DLS FlexxPump 500 User manual

Revision: 0
FlexxPump 500 DLS
Continuation sheet
01
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
2. Continuation sheet for user manual
2.1 Revision history
The present continuation sheet ist only valid for:
Product:
Product designation: FlexxPump 500 DLS
Product revision: ---
with part-number: 235-511-210; 235-512-210; 235-522-210; 235-523-210;
235-524-210
The chapters described in this continuation sheet replace the chapters in the
Anleitung:
Date of creation: 09.2019
Revision of the user manual: 0
for the
Product:
Product designation: FlexxPump 400 DLS
Product revision: ---
The chapters which are not replaced by this continuation sheet, are still valid without
exception. Further continuation sheets for the original user manual are additional to this
continuation sheet valid.
This document is protected by copyright.
All rights for layout, content, texts and corporate design are reserved by DLS Schmier-
systeme GmbH.
All rights, including those of photo-mechanical 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.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
02
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
3. Description of function
3.1 General information
The FlexxPump 500 DLS is designed as an extremely compact piston pump for the
lubricant oil. The pistons run force-controlled and counter-rotating. The FlexxPump 500
DLS is available as a version with one lubricant outlet, two outlets, thee outlets or four
outlets. The outlets are secured by an integrated non-return valve. Approx. 0.15 cm³
of lubricant is pumped during each dispensing operation. The FlexxPump 500 DLS
needs to be connected to an external control unit (e.g. PLC). FlexxPump 500 DLS has
an electric interface, by which the FlexxPump can be controlled. Furthermore remote
monitoring is possible via output signals,to retrieve the condition and potential error
messages (e.g. empty grease cartridge). The FlexxPump 400 DLS-HE is controlled
by di󰀨erent input signals, which are processed by the microelectronics, to supply the
lubrication points with the ideal quantity of lubricant.
The FlexxPump 500 DLS is equipped with a special oil cartridge, which must no be
exchanged. Further is a float integrated in the oil cartridge, which transmits a signal to
the microelectronics when the cartridge is empty.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
03
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
Nr. Description
0 FlexxPump 500 DLS
1 Lubricant outlet/ outlets (di󰀨erent versions possible)
2 Retaining ring
3 Housing
4 M12x1-electrical interface
5 Nameplate with designation, CE mark and serial number
6 Through hole for assembly
7 Lubricant inlet with thread for cartridge
8 Float
9 Oil cartridge
7
6
Fig. 1: Overview 500 DLS
1
2
0
4
3
5
8
9

Revision: 0
FlexxPump 500 DLS
Continuation sheet
04
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
3.4 Technical data
Lubricant and hydraulic system
Volume cartridge 400 ml
Lubricant oil

Revision: 0
FlexxPump 500 DLS
Continuation sheet
05
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
6.2 Mounting
2. Remove the housing from the power unit
of the FlexxPump 500 DLS.
Separate the housing from the power unit
by turning the retaining ring counterclock-
wise.
 Make sure that no dirt, water or foreign
bodies enters the lubricant inlet.
As alternative you can remove the lid of
the oil cartridge, to lay open the oil reservoir.
Turn the lid to the position OPEN and pull
of.
1. Delivery state
The FlexxPump 500 DLS is delivered in a
cardboard box. Depending on the version
ordered, further accessories such as a lubri-
cant cartridge or additional connection parts
are included.
3. Filling the cartridge with oil
Fil the cartridge with oil, until you reach the
mark "max. Füllstand".
Fill in the oil carefully, make sure that no
dirt, water or foreign bodies enters the oil
cartridge.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
06
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
6. Remove the protective caps on the side
of the FlexxPump 500 DLS.
Remove the black protective cap from the
side of the electrical M12x1 interface.
7. Connect the electrical interface
Connect the FlexxPump 500 DLS to the
external power supply or controller via the
M12x1 interface on the side of the Flexx-
Pump 500 DLS using a suitable connecting
cable.
Depending on the application, both
connection cables with straight or angled
sockets can be used.
 Please refer to chapter 8.1 for the condi-
tion of the connection cable.
5. Assembling the housing on the power unit
of the FlexxPump 500 DLS.
Place the dismantled housing on the
FlexxPump 500 DLS and press it onto the
power unit.
Fasten the housing to the power unit by
turning the retaining ring clockwise.
 The retaining ring must snap into place
when turning and be completely tightened.
 If you only removed the lid to ll the
cartridge, put it back onto the housing and
move it to the position CLOSE.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
07
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
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.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
08
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
6.3 Commissioning
Mount the FlexxPump 500 DLS carefully according to the steps described in chapter
6.2.
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 500 DLS mechanically. Pay particular attention to the maximum
tightening torques permissible for the M5 female threads!
2. Electrical connection
Connect the FlexxPump 500 DLS to the external power supply or external controller
(PLC) via the M12x1 interface using a suitable cable. Die FlexxPump 500 DLS is now
switched on.
3. Check the assembly
Make sure that the FlexxPump 500 DLS is properly and completely assembled. In par-
ticular the voltage supply has to be ensured.
4. Execute 12 Second signal
Execute the 12 sec signal. For a detailed description please take a look at chapter
8.2.4. The FlexxPump 500 DLS executes a certain number of strokes and delivers the
lubricant from the cartridge to the outlet
5. Hydraulic connection
Connect the consumer hydraulically to the FlexxPump 500 DLS. If you connect tubes to
the FlexxPump 500 DLS, make sure that the tubes and connectors are installed tightly,
cleanly and correctly.
 Ideally, use tubes pre-filled with the appropriate lubricant!
6. Check the settings on FlexxPump FlexxPump 500 DLS
Check the factory settings of FlexxPump 500 DLS with the required values for the lubri-
cation point and adjust them if necessary. Changes have to be made in the
PLC-program.

