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Instructions - Parts
Python
Injection Pump
For pneumatic pumps injecting chemicals at well sites. For use with compressed air or
compressed natural gas (CNG) only. CNG power source is not allowed for explosive
atmospheres. Not for use with sour gas. For professional use only.
See page 3 for model information, including
maximum working pressure and approvals.
Important Safety Instructions
Read all warnings and instructions in
this manual before using the
equipment. Be familiar with the
proper control and usage of the
equipment. Save these instructions.
®
XL Chemical
3A9514A
EN
II 2 G Ex h IIC T5 Gb
-40° ≤ Ta ≤ 80° C
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Summary of Contents for Graco Python XL 2A25406
- Page 1 Instructions - Parts ® Python XL Chemical Injection Pump 3A9514A For pneumatic pumps injecting chemicals at well sites. For use with compressed air or compressed natural gas (CNG) only. CNG power source is not allowed for explosive atmospheres. Not for use with sour gas. For professional use only. See page 3 for model information, including maximum working pressure and approvals.
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Page 2: Table Of Contents
Tighten Threaded Connections ... . . 17 Graco Standard Warranty....42 Tighten Packings . -
Page 3: Models
Models Models Maximum Working Maximum Pneumatic Inlet Configuration Part Pressure psi Pressure psi Number (MPa, bar) (MPa, bar) 2A25406 PCI-450-38-XBS-0 7250 2A25411 PCI-450-38-XCS-0 (50, 500) (0.34, 3.4) 2A25416 PCI-450-38-XDS-0 2A25409 PCI-450-75-XBL-0 3600 2A25414 PCI-450-75-XCL-0 (25, 248) (0.7, 7) 2A25419 PCI-450-75-XDL-0 2A25205 PCI-250-25-XBS-0 7250... -
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-450-38-XBS-0 Pneumatic Pneumatic Motor Plunger Size Plunger Material... -
Page 5: Safety Symbols
Safety Symbols Safety Symbols The following safety symbols appear throughout this manual and on warning labels. Read the table below to understand what each symbol means. Symbol Meaning Symbol Meaning Do Not Place Hands or Other Body Equipment Misuse Hazard Parts Near Fluid Outlet Do Not Stop Leaks with Hand, Fire and Explosion Hazard... -
Page 6: General Warnings
General Warnings General Warnings The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this equipment. Failure to follow these warnings can result in serious injury. WARNING FIRE AND EXPLOSION HAZARD When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. - Page 7 General Warnings WARNING 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 component.
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Page 8: Component Identification
Component Identification The installation shown in F . 2 is only a guide for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to meet your needs. Key: Pneumatic Motor Dust Shield... -
Page 9: Typical Installation
Typical Installation The installation shown in F . 2 is only a guide for selecting and installing system components and accessories. Contact your Graco distributor for assistance in designing a system to meet your needs. . 2: Typical Installation Key:... -
Page 10: Installation
Installation Installation Required Accessories Install the following required accessories in the order shown in F . 2, using adapters as necessary. See Kits If using compressed natural gas to drive the motor, and Accessories starting on page 34. to reduce the risk of fire or explosion, route the exhaust away from all sources of ignition. -
Page 11: Mount Pump And Connect Chemical Supply
For an application, or mounting configuration, that requires installation different than shown in F . 2, page 9, please contact your Graco distributor for assistance. Route Exhaust to Remote Location NOTE: A y-strainer (G), or chemical filter, is required before to be installed before the pump inlet. -
Page 12: Minimum Pneumatic Pressures By Fluid Plunger Size And Outlet Pressures
Installation Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet Pressures Actual running pressure must be set in field to avoid stalling. See Performance Charts, beginning on page 37. for maximum flows at any given pressure. 250 Pneumatic Motor Minimum Gas Pressure psi (MPa, bar) Outlet Pressure 1/4 In. - Page 13 Installation 450 Pneumatic Motor Minimum Gas Pressure psi (MPa, bar) Outlet Pressure 3/8 In. 3/4 In. Fluid Plunger Fluid Plunger 15.0 15.0 17.2 15.0 15.0 34.5 15.0 15.0 51.7 15.0 20.8 1000 68.9 15.0 27.8 1250 86.2 15.0 34.7 1500 10.3 103.4 15.0...
