LMI KBL-SERIES Peristaltic Metering Pump Instruction Manual

LMI KBL-SERIES Peristaltic Metering Pump

Product Information

Specifications

• Product Name: KBL-Series Peristaltic Metering Pump
• Model: KBL – SERIES
• Materials of Construction: Varies according to model
• Power Requirements: Refer to installation section
• Manufacturer: LMI
• Website: www.lmipumps.com

Product Usage Instructions

1. Installation

Before starting, ensure that all items supplied match the order confirmation and inspect for any damages. Follow the power requirements and control wiring instructions for proper installation.

2. Getting Started

Familiarize yourself with the user interface, display, keypad, and icons for efficient operation. Refer to the Quick Start Guide for initial setup.

3. Maintenance

Regularly inspect the pump for any issues, replace tubes and roller assembly as needed. Keep spare parts on hand for quick replacements.

4. Troubleshooting

Refer to the Troubleshooting Guide for common issues and error codes. Follow the instructions to resolve any problems.

FAQs

• Q: What should I do if any items are missing or damaged upon delivery?
  • A: Contact your distributor immediately to report any missing or damaged items.
• Q: Where can I find more information about the product?
  • A: Visit the manufacturer’s website at www.lmipumps.com for more information.

KBL-SERIES
Peristaltic Metering Pump / Operation and Maintenance Manual

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KBL – SERIES

Introduction

Thank you for purchasing an LMI KBL Peristaltic Metering Pump. Items supplied vary according to product configuration. Make sure that the items supplied and the information on the nameplate correspond to the order confirmation. Check the individual packaging and the product visually for damage caused by inappropriate handling during shipment. Contact your distributor immediately if any items are missing or damaged. For more information please visit www.lmipumps.com
1.1 | HOW TO USE THIS MAINTENANCE MANUAL This manual is specific to LMI PUMPS KBL series peristaltic pumps. It allows the users to install, to start and to carry out maintenance on these pumps. All persons, fitters and users must read this maintenance manual in its entirety. Documents concerning the gearbox, the electrical motors, as well as all other options (hose rupture detector, etc.) are provided in annex. Refer to the applicable section in this document to understand specific details regarding that component. Your local LMI distributor can be contacted regarding information not contained in this manual. For a quicker reply, please provide the following information:
» Pump Model Code » Pump serial number » Reference of order 1.2 | TRAINING OF THE USER AND INSTRUCTIONS Every person who installs, uses or performs any operations of maintenance on the pump must be qualified and must have previously read this technical manual. Any temporary personnel must be supervised by skilled users. The order of execution of operations defined in this manual must be absolutely respected. Store this manual next to the pump so that it can be consulted at any time. 1.3 | HANDLING AND STORAGE For best results, store this equipment with care according to these recommendations. Pumps should not be placed in storage with tube element installed and under compression. Tube elements and accessories should be used within [two years] of date of manufacture. Store all pumps and accessories indoors in a dry environment with no exposure to UV light. Storage temperature: -40°C to 70°C (-40°F to 158°F).
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Introduction
1.4 | PUMP SPECIFICATIONS Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -10°C – 50°C (14°F – 122°F) Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80% at 31°C, 50% at 40°C Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Max. 2000m (6560 ft) Power Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KBL2 [180W], KBL3 [180W], KBL4 [300W] Power Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-230 VAC, 50-60 hz Sound Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <70 dB (A) at 1m Maximum Flow Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KBL2 – 17 gph / 65 lph
KBL3 – 34 gph / 130 lph KBL4 – 160 gph / 608 lph Maximum Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Up to 7.6 bar (110 psi) Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KBL: 200:1 Motor Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-100% Weight KBL2/KBL3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 lbs (16.1kgs) KBL4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 lbs (32.6kgs) 1.5 | NAMEPLATE DETAILS
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Introduction
1.6 | SERVICE POINT Pumps are given a special QR code before shipping. When maintenance is necessary, a plant engineer or technician uses a phone to scan the code, bringing up a list of replacement parts, service guidelines, a contact request, and other information. You may obtain information about ordering spare parts, documentation, and manuals here.
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Model Description Chart

2.1 | MODEL CODE EXPLANATION

Sample Part Number: KBL2-4-ACG1-0

KBL –

X

–

X

–

X

– XX –

X

– X

Series
KB
Frame
2 – Size 2 3 – Size 3 4 – Size 4
Power Cord
4 – US 115V 5 – US 230V 6 – EU 8 – Australia / New Zealand 9 – UK
Connector
A – 1/2″ NPT / BSPT (KBL2 and KBL3 include 3/8″ tube compression fitting)
Tube Material
A – XL Extended Life B – CR Chemical Resistant C – PT Petro-Tough
Tube Detail – ID [in] and Count
Various Diameters
Control Levels
0 – Basic: Keypad control only 1 – SCADA: Speed control: 4-20 mA i/o
Three contact inputs Four configurable relay outputs Frequency 2 – Advanced: Modbus TCP

NOTICE: All possible options are shown in 2.4 section, however, certain combinations may not be recommended. Consult a representative or the factory if you have questions concerning availability.
TUBE ASSEMBLY CODE EXPLANATION

A

A

Connector Type
A – 1/2″ NPT / BSPT (KBL2 and KBL3 include 3/8″ tube compression fitting)

Tube Material Information
A – XL Extended Life B – CR Chemical Resistant C – PT Petro-Tough

