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DLS FlexxPump 250 User Manual

Power supply (24v dc) time-controlled
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User Manual
FlexxPump 250/400 Power Supply (24V DC)
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Summary of Contents for DLS FlexxPump 250

  • Page 1 User Manual FlexxPump 250/400 Power Supply (24V DC) time-controlled...

  • Page 2: Revision History & Imprint

    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 specifications are subject to change without notice.

  • Page 3: Table Of Contents

    FlexxPump 250/400 (24V); time-controlled User Manual I.III Table of contents Chapter Content Page Revision history & Imprint Revision history I.II Imprint of the manufacturer, distribution and service I.III Table of contents General information about this manual Signal words Warning symbols...
  • Page 4 FlexxPump 250/400 (24V); time-controlled User Manual Chapter Content Page Menu and LCD messages 6.3.1 6.3.2 Actions with the activation and programming key 6.3.3 Switching on and off 6.3.4 INF-Menu Hour-Mode -h- 6.3.5 INF-Menu operating mode Empty-Time-Mode Et 6.3.6 SET-Menu 6.3.7 RUN-Menu 6.3.8...

  • Page 5: General Information About This Manual

    User Manual General information about this manual This user manual contains all necessary information to use FlexxPump 250/400 in the power supply 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.

  • Page 6: Warning Symbols

    FlexxPump 250/400 (24V); time-controlled User Manual Warning symbols The following warning symbols are used in this user manual to alert you to hazards, prohibitions and important information: General Electricity Flammable warning sign hazard material Structure of the safety instructions The safety instructions in this user manual are structured according to the following...

  • Page 7: Safety

    EC/EU Directive Within the scope of the EC/EU Directive, (re)commissioning of a machine on which the FlexxPump 250/400 has been installed and/or fitted is prohibited until it has been clearly established that the machine complies with the provisions of the applicable Directive.

  • Page 8: Usage For The Intended Purpose

    Relevant regulations and rules on work safety, accident prevention and environmental protection must be observed. Work and activities with and on the FlexxPump 250/400 are only permitted with appropriate 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.

  • Page 9: General Safety Instructions

    FlexxPump 250/400 (24V); time-controlled User Manual General safety instructions The following safety instructions are given for the FlexxPump 250/400: 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 qualified personnel only.

  • Page 10: Description Of Function

    Description of function General information The FlexxPump 250/400 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 FlexxPump 250/400 is available as a version with one lubricant outlet or as a version with two lubricant outlets.

  • Page 11: Nameplate And Designation

    User Manual Nameplate and designation The nameplate of the FlexxPump 250/400 is visibly attached to the side of the pump itself. There the CE mark and the serial number of the FlexxPump 250/400 are visible. Refer to chapter 3, Fig. 1 for the location of the nameplate and serial number.

  • Page 12: Technical Data

    FlexxPump 250/400 (24V); time-controlled User Manual Technical data Housing Dimensions without cartridge 111 x 56,5 x 108 (W x H x D) Dimensions with housing for 250ml cartridge 111 x 165 x 108 (W x H x D) Dimensions with housing for 400ml cartridge 111 x 198,5 x 108 (W x H x D) Weight (without cartridge) appx.

  • Page 13: Transport And Storage

    Do not throw the FlexxPump 250/400. Storage Store the FlexxPump 250/400 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.

  • Page 14: Mounting

    FlexxPump 250/400 (24V); time-controlled User Manual Mounting Preparations Before starting to work, inform yourself in detail about the FlexxPump 250/400 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 250/400 and can transport dirt and foreign matter into the FlexxPump 250/400 or the lubricant.
  • Page 15 4. Assembling the housing on the power unit of the FlexxPump 250/400.  Place the dismantled housing on the FlexxPump 250/400 and press it onto the power unit.  Fasten the housing to the power unit by turning the retaining ring clockwise.
  • Page 16  Remove the black protective cap from the side of the electrical M12x1 interface. 6. Connect the electrical interface  Connect the FlexxPump 250/400 to the external power supply or controller via the M12x1 interface on the side of the FlexxPump 250/400 using a suitable connecting cable.

