LMI KBL Series User manual

KBLSERIES
Peristaltic Metering Pump / Operation and Maintenance Manual

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1 | INTRODUCTION ..............................3
1.1 - How to use this maintenance manual ......3
1.2 - Training of the user and instructions .......3
1.3 - Handling and Storage...................3
1.4 - Pump Specications....................4
1.5 - Nameplate Detail ......................4
1.6 - Service Point information ................5
2 | MODEL DESCRIPTION CHART. ..................6
2.1 - Model Code Explanation ................6
2.2 - Materials Of Construction................7
2.4 - Available Tube Assemblies ...............8
2.5 - Dimensions ...........................8
3 | OPERATING AND SAFETY PRECAUTIONS .........9
3.1 - Safety Symbol Identication..............9
3.2 - Explanation Of Safety Signal Words........9
3.3 - Product Parts Information ..............10
4 | INSTALLATION .............................. 11
4.1 - Power Requirements ..................11
4.2 - Control Wiring........................11
4.2.1 - I/O Board.......................12
4.3 - Best Practices. . . . . . . . . . . . . . . . . . . . . . . .13
4.3 - Pre Operation Checklist ................14
5 | GETTING STARTED ..........................15
5.1 - User Interface ........................15
5.2 - Understanding the display (Home Screen)..15
5.2.1 - Welcome screen .................15
5.3 - Keypad .............................16
5.4 - Icons ...............................17
5.5 - Quick Start Guide .....................19
6 | OPERATING MODES .........................30
6.1 - Manual Mode ........................30
6.2 - Remote Mode ........................30
6.2.1 - SCADA ........................30
6.2.2 - Industrial protocols ...............32
6.2.2.1 - Modbus RTU ...............33
6.2.2.2 - Modbus TCP ...............33
6.2.2.3 - RS 485....................34
6.2.3 - Batch / Dose Mode ...............34
6.2.3.1 - Dosing ....................34
6.2.3.2 - Batching ..................35
7 | MAINTENANCE .............................36
7.1 - Routine Inspection ....................36
7.2 - Tube Replacement ....................36
7.3 - Roller Assembly Replacement ...........38
7.4 - Spare Parts..........................39
8 | TROUBLESHOOTING .........................42
8.1 - Troubleshooting Guide .................42
8.2 - Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . .44
9 | AGENCY & COMPLIANCE ....................45
10 | WARRANTY DECLARATION...................46
10.1 - Flush & Decontamination ..............46
KBL - SERIES
Table of Contents

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KBL - SERIES
Introduction
Thank you for purchasing an LMI KBL Peristaltic Metering Pump. Items supplied vary according to product
conguration. Make sure that the items supplied and the information on the nameplate correspond to
the order conrmation. 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 specic 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, tters 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 specic
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 qualied
and must have previously read this technical manual. Any temporary personnel must be supervised by skilled
users. The order of execution of operations dened 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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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
KBL - SERIES
Introduction

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KBL - SERIES
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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KBL - SERIES
Model Description Chart
2.1 | MODEL CODE EXPLANATION
KBLX
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.
Frame
3 - Size 3
4 - Size 4
Power Cord
X
A - 1/2" NPT / BSPT (KBL2 and KBL3 include 3/8” tube compression tting)
Tube Material
XX
Tube Detail - ID [in] and Count
Control Levels
X
Series
KB
X
Connector
X
2 - Size 2
5 - US 230V
6 - EU
4 - US 115V
8 - Australia / New Zealand
9 - UK
B - CR Chemical Resistant
C - PT Petro-Tough
A - XL Extended Life
Various Diameters
Sample Part Number: KBL2-4-ACG1-0
1 - SCADA: Speed control: 4-20 mA i/o
Three contact inputs
Four congurable relay outputs
Frequency
2 - Advanced: Modbus TCP
0 - Basic: Keypad control only
----
--
TUBE ASSEMBLY CODE EXPLANATION
AD1
Connector Type
A
Tube Material Information
A - XL Extended Life
B - CR Chemical Resistant
C - PT Petro-Tough
Tube Diameter
No. of tubes
1- Single
2 - Double
A - 1/2” NPT / BSPT
(KBL2 and KBL3 include 3/8” tube compression tting)
K - 0.375"
L - 0.50"
P - 0.75"
D - 0.075”
E - 0.093” / 0.125"
H - 0.25"
G - 0.187"