D

1

No. of tubes
1- Single
2 – Double

Tube Diameter

D – 0.075″

K – 0.375″

E – 0.093″ / 0.125″ L – 0.50″

G – 0.187″

P – 0.75″

H – 0.25″

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Model Description Chart
2.2 | MATERIALS OF CONSTRUCTION
Enclosure Pumphead

Roller

Roller Assembly

Tube Element Pumphead Cover

Cover Screws

MATERIAL OF CONSTRUCTION

ENCLOSURE

POWDER COATED ALUMINUM

PUMP HEAD

PBT THERMOPLASTIC

COVER

PLOYCARBONATE

ROTOR

PBT THERMOPLASTIC

ROLLERS

NYLON

MATERIAL OF CONSTRUCTION

ROLLER BEARINGS

316 SS

ROLLER SHAFT

316 SS

MOTOR SHAFT COVER SCREWS TUBE CONNECTORS

CHROME STEEL PLASTIC / 316 SS
PVDF

LMI XL – Extended Life tubing has excellent acid and alkali resistance, and is compatible with numerous oxidizing agents such as sodium hypochlorite. Tygon is best for fatigue life and is the longest-lasting tube in compatible applications. Min/max temperature: 0-80°C (32-176°F).
LMI CR – Chemical Resistant is suited for handling strong acids and bases, and is virtually unaffected by most commercial sanitizers & cleaners. Min/max temperature: 0-54°C (32-130°F).
LMI PT – Petro-Tough can be used with fats and oils, lubricants, and some solvents. Min/max temperature: 0-54°C (32-130°F).

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Model Description Chart

2.4 | AVAILABLE TUBE ASSEMBLIES

MATERIAL
XL KBL2
CR PT

PART # GPH L/H PSI BAR

AAD1 AAE2 AAG2 ABH1 ACG1 ACG2

1.7 6.5 100 6.9 4.4 16.8 110 7.6 17.1 65.1 110 7.6 14.2 54 50 3.4 9.3 35.2 65 4.5 14.9 56.7 65 4.5

MATERIAL
XL KBL3
CR PT

PART # GPH L/H PSI BAR

AAD1 2.1 7.9 100 6.9

AAE2 4.7 18 100 6.9

AAG2 AAK1

18.9 72 110 7.6 33.2 126 100 6.9

AAKL 33.2 126 30 2.1

ABK1 ACG1 ACG2 ACK1

28.4 108 50 3.4 10.1 38.4 65 4.5 18.2 69 65 4.5 28.4 108 65 4.5

2.5 | DIMENSIONS
mm (Inch)
B

MATERIAL
XL
KBL4 CR
PT

PART # GPH L/H PSI BAR

AAH1 AAH2

28.4 108 100 6.9 53.7 204 100 6.9

AAL1 99.5 378 50 3.4

AAP1 158.5 600 30 2.1

ABK1 53.7 204 30 2.1

ABK2 125.5 477 30 2.1

ACH1 ACK1 ACK2

39.5 150 65 4.5 55.3 210 65 4.5 99.5 378 65 4.5

Flow rates shown are at maximum pump speed. For best tube life, select a large tube and run the pump slowly.

C

A

DIMENSION A B C
Weight kg (lb)

KBL2 246 (10.4) 206 (8.125) 361 (14.2) 35.6 (16.1)

KBL3 246 (10.4) 206 (8.125) 361 (14.2) 35.6 (16.1)

KBL4 363 (14.3) 308 (12.125) 455 (17.9) 72 (32.6)

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KBL – SERIES

Operating and Safety Precautions

3.1 | SAFETY SYMBOL IDENTIFICATION

Hot Surface

Do not scrub static spark Explosion Hazard

Crushing Hazard

Read Manuals Supplied
With Product

3.2 | EXPLANATION OF SAFETY SIGNAL WORDS

DANGER! Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.
NOTICE! Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property.
For safety purposes, this equipment should only be used by appropriately- trained personnel after they have read and understood this manual, and accounted for any and all potential hazards. If the pump is used in a manner not recommended by LMI Pump, the warranty may be voided and risk to equipment and personnel could occur. The following precautions should be taken when working with LMI Pumps. Please read this section carefully prior to installation.
Protective Clothing: ALWAYS wear protective clothing, face shield, safety glasses and gloves when working on or near your metering pump. Additional precautions should be taken depending on the solution being pumped. Refer to Safety Data Sheets (SDS) precautions from your solution supplier.
Liquid Compatibility: Determine if the materials of construction included in the liquid handling portion of your pump are adequate for the solution (chemical) to be pumped. Always refer to the solution supplier and the LMI Pump Chemical Resistance Chart for compatibility of your specific pump. Contact your local LMI Pump distributor for further information.
Electrical Connections: WARNING: To reduce the risk of electrical shock, the metering pump must be plugged into a properly grounded grounding-type receptacle with ratings conforming to the data on the pump control panel. The pump must be connected to a good ground. Do not use adapters! All wiring must conform to local electrical codes. If the supply cord is damaged, it must be replaced by the manufacturer, stocking distributor, or authorized repair center in order to avoid a hazard.
Flooding: WARNING: Install this pump in a location where flooding cannot occur.
Ground Fault Circuit Interrupter: WARNING: To reduce the risk of electric shock, install only on a circuit protected by a Ground Fault Circuit Interrupter (GFCI).
Line Depressurization: To reduce the risk of chemical splash during disassembly or maintenance, all installations should be equipped with line depressurization capability.