  • Page 17: Commissioning

    4. Power on If you want to put the FlexxPump 250/400 into operation, switch on the FlexxPump 250/400. Only if you switch the FlexxPump 250/400 on, it delivers lubricant to the lubrication point according to the settings.

  • Page 18: Operation And Settings

    (strokes) per outlet are made in direct succession. After the end of the lubrication cycle, the FlexxPump 250/400 rests until the set break time time h has elapsed and automatically carries out the next lubrication cycle after the set break time time h has elapsed.
  • Page 19 User Manual D If you have any questions about your application and the correct settings for FlexxPump 250/400, please contact the manufacturer (chapter I.II).  If you have purchased a FlexxPump 400, you can use the 250ml and 400ml cartridge sizes. If you have purchased a FlexxPump 200, you can only use the 250ml cartridge size.

  • Page 20: Factory Settings

    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 250/400 with the default settings in the Hour-Mode -h-.

  • Page 21: Default Settings Empty-Time-Mode Et

    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 250/400 with the default settings in the Empty-Time-Mode Et.

  • Page 22: Menu And Lcd Messages

    User Manual Menu and LCD messages The LCD of the FlexxPump 250/400 can be used to read information optically, to change settings in conjunction with the activation and programming key on the underside of the FlexxPump 250/400, or to trigger individual actions.
  • Page 23 User Manual The graphic above illustrates the unchangeable basic flowchart of the FlexxPump 250/400 menu navigation as well as the options for branching to the Sub- Menus. The FlexxPump 250/400 can be switched on and off at several points in the menu navigation.
  • Page 24 User Manual The PRO-Menu is only accessible from the ON mode (FlexxPump 250/400 is switched on). The PRO-Menu allows you to make changes to the FlexxPump 250/400 settings - and thus to its dispensing behavior. For details see chapter 6.3.8, 6.3.9.

  • Page 25: Lcd

    For optical output, information in the various states is displayed on the LCD via FlexxPump 250/400. You will be supported by three coloured LEDs to the right of the LCD, depending on the state of the FlexxPump 250/400. This allows you to assess the condition of the FlexxPump 250/400 from a distance;...
  • Page 26 Meaning Chapter dark Power supply not connected FlexxPump 250/400 is switched off 6.3.3 FlexxPump 250/400 is ready for operation; 6.3.3 FlexxPump 250/400 dispenses lubricant in accordance to the operation mode and the set values Errors Error E1 (Empty Cartridge) Error E2 (Overload)
  • Page 27 If the process is aborted during the FIL command, Clr appears first. Additional character on the LCD After each cycle the maximum back pressure is displayed in bar. During a dispensing process, the 1 / 2 FlexxPump 250/400 indicates from which outlet lubricant is being pumped. revision: 1...

  • Page 28: Actions With The Activation And Programming Key

    The activation and programming key attached to the housing of the FlexxPump 250/400 allows you to perform actions and changes in the settings of the FlexxPump 250/400. This activation and programming key can be easily and permanently stored on the FlexxPump 250/400.
  • Page 29  At the end of the action or settings, insert the activation and programming key again into the hole provided on the housing of the FlexxPump 250/400. Then turn the activation and programming key to the CLOSE position to restore the sealing effect.

  • Page 30: Switching On And Off

    ON is displayed in the LCD. The yellow LED disappears; the LCD flashes together with the green LED twice. Ü If no error is detected during the FlexxPump 250/400 self-check, ON is displayed in the LCD. The green LED lights up once every 5 seconds, FlexxPump 250/400 is ready for operation and will dispense lubricant according to the set values.

  • Page 31: Inf-Menu Hour-Mode -H

    INF is displayed in the LCD. The yellow LED disappears; the LCD flashes together with the green LED twice. Ü FlexxPump 250/400 informs you optically on the LCD about the set values. Insert the activation and programming key into the hole provided on the housing of the FlexxPump 250/400.

