Graco A22600 User manual

3A6831G

Instructions-Parts

Python®XL-DA25

Pump

Pneumatic pump for injecting chemicals at well sites. Not for use with sour gas.

For professional use only.

Not approved for use in European explosive atmosphere locations.

See page 3 for model information, including maximum working pressures.

Important Safety Instructions

Read all warnings and instructions in this manual

before using the equipment. Save all instructions.

23A6831G

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Configuration Number Matrix . . . . . . . . . . . . . . . . . 4

Pump Configuration . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . .5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Required Accessories . . . . . . . . . . . . . . . . . . . . . 7

Flush Before Using Equipment . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8

Mount the Pump and Connect Chemical Supply 8

Connect Pneumatic Supply . . . . . . . . . . . . . . . . . 9

Route Exhaust to Remote Location . . . . . . . . . . 9

Connect Chemical Outlet . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . 12

Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 12

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 13

Calibrate Chemical Dosage . . . . . . . . . . . . . . . 13

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preventive Maintenance Schedule . . . . . . . . . . 14

Tighten Threaded Connections . . . . . . . . . . . . . 14

Tighten Packings . . . . . . . . . . . . . . . . . . . . . . . 14

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Repair - Pump Lower . . . . . . . . . . . . . . . . . . . . . . . 16

Disconnect the Pump Lower . . . . . . . . . . . . . . . 16

Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Reconnect the Pump Lower . . . . . . . . . . . . . . . 19

Repair - Pneumatic Motor . . . . . . . . . . . . . . . . . . . 20

Pneumatic Valve . . . . . . . . . . . . . . . . . . . . . . . . 20

Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 23

Repair Pneumatic Motor . . . . . . . . . . . . . . . . . . 24

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Python XL-DA25 Pneumatic Pump . . . . . . . . . . 28

Pump Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pneumatic Motor Parts . . . . . . . . . . . . . . . . . . . 32

Pneumatic Valve Parts . . . . . . . . . . . . . . . . . . . 34

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 36

Pump Lower Models . . . . . . . . . . . . . . . . . . . . . 36

Additional Kits & Accessories . . . . . . . . . . . . . . 36

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Python XL-DA25 Pump Dimensions . . . . . . . . . 37

Wall Bracket Mounting Hole Diagram . . . . . . . . 38

Pneumatic Mounting Hole Diagrams . . . . . . . . 39

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 40

6 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Technical Specifications . . . . . . . . . . . . . . . . . . . . 43

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44

Models

3A6831G 3

Models

NOTE: See the Configuration Number Matrix, page 4, to find the plunger and pneumatic motor size for your unit.

Pump Models

Plunger

Size Pneumatic

Motor Size Pump Working (Stall) Pressure

psi (MPa, bar) Max Dynamic (Run) Pressure

psi (MPa, bar) Max Pneumatic Inlet Pressure

psi (MPa, bar)

1/2 in. 6.0 in. 15,000 (103.4, 1034) 11,500 (100.0, 1000)

100 (0.69, 6.9)

3/4 in. 6,400 (44.1, 441) 4,500 (31.0, 310)

1 in. 3,800 (26.2, 262) 3,500 (24.1, 241)

3/4 in. 7.5 in. 10,000 (68.9, 689) 7,500 (51.7, 517)

1 in. 6,100 (42.1, 421) 5,500 (37.9, 379)

Part Number Configuration Code Motor Size Lower Size Lower Coating Seal Material

A22600 PCI-0600-050-075-XC-2-0

6.0 in.

1/2 in. Chromex HNBR

A22601 PCI-0600-050-075-XD-2-0 FFKM

A22602 PCI-0600-050-075-XE-2-0 TFE/P

A22606 PCI-0600-075-113-XC-2-0 3/4 in. Chromex HNBR

A22607 PCI-0600-075-113-XD-2-0 FFKM

A22608 PCI-0600-075-113-XE-2-0 TFE/P

A22612 PCI-0600-100-138-XC-2-0 1 in. Chromex HNBR

A22613 PCI-0600-100-138-XD-2-0 FFKM

A22614 PCI-0600-100-138-XE-2-0 TFE/P

A22706 PCI-0750-075-113-XC-2-0

7.5 in.

