DLS FlexxPump 250 OLED User manual

User manual
FlexxPump 250 / 400 OLED

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 250/400 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250/400OLEDonando󰀨 28
6.3.2. Get information about the FP 250/400 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 53
6.5. Empty level warning 54
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Table of contents

7. Output signals – Time control 55
7.1. Pin assignment – Time control 55
7.2. Output signals – Time control 56
8. Input and output signals – External control (PLC) 57
8.1. Pin assignment – External control (PLC) 57
8.2. Input signals – External control (PLC) 58
8.2.1. Control/input signal „1 lubrication stroke“ 60
8.2.2. Control/input signal „Filling“ 62
8.2.3.Control/inputsignal„Cancellling“ 64
8.2.4. Control/input signal „Status request“ 65
8.2.5. Control/input signal „Acknowledge error“ 66
8.3. Output signals – External control (PLC) 67
9. Maintenance and disposal 70
9.1. Maintenance schedule 70
9.1.1. Visual inspection 70
9.1.2. Cleaning 71
9.1.3. Recommissioning after maintenance 71
9.2. Cartridge change 72
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
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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 250/400 OLED (FP 250/400 OLED)
Product revision: ---
User manual:
Date of creation: 05.2022
Revision of the user manual: 0
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.
II. Imprint of the manufacturer
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

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1. General information about this manual
This user manual contains all necessary information to use the FlexxPump4 in the power supply
version, hereinafter referred to as FP 250/400 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 250/400 OLED. Therefore, keep these instructions in a suitable
place, ideally in an easily accessible place, in the surrounding area of the FP 250/400 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.
INFORMA TION This signal word refers to practical application tips or particularly important
information when using the FP 250/400 OLED.
The design of the signal boxes is based on ANSI Z535.

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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:

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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 250/400 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250/400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 250/400 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 250/400 OLED is
used, the FP 250/400 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250/400OLED.
Local and/or company regulations apply accordingly.

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2.4. Reasonably predictable misuse
Any use of the FP 250/400 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 250/400 OLED:
• The FP 250/400 OLED is exclusively approved for industrial use.
• The FP 250/400 OLED may be used exclusively in accordance with the technical data.
• Unauthorized structural alterations to the FP 250/400 OLED are not permitted.
• Read the user manual and act accordingly.
• During operation of the FP 250/400 OLED, a visual inspection of the FP 250/400 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 250/400 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 250/400 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 250/400 OLED with defective protective devices and devices;
• Operation of the FP 250/400 OLED without lubricant;
• Operation of the FP 250/400 OLED with non-approved lubricant;
• Operation of heavily contaminated FP 250/400 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 250/400 OLED.

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2.7. General safety instructions
The following safety instructions are given for the FP 250/400 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 250/400 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.

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CAUTION
Lubricants can cause skin irritations.
Avoid direct skin contact.
NOTICE
Lubricants can contaminate soil and water.
Use and dispose lubricants properly.

10
9
2
1
4
5
3
0
7
6
8
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3. Description of function
3.1. General information
Nr. Description
0 FlexxPump 250/400 OLED (FP 250/400 OLED)
1 OLED-Display
2 Action area (for actions with the activation and programming key)
3 Activation and programming key
4Lubricantoutlet,outlets(di󰀨erentversionpossible)
5 Retaining ring
6 Upper housing
7 M12x1 electrical interface
8 Nameplate with designation, CE mark and serial number
9 Through hole for assembly
10 Lubricant inlet with thread for cartridge
Fig. 1: Overview FP 250/400 OLED

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The FP 250/400 OLED is designed as an extremely compact double piston pump for autonomous
operation with grease as the lubricant. The two pistons run force-controlled and counter-rotating. The
FP 250/400 OLED is available as a version with one lubricant outlet or as a version with two lubricant
outlets. The outlets are 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 display on the front panel displays the various operating states; further information (empty level
tracking, empty cartridge, error) can be read.
The present FlexxPump4 as power supply version has an electrical interface. The supplied activation
andprogrammingkeycanbeusedtoadjusttheoperationmodeandthequantityoflubricantpumped
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 250/400 OLED is visibly attached to the bottom of the pump itself. There the
CE mark and the serial number of the FP 250/400 OLED are visible. Refer to Fig. 1 for the location of
the nameplate and serial number.
3.3. Scope of delivery
TheFP250/400OLEDisavailableinseveraldi󰀨erentversions.Theydi󰀨erinthedesign(housingfor
250 cm³ cartridge or housing for 400 cm³ cartridge), the number and type of lubricant outlets and the
scope of accessories supplied.

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Housing
Dimensions with housing for 250cm³ cartridge 111 x 165 x 108 (B x H x T)
mm
Dimensions with housing for 400cm³ cartridge 111 x 200 x 108 (B x H x T)
Weight (without cartridge) appx. 1130 g
Mounting options through holes for screws M6x35 DIN 912
Prefered mounting position upright
Material Zinc die-cast / PA 6.6 GF30 / POM
Material outlet Nickel-plated brass
Operating temperature – 20 ... + 70 °C
Lubricant and hydraulics
Cartridge volume 250 / 400 cm³
Lubricant characteristics grease until NLGI class 2
Number of outlets 1 / 2
Hydraulic connection via PA-tube Ø 6mm
Number of lubrication points per outlet depending on the selected accessories
Max. pressure 70 bar
Grease delivery per stroke 0,15 cm³
Electrics
Display OLED-Display
Operating voltage 24 (+/- 5%) V DC
Protection 0,75 (slow blow) A
Protection class IP 54
Current consumption Imax < 0,3
Iquiescent < 0,025
A
3.4. Technical data

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4. Transport and storage
4.1. Packaging
The FP 250/400 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 250/400 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 250/400 OLED.
Do not throw the FP 250/400 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 250/400 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.