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Operating and Safety Precautions
Over Pressure Protection: To ensure safe operation of the pump it is recommended that some type of safety / pressure relief valve be installed to protect the piping and other system components from failing due to excessive pressure. Flow Display: The accuracy of the flow value as shown on the pump display is highly dependent on the specific application. Calibration is necessary in order to display an accurate measure of the flow. Chemicals: Safety procedures for hazardous fluids must be put in place to protect against injury to personnel. Operation of the pump after failure of the peristaltic tube can cause buildup of chemical in the pumphead. Some pumphead parts may not be compatible with certain aggressive chemicals. This can cause damage to the pumphead components, and pump internals if chemical spills are not promptly addressed. CAUTION: Spills of Dangerous chemicals should be cleaned up immediately. Lifting, transportation, installation, starting-up, maintenance and repair should be performed by qualified personnel only. The unit should be electrically isolated while work is being carried out. There is a replaceable fuse on the I/O Board.
3.3 |PRODUCT PARTS INFORMATION
CAUTION!
Only allow LMI PUMP trained technicians to perform maintenance on the products. For additional information contact LMI PUMP or nearest authorized distributor. The use of other than genuine LMI PUMP replacement parts may result in safety hazards, decreased pump performance and increased maintenance and will invalidate all warranties. The original language of this manual is English. Other languages are a translation of the original manual. Manuals can be downloaded from www.lmipumps.com Refer all communications to the nearest LMI PUMP Office or Distributor.
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Installation

4.1 | POWER REQUIREMENTS Electric shock is a real possibility with any electrical device. Grounding conductors and grounding-type attachment plugs are included with pumps. To reduce risk of electric shock, ensure that it is connected to a properly grounded receptacle. Use correct supply voltage. Using incorrect voltage will damage pump and may result in injury. Ensure that all electrical cable glands are placed and sealed appropriately. Never connect power and control cables together. Equipment may start automatically. This pump has a user-selectable automatic restart capability that can either put the pump back in operation after a power outage or restart it completely. If in doubt, contact a certified electrician.
4.2 | CONTROL WIRING
Remove the pump terminal box for access to the control terminals. Conduit holes are 3/8″ and ½”. Use appropriate cable glands to ensure proper sealing is achieved. For safety, do not apply 110-230VAC to control terminals. Signals applied to terminals must be within appropriate limits. Damage from misapplied signals can destroy the pump and is not covered under warranty.
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Installation
4.2.1 | I/O BOARD
INPUT: DCI-1 ­ Dry Contact Input for remote stop signal DCI-2 ­ Dry Contact Input pump direction DCI-3 ­ Dry Contact Input for start signal PWM ­ Input for Frequency (10-2000Hz) control 0-10V ­ Analog speed control 4-20 mA ­ Analog speed control OUTPUT: 4-20 mA ­ Analog speed feedback signal PWM ­ Frequency (10-2000Hz) speed feedback signal RS-485: RS-485 terminal for MODBUS RTU POWER: 110-230 VAC input USB: USB-C interface for uploading software and downloading log files ETHERNET: Ethernet cable port for industrial protocol communications FUSE: Fuse compartment with replaceable 6.3A 250V AC/DC Fuse Cartridge, 5mm x 20mm
(Equivalent to Bel Fuse Inc. 5ST 6.3R) RELAYS: 4 configurable digital form-C relays
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Installation
4.3 | BEST PRACTICES
Peristaltic pumps are self-priming and do not allow backflow up to rated pressure. No valves are required in inlet or discharge line, however may be useful in some circumstances:
» In case of a pumphead or tube failure, users can install a check valve between the pump and the discharge pipework to prevent pressurised fluid from backflowing.
» Any valves in the process flow must be open before starting the pump. Include a pressure relief device in the discharge line prior to any valves to protect against damage caused by accidental operation against a closed valve.
Tube selection: Refer to the LMI Pump website for a chemical compatibility guide. For help with compatibility issues, contact a distributor or LMI Pump customer care. In normal operation, the pump rotates in a counter-clockwise direction and the ports are left-facing. In this configuration, the bottom port is used for suction, and the top port is used for discharge. However, pump has no impact on performance if the pump is configured to run in either direction. Install the pump on a stable and level horizontal surface. Pump is equipped with rubber feet, however if desired, the pump includes threaded holes on the bottom that could be used to bolt the pump in place. In order to allow the pump to dissipate heat, ventilation is crucial. Keep dirt and dust out of the pump enclosure. Ambient temperature (surrounding temperature) should be within the recommended limits. Do not stack pumps. Keep the pipes for suction and discharge as short and straight as possible. Use bends with a big radius, at least four times the tube diameter. Use of suction pipe or tube with a bore smaller than the pump tube bore should be avoided. Connect the pump to the hard pipe using a flexible tubing portion to reduce any pulsation and make it easier to access the pumphead. The pump can lift 10 feet or more of suction depending on which tube is installed. For maximum performance and longest tube life, a slightly flooded suction is recommended. After changing a tube or any application or process, calibrate the pump. To keep accuracy, calibrate on a regular basis. When pumping viscous fluids:
» Use tubes or pipes several times larger than the pump tube for suction and discharge. » Run the pump slowly. » Maximize NPSHa
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Installation
4.4 | PRE OPERATION CHECK LIST
CHECK LIST Pumps have been completely installed in their final location, piping has been connected, and motors are energized to allow running of the pumps. Proper electrical voltage is supplied and connected to pumps and controls Remote signal amperage and voltage is within pump limits. Pumps are freely accessible from all sides. Sufficient space is available to perform maintenance. Pumps are mounted on a clean, level platform. Pumps are stable. Pipework design is optimal for pump performance. Accessories are correctly installed. Flange covers/dust covers and caps are removed. Appropriate valves are open.
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Getting Started
5.1 | USER INTERFACE A User interface is the Point of User -System interaction and communication on a device. This included Dispaly screen and Keypad. User interface enables users to effectively control the device they are interacting with.
5.2 | UNDERSTANDING THE DISPLAY 5.2.1 | HOME SCREEN