3/4 in. Chromex HNBR

A22707 PCI-0750-075-113-XD-2-0 FFKM

A22708 PCI-0750-075-113-XE-2-0 TFE/P

A22712 PCI-0750-100-138-XC-2-0 1 in. Chromex HNBR

A22713 PCI-0750-100-138-XD-2-0 FFKM

A22714 PCI-0750-100-138-XE-2-0 TFE/P

Configuration Number Matrix

43A6831G

Configuration Number Matrix

Check the identification plate (ID) for the 17-digit Configuration Number of your pump. Use the following matrix to

define the components of your pump.

NOTE: Not all combinations are possible.

Sample Configuration Number: PCI-0600-075-113-XC-2-0

Pump Configuration

PCI 0600 075 113 X C 2 0

Pneumatic

Chemical

Injection

Pneumatic

Motor Size Pump Lower

Primary Seal

Size

Pump Lower

Secondary

Seal Size

Plunger

Coating Seal Material Pump Stroke

Length Qualifier

Pneumatic

Motor Size Pump Lower

Primary Seal Size Pump Lower

Secondary Seal Size Plunger

Coating Seal

Material PumpStroke

Length Qualifier

0600 6.0 in. 050 1/2 in. diameter 075 3/4 in. diameter X Chromex C HNBR 2 2.5 inch 0 None

0750 7.5 in. 075 3/4 in. diameter 113 1-3/8 in. diameter DFFKM

100 1 in. diameter 138 1-3/8 in. diameter ETFE/P

Warnings

3A6831G 5

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific

hazard symbols and warnings not covered in this section may appear throughout the body of this manual where

applicable.

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area be aware that flammable fumes can ignite or

explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Ground all equipment in the work area.

• Keep work area free of debris, including rags and spilled or open containers of solvent.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Use only grounded hoses.

•Stopoperation immediatelyifstatic sparking occursoryou feelashock.Do notuse equipmentuntil

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This

may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or

swallowed.

• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

Warnings

63A6831G

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including

eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not

limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-

ponent. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information

about your material, request Safety Data Sheet (SDS) from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Checkequipmentregularly.Repairorreplacewornordamagedpartsimmediatelywithgenuineman-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

Installation

3A6831G 7

Installation

Grounding

Pump: ground through electrically conductive pneu-

matic and fluid lines.

Pneumatic and fluid lines: use only electrically con-

ductive lines.

Air compressor: follow manufacturer’s recommenda-

tions.

Fluid supply container: follow local code.

Required Accessories

Install the following required accessories as shown in

FIG. 1, using adapters as necessary.

Pneumatic Line

•Primary bleed-type master pneumatic valve (D):

required in your system to relieve air/gas trapped

between it and the pneumatic motor when the valve

is closed.

• Be sure the valve is easily accessible from the

pump and located downstream from the pneu-

matic pressure regulator.

•Pump pneumatic pressure regulator (E): to con-

trol pump speed and outlet pressure. Locate it close

to the pump.

•Pneumatic filter (C): removes harmful dirt and

moisture from compressed air/gas supply.

•Secondary bleed-type pneumatic valve (pneu-

matic shutoff valve) (B): isolates pneumatic line

accessories for servicing. Locate upstream from all

other pneumatic line accessories.

Fluid Line

•Fluid filter (Y-strainer) (included in G): with a 60

mesh (250 micron) stainless steel element to filter

particles from the fluid before in reaches the pump.

•Fluid shutoff valve (H): shuts off fluid flow.

•Pressure relief valve (J): overload protection.

Flush Before Using Equipment

The equipment was tested with lightweight oil, which is

left in the fluid passages to protect parts. To avoid con-

taminating your fluid with oil, flush the equipment with a

compatible solvent before using the equipment. See

Flush the Equipment, page 12.

