DLS FlexxPump 125 OLED User manual

User manual
FlexxPump 125 OLED

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 1 of 79
FlexxPump 125 OLED
User manual
Table of contents
Table of contents 1
I. Revision history 3
II. Imprint of the manufacturer 3
1. General information about this manual 4
1.1 Signal words 4
1.2. Warning symbols 5
1.3. Structure of the safety instructions 5
1.4. Symbols for information 6
2. Safety 6
2.1. EG/EU Directive 6
2.2. Hazards 6
2.3. Sta󰀨 6
2.4. Reasonably predictable misuse 7
2.5. Usage for the intended purpose 7
2.6. Warranty and liability 7
2.7. General safety instructions 8
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. Mechanical mounting 14
5.3. Mounting height 15
5.4. Mounting of the FP 125 OLED 16
5.5. Start-up 19
6. Operation and settings 20
6.1. General information 20
6.2. Menu and display messages 23
6.3. Actions with the actication and programming key 26
6.3.1. Switching FP 125 OLED on and o󰀨 28
6.3.2. Get information about the FP 125 OLED 30
6.3.3. Perform a Quick-Check 32
6.3.4. Set operating mode and cartridge size 34
6.3.4.1. Operating mode Setting Lubrication cycle duration 37
6.3.4.2.Operating mode Setting Emptying time 44
6.3.4.3.Operating mode pulse control 51
6.3.5. Activate the Filling-menu 52
6.4. Error and information messages on the display 54
6.5. Empty level warning 55

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 2 of 79
FlexxPump 125 OLED
User manual
7. Output signals – Time control 56
7.1. Pin assignment – Time control 56
7.2. Output signals – Time control 57
8. Input and output signals – External control (PLC) 58
8.1. Pin assignment – External control (PLC) 58
8.2. Input signals – External control (PLC) 59
8.2.1. Control/input signal „1 lubrication stroke“ 61
8.2.2. Control/input signal „Filling“ 63
8.2.3. Control/input signal „Cancel lling“ 65
8.2.4. Control/input signal „Status request“ 66
8.2.5. Control/input signal „Acknowledge error“ 67
8.3. Output signals – External control (PLC) 68
9. Maintenance and disposal 71
9.1. Maintenance schedule 71
9.1.1. Visual inspection 71
9.1.2. Cleaning 72
9.1.3. Recommissioning after maintenance 72
9.2. Cartridge change 73
9.3. Disposal 75
10. Further notes 76
10.1. Lubricants 76
10.2. Pipe lengths 76
11. Appendix 77
11.1. Dimension sheet and installation dimension 77
11.2. EC/EU Declaration of conformity 78

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 3 of 79
FlexxPump 125 OLED
User manual
I. Revision history
This manual was written in German, all other language versions are translations of this manual.
This user manual is only valid for
Product:
Product designation: FlexxPump 125 OLED (FP 125 OLED)
Product revision: from serial number 2231345
User manual:
Date of creation: 05.2022
Revision of the user manual: DS-20230308
Language: EN
This document is protected by copyright.
All rights for layout, content, texts and corporate design are reserved by DLS Schmiersysteme GmbH,
© 2022. 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.
Address:
DLS Schmiersysteme GmbH
Gewerbering 5
D-82140 Olching
Phone: +49 - (0) 8142 - 650 69 - 0
Fax: +49 - (0) 8142 - 650 69 - 30
E-Mail: [email protected]
Internet: www.dls-schmiersysteme.de
Personally Liable Company: DLS Schmiersysteme GmbH
Headquarters of the company:
Olching
Handelsregister München
HRB 156604
USt.-IdNr.: DE128578324
Managing directors: Reiner Hochholzer
Helmut Feicht
II. Imprint of the manufacturer