REMOTE

LOCAL

Control: MANUAL

5.59
Gal / Hr

Displays where control of pump is located (i.e. if pump is locally controlled, all network control is disabled. Remote control allows control from network or local).
Current Pump Speed: » Units displayed according to Menu options. » Zero Speed is displayed as 0, Stop is displayed as 0 with Red background.
Units displayed here are what is selected in the Display Settings Screen.
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Getting Started

5.3 | KEYPAD LMI KBL-Series pumps are equipped with a 13-button keypad and color display.
h

i

g

j

k g

f

c

e

d

RUN Button » When pump is OFF, press and hold to turn pump ON. » From Home screen, press to start pump. Press and hold to prime the pump.
STOP Button: » Press to stop pump. » Press and hold to turn pump OFF.
NAVIGATION Buttons (Up and down cycle through menu items): » Center button selects highlighted menu item. Also accepts value entered. In situations where user is in editing mode, pressing the center button, accepts value. » When adjusting pump speed or other quantity, press of left or right to highlight the first digit. Additional presses move the cursor to adjacent digits. Up and down adjust the value, and select accepts the value.

HOME Button » Always returns to home screen. Edited data is saved. » From Home screen, press to start pump. Press and hold to prime the pump.
RETURN / ESCAPE Button : » Always returns to previous screen/previous mode (i.e. exiting editing mode) » Only accepted values are stored (through center button press). If center button was not pressed prior, previous value is valid.
SOFT Buttons: » Use to select the menu item to the right that currently being displayed.
LOC/REM toggles between local and remote control from home screen.
Adjust pump speed from home screen
Go to Settings screen from home screen
More options (offers batch/dose mode and lock) from home screen

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Getting Started

5.4 | ICONS
ICON

NAME Pump Speed

FUNCTION Adjust pump speed in manual mode

Settings System

Settings menu contains access to system menu, tube settings, calibration, communications, and log files
Adjust display settings, languages, display units, password and security, auto restart, and about information

Tube Settings

Tube settings options

Calibration

Enter calibration mode

I/O Settings

Select remote control modes, i.e., SCADA, Pulse, and industrial protocols

About

View serial number and upgrade software

Log

View and download pump operating history

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Getting Started

ICON

NAME Lock

FUNCTION Enables passcode security

Rotation direction CCW

Direction setting is counterclockwise

Rotation direction CW

Direction setting is clockwise

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Getting Started

5.5 | QUICK START GUIDE 5.5.1 | SETTINGS SCREEN

HOME I SETTINGS

SYSTEM

TUBING SETTINGS CALIBRATION

IO SETTINGS

LOG FILES

ABOUT

5.5.1.1 | SYSTEM SCREEN
Selecting the System menu offers the following options:
HOME I SETTINGS I SYSTEM
Display Settings Password Auto Restart Real Time Clock

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Getting Started

SYSTEM – DISPLAY SETTINGS:

HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS
Language: English

Units

Home Screen Timeout: 600

Backlight Timeout:

seconds
600

SYSTEM – DISPLAY SETTINGS – LANUGAGE:

HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS l LANGUAGE

Select language
English

SAVE & EXIT

English Francais Deutsch Español

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Getting Started

SYSTEM – DISPLAY SETTINGS – UNITS

HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS l UNITS

Select units and Press OK
Gal/Hr

SAVE & EXIT

mL/min L/Hr Gal/min
Gal/Hr % of MAX SPEED

SYSTEM – DISPLAY SETTINGS – HOME SCREEN TIMEOUT AND BACKLIGHT:
Use soft buttons to select Home Screen or Backlight Timeout. Use navigation buttons to adjust values. Press SELECT to save.

Press soft buttons
to edit value

HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS
Language: English

Units

Home Screen Timeout: 600

Backlight Timeout:

seconds
600

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Getting Started
SYSTEM – AUTO-RESTART
HOME I SETTINGS I SYSTEM l AUTO RESTART
Once Power is restored: Return to last configuration Return to local mode with pump stopped SAVE & EXIT
5.5.2 | TUBE CHANGE SCREEN Tube change screen under settings menu gives users two options: install new tube element or view and edit maintenance interval settings.
HOME I SETTINGS I TUBING
Install/replace tube element Maintenance reminder settings
Press the soft button for Install new tube element to enter maintenance mode.
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Getting Started

TUBE CHANGE ­ INSTALL NEW TUBE ELEMENT
The pump will display brief instructions for the tube change procedure. For complete instructions including safety protocols see Section 7.0 Maintenance, follow the on-screen prompts, or scan the pump QR code to access a tube change maintenance video online.

HOME I SETTINGS I TUBING I TUBE CHANGE (3)
MAINTENANCE MODE
Using both thumbs, press and hold START & STOP buttions. Release when red rotor buttion position matches the image below.
FRONT

Left-facing
NEXT START

Right-facing
STOP

FRONT FRONT

Press NEXT to continue

HOME I SETTINGS I TUBING I TUBE CHANGE (4)
MAINTENANCE MODE
Press red rotor button.

