Graco Python A25115 Parts list manual

3A4386E

Instructions-Parts

Python™Chemical

Injection Pump

(For Applications Requiring ATEX Approval)

Pneumatic pump for injecting chemicals at well sites. For use with compressed air only.

For professional use only.

See page 3 for model information, including maximum working

pressures. Important Safety Instructions

Read all warnings and instructions in this manual.

Save all instructions.

II 2 G Ex h T6 Gb

23A4386E

Contents

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

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

Key Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Component Identification . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Required Accessories . . . . . . . . . . . . . . . . . . . . . 8

Flush Before Using Equipment . . . . . . . . . . . . . . 8

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9

Mount the Pump and Connect Chemical Supply 9

Connect Pneumatic Supply . . . . . . . . . . . . . . . . 10

Connect Chemical Outlet . . . . . . . . . . . . . . . . . 10

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pressure Relief Procedure . . . . . . . . . . . . . . . . 17

Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 17

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 18

Calibrate Chemical Dosage . . . . . . . . . . . . . . . 19

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Preventive Maintenance Schedule . . . . . . . . . . 22

Tighten Threaded Connections . . . . . . . . . . . . . 22

Tighten Packings . . . . . . . . . . . . . . . . . . . . . . . 22

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Timing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Python Pneumatic Pump . . . . . . . . . . . . . . . . . 37

Python Timing Valve Assembly . . . . . . . . . . . . 41

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 43

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Python Pump Dimensions . . . . . . . . . . . . . . . . . 44

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . 45

1 1/4” Air Motors (PCI-125) . . . . . . . . . . . . . . . . 45

1 3/4” Air Motors (PCI-175) . . . . . . . . . . . . . . . . 49

2” Air Motors (PCI-200) . . . . . . . . . . . . . . . . . . . 52

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

California Proposition 65 . . . . . . . . . . . . . . . . . . . 57

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 58

Models

3A4386E 3

Models

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

Plunger Size Air Motor Size Maximum Working Pressure

psi (MPa, bar) Maximum Pneumatic Inlet Pressure

psi (MPa, bar)

1/8 in.

1-1/4 in.

12,000 (82.7, 827) 170 (1.17, 11.7)

3/16 in. 6500 (44.8, 448)

200 (1.40, 14.0)

1/4 in. 3500 (24.1, 241)

3/8 in. 1500 (10.3, 103)

1/2 in. 875 (6.0, 60)

5/8 in. 500 (3.4, 34)

3/4 in. 400 (2.8, 28)

1/8 in.

1-3/4 in.

12,000 (82.7, 827) 87 (0.60, 6.0)

3/16 in. 12,000 (82.7, 827) 163 (1.12, 11.2)

1/4 in. 7000 (48.3, 483)

200 (1.40, 14.0)

3/8 in. 3000 (20.6, 206)

1/2 in. 1750 (12.1, 121)

5/8 in. 1000 (6.9, 69)

3/4 in. 800 (5.5, 55)

1/8 in.

2 in.

12,000 (82.7, 827) 66 (0.46, 4.6)

3/16 in. 12,000 (82.7, 827) 125 (0.86, 8.6)

1/4 in. 9500 (65.5, 655) 168 (1.16, 11.6)

3/8 in. 4000 (27.6, 276)

200 (1.40, 14.0)

1/2 in. 2250 (15.5, 155)

5/8 in. 1500 (10.3, 103)

3/4 in. 1000 (6.9, 69)

Configuration Number Matrix

43A4386E

Configuration Number Matrix

Check the identification plate (ID) for the 12-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-125-19S-XA-A

Key Points

• Standard pressure pumps feature 1/4 in. NPT(F)

inlet and outlet connections.

• High pressure pumps feature 1/4 in. NPT(F) inlet

and HiP HF4 outlet connections.

• B32240 can be used to convert HF4 outlet connec-

tion to 1/4 in. NPT(F) for applications 10,000 psi and

under.

PCI 125 19 S X A A

Pneumatic

Chemical

Injection

Air Motor Size Plunger Size Pressure Range Plunger Material Seal Material Qualifier

Air Motor Size Plunger Size Pressure Range Plunger Material Seal

Material Qualifier

125 1-1/4 inch 13 1/8” Diameter S StandardPressure

(1/4”, 3/8”, 1/2”, 5/8”,

3/4” plungers)

C Ceramic Coated

17-4 PH Stainless AFKM AATEX

175 1-3/4 inch 19 3/16” Diameter H High Pressure

(1/8” & 3/16” plung-

ers)

X Chromex Coated

17-4 PH Stainless B FKMETP

200 2 inch 25 1/4” Diameter CHNBR

38 3/8” Diameter D FFKM

50 1/2” Diameter

63 5/8” Diameter

75 3/4” Diameter

Warnings

3A4386E 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.