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 4 of 79
FlexxPump 125 OLED
User manual
1. General information about this manual
This user manual contains all necessary information to use the FlexxPump 125 OLED in the power
supply version, hereinafter referred to as FP 125 OLED, 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.
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 FP 125 OLED. Therefore, keep these instructions
in a suitable place, ideally in an easily accessible place, in the surrounding area of the
FP 125 OLED.
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
DANGER
WARNING
CAUTION
NOTICE
This signal word points you to an immediate and threatening risk of
serious injury or death.
This signal word indicates a potentially imminent danger which can
result in serious injury or even death.
This signal word indicates a potentially imminent danger that can
result in minor to severe injuries.
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 FP 125 OLED.
The design of the signal boxes is based on ANSI Z535.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 5 of 79
FlexxPump 125 OLED
User manual
CAUTION
The text explains the consequences of disregarding the reference.
• The text shows what to do as an instruction.
1.2. Warning symbols
GENERAL WARNING
SIGN
ELECTRICITY
HAZARD
FLAMMABLE
MATERIAL
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:

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 6 of 79
FlexxPump 125 OLED
User manual
1.4. Symbols for information
The following information symbols are used in the text and instructions in this manual
Requests you to take action
Shows the consequences of an action
Additional information about the action
2. Safety
All persons working with the FP 125 OLED 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 environmenal
protection must be observed.
2.1. EG/EU Directive
Within the scope of the EC/EU Directive, (re)commissioning of a machine on which the FP 125 OLED
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 FP 125 OLED can be found in the appendix.
2.2. Hazards
In order to avoid danger to the user or damage to the machine on which the FP 125 OLED is
used, the FP 125 OLED may only be used for its intended purpose and in a technically safe
condition.
Always inform yourself about the general safety instructions before starting to work.
2.3. Sta󰀨
Only qualied sta󰀨 who has read and understood this manual may work with the FP 125 OLED.
Local and/or company regulations apply accordingly.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 7 of 79
FlexxPump 125 OLED
User manual
2.4. Reasonably predictable misuse
Any use of the FP 125 OLED which exceeds the maximum permissible technical data is generally
considered to be improper and therefore prohibited.
2.5. Usage for the intended purpose
The following points must be observed for the intended purpose of using the FP 125 OLED:
• The FP 125 OLED is exclusively approved for industrial use.
• The FP 125 OLED may be used exclusively in accordance with the technical data.
• Unauthorized structural alterations to the FP 125 OLED are not permitted.
• Read the user manual and act accordingly.
• During operation of the FP 125 OLED, a visual inspection of the FP 125 OLED 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 FP 125 OLED 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 environmental
• protection must be observed.
• Work and activities with and on the FP 125 OLED are only permitted with appropriate authorisation.
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 liability
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 FP 125 OLED with defective protective devices and devices;
• Operation of the FP 125 OLED without lubricant;
• Operation of the FP 125 OLED with non-approved lubricant;
• Operation of heavily contaminated FP 125 OLED;
• 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 FP 125 OLED.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 8 of 79
FlexxPump 125 OLED
User manual
2.7. General safety instructions
The following safety instructions are given for the FP 125 OLED:
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
FP 125 OLED.
• 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 manufacturer on the
safety data sheet of the lubricant used.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 9 of 79
FlexxPump 125 OLED
User manual
CAUTION
Lubricants can cause skin irritations.
• Avoid direct skin contact.
NOTICE
Lubricants can contaminate soil and water.
• Use and dispose lubricants properly.

10
9
7
11
4
5
0
3
1
2
6
8
User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 10 of 79
FlexxPump 125 OLED
User manual
3. Description of function
3.1. General information
Fig. 1: Overview FP 125 OLED
No. Description
0 FlexxPump 125 OLED (FP 125 OLED)
1 OLED-Display
2 Action area (for actions with the activation and programming key)
3 M12x1 electrical interface
4 Activation and programming key
5 Lubricant outlet with external thread G1/4“ and internal thread M6x1
6 M5 female thread for bottom mounting
7 Serial number of the FP 125 OLED
8 M5 female thread for rear mounting
9 Cartridge sensor
10 Lubricant inlet with thread for cartridge
11 Nameplate with designation and CE mark

