Table of Contents
Advertisement
Quick Links
Instructions-Parts
Python
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.
™
Chemical
3A4386E
EN
II 2 G Ex h T6 Gb
Advertisement
Table of Contents
Related Manuals for Graco Python A25115
Summary of Contents for Graco Python A25115
- Page 1 Instructions-Parts ™ Python Chemical Injection Pump 3A4386E (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.
-
Page 2: Table Of Contents
California Proposition 65 ....57 Graco Standard Warranty ....58... -
Page 3: Models
Models Models Maximum Working Pressure Maximum Pneumatic Inlet Pressure Plunger Size Air Motor Size psi (MPa, bar) psi (MPa, bar) 1/8 in. 12,000 (82.7, 827) 170 (1.17, 11.7) 3/16 in. 6500 (44.8, 448) 1/4 in. 3500 (24.1, 241) 3/8 in. 1-1/4 in. -
Page 4: Configuration Number Matrix
Configuration Number Matrix 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 Pneumatic Air Motor Size Plunger Size Pressure Range Plunger Material... -
Page 5: Warnings
Warnings 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. - Page 6 Warnings 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. •...
-
Page 7: Component Identification
Component Identification Component Identification . 1 Pump Components Numbered items in the key below correspond to the numbers in the Parts Lists starting on page 37. Key: Air Motor Housing Air Piston Cylinder Dust Shield Fluid Cylinder Inlet Valve Check Outlet Valve Check Priming Bleed Valve Pump Stroke Adjuster... -
Page 8: Installation
Installation Installation Required Accessories Install the following required accessories in the order shown in F . 2, using adapters as necessary. See Kits Grounding and Accessories starting on page 43. Air Line • Bleed-type master air valve (D): required in your The equipment must be grounded to reduce the risk system to relieve air trapped between it and the air of static sparking. -
Page 9: Typical Installation
Chemical Supply from what is shown here. (See Required Accessories, page 8.) The Python pump (F) is the only component in . 2 supplied by Graco. All other components are sup- plied by customer. Key: If you have an application, or mounting configuration,... -
Page 10: Connect Pneumatic Supply
Next, using NOTE: A pressure relief valve is available from Graco the column that corresponds to the air motor size, find and can be connected back to the tank or directly to the the row equal to or slightly greater than the outlet pres- inlet side of the pump. - Page 11 Installation Minimum Gas Pressures by Fluid Plunger Size and Outlet Pressures See Performance Charts, starting on page 45, for maximum flows at any given pressure. 1/8 in. Fluid Plunger Pumps 3/16 in. Fluid Plunger Pumps Minimum Gas Pressure Minimum Gas Pressure psi (MPa, bar) psi (MPa, bar) Outlet Pressure...
- Page 12 Installation 1/4 in. Fluid Plunger Pumps Minimum Gas Pressure psi (MPa, bar) Outlet Pressure psi (MPa, bar) 1.25 in. Air Motor1.75 in. Air Motor 2 in. Air Motor 0 (0, 0) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 250 (1.7, 17.2) 60 (0.41, 4.1) 50 (0.34, 3.4)
- Page 13 Installation 3/8 in. Fluid Plunger Pumps Minimum Gas Pressure psi (MPa, bar) Outlet Pressure psi (MPa, bar) 1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor 0 (0, 0) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 150 (1, 10.3) 63 (0.44, 4.4) 50 (0.34, 3.4)
- Page 14 Installation 1/2 in. Fluid Plunger Pumps Minimum Gas Pressure psi (MPa, bar) Outlet Pressure psi (MPa, bar) 1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor 0 (0, 0) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 100 (0.7, 6.9) 66 (0.45, 4.5) 50 (0.34, 3.4)
- Page 15 Installation 5/8 in. Fluid Plunger Pumps Minimum Gas Pressure psi (MPa, bar) Outlet Pressure psi (MPa, bar) 1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor 0 (0, 0) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 75 (0.5, 5.2) 68 (0.47, 4.7) 50 (0.34, 3.4)
- Page 16 Installation 3/4 in. Fluid Plunger Pumps Minimum Gas Pressure psi (MPa, bar) Outlet Pressure psi (MPa, bar) 1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor 0 (0, 0) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.3, 3.4) 68 (0.47, 4.7) 50 (0.34, 3.4)
-
Page 17: Operation
Operation Operation Pressure Relief Procedure sure. (Use a hex wrench for PCI-xxx-xxH pumps. See Configuration Number Matrix, page 4.) Follow the Pressure Relief Procedure whenever 5. Slowly disconnect fluid lines (K & P) from check you see this symbol. valves (L & M). 6. -
Page 18: Prime The Pump
Operation Prime the Pump 1. Verify all connections and fluid lines are tight. 2. In order to prime the pump, turn the prime valve (20) counter-clockwise. NOTE: PCI-xxx-xxH pumps feature a one-piece valve (19) that requires a hex wrench to turn. See Configura- tion Number Matrix, page 4. -
Page 19: Calibrate Chemical Dosage
Operation Calibrate Chemical Dosage Stroke Adjustment This pump has infinite stroke adjustment between full and 1/4 stroke, and has four marked stroke adjustment positions. 1. Begin the process by setting the timing valve (22) to 1/4 stroke an estimated setting of the flow rate. See Baseline (1/4”, 6 mm) Chemical Dosage Settings, page 20, for tables of cycles per minute (CPM), and corresponding gal-... - Page 20 Operation Baseline Chemical Dosage Settings See Stroke Adjustment, page 19, for stroke adjust settings. See Performance Charts, starting on page 45, for maximum flows at any given pressure. 1/8 in. Fluid Plunger Pumps 3/16 in. Fluid Plunger Pumps GPD (LPD) GPD (LPD) Full Stroke 3/4 Stroke...
