Page 1
Instructions-Parts ™ Python Chemical Injection Pump 3A4386C (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.
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.
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...
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. •...
Component Identification Component Identification . 1 Pump Components Numbered items in the key below correspond to the numbers in the Parts Lists starting on page 36. Key: Air Motor Housing Air Piston Cylinder Dust Shield Fluid Cylinder Inlet Valve Check Outlet Valve Check Priming Bleed Valve Pump Stroke Adjuster...
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 42. 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.
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,...
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 44, 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)
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.
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.
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 an estimated setting of the flow rate. See Baseline Chemical Dosage Settings, page 20, for tables of cycles per minute (CPM), and corresponding gal- lons per day (GPD) and liters per day (LPD).
Page 20
Operation Baseline Chemical Dosage Settings See Stroke Adjustment, page 19, for stroke adjust settings. See Performance Charts, starting on page 44, 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...
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.
Troubleshooting Troubleshooting 1. Follow Pressure Relief Procedure, page 17, before checking or repairing pump. 2. Check all possible problems and causes before dis- assembling pump. Problem Cause Solution Air bubbles in fluid Suction line is loose Tighten Timing valve not cycling Debris in timing valve Clean or rebuild timing valve Worn timing valve seals...
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 25
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 26
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 27
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 28
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.
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)
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 33
(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 34
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 35
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).
Parts Parts Python Pneumatic Pump PCI-200-13S-SA-A shown 3A4386C...
Page 37
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 38 smaller fluid plungers Packing B32164 Air motor housing, for 5/8” and Table 3, larger fluid plungers pg 38...
Page 38
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 39
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
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;...
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”...
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.
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.