Maßstab/Scale
Benennung / Title
Material
NameDatum/Date
Warengruppe
Zeichnungsnr. / Drawing no. Blatt/Sheet
Gewicht/Weight
Toleranzen / Tolerances: ISO 2768-1 m K
Schaumstoffteile nach DIN 7715 Teil 5 Klasse P2
Dieses Dokument ist Eigentum von: This document is ownership of:
3/3
FlexxPump4 N412x_ZOF
Bearb.
Gepr.
Änd./Index
a
J. Niederg.
J. Niederg.
1:2
DIN A4
Maße in mmVK-Artikel-Nr.
Zust.
Änderung Datum Name Gepr.
FlexxPump4 N412x
04.12.2019
04.12.2019
d
a
b
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5. Mounting
5.1. Preparations
Before starting to work, inform yourself in detail about the FP 250/400 OLED using this user manual; in
particular about the general safety instructions (section 2.7). Prepare the installation site carefully.
NOTE
Pressurised air can damage the seals of the FP 250/400 OLED and can
transport dirt and foreign matter into the FP 250/400 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
Two through holes are provided on the housing
for mounting the FP 250/400 OLED at the
intended mounting location.
Fasten the FP 250/400 OLED using two DIN
912 socket head screws of size M6x35 or longer.
Secure the screws with suitable threadlocker.
Suitable mounting brackets and plates are
also available as accessories.
Measurements
a 96 mm
b 33,5 mm
d 6,6 mm
Prefered mounting position upright

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5.3. Mounting height
When selecting the mounting location, observe the minimum mounting heights required for the
FP 250/400 OLED in the version with 250 cm³ cartridge volume or 400 cm³ cartridge volume for
disassembly and assembly of the upper housing.
min. mounting height
version 250 cm³ [mm]
min. mounting height
version 400 cm³ [mm]

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1. Remove the housing from the power unit of the
FP 250/400 OLED.
Loosen the retaining ring from the power unit by
turning it counterclockwise.
Separate the upper housing from the
FP 250/400 OLED.
For easier loosening, grip the retaining ring on
the right and left outside.
Make sure that no dirt, water or foreign bodies
enter/s the lubricant inlet.
2. Mounting the lubricant cartridge
Unscrew the lubricant cartridge cap
counterclockwiseandpullito󰀨.
Placethelledlubricantcartridgeonthe
FP 250/400 OLED with the label facing forwards.
Screw the lubricant cartridge clockwise onto the
FP 250/400 OLED.
The end position is reached after two
full rotations when the label of the lubricant
cartridge is in alignment with the front of the
FP 250/400 OLED.
5.4. Mounting of the FP 250/400 OLED

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4. Remove the protective cap on the side of the
FP 250/400 OLED.
Remove the black protective cap in the direction
of the arrow from the side of the electrical M12x1
interface.
3. Assembling the upper housing on the power unit
of the FP 250/400 OLED.
Place the dismantled housing on the
FP 250/400 OLED and press it onto the power unit.
Fasten the housing to the power unit by turning
the retaining ring clockwise.
For easier fastening, grip the retaining ring on
the right and left outside.
The retaining ring must snap into place when
turning and be completely tightened.

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5. Connect the electrical interface
Connect the FP 250/400 OLED to the external
power supply or controller via the M12x1 interface
on the side of the FP 250/400 OLED using a
suitable connecting cable.
Depending on the application, 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.
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.
DANGER
Machine elements that are not lubricated can cause failures resulting in
serious injury or even death.
• Never operate the FP 250/400 OLED without the upper housing. Especially
when changing the cartridge or during start-up, make sure to remount the
upper housing after disassembly.

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5.5. Start-up
Mount the FP 250/400 OLED carefully according to the steps described in chapters before.
Depending on the scope of delivery, you must also carry out the following additional measures for the
rst-timestart-up:
1. Check the assembly
Make sure that the FP 250/400 OLED is properly and completely assembled. In particular, the battery
mustbeinsertedandalubricantcartridgemustbetted.
2. Power on
If you want to put the FP 250/400 OLED into operation, switch on the FP 250/400 OLED. Only if you
switch the FP 250/400 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.Activatellingmenu
Executethellingmenu.ThedetaileddescriptionofthiscanbefoundinChap.6.3.5.The
FP 250/400 OLED thus carries out a pump cycle „PZ“ with a total of 40 lubrication strokes „C“ with the
activation.
4. Hydraulic connection
Connect the consumer hydraulically to the FP 250/400 OLED. If you connect tubes to the
FP 250/400 OLED, make sure that the tubes and connectors are installed tightly, cleanly and correctly.
Ideally, use tubes prefilled with the appropriate lubricant!
5. Check the settings on the FP 250/400 OLED
Check the factory settings of the FP 250/400 OLED with the required values for the lubrication point
andadjustthemifnecessary.ChangestotheFP250/400OLEDmustbemadeintheSettingsmenu,
see Chap. 6.3.4.