the lubrication
point according to the settings. The detailed description for powering on can be found
in chapter 6.3.3.
4. Execute FIL function
Execute the FIL function. The detailed description can be found in chapter 6.3.10.
FlexxPump 125 B performs a certain number of strokes and transports the lubricant
from the cartridge to the outlet.
5. Hydraulic connection
Connect the consumer hydraulically to the FlexxPump 125 B. If you connect tubes to
the FlexxPump 125 B, make sure that the tubes and connectors are installed tightly,
cleanly and correctly.
 Ideally, use tubes prefilled with the appropriate lubricant!
6. Check the settings on FlexxPump 125 B
Check the factory settings of FlexxPump 125 B with the required values for the
lubrication point and adjust them if necessary. The factory settings are recorded
in chapter 6.2; changes at the FlexxPump 125 B must be made in the SET-Menu,
chapter. 6.3.6, and in the PRO-Menu, chapter 6.3.8 to 6.3.9.

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6. Operation and settings
6.1 General information
What you should know about operating and setting the FlexxPump 125 B:
FlexxPump 125 B is designed as a single point lubricator for one lubrication point.
However, depending on the specific application, FlexxPump 125 B can also supply a
limited number of lubrication points reliably and cleanly with lubricant. Accessories from
the manufacturer can be connected to the FlexxPump 125 B. If necessary, changes
must be made to the FlexxPump 125 B settings to ensure safe and reliable operation.
The FlexxPump 125 B is a cycle-controlled lubricant dispenser which operates
autonomously and time-based via the integrated microelectronics.
The FlexxPump 125 B cyclically delivers a dened quantity of lubricant from the
cartridge to the outlet. Two operating modes can be selected. The Hour-Mode -h-
allows setting the number of cycles (c) within a dispensing time (h) in hours. The cycles
(c) are evenly distributed over the dispensing time. Dispensing times (h) between
1...24 hour(s) and cycles (c) between 1...10 can be set.
The Empty-Time-Mode Et allows the emptying time of the cartridge to be set in
months. Emptying times between 1...24 month(s) can be set.
The disposable interchangeable cartridge with 125ml lubricant guarantees a
controlled and constant quality of the lubricant and is lled without air bubble inclusions.
The FlexxPump 125 B allows a high supply security of the lubrication point and
prevents failures. The FlexxPump 125 B in its present version is designed for the
lubricant grease and oil.
The FlexxPump 125 B cannot be used in the present version without a lubricant
cartridge and suitable battery. Both can - depending on the version ordered - already
be included in the scope of delivery and may already be connected and installed in the
FlexxPump 125 B.
For operation under normal operating conditions, FlexxPump 125 B can be operated
with an alkaline battery, for increased requirements with the more powerful lithium
battery.
The respective conditiones of the FlexxPump 125 B can be seen in the LCD, which
additionally enables the optical recognition of the condition by means of coloured LEDs.
If you have any questions about your application and the correct settings for
FlexxPump 125 B, please contact the manufacturer (chapter I.II).

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6.2 Factory settings
FlexxPump 125 B is always delivered ex works with the following settings:
operating mode Hour-Mode -h-
Mode OFF FlexxPump 125 B is switched off
The factory settings foresee using the FlexxPump 125 B in the Hour-Mode -h-. If
you want to operate the FlexxPump 125 B in Empty-Time-Mode Et, you have to make
changes in the SET-Menu of the FlexxPump 125 B to set the Empty-Time-Mode Et
(chapter 6.3.6).
Dispensing time h = 6 The dispensing time is 6 hours.
Number of cycles c = 1 The number of cycles is one (1) stroke
during the dispensing time.
The default settings in the Hour-Mode result in an emptying time (service life) of 195
days (= 6.4 months) for a full 125 ml lubricant cartridge, provided that the FlexxPump
125 B is permanently switched on and no special dispensations have been made.
Within approx. 6 hours, the FlexxPump 125 B will deliver one donation per stroke
(0.15 cm³).
Verify that the default settings are appropriate for your application and that the
lubrication point is supplied with the correct amount of lubricant per time unit.
If this is the case, you can operate the FlexxPump 125 B with the default settings in the
Hour-Mode -h-.
If this is not the case, change the values for the dispensing time t and number of cycles
c accordingly; see chapter 6.3.8 for an explanation of how to make these changes.
To use FlexxPump 125 B, it must first be properly mounted and installed and then
switched on. Installation is very simple and described in detail in chapter 5.2; switching
on is described in chapter 6.3.3.
If you order a special version of FlexxPump 125 B from the factory, the information
contained in the supplement is authoritative for you!
6.2.1 Default settings operating mode Hour-Mode -h-

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Emptying time Et = 6 The emptying time of one (1) cartridge is 6 months.
The default settings in the Empty-Time-Mode result in an emptying time (service
life) of 6 months for a full 125 ml lubricant cartridge, provided that the FlexxPump 125
B is permanently switched on and no special dispensations have been made. Within
approx. 5.6 hours, the FlexxPump 125 B will deliver one donation per stroke (0.16 cm³).
Verify that the default settings are appropriate for your application and that the
lubrication point is supplied with the correct amount of lubricant per time unit.
If this is the case, you can operate the FlexxPump 125 B with the default settings in the
Empty-Time-Mode Et.
If this is not the case, change the values for the emptying time t accordingly; see
chapter 6.3.9 for an explanation of how to make these changes.
To use FlexxPump 125 B, it must first be properly mounted and installed and then
switched on. Installation is very simple and described in detail in chapter 5.2; switching
on is described in chapter 6.3.3.
If you order a special version of FlexxPump 125 B from the factory, the information
contained in the supplement is authoritative for you!
6.2.2 Default setting operating mode Empty-Time-Mode Et