If using a flammable gas to drive the motor, to reduce

the risk of fire or explosion, route the exhaust away

from all sources of ignition. See Route Exhaust to

Remote Location on page 9.

NOTE: A small amount of the exhaust is not recover-

able, and will vent to atmosphere at the pump. How-

ever, a 100% Exhaust Capture Kit, B32651, is

available.

To reduce the risk of injury from ejected ice, do not

operate the motor without a plumbed exhaust line or

muffler installed.

Installation must comply with all local codes and regu-

lations.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Grounding provides an escape wire

for the electric current.

Installation

83A6831G

Typical Installation

FIG. 1 is an example of an installation with a Python

XL-DA25 chemical injection pump. Your installation may

differ from what is shown here. (See Required Acces-

sories, page 7.) The Python XL-DA25 pump (F) and

secondary bleed-type pneumatic valve (B) are the only

components in FIG. 1 supplied by Graco. All other com-

ponents are supplied by customer.

Key:

A Main pneumatic supply line

B Secondary bleed-type pneumatic valve

C Pneumatic filter

D Primary bleed-type master pneumatic valve

E Pneumatic pressure regulator

FPump

G Manifold assembly (includes Y-strainer and fluid shutoff

valve (H))

H Fluid shutoff valve (inlet & outlet)

J Fluid pressure relief valve

K Fuid inlet line

L Inlet port

MOutletport

N Pneumatic lubricator

P Fluid outlet line

R Speed control valve

S Lift ring (for lifting the pump only)

T Check valve

Mount the Pump and Connect

Chemical Supply

The pump can be bolted to a wall or skid by the attached

bracket.

NOTE: The pump must always be mounted vertically.

If you have an application, or mounting configuration,

that requires installation in a manner different than

depicted in FIG. 1, please contact your Graco distributor

for assistance.

NOTE: A Y-strainer (G) or chemical filter is required

before the pump inlet. This will keep debris from the

tank from reaching the pump seals. Fluid filters are

available from Graco.

1. Mount the pump (F) and connect the fluid inlet

line (K).

FIG. 1:

Installation

3A6831G 9

Connect Pneumatic Supply

1. Install the pneumatic pressure regulator (E) and

gauge to control the inlet pressure. See Models on

page 3 for your model’s maximum pneumatic pres-

sure.

NOTE: If less than 100 psi supply pressure is used, the

pump’s maximum output pressure will be decreased

proportionally.

Minimum pneumatic pressure can be found by first find-

ing the table that corresponds to the pneumatic motor

size (see Minimum Pneumatic Pressures by Fluid

Plunger Size and Outlet Pressures on page 10). Next,

using the column that corresponds to the plunger size,

find the row equal to or slightly greater than the outlet

pressure of the pump. The value is the minimum pneu-

matic pressure required to achieve the fluid outlet pres-

sure.

2. Install a pneumatic filter (C) to keep debris from

affecting pump performance and to increase pump

life.

NOTE: Keep the secondary bleed-type pneumatic

valve (B) closed at this point to keep the pump from

operating without fluid, which minimizes seal wear.

3. Attach a pneumatic line to the 1/4 in. female NPT

port on the secondary bleed-type pneumatic

valve (B).

Route Exhaust to Remote

Location

Replace the muffler (18) with a pneumatic line to route

exhaust to a remote location.

Connect Chemical Outlet

1. Connect a fluid line from the pump outlet port (M) to

the injection point.

2. Install a check valve (T).

3. Install a fluid pressure relief valve (J) on the outlet

side of the pump.

NOTE: A pressure relief valve is required and is avail-

able from Graco, and can be connected back to the tank

or directly to the inlet side of the pump. See Kits and

Accessories on page 36.

4. Set the pressure relief valve at or below the maxi-

mum working pressure of the pump.