•Stopoperationimmediatelyifstaticsparkingoccurs oryoufeel ashock.Donotuseequipmentuntil

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

63A4386E

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.Repairorreplacewornordamagedparts immediately with genuineman-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterationsor 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.

Component Identification

3A4386E 7

Component Identification

Numbered items in the key below correspond to the

numbers in the Parts Lists starting on page 37.

Key:

FIG. 1 Pump Components

120

1 Air Motor Housing

8 Air Piston Cylinder

12 Dust Shield

13 Fluid Cylinder

17 Inlet Valve Check

18 Outlet Valve Check

20 Priming Bleed Valve

21 Pump Stroke Adjuster

22 Timing Valve

Installation

83A4386E

Installation

Grounding

Pump: ground through electrically conductive air and

fluid lines.

Air and fluid lines: use only electrically conductive

lines.

Air compressor: follow manufacturer’s recommenda-

tions.

Fluid supply container: follow local code.

Required Accessories

Install the following required accessories in the order

shown in FIG. 2, using adapters as necessary. See Kits

and Accessories starting on page 43.

Air Line

•Bleed-type master air valve (D): required in your

system to relieve air trapped between it and the air

motor when the valve is closed.

• Be sure the valve is easily accessible from the

pump and located downstream from the air reg-

ulator.

•Pump air regulator (E): to control pump speed and

outlet pressure. Locate it close to the pump.

•Air line filter (C): removes harmful dirt and mois-

ture from compressed air supply.

•Second bleed-type air valve (air shutoff valve)

(B): isolates air line accessories for servicing.

Locate upstream from all other air 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 17.

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

3A4386E 9

Typical Installation

FIG. 2 is an example of an installation with a Python

chemical injection pump. Your installation may differ

from what is shown here. (See Required Accessories,

page 8.) The Python pump (F) is the only component in

FIG. 2 supplied by Graco. All other components are sup-

plied by customer.

Key:

A Main Air Supply Line

B Air Shutoff Valve

CAirFilter

D Bleed-type Master Air Valve

E Air 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 Fluid Inlet Line

LInletPort

MOutletPort

N Air Lubricator

P Fluid Outlet Line

Mount the Pump and Connect

Chemical Supply

If you have an application, or mounting configuration,

that requires installation in a manner different than

depicted in FIG. 2, please contact your Graco distributor

for assistance.

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

before the pump inlet. This will keep any debris from the

tank from reaching the pump seals. Fluid filters are

available from Graco. See Kits and Accessories on

page 43.

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

line (K).

The pump is designed to be vertically mounted directly

from the 1/4 female NPT inlet port (L). The inlet port (L)

is on the bottom and is designated by a flow arrow point-

ing into the pump. Verify the inlet plumbing is sufficiently

strong to support the weight of the pump.

FIG. 2: Typical Installation

Installation

10 3A4386E

Connect Pneumatic Supply

1. Install the pneumatic regulator (E) and gauge to

control the inlet pressure. See Models on page 3for

your model’s maximum pneumatic pressure.

NOTE: If less than 200 psi supply pressure is used, the

pump’s maximum output pressure will be decreased

proportionally. See Minimum Gas Pressures by Fluid

Plunger Size and Outlet Pressures on page 11. Mini-

mum Gas Pressure can be found by first finding the

table that corresponds to the plunger size. Next, using

the column that corresponds to the air motor size, find

the row equal to or slightly greater than the outlet pres-

sure of the pump. The value is the Minimum Gas Pres-

sure required to achieve the fluid outlet pressure.

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

affecting pump performance and to increase pump

life.

NOTE: Keep the timing valve knob closed at this point

to keep the pump from operating without fluid, which

minimizes seal wear.

3. Attach a pneumatic line to the 1/8 in. female NPT

port (116) on the timing valve. (See Python Timing

Valve Assembly, page 41.) An 1/8 in. NPT fitting is

preferred, though a 1/8 in. - 1/4 in. NPT adapter is

included for convenience.

Connect Chemical Outlet

1. Connect a 1/4 npt(f) fluid line from the outlet check

valve (M) to the injection point.

NOTE: On high pressure configurations

(PCI-xxx-xxH-xx-x), the 1/4 npt(f) fitting is replaced with

an HiP HF4 fitting.

2. Install a pressure relief valve (J) on the outlet side of

the pump.

NOTE: A pressure relief valve is available 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 43.

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

mum working pressure of the pump.

4. Connect a 10-32 UNF fluid outlet from the

prime/bleed valve (21) to the fluid source or waste

reservoir.

NOTE: On high pressure configurations

(PCI-xxx-xxH-xx-x), the 10-32 fitting is replaced with a

1/16 in. NPT(F) fitting.

In the event of an injection line blockage, to reduce the

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.

This manual suits for next models

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