- Page 21 Operation 1/2 in. Fluid Plunger Pumps 5/8 in. Fluid Plunger Pumps GPD (LPD) GPD (LPD) Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke 4.9 (18.5) 3.7 (13.9) 2.4 (9.3) 1.2 (4.6) 7.6 (29.0) 5.7 (21.7) 3.8 (14.5) 1.9 (7.2)
-
Page 22: Maintenance
Maintenance Maintenance Preventive Maintenance Schedule The operating conditions of your particular pump deter- mines how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your pump. Tighten Threaded Connections Check that all threaded connections are tight at routine intervals. -
Page 23: Troubleshooting
Pump does not stroke. lubrication. Add an oiler if pneumatic supply gas contains solvents that are washing out the factory grease. Graco oiler 237212. Fluid back pressure Verify pump is sized to back pressure. Check is too high. inlet gas. - Page 24 Plunger coating. Inspect plunger for coating failure due to chemi- cal or abrasive attack. Replace plunger as required. a. Find the Graco ONG Chemical Compatibility Guide at www.graco.com. b. Find the Graco ONG Chemical Compatibility Guide at www.graco.com. 3A4386E...
-
Page 25: Repair
Repair Repair Before servicing or repairing your pump, verify that pressure is relieved according to the Pressure Relief Procedure, page 17, and that all fluid and pneumatic lines are properly shut off, or sealed with compatible valves and disconnected. Pump 4. - Page 26 Repair Pump Repair 3. Replace packing (15) and bearings (14), if neces- sary. Lubricate prior to reassembly. 1. Remove packing nut (16) from fluid cylinder (13). 2. Carefully remove bearings (14) and packing (15) from the fluid cylinder (13). Gray Seal lips Gray facing down...
- Page 27 Repair Reconnect Fluid Cylinder 3. Tighten the packing nut (16) to a torque of 15 in-lbs (1.7 N•m), then loosen and tighten again it to a final 1. Carefully guide the fluid plunger (5) into the packing torque of 5 in-lbs (0.6 N•m). nut (16) and through the packing (15) as the threads on the fluid cylinder (13) are brought closer to the air motor housing (1).
- Page 28 Repair Remove Air Piston and Fluid Plunger NOTE: The upper air motor is under light spring tension; therefore, it is necessary to hold downward pressure on Assembly the air piston cylinder (8) as the set screws (10) are 1. Follow the Pressure Relief Procedure, page 17. loosened.
- Page 29 Repair Replace Air Motor Seal Air Piston, Fluid Plunger, and Upper Cylinder Reassembly 1. Remove the air piston o-ring (7) with a plastic pick from the air piston (6), taking great care not to 1. Ensure that all parts are cleaned before reassem- scratch any of the groove surfaces on the piston.
-
Page 30: Check Valves
Repair pushed down to the hard stop so that the set screws Check Valves (10) engage the groove. 6. Reinstall and tighten the three set screws (10) to hold the air piston cylinder (8) in place. 7. Tighten the packing nut (16) to a torque of 15 in-lbs Inlet Check Valve Repair (all models except (1.7 N•m), then loosen and tighten again it to a final PCI-xxx-xxH) - Page 31 Repair Inlet Check Valve Repair (models Outlet Check Valve Repair (all models PCI-xxx-xxH only) except PCI-xxx-xxH) 1. Follow the Pressure Relief Procedure, page 17. 1. Follow the Pressure Relief Procedure, page 17. 2. Remove the inlet check valve assembly (17). 2.
- Page 32 Repair Outlet Check Valve Repair (models PCI-xxx-xxH only) 1. Follow the Pressure Relief Procedure, page 17. 2. Remove the outlet check valve assembly (18). . 20 Outlet check valve assembly 3. Separate the front housing (18e) from the back housing (18f). 4.