FRONT

Left-facing
NEXT

Right-facing

Press NEXT to continue

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Getting Started
TUBE CHANGE ­ INSTALL NEW TUBE ELEMENT
The tube change is now complete. It is recommended to calibrate the pump after a new tube is installed, and reset the maintenance interval counter if desired.
HOME I SETTINGS I TUBING I TUBE CHANGE (9)
Reset tube run time counter Calibrate pump Maintenance reminder settings Return home

TUBE CHANGE ­ MAINTENANCE INTERVAL SETTINGS
The Maintenance Interval function enables the pump to generate a warning on the Home screen to alert the user that a pre-programmed number of run hours is approaching. This reminder will help avoid unplanned maintenance.

HOME I SETTINGS I TUBING I MAINTENANCE INTERVAL

ENABLED

DISABLED

Maintenance Interval
Run hours since last maintenance
SAVE & EXIT

00000
HOURS
47:28

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Getting Started

SETTINGS ­ TUBE CHANGE ­ MAINTENANCE INTERVAL SETTINGS Once 90% of the maintenance interval has passed, the pump will display a notice on the home screen:

Set: 471 Enc: 0

REMOTE

LOCAL

Control: MANUAL

5.59

Gal / Hr

<10% Tube Life Remaining

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Getting Started

5.5.3 | CALIBRATION SCREEN
CALIBRATION SCREEN – CALIBRATION PROCEDURE
» Enter Calibration Mode » Press start button. Pump will run for 30 seconds. » Pump will ask user to input volume pumped in mL » Input volume and press [save] NOTE: Resetting Factory Calibration will reset pump flow rate to initial
tubeset default provided with pump. TIP: Pump calibration will run at the current speed setup in manual mode. For best results, calibrate the pump
at a speed where the pump would typically operate. Pump will not calibrate at zero speed.

HOME I SETTINGS I CALIBRATION l CALIBRATION (2)

CALIBRATION VOLUME
Measured Volume (mL)
00000

PROGRESS

Ready for START

Restore Factory Calibration Data

Press GREEN button to START SAVE & EXIT

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Getting Started
5.5.4 | I/O SETTINGS I/O SETTINGS SCREEN
Select an option to modify parameters. Active I/O method is highlighted. NOTE: The highlighted option is what the pump will automatically switch to when the LOCAL/REMOTE button is pressed from the home screen.
HOME I SETTINGS I IO SETTINGS
SCDA Industrial Protocols
SCADA includes analog speed control, input contacts and speed feedback outputs. Industrial Protocols includes Modbus RTU and Modbus TCP/IP. Section 6.0 contains setup instructions for each I/O protocol.
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Getting Started
5.5.5 | LOG LOG SCREEN
Use this screen to export logged events to USB.
HOME I SETTINGS I LOG FILES
Export Log File

View alarms, warnings, and logged events on-screen by selecting the information icon from the home screen.

REMOTE

LOCAL

Control: MANUAL

5.59
Gal / Hr

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Getting Started
5.5.6 | ABOUT ABOUT SCREEN
Use this screen to display pump serial number. This screen is also used for firmware updates and communications upgrades. Contact your distributor or www.lmipumps.com for questions regarding firmwware updates and communication upgrades.. For communication upgrades, once provided an upgrade code, use navigation buttons to input code and press Select. For firmware updates insert USB with provided update file and press Select. Pump will automatically reboot after installation
HOME I SETTINGS I ABOUT
Serial Number: NO_SERIAL_NUMBER Pump Run Hours: 47:28 Software Update Communications Upgarde
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KBL – SERIES

Operating Modes

6.1 | MANUAL MODE
In manual mode, also called local mode, the pump is looking for speed, direction, and start/stop command at the keypad only. The pump will not accept any remote inputs other than remote stop (E-stop) while in Manual mode.
Press `Pump Speed’ soft button then use navigation buttons to adjust speed. Press center navigation button to save.

REMOTE

LOCAL

Control: MANUAL

5.59
Gal / Hr

6.2 | REMOTE MODE 6.2.1 | SCADA 4-20 mA, 0-10VDC or Frequency (PWM) Select SCADA from I/O Settings Screen shown in 5.5.4 .
HOME I SETTINGS I IO SETTINGS I SCADA
Speed Input Input Contacts Output Relayas Speed Feedback
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Operating Modes

The pump can be configured to accept an analog signal for speed control The pump can also scale the signal as needed. Speed input displays the scaled value for pump operation according to the the incoming signal value.

HOME I SETTINGS I IO SETTINGS l SCADA l SPEED INPUT
OFF 4-20 mA 0-10V FREQ

Min 4mA
SCALE 04.000

Max 20mA
20.000

FLOW 00.000 100.00

SAVE & EXIT

0% OF MAX

Digital inputs (dry contact):
» Start/stop (NOTE: Using SCADA mode requies the use of the Start/Stop Contact. If none will be implemented, selecting NC (Normally Closed) will keep the contact always in a ‘Start’ mode)
» Direction » Remote stop – Allows pump to be stopped by an appurtenance such as a pressure switch, level switch,
or an emergency stop button.