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2.2 | MATERIALS OF CONSTRUCTION
Enclosure
Pumphead
Roller Assembly
Tube Element
Pumphead Cover
Cover Screws
Roller
KBL - SERIES
Model Description Chart
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 CHROME STEEL
COVER SCREWS PLASTIC / 316 SS
TUBE CONNECTORS 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 unaected 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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KBL - SERIES
Model Description Chart
2.4 | AVAILABLE TUBE ASSEMBLIES
MATERIAL PART # GPH L/H PSI BAR
KBL2
XL
AAD1 1.7 6.5 100 6.9
AAE2 4.4 16.8 110 7.6
AAG2 17.1 65.1 110 7.6
CR ABH1 14.2 54 50 3.4
PT ACG1 9.3 35.2 65 4.5
ACG2 14.9 56.7 65 4.5
MATERIAL PART # GPH L/H PSI BAR
KBL3
XL
AAD1 2.1 7.9 100 6.9
AAE2 4.7 18 100 6.9
AAG2 18.9 72 110 7.6
AAK1 33.2 126 100 6.9
AAKL 33.2 126 30 2.1
CR ABK1 28.4 108 50 3.4
PT
ACG1 10.1 38.4 65 4.5
ACG2 18.2 69 65 4.5
ACK1 28.4 108 65 4.5
MATERIAL PART # GPH L/H PSI BAR
KBL4
XL
AAH1 28.4 108 100 6.9
AAH2 53.7 204 100 6.9
AAL1 99.5 378 50 3.4
AAP1 158.5 600 30 2.1
CR
ABK1 53.7 204 30 2.1
ABK2 125.5 477 30 2.1
PT
ACH1 39.5 150 65 4.5
ACK1 55.3 210 65 4.5
ACK2 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.
2.5 | DIMENSIONS
mm (Inch)
B
A
C
DIMENSION KBL2 KBL3 KBL4
A 246 (10.4) 246 (10.4) 363 (14.3)
B 206 (8.125) 206 (8.125) 308 (12.125)
C 361 (14.2) 361 (14.2) 455 (17.9)
Weight kg (lb) 35.6 (16.1) 35.6 (16.1) 72 (32.6)

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KBL - SERIES
Operating and Safety Precautions
3.1 | SAFETY SYMBOL IDENTIFICATION
Hot Surface Crushing Hazard Read Manuals
Supplied
With Product
Do not scrub static
spark Explosion
Hazard
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 specic 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 ooding 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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KBL - SERIES
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 ow value as shown on the pump display is highly dependent on the
specic application. Calibration is necessary in order to display an accurate measure of the ow.
Chemicals: Safety procedures for hazardous uids 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 qualied
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 Oce or Distributor.

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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 certied 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.
KBL - SERIES
Installation

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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 les
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 congurable digital form-C relays
KBL - SERIES
Installation

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4.3 | BEST PRACTICES
Peristaltic pumps are self-priming and do not allow backow 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 uid from backowing.
» Any valves in the process ow 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
conguration, 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 congured 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 exible 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 ooded 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 uids:
» Use tubes or pipes several times larger than the pump tube for suction and discharge.
» Run the pump slowly.
» Maximize NPSHa
KBL - SERIES
Installation

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4.4 | PRE OPERATION CHECK LIST
CHECK LIST
Pumps have been completely installed in their nal 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.
Sucient 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.
KBL - SERIES
Installation

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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 eectively control the device they are interacting with.
5.2 | UNDERSTANDING THE DISPLAY
5.2.1 | HOME SCREEN
REMOTE
Control: MANUAL
LOCAL5.59
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.
KBL - SERIES
Getting Started

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5.3 | KEYPAD
LMI KBL-Series pumps are equipped with a 13-button keypad and color display.










KBL - SERIES
Getting Started
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 rst 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 (oers batch/dose mode and lock)
from home screen

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5.4 | ICONS
ICON NAME FUNCTION
Pump Speed Adjust pump speed in manual mode
Settings Settings menu contains access to system menu, tube settings, calibration,
communications, and log les
System 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
KBL - SERIES
Getting Started

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ICON NAME FUNCTION
Lock Enables passcode security
Rotation direction CCW Direction setting is counterclockwise
Rotation direction CW Direction setting is clockwise
KBL - SERIES
Getting Started

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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 oers the following options:
HOME I SETTINGS I SYSTEM
Display Settings
Password
Auto Restart
Real Time Clock
KBL - SERIES
Getting Started

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SYSTEM - DISPLAY SETTINGS:
HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS
Language: English
Units
Home Screen Timeout:
Backlight Timeout: 600
seconds
✔
✔
600
SYSTEM - DISPLAY SETTINGS - LANUGAGE:
HOME I SETTINGS I SYSTEM I DISPLAY SETTINGS l LANGUAGE
SAVE & EXIT
Select language
English
English
Francais
Deutsch
Español
KBL - SERIES
Getting Started