  • Page 32: Inf-Menu Operating Mode Empty-Time-Mode Et

    INF-Menu operating mode Empty-Time-Mode Et The INF-Menu is used to inform the user about the firmware used in the FlexxPump 250/400 and the settings made and currently active (value of the adjustable variable Et that can be changed in the PRO-Menu).

  • Page 33: Set-Menu

    250/400 Changeable parameter of the cartridge size FlexxPump 400/200 is switched off (OFF). Remove the activation and programming key from the bottom of FlexxPump 250/400 and place it on the action area. Hold the activation and programming key on the action surface. The yellow LED lights up.
  • Page 34 Ü The LCD flashes together with the green LED twice, whereby the cartridge size is displayed in the LCD. The SET-Menu can only be accessed from the OFF mode (FlexxPump 250/400 is switched off). When you have entered the SET-Menu, you will return to the OFF mode.

  • Page 35: Run-Menu

    The RUN-Menu is used for manual activation of the FlexxPump 250/400. A special donation from FlexxPump 250/400 can be triggered in this way. This function can, for example, be used for the advantageous "Quick Check" to manually check the condition of the lubrication point.

  • Page 36: Pro-Menu Operating Mode Hour-Mode -H

    (number of strokes). The basic rule is that during a dispensing cycle the FlexxPump 250/400 performs exactly the number c of strokes (each 0.16 cm³) specified in the number c of cycles. The dispensing cycle repeats itself after the number of hours specified in the break time time h.
  • Page 37 FlexxPump 250/400 (24V); time-controlled User Manual Changing the value of the break time time h:  If you want to change the value of the break time time h, move the activation and programming key back to the action area.
  • Page 38 If you have made changes to the values of the break time time h or the values of the number of cycles c in the PRO-Menu and the FlexxPump 250/400 is otherwise ready for operation (cartridge fitted), the FlexxPump 250/400 will immediately start with the calculated waiting time until the next break time.

  • Page 39: Pro-Menu Operating Mode Empty-Time-Mode Et

    If you are in the Empty-Ttime-Mode Et, you can change the emptying time Et in months and the number of cycles c. The FlexxPump 250/400 automatically calculates the break time time between two cycles to reach the set emptying time in months.
  • Page 40 Ü The LCD as well as the green LED flashes twice and the number of cycles c is displayed in the LCD.  Insert the activation and programming key into the hole provided on the housing of the FlexxPump 250/400. The PRO-Menu can only be reached from the ON mode (FlexxPump 250/400 revision: 1...
  • Page 41 If you have made changes to the values of the break time time h or the values of the number of cycles c in the PRO-Menu and the FlexxPump 250/400 is otherwise ready for operation (cartridge fitted), the FlexxPump 250/400 will immediately start with the calculated waiting time until the next break time.

  • Page 42: 6.3.10 Fil-Menu

    Remove the activation and programming key from the housing of the FlexxPump 250/400 and place it on the action area. The yellow LED will light up. Leave the activation and programming key on the action area until FIL is displayed in the LCD.

  • Page 43: Error Codes

    If you use the FIL function in the Emptying-Time-Mode, the Emptying time is reduced. The FIL-Menu can only be reached from the ON mode (FlexxPump 250/400 switched on). When you enter the FIL-Menu, you will return to the ON mode.
  • Page 44 FlexxPump 250/400 (24V); time-controlled User Manual Name Description Remedy Error Fatal error  The error E4 can have different causes: 1. The voltage is too high for a short time, 28 ... 30V, causing the motor to run too short.

  • Page 45: Input And Output Signals

    Type: M12x1 female connector; 4-pin, A-coded The FlexxPump 250/400 can be switched off completely by switching off the supply voltage. The settings will not be lost. The elapsed time until the next scheduled lubrication cycle is automatically stored by the FlexxPump 250/400 in the integrated microelectronics.

  • Page 46: Output Signals At Pin 4 - Time Control

    PIN 4 Description: A permanent low level (0V) at PIN 4 means that the FlexxPump 250/400 is either switched off or - if it is switched on - there is an error. The error must be read on the LCD of the FlexxPump 250/400 (chapter 6.4). The FlexxPump 250/400 does not pump...
  • Page 47 PIN 4 Description: The integrated microelectronics of the FlexxPump 250/400 is equipped with an automatic counter which counts the number of dispensing operations after a new and full cartridge has been fitted. For a cartridge with 250ml lubricant there are 1687 strokes, for a cartridge with 400ml lubricant there are 2700 strokes.