HOME I SETTINGS I IO SETTINGS l SCADA l INPUT CONTACTS

Start:

OFF OPEN CLOSED

Direction OFF OPEN CLOSED

Remote Stop: OFF OPEN CLOSED

SAVE & EXIT

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KBL – SERIES
Operating Modes

Four Configurable Relay outputs: » Disabled » General Alarm » In Auto » Door Open » Leak Detected » Pump Off » Remote Stop Alarm » Remotely Controlled

HOME I SETTINGS I IO SETTINGS I SCADA l OUTPUT RELAYS
RELAY 1 RELAY 2 RELAY 3 RELAY 4
Disabled Disabled Disabled Disabled
Disabled

SAVE & EXIT

Disabled
General Alarm
In Auto Door Open Leak Detected Pump Off

6.2.2 | INDUSTRIAL PROTOCOLS Select Industrial Protocols from I/O Settings Screen shown in 5.5.4″
HOME I SETTINGS I IO SETTINGS I INDUSTRIAL PROTOCOLS
Modbus RTU RS485 Settings Modbus TCP Ethernet Settings

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Operating Modes
6.2.2.1 | MODBUS RTU Configure device address to connect MODBUS RTU”

HOME I SETTINGS I IO SETTINGS I INDUSTRIAL PROTOCOLS I MODBUS RTU
RS485: 115200, 8-NONE-1

DEVICE ADDRESS SAVE & REBOOT

010
0 -> 255

6.2.2.2 | MODBUS TCP Configure TCP port to connect MODBUS TCP”

HOME I SETTINGS I IO SETTINGS I INDUSTRIAL PROTOCOLS I MODBUS TCP
IP: 0.0.0.0 (DHCP)

TCP PORT

00502
0 -> 65535

SAVE & REBOOT

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KBL – SERIES
Operating Modes

6.2.2.3 | RS 485 Configure RS485 BAUD, Parity and Stop parameters

HOME I SETTINGS I IO SETTINGS I COMM SETTINGS l RS485 SETTINGS

BAUD

PARITY

STOP

115200

NONE

1

DATA BITS: 8

Disabled

SAVE & REBOOT

6.2.3 | BATCH / DOSE MODE Navigate to dose settings by selecting the pump speed icon on the home screen.

HOME I PUMP SPEED I BATCH / DOSE SETTING
Disabled Batch / Dose

Dose Volume
00076

Dose Units
Milliliters

Initial Delay (s)
00001

Pause Delay (s)
00005

Batch Count
ENABLE

SAVE & EXIT

6.2.3.1 | DOSING Fixed number of multiple doses with a programmable start delay and intra-dose time interval. Batch size can be user specified & pump counts down until completion.
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Operating Modes

6.2.3.2 | BATCHING
In Dose mode, the doses will continue until the pump is manually stopped.
Minimum dose size will be limited to the volume of one revolution of the rotor. This is automatically calculated by the factory or calibrated values.
Dose speed will default to the manual set speed speed. However, for small doses, the pump will automatically slow down the pump if required to maintain accuracy. Display in Batch Mode

REMOTE
Control: BATCH

LOCAL

Set: 471 Enc: 0
0

DOSES
BATCH MODE: READY 11 To Go
Dose: 76 mL Total: 0 mL

Display in Dose Mode

REMOTE
Control: DOSE

LOCAL

Set: 471 Enc: 0
0

DOSES
DOSE MODE: READY

Dose: 76 mL Total: 0 mL

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KBL – SERIES

Maintenance

7.1 | ROUTINE INSPECTION Pump and accessories should be inspected weekly. Inspect all components for signs of leaking or chemical attack. Replace damaged or worn components immediately. Cracking, crazing, discoloration and the like during first week of operation are signs of chemical attack. Inspect check valve and pressure relief valves periodically to ensure performance. KBL pump motor and gearbox does not require maintenance. Inspect optical sensor for obstructions or fluid
7.2 | TUBE REPLACEMENT » Isolate pump from the system, depressurize and drain suction and discharge lines. » In Maintenance Mode, jog the pump to index the rotor assembly such that the red button is between
the tube connections. » Remove the front cover taking proper precautions:

• If the tube has failed, chemical or residue may be present in the pumphead and/or tube. * If the tube has not failed, product is contained within the tube and will drain as the tube is removed. » Press the red button on the rotor to disengage the rotor assembly from the tube.
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KBL – SERIES
Maintenance
» Remove the tube. » Inspect the pump head chamber, rotor assembly, and pump head cover. Wipe away any dirt and debris. » Install the new tube. Ensure the tube fittings are properly aligned and secure within the pumphead. » Jog pump to reengage rotor assembly. » Replace front cover. » Connect suction and discharge lines and open valves as appropriate.
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KBL – SERIES
Maintenance
7.3 | Rotor Assembly Replacement » Remove the tube assembly according to O&M Instructions. » The rotor assembly can be removed by hand. » Inspect and wipe down the pump head and shaft. » Inspect and wipe down the optical sensor » Install the new rotor assembly with new spacers as shown.