NOTICE

Due to the operational design of the pneumatic valve,

a small amount of the exhaust is not recoverable, and

will vent to atmosphere. However, a 100% Exhaust

Capture Kit, B32651, is available.

In the event of an injection line blockage, to reducethe

risk of skin injection and damage to the pump, ensure

the pressure relief valve is set at or below the maxi-

mum working pressure of the pump.

Installation

10 3A6831G

Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet Pressures

Actual running pressure must be set in field to avoid stalling. See Performance Charts, starting on page 40, for max-

imum flows at any given pressure.

0600 (6.0 in) Pneumatic Motor Minimum Gas Pressure

psi (MPa, bar)

Outlet Pressure psi

(MPa, bar)

1/2 Inch

Fluid Plunger

3/4 Inch

Fluid Plunger

1 Inch

Fluid Plunger

0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)

500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)

1000 (6.9, 68.9) 15.0 (0.1, 1.0) 15.6 (0.1, 1.1) 26.3 (0.2, 1.8)

1500 (10.3, 103.4) 15.0 (0.1, 1.0) 23.4 (0.2, 1.6) 39.5 (0.3, 2.7)

2000 (13.8, 137.9) 15.0 (0.1, 1.0) 31.3 (0.2, 2.2) 52.6 (0.4, 3.6)

2500 (17.2, 172.4) 17.4 (0.1, 1.2) 39.1 (0.3, 2.7) 65.8 (0.5, 4.5)

3000 (20.7, 206.8) 20.8 (0.1, 1.4) 46.9 (0.3, 3.2) 79.0 (0.5, 5.4)

3500 (24.1, 241.3) 24.3 (0.2, 1.7) 54.7 (0.4, 3.8) 92.1 (0.6, 6.4)

3800 (26.2, 262.0) 26.4 (0.2, 1.8) 59.4 (0.4, 4.1) 100.0 (0.7, 6.9)

4000 (27.6, 275.8) 27.8 (0.2, 1.9) 62.5 (0.4, 4.3)

4500 (31.0, 310.3) 31.3 (0.2, 2.2) 70.3 (0.5, 4.8)

5000 (34.5, 344.7) 34.7 (0.2, 2.4) 78.1 (0.5, 5.4)

5500 (37.9, 379.2) 38.2 (0.3, 2.6) 85.9 (0.6, 5.9)

6000 (41.4, 413.7) 41.7 (0.3, 2.9) 93.8 (0.6, 6.5)

6400 (44.1, 441.3) 44.4 (0.3, 3.1) 100.0 (0.7, 6.9)

6500 (44.8, 448.2) 45.1 (0.3, 3.1)

7000 (48.3, 482.6) 48.6 (0.3, 3.4)

7500 (51.7, 517.1) 52.1 (0.4, 3.6)

8000 (55.2, 551.6) 55.6 (0.4, 3.8)

8500 (58.6, 586.1) 59.0 (0.4, 4.1)

9000 (62.1, 620.5) 62.5 (0.4, 4.3)

9500 (65.5, 655.0) 66.0 (0.5, 4.5)

10000 (68.9, 689.5) 69.4 (0.5, 4.8)

10500 (72.4, 723.9) 72.9 (0.5, 5.0)

11000 (75.8, 758.4) 76.4 (0.5, 5.3)

11500 (79.3, 792.9) 79.9 (0.6, 5.5)

12000 (82.7, 827.4) 83.3 (0.6, 5.7)

12500 (86.2, 861.8) 86.8 (0.6, 6.0)

13000 (89.6, 896.3) 90.3 (0.6, 6.2)

13500 (93.1, 930.8) 93.8 (0.6, 6.5)

14000 (96.5, 965.3) 97.2 (0.7, 6.7)

14400 (99.3, 992.8) 100.0 (0.7, 6.9)

For applications where the exhaust is ported to

a pressurized location, compute the difference

between the inlet and outlet pressures to get

the pneumatic pressure to be used in the

above tables. Minimum pressure differential is

15 psi (0.1 MPa, 1.0 bar).

This manual suits for next models

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