-
Page 33: Timing Valve
Repair Timing Valve 5. Pull the spool (103) out of the lower housing (101). Inspect and replace as necessary. Timing Valve Repair 1. Follow the Pressure Relief Procedure, page 17. 2. Remove the spring retainer (112) from the bottom of the timing valve. - Page 34 (118) and replace as necessary. 9. Inspect the seal (108) and piston (107), and replace if necessary. The repair parts from Graco come as a 13. Clean and inspect all parts before reassembly. piston assembly with the seals factory installed.
- Page 35 Repair 16. Place the timing valve knob (122) over the needle the housing lead-in (130) to ease installation and valve (117), with the “0” lined up with the marker on ensure that the seals are not damaged. the label (121). Tighten the hex set screws (123). Marker Lead-in 102 (w/105 &...
- Page 36 Repair 20. Connect the upper and lower housings by lining up Final Reassembly the dowel pins (113) in lower housing (101) with the 1. After all inspections and repairs are completed, receiving holes in the upper housing (110). Tighten reconnect all fluid lines. the screws (111).
-
Page 37: Parts
Parts Parts Python Pneumatic Pump PCI-200-13S-SA-A shown 3A4386E... - Page 38 Parts Python Pneumatic Pump Parts List Ref. Part Description Qty. Plunger bearings, included with Ref. Part Description Qty. Table 3, packing (ref. 15) B32163 Air motor housing, for 1/2” and pg 39 smaller fluid plungers Packing B32164 Air motor housing, for 5/8” and Table 3, larger fluid plungers pg 39...
- Page 39 Parts Table 1: Fluid Plungers (ref. 5) Part Numbers by Fluid Plunger Size Diameter 1/8 in. 3/16 in. 1/4 in. 3/8 in. 1/2 in. 5/8 in. 3/4 in. Qty. 17-4 Stainless Steel Fluid Plungers B32066 B32067 B32068 B32135 B32136 B32137 B32138 Chromex-Coated Fluid Plungers B32139...
- Page 40 Parts Table 5: Inlet Valve Check (ref. 17) Part Numbers by Fluid Plunger Size Diameter 1/8 in. 3/16 in. 1/4 in. 3/8 in. 1/2 in. 5/8 in. 3/4 in. Qty. B32226 B32226 B32216 B32024 B32024 B32024 B32024 FKMETP B32228 B32228 B32218 B32026 B32026...
-
Page 41: Python Timing Valve Assembly
Parts Python Timing Valve Assembly B32069 123‡ 108* 107* 106* 104* 103* 125* 105* 124* 102* ‡ 105* 124* 130* 105* 124* 102* 105* 124* 129* 3A4386E... - Page 42 Parts Timing Valve Assembly (B32069) Parts List Ref. Part Description Qty. Ref. Part Description Qty. Internal Ring, Stainless Steel; B32193 Lower Housing included with timing valve nee- 102* Seal Cartridge dle (ref. 117) 103* Spool Knob Spring; included with tim- 104* Ball, 316 stainless steel;...
-
Page 43: Kits And Accessories
Kits and Accessories Kits and Accessories Additional Kits & Accessories B32225 FKM ETP Small (1/8” - 1/4”) Inlet and Outlet Check Valve Repair Kit (includes a spring Part No. Description and piston o-rings) B32045 225-750 PSI Pressure Relief Valve Kit B32235 FFKM Small (1/8”... -
Page 44: Dimensions
Dimensions Dimensions Python Pump Dimensions . 30 Python Pump Dimensions 13.26 in. 5.3 in. 2.34 in. 2.3 in. 9.125 in. (33.7 cm) (13.5 cm) (5.9 cm) (5.8 cm) (23.2 cm) 3A4386E... -
Page 45: Performance Charts
Performance Charts Performance Charts 1 1/4” Air Motors (PCI-125) 1/8” Plunger (PCI-125-13) (17.0) (15.1) (13.3) Inlet Pressure (11.4) (LPD) (MPa, Bar) (9.5) A-50 (0.35, 3.5) B-100 (0.69, (7.6) 6.9) (5.7) (3.8) (1.9) 2000 4000 6000 8000 10000 12000 (13.79) (27.58) (41.37) (55.16) (68.95) - Page 46 Performance Charts 3/16” Plunger (PCI-125-19) (45.4) (37.9) Inlet Pressure (30.3) - PSI (LPD) (MPa, Bar) A-50 (0.35, (22.7) 3.5) B-100 (0.69, (15.2) (7.6) 1000 2000 3000 4000 5000 6000 7000 (6.89) (13.79) (20.68) (27.58) (34.47) (41.37) (48.26) (68.9) (137.9) (206.8) (275.8) (344.7) (413.7)
- Page 47 Performance Charts 3/8” Plunger (PCI-125-38) (170) (151) (133) Inlet Pressure (114) - PSI (LPD) (MPa, Bar) (95) A-50 (0.35, 3.5) (76) B-100 (0.69, (57) (38) (19) 1000 1200 1400 1600 1800 (1.38) (2.76) (4.14) (5.52) (6.90) (8.27) (9.65) (11.03) (12.41) (13.8) (27.6) (41.4)
- Page 48 Performance Charts 5/8” Plunger (PCI-125-63) (454) (379) Inlet Pressure (303) - PSI (LPD) (MPa, Bar) A-50 (0.35, (227) 3.5) B-100 (0.69, (151) (76) (0.69) (1.38) (2.07) (2.76) (3.45) (4.14) (6.9) (13.8) (20.7) (27.6) (34.5) (41.4) Outlet Pressure - PSI (MPa, Bar) .