Rotor Assembly
Washer

Washer

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KBL – SERIES
Maintenance
7.4 | SPARE PARTS Contact your distributor or www.lmipumps.com for ordering information, or access LMI Service Point via the QR code on your pump.
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KBL – SERIES
Maintenance

KBL2 SPARE PARTS Item Description

1

Rotor Assembly for AD1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.075″ ID

1

Rotor Assembly for BH1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, CR, 0.25″ ID

1

Rotor Assembly for CG1 and CG2 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, PT, 0.187″ ID

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, PT, 0.187 ID twin

1

Rotor Assembly for AE2 and AG2 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.125 ID twin

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.187 ID twin

3

Pump Head Cover with Bearing and Thumbscrews

not shown mounting bracket with fasteners not shown extended mounting bracket with fasteners not shown rubber feet
not shown installation kit: suction and discharge tubing with foot valve and check valve

Max Flow gph L/h 1.7 6.5

Max Pressure psi bar
125 8.6

Part Number
K2-R-A K2-AAD1

K2-R-B 14.2 54 50 3.4 K2-ABH1

K2-R-C 9.3 35.2 65 4.5 K2-ACG1 14.9 56.7 65 4.5 K2-ACG2

4.4 16.8 110 7.6 17.1 65.1 110 7.6

K2-R-D K2-AAE2 K2-AAG2

K2-COVER

K2-STDB K2-EXTB K2-FEET
K2-INSKIT

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KBL – SERIES
Maintenance

KBL3 SPARE PARTS Item Description

1

Rotor Assembly for AD1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.075″ ID

1

Rotor Assembly for KL tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.375″ ID

1

Rotor Assembly for CG1, CG2, and CK1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, PT, 0.187″ ID

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, PT, 0.187 ID twin

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, PT, 0.375″ ID

1

Rotor Assembly for AE2, AG2, AK1, and BK1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.125 ID twin

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.187 ID twin

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, XL, 0.375″ ID

2

Tube Assembly, 1/2″ NPT/BSPT and 3/8″ tube compression, CR, 0.375″ ID

3

Pump Head Cover with Bearing and Thumbscrews

not shown mounting bracket with fasteners not shown extended mounting bracket with fasteners not shown rubber feet not shown installation kit: suction and discharge tubing with foot valve and check valve

Max Flow gph L/h 2.1 7.9

Max Pressure psi bar
125 8.6

Part Number
K3-R-A K3-AAD1

K3-R-B 33.2 126 30 2.1 K3-AAKL

K3-R-C 10.1 28.4 65 4.5 K3-ACG1 18.2 69 65 4.5 K3-ACG2 28.4 108 65 4.5 K3-ACK1

K3-R-D 4.7 18 125 8.6 K3-AAE2 18.9 72 110 7.6 K3-AAG2 33.2 126 125 8.6 K3-AAK1 28.4 108 50 3.4 K3-ABK1

K3-COVER

K3-STDB K3-EXTB K3-FEET K3-INSKIT

KBL4 SPARE PARTS Item Description

1

Rotor Assembly for AH1 and AH2 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT, XL, 0.25″ ID

2

Tube Assembly, 1/2″ NPT/BSPT, XL, 0.25 ID twin

1

Rotor Assembly for BK1 and BK2 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT, CR, 0.375 ID

2

Tube Assembly, 1/2″ NPT/BSPT, CR, 0.375 ID twin

1

Rotor Assembly for CH1, CK1, and CK2 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT, PT, 0.25″ ID

2

Tube Assembly, 1/2″ NPT/BSPT, PT, 0.375″ ID

2

Tube Assembly, 1/2″ NPT/BSPT, PT, 0.375 ID twin

1

Rotor Assembly for AL1 and AP1 tubes, includes spacer bushings

2

Tube Assembly, 1/2″ NPT/BSPT, XL, 0.5″ ID

2

Tube Assembly, 1/2″ NPT/BSPT, XL, 0.75″ ID

3

Pump Head Cover with Bearing and Thumbscrews

not shown mounting bracket with fasteners not shown extended mounting bracket with fasteners not shown rubber feet

Max Flow gph L/h
28.4 108 53.7 204

Max Pressure psi bar
125 8.6 100 6.9

Part Number
K4-R-A K4-AAH1 K4-AAH2

K4-R-B 53.7 204 30 2.1 K4-ABK1 125.5 477 30 2.1 K4-ABK2

K4-R-C 39.5 150 65 4.5 K4-ACH1 55.3 210 65 4.5 K4-ACK1 99.5 378 65 4.5 K4-ACK2

K4-R-D 99.5 378 50 3.4 K4-AAL1 157.9 600 30 2.1 K4-AAP1

K4-COVER

K4-STDB K4-EXTB K4-FEET

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KBL – SERIES

Troubleshooting

8.1 | TROUBLESHOOTING GUIDE

PROBLEM
Low Flow Low Discharge Pressure

POSSIBLE REASON

RESOLUTION

Viscosity too high.

Run pump slower to allow more time for tube to restitute. Select larger tube and run slower. Improve suction pressure.

Run pump slower to allow more time for tube to restitute.

Ensure fittings and connections are tight so that no air may enter suction line.

Poor suction conditions.

Clean suction strainer (if used).
Increase tank level and/or tank height.
Apply best hydraulic practices – use large pipework, minimize pipe length, reduce obstructions, and use a suction accumulator.
Check suction line for obstructions.

Tube dimensions do not match the specifications of the rotor assembly.

Install matched roller assembly and tube.

Discharge pressure too high, causing excessive backflow.
Using third-party tubing. Tube obstruction. Pump not properly calibrated.

Reduce discharge pressure. Decrease friction losses in discharge pipework. Use only LMI tube assemblies. Check tube for obstructions. Perform calibration under application conditions per O&M.

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KBL – SERIES
Troubleshooting

8.1 | TROUBLESHOOTING GUIDE

PROBLEM Tube Fails Prematurely.
Excessive Noise and/or Vibration. Tube Leak Not Detected. High Pump Temperature

POSSIBLE REASON

RESOLUTION

Tube not installed correctly.