  • Page 48: Maintenance And Disposal

     Check the condition of the lubrication point for correct supply of lubricant.  Replace damaged or defective parts immediately to ensure permanent lubrication.  Check the filling level of the cartridge on the FlexxPump 250/400.  Check possible error messages on the FlexxPump 250/400 and remedy the causes accordingly. revision: 1...

  • Page 49: Cleaning

    FlexxPump 250/400 (24V); time-controlled User Manual 8.1.2 Cleaning  Clean the FlexxPump 250/400 from dirt using suitable cleaning agents (e.g. absorbent towels, cloths). NOTICE Compressed air can damage the seals of the FlexxPump 250/400 as well as transport dirt and foreign bodies into the FlexxPump 250/400 or the lubricant.

  • Page 50: Cartridge Change

    User Manual Cartridge change NOTICE A used lubricant cartridge must not be replaced on the FlexxPump 250/400, as the integrated stroke counter of the FlexxPump 250/400 is automatically reset by the cartridge sensor after a cartridge has been removed. §...
  • Page 51 2. Remove the empty cartridge  Unscrew the lubricant cartridge counterclockwise from the FlexxPump 250/400 and discard it.  Pay attention to cleanliness when carrying out the work. It is imperative that dirt and foreign bodies do not enter the cartridge.
  • Page 52 5. Assembling the housing on the power unit of the FlexxPump 250/400.  Place the dismantled housing on the FlexxPump 250/400 and press it onto the power unit.  Fasten the housing to the power unit by turning the retaining ring clockwise.
  • Page 53 LED. A separate confirmation is not necessary. The green LED flashes briefly every 5 seconds. Ü The FlexxPump 250/400 automatically returns to the last active mode (ON or OFF) before the completion of this work.

  • Page 54: Disposal

    FlexxPump 250/400 (24V); time-controlled User Manual Disposal  When disposing the FlexxPump 250/400, empty or opened cartridges, observe the relevant national regulations in force.  When disposing the FlexxPump 250/400, observe the relevant safety data sheets and disposal instructions for the individual components.

  • Page 55: Released Accessories

    The present FlexxPump 250/400 can be considerably extended by the extensive system and accessory program. This may necessitate changes to the factory and/or the default settings of the FlexxPump 250/400 to ensure reliable and proper operation of the FlexxPump 250/400 together with the hydraulically connected accessories.
  • Page 56 FlexxPump 250/400 (24V); time-controlled User Manual 134-002-029 Cable M12x1; angled plug; 4-pin; open end; 5 m 134-002-030 Cable M12x1; angled plug; 4-pin; open end; 10m on request Splitter: 2 to 4 outlets multipoint lubrication on request Aluminium progressive distributor: 2 to 10...

  • Page 57: Lubricants

    FlexxPump 250/400 and the lubrication point (or distributor). If the case arises that you cannot mount the FlexxPump 250/400 directly at the lubrication point, contact the manufacturer to verify your application. The influence of temperature, the grease used, the hoses and accessories used does not allow a general statement to be made about the possible hose length on the FlexxPump 250/400.

  • Page 58: Appendix

    FlexxPump 250/400 (24V); time-controlled User Manual Appendix 10.1 Dimension sheet and installation dimension 198.5 45.5 33.5 M12x1 revision: 1...

  • Page 59: Ec/Eu Declaration Of Conformity

    FlexxPump 250/400 (24V); time-controlled User Manual 10.2 EC/EU Declaration of conformity revision: 1...
  • Page 60 DLS Schmiersysteme GmbH Gewerbering 5 D-82140 Olching Tel: +49-(0)8142 650 69-0 Fax: +49-(0)8142 650 69-29 mail@ DLS-Schmiersysteme.de www.DLS-Schmiersysteme.de...

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Flexxpump 400

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