Revision: 0
FlexxPump 500 DLS
Continuation sheet
09
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
7. Operation and settings
7.1 General information
What you should know about operating and setting the FlexxPump 500 DLS:
For operation, the FlexxPump 500 DLS must be integrated into a control system
(PLC) and must be commanded and controlled via the PLC. The FlexxPump 500 DLS
delivers one or more strokes (one stroke = 0.15 cm³) depending on the signals of the
external control (PLC). Depending on the internal status of the FlexxPump 500 DLS
(e.g. cartridge empty), di󰀨erent output signals are issued by the FlexxPump 500 DLS.
If you have any questions about your application and the correct settings for Flexx-
Pump 500 DLS, please contact the manufacturer (chapter I.II).
Make sure that your PLC program is correct for your application and that the lubricati-
on point is supplied with the correct amount of lubricant per time unit.
If this is the case, you can operate the FlexxPump 500 DLS.
If this is not the case, change your PLC program accordingly.
To use the FlexxPump 500 DLS, it rst has to be properly mounted and installed. The
installation is very simple and described in detail in chapter 6.2.
If you order a special version of the FlexxPump 500 DLS from the factory, the infor-
mation on the supplement sheet is decisive for you!

Revision: 0
FlexxPump 500 DLS
Continuation sheet
10
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
9.1 Maintenance
The following maintenance schedule must be observed for the FlexxPump 500 DLS:
Maintenance Commis-
sioning
After 500
hours or after
3 months
Every
year
If required
Cleaning x x x x*
Visual check x x x x*
Cartridge change x** x*
* Depending on operating conditions and lubricant consumption
** Depending on delivery status (ordered version)

Revision: 0
FlexxPump 500 DLS
Continuation sheet
11
EN-
SCHMIERSYSTEME
DIRECT LUBRICATION SYSTEMS
D L S
9.2 Oil-rell
1. Remove the housing from the power unit
of the FlexxPump 500 DLS.
Separate the housing from the power unit
by turning the retaining ring counterclock-
wise.
 Make sure that no dirt, water or foreign
bodies enters the lubricant inlet.
As Alternative you can remove the lid on
top of the housing,drehe to lay open the oil
reservoir. Turn the lid to OPEN and pull it
o󰀨.
2. Filling of the cartridge with oil
Fill the cartridge with oil until the mark
"max. Füllstand" is reached.
 Make sure you ll the cartridge neat, that
no dirt, water or foreign bodies enters the
lubricant inlet.
3. Assembling the housing on the power unit
of the FlexxPump 500 DLS.
Place the dismantled housing on the
FlexxPump 500achte and press it onto the
power unit.
Fasten the housing to the power unit by
turning the retaining ring clockwise.
 The retaining ring must snap into place
when turning and be completely tightened.
 Mount the lid back onto the housing, if
you removed it for filling the oil cartridge.
The lid has to be in the position CLOSE.