Check installation of tube.

Fluid temperature too high. Mechanical damage to tube from solids.

Reduce fluid temperature. Use suction strainer to prevent solids from entering pump.

Possible chemical attack.

Check compatibility of tube material with product being pumped.

Operating pressure too high.

Reduce discharge pressure.

Tube dimensions do not match the specifications of the rotor assembly.

Install matched roller assembly and tube.

Tube dimensions do not match the specifications of the rotor assembly.

Install matched roller assembly and tube.

Loose fittings and/or pipework.

Ensure fittings are tight and pipework is properly secured and supported.

Pulsation – wide swing in discharge pressure during operation.

Apply best hydraulic practices – use large pipework, minimize pipe length, reduce obstructions, and use a pulsation dampener.

Optical sensor is dirty.

Clean contamination from the surface of the optical sensor.

Rotor assembly is worn.

Check that all rollers are free to spin and that there is no interference or binding of the rotor assembly within the pumphead or front cover.

Fluid temperature too high.

Reduce fluid temperature.

High discharge pressure or poor suction conditions.

Reduce discharge pressure and/or improve suction conditions.

Operate within recommended limits.

Ambient temperature too high.

Locate pump out of direct sunlight.

Locate pump away from other equipment which may be hot.

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KBL – SERIES
Troubleshooting
8.2 | ERROR CODES
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KBL – SERIES
Agency & Compliance
9.1 | CERTIFICATES
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KBL – SERIES

Warranty Declaration.

10.1 | FLUSH & DECONTAMINATION
Any returns of pumps or parts for repair or warranty inspection must be pre- approved by customer service. Also, the Flush and Decontamination document on the following pages must be completed and submitted to customer service for approval.
RETURN MATERIAL INFORMATION PAGE 1 OF 2
Select location where Flush & Decon was performed:

Company: _____ Address:

Performed By: _____ Email: ____ Phone:

Pump Model / Part #: ____

Company: _____ Address:

Performed By: _____ Email: ____ Phone:

Quantity: Serial #: ____

RETURN SHIP TO: If this section is not completed, return defaults to ship to address on original order. Company Name: ____ Attn: Phone: __ City: ____ State: Zip Code: ___

PRE- APPROVAL REQUIRED PROCESS: Flush & Decon must be submitted PRIOR to receiving RMA # with return shipping instructions. Failure to provide completed form will result in the quarantine of equipment along with CHARGE BACK FEE
applied for handling and disposal of unknown material (see page 2).

INSTRUCTIONS:

INITIAL EA.

1. Triple FLUSH & decontaminate liquid end or wetted part. (see page 2) In case of failure to decontaminate, delivery of shipment will be refused and returned with freight charge billed to customer.
2. For pumps, remove BOTH check valves from head, FLUSH checks & head. Reinstall checks or RETURN CHECKS WITH PUMP properly packaged separately to eliminate damage.
3. DRAIN “ALL” oil from pump 4. INCLUDE SDS covering all chemical handled by the pump. 5. Make sure INTERIOR (Liquid end & drive) of pump is cleaned of any chemical 6. Thoroughly CLEAN exterior of pump to remove dirt. 7. Parts: Remove entire accessory component from piping along with any welded
piping attached to accessory union or flange. 8. When RMA# is provided, make sure RMA # is prominently shown on BOL

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KBL – SERIES
Warranty Declaration.

FLUSHING & DECONTAMINATION CERTIFICATION PAGE 2 OF 2
Process Liquid: __ Decontamination Liquid: _ Flushing Liquid: ___

· All equipment returned must be completely drained, flushed & decontaminated of all process fluids internally & externally.
· Completed form along with SDS must be submitted PRIOR to receiving RMA # & return shipping instructions.
· Failure to provide completed 2-page forms will result in quarantine of equipment along with CHARGE BACK FEE applied for handling unknown material.
· RMA # should be visible on return BOL.

I certify this equipment has been drained, flushed, decontaminated and check valves are sent along with the pump in accordance with Milton Roy Company’s procedures. All information contained herein is accurate.

Name (Print): ____ Title:

Signed: _____

Date: __

Return Address:

Milton Roy Americas 201 Ivyland Road Ivyland, PA 18974 USA

CHARGE BACK FEE ­ handling unknown material:
PARTS……….. $1,500.00 PUMPS………. $2,000.00

IMPORTANT Please return pump base if suction check valve is lower than the bottom of the pump. This is needed to test and ship unit.

INTERNAL USE ONLY To be completed by Milton Roy internal EHS.
RMA#: ___ Approved for return: Yes No Received Date:

Approval Date: ____

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About Ingersoll Rand Inc.
Ingersoll Rand Inc. (NYSE:IR), driven by an entrepreneurial spirit and ownership mindset, is dedicated to helping make life better for our employees, customers and communities. Customers lean on us for our technology-driven excellence in mission-critical flow creation and industrial solutions across 40+ respected brands where our products and services excel in the most complex and harsh conditions. Our employees develop customers for life through their daily commitment to expertise, productivity and efficiency. For more information, visit www.IRCO.com.
We are committed to using environmentally conscious print practices ©2023 Ingersoll Rand LMI-0823-005-EN

References

• Controlled-volume Metering Pumps | LMI Pumps
• IRCO.com
• Controlled-volume Metering Pumps | LMI Pumps

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