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 11 of 79
FlexxPump 125 OLED
User manual
The FP 125 OLED is designed as an extremely compact piston pump for the lubricant grease.
The outlet is secured by an integrated check valve. Approx. 0.15 cm³ of lubricant is delivered with each
lubrication stroke; several lubrication strokes in succession can be set. The various operating states
are shown in the front-mounted display; further information (empty level warning, empty cartridge level,
errors) can be accessed. The present FP 125 OLED as 24V DC version has an electrical interface.
The supplied activation and programming key can be used to adjust or set the operating mode and the
quantity of lubricant delivered per time in order to supply the lubrication point with the ideal quantity
of lubricant.
3.2. Nameplate and designation
The nameplate of the FP 125 OLED is visibly attached to the side of the pump itself. There the CE
mark and the serial number of the FP 125 OLED are visible. Refer to Fig. 1 for the location of the
nameplate and serial number.
3.3. Scope of delivery
The scope of delivery includes the FP 125 OLED and any accessories ordered. The FP 125 OLED is
delivered without lubricant cartridge.
All versions of the FP1 N 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 Total Ceran FG.
Further data and documentation on the lubricant Total Ceran FG are available on request from DLS
Schmiersysteme GmbH.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 12 of 79
FlexxPump 125 OLED
User manual
Housing
Dimensions without cartridge 83 x 82 x 85 (B x H x T)
mm
Dimensions with 125 cm³ cartridge 83 x 149 x 85 (B x H x T)
Dimensions with 250 cm³ cartridge 83 x 185 x 85 (B x H x T)
Weight (without cartridge) approx. 350 g
Mounting options Back: female thread M5 (2x)
Bottom: female thread M5 (1x)
Bottom: male thread G1/4“ (1x)
Preferred mounting position upright
Material housing PA 6.6 GF30 / POM
Material outlet stainless steel
Operating temperature – 20 ... + 70 °C
Lubricant and hydraulics
Volume cartridge 125 / 250 cm³
Lubricant characteristics Grease until NLGI class 2
Number of outlets 1
Hydraulic connection via PA-tube Ø 6mm
directly (with adapter)
Number of lubrication points depending on accessories
Max. pressure build-up 50 bar
Lubricating volume per stroke 0,15 cm³
Electrics
Display OLED-Display
Operating voltage 24 (+/- 5%) V DC
Protection 0,75 (träge) A
Protection class IP 54
Current consumption Imax < 0,3 Iqiescent < 0,025 A
3.4. Technical data

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 13 of 79
FlexxPump 125 OLED
User manual
4. Transport and storage
4.1. Packaging
The FP 125 OLED 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.
Dispose the packaging materials at the designated disposal points in compliance with the
relevant national and company regulations.
After receiving the FP 125 OLED, 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 FP 125 OLED.
• Do not throw the FP 125 OLED.
• When using lifting equipment, only use hoists and load handling attachments
in perfect condition and with su󰀩cient load capacity.
• The permissible lifting weight of the lifting device must not be exceeded.
4.3. Storage
Store the FP 125 OLED in its original packaging in a vertical position in a dry, frost-free environment
at an ambient temperature of 0°C to + 40°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.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 14 of 79
FlexxPump 125 OLED
User manual
5. Mounting
5.1. Preparations
Before starting to work, inform yourself in detail about the FP 125 OLED 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 FP 125 OLED and can
transport
dirt and foreign matter into the FP 125 OLED or the lubricant.
• Do not use pressurised air.
• Make sure that there is no coarse dirt in the mounting area.
5.2. Mechanical mounting
Three brass inserts with internal threads on the housing
and an G1/4“ external thread on the lubricant outlet are
available for fastening the FP 125 OLED at the intended
mounting location.
Fasten the FP 125 OLED using a minimum of two
DIN 912 socket head screws of size M5x8 (screw-in
depth on the FP 125 OLED > 6mm) or longer on the
housing or with an G1/4“ nut on the lubricant outlet.
Secure the screws or nuts with suitable threadlocker.
Suitable adapters, brackets and plates are also
available as accessories for mounting.