-
Page 49: 3/4" Air Motors (Pci-175)
Performance Charts 1 3/4” Air Motors (PCI-175) 1/8” Plunger (PCI-175-13) (15.1) (13.3) (11.4) Inlet Pressure (9.5) - PSI (LPD) (MPa, Bar) A-50 (0.35, (7.6) 3.5) B-100 (0.69, (5.7) (3.8) (1.9) 2000 4000 6000 8000 10000 12000 14000 (13.79) (27.58) (41.37) (55.16) (68.95) (82.74) - Page 50 Performance Charts 1/4” Plunger (PCI-175-25) (68.1) (60.6) (53.0) Inlet Pressure (45.4) - PSI (MPa, Bar) (LPD) (37.9) A-50 (0.35, 3.5) (30.3) B-100 (0.69, (22.7) (15.2) (7.6) 1000 2000 3000 4000 5000 6000 7000 8000 (6.89) (13.79) (20.68) (27.58) (34.47) (41.37) (48.26) (55.16) (68.9)
- Page 51 Performance Charts 1/2” Plunger (PCI-175-50) (303) (265) (227) Inlet Pressure - PSI (189) (LPD) (MPa, Bar) A-50 (0.35, (151) 3.5) B-100 (0.69, (114) (76) (38) 1000 1500 2000 (3.45) (6.90) (10.34) (13.79) (34.5) (69.0) (103.4) (137.9) Outlet Pressure - PSI (MPa, Bar) .
-
Page 52: 2" Air Motors (Pci-200)
Performance Charts 3/4” Plunger (PCI-175-75) (681) (606) (530) Inlet Pressure (454) (MPa, Bar) (LPD) (379) A-50 (0.35, 3.5) B-100 (0.69, (303) 6.9) (227) (151) (76) (0.69) (1.38) (2.07) (2.76) (3.45) (4.14) (6.9) (13.8) (20.7) (27.6) (34.5) (41.4) Outlet Pressure - PSI (MPa, Bar) . - Page 53 Performance Charts 3/16” Plunger (PCI-200-19) (30.3) (26.5) Inlet Pressure (22.7) - PSI (MPa, Bar) (19.0) A-50 (0.35, (LPD) 3.5) (15.2) B-100 (0.69, (11.4) (7.6) (3.8) 2000 4000 6000 8000 10000 12000 14000 (13.79) (27.58) (41.37) (55.16) (68.95) (82.74) (96.53) (137.9) (275.8) (413.7) (551.6)
- Page 54 Performance Charts 3/8” Plunger (PCI-200-38) (170) (151) (133) Inlet Pressure (114) (MPa, Bar) (LPD) (95) A-50 (0.35, 3.5) (76) B-100 (0.69, (57) (38) (19) 1500 2500 3500 1000 2000 3000 4000 4500 (3.45) (6.89) (10.34) (13.79) (17.24) (20.68) (24.13) (27.58) (31.03) (34.5) (103.4)
- Page 55 Performance Charts 5/8” Plunger (PCI-200-63) (454) (379) Inlet Pressure (303) - PSI (LPD) (MPa, Bar) A-50 (0.35, (227) 3.5) B-100 (0.69, (151) (76) 1000 1200 1400 (1.38) (2.76) (4.14) (5.52) (6.90) (8.27) (9.65) (13.8) (27.6) (41.4) (55.2) (69.0) (82.7) (96.5) Outlet Pressure - PSI (MPa, Bar) .
- Page 56 Performance Charts 3A4386E...
-
Page 57: Technical Data
Technical Data Technical Data Python Chemical Injection Pump Metric Maximum air inlet pressure See Models on page 3. Maximum fluid working pressure See Models on page 3. Environmental temperature range -40°–176°F -40°–80°C Noise (dBa) Maximum sound pressure <70 dBa with included muffler installed. Inlet/Outlet Sizes Fluid inlet size 1/4 in. -
Page 58: Graco Standard Warranty
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.