147,8
43,5
60
16M x1,5
73Ø82,9Ø
Schmierstoffanschluss
M10x1-7mm tief innen
85
Stecker M12x1
M12x1 connector
Befestigungsgewinde
M5-8mm tief
Fastening thread
M5-8mm deep
176min.
11
Lubricant connection
M10x1-7mm deep inside
82,7
183,8
43,5
60
16M x1,5
73Ø82,9Ø
Schmierstoffanschluss
M10x1-7mm tief innen
85
Stecker M12x1
M12x1 connector
Befestigungsgewinde
M5-8mm tief
Fastening thread
M5-8mm deep
212min.
11
Lubricant connection
M10x1-7mm deep inside
82,7
User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 15 of 79
FlexxPump 125 OLED
User manual
min. mounting height version 125 cm³
[mm]
min. mounting height version 250 cm³
[mm]
5.3. Mounting height
When selecting the mounting location, observe the minimum mounting heights required for the FP 125
OLED in the version with 125 cm³ cartridge volume or 250 cm³ cartridge volume for disassembly and
assembly of the cartridge.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 16 of 79
FlexxPump 125 OLED
User manual
5.4. Mounting of the FP 125 OLED
1. Remove the protective cap from the top of the FP 125
OLED.
Remove the yellow protective cap from the
top of the lubricant inlet of the FP 125 OLED.
Dispose of the protective cap properly.
Make sure that no dirt, water or foreign bodies
enter/s the lubricant inlet.
2. Mounting the lubricant cartridge
Turn the cap on the lubricant cartridge counterclockwise
and pull it o󰀨.
Place the full lubricant cartridge on the FP 125 OLED
with the label facing forwards.
Turn the lubricant cartridge clockwise until it physically
stops on the FP 125 OLED.
The end position should be reached after two full
rotations when the lubricant cartridge label is aligned
with the front of the FP 125 OLED.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 17 of 79
FlexxPump 125 OLED
User manual
4. Connect the electrical interface
Connect the FP 125 OLED to the external power supply
or controller via the M12x1 interface on the side of the FP
125 OLED using a suitable connecting cable.
 Depending on the application, both connection
cables with straight or angled socket can
be used.
Please refer to chapter 7.1. or chapter 8.1. for the
condition of the connection cable.
3. Remove the protective caps from the bottom of the FP
125 OLED.
Unsrew the yellow protective cap counterclockwise
from the bottom of the lubricant outlet of the FP 125
OLED.
 Pull the black protective cap o󰀨 the M12x1 electrical
interface at the bottom in the direction of the arrow.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 18 of 79
FlexxPump 125 OLED
User manual
DANGER
Defective or faulty electrical connections or unauthorized live components
can 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.
• Before carrying out any electrical installation work, observe the ve safety
rules of electrical engineering:
• Unlocking
• Secure against unintentional restarting.
• Check that there is no voltage.
• Ground and short-circuit.
• Cover adjacent live parts.

User manual FlexxPump 125 OLED
Rev.: DS-20230308
Page 19 of 79
FlexxPump 125 OLED
User manual
5.5. Start-up
Mount the FP 125 OLED carefully according to the steps described in the chapters before. Depending
on the scope of delivery, you must also carry out the following additional measures for the rst-time
commissioning:
1. Check the assembly
Make sure that the FP 125 OLED is properly and completely assembled. In partricular, the battery
must be inserted and a lubricant cartridge must be tted.
2. Power on
If you want to put the FP 125 OLED into operation, switch on the FP 125 OLED. Only if you switch the
FP 125 OLED on, it delivers lubricant to the lubrication point according to the settings. The detailed
description for powering on can be found in chapter 6.3.1.
3. Setting the cartridge size
The FP 125 OLED is factory-set to use cartridges with a 125 cm3capacity. If you use a cartridge with
a 125 cm3capacity during operation, you can skip this step. If you use a cartridge with a capacity of
250 cm3 , you must adjust this in the software of the FP 125 OLED in the Settings menu, see Chapter
6.3.4.
4. Hydraulic connection
Connect the consumer hydraulically to the FP 125 OLED. If you connect tubes to the FP 125 OLED,
make sure, that the tubes and connectors are istalled tightly, cleanly and correctly.
 Ideally, use tubes prelled with the appropiate lubricant!
5. Activate lling function
Execute the lling function. The detailes description can be found in chapter 6.3.5. The FP 125 OLED
carries out a pump cycle PZ with a total of 40 lubrication strokes C with the activation.
6. Check the settings on the FP 125 OLED
Compare the basic settings of the FP 125 OLED with the values required for the lubrication point and
adjust them if necessary. Changes to the FP 125 OLED must be made in the Settings menu, see
Chap. 6.3.4.