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Page 14: Operation
Operation Operation Pressure Relief Procedure Flush the Equipment Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is To avoid fire and explosion, always ground equip- manually relieved. To help prevent serious injury from ment and waste container. -
Page 15: Calibrate Chemical Dosage
Operation NOTICE Pump runaway may occur if the needle valve is opened too far for pressure settings, causing dam- age to the packing seals (103). 5. Keep the pump cycle rate less than 1 cycle every 3 seconds. The pump is primed when discharge from the prime valve (107) has transitioned from air, to bubbly liquid chemical, to pure liquid chemical. - Page 16 Operation Baseline Chemical Dosage Settings See Stroke Adjustment, page 15, for stroke adjust settings. See Performance Charts, starting on page 37, for maximum flows at any given pressure. 1/4 in. Fluid Plunger Pumps 3/8 in. Fluid Plunger Pumps GPD (LPD) GPD (LPD) Long Stroke Standard Stroke Short Stroke Long Stroke...
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Page 17: Maintenance
Maintenance Maintenance Preventive Maintenance Recycling and Disposal Schedule End of Product Life The operating conditions of the pump determines how often maintenance is required. Establish a preventive At the end of the product’s useful life, dismantle and maintenance schedule by recording when and what recycle it in a responsible manner. -
Page 18: Troubleshooting
Troubleshooting Troubleshooting Follow Pressure Relief Procedure, page 14, before checking or repairing the equipment. NOTE: Check all possible problems and causes before disassembling the equipment. Problem Cause Solution Inlet check is clogged with debris. Remove debris from check valve. Evaluate the o-ring chemical compati- Inlet check o-ring is damaged. - Page 19 Inadequate internal lubrication. Pump does not stroke. Add an oiler if pneumatic supply gas contains solvents that are washing out the factory grease. Graco oiler 237212. Inconsistent pump changeover. Replace the pilot valves. Rebuild or replace the pneumatic valve.
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Page 20: Repair
Repair Repair Before servicing or repairing the pump, verify that pressure is relieved according to the Pressure Relief Procedure, page 14, and that all fluid and pneumatic lines are properly shut off, or sealed with compatible valves and disconnected. Pump Disconnect Pump 1. - Page 21 Repair 2. Remove the bearings (102) and packing (103) care- 3. Replace the packing (103) and bearings (102), if fully from the fluid cylinder (101). necessary. Lubricate prior to reassembly. . 9 Packing detailed view . 8 Remove parts from fluid cylinder 3A9514A...
- Page 22 Repair Fluid Plunger Repair 4. Reinsert the packing nut (104), the packing (103), and the bearings (102) into the fluid cylinder (101). 1. Disconnect Pump, page 20. Tighten the packing nut (104) to distance, as shown in F . 10. 2.
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Page 23: Pneumatic Valve
Repair Pneumatic Valve Replace Complete Pneumatic Valve 1. Stop the pump. 2. Follow Pressure Relief Procedure, page 14. 3. Disconnect the pneumatic line to the motor. 4. Remove the four screws (211). 5. Remove the pneumatic valve (214) and the gasket (209*◆). - Page 24 Repair . 14. Pneumatic Plate Removal 4. Remove the snap ring (310 ✚) from each end. Use the piston to push the end caps (307❖) out of the ends. 5. Remove end cap o-rings (306†❖◆). See F . 15, page 25. 6.
- Page 25 Repair . 15. Pneumatic Valve Assembly 3A9514A...
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Page 26: Replace Pilot Valves
Repair Reassemble the Pneumatic Valve 7. Install the spring (311◆). Lubricate and install the pneumatic valve cup (312◆), see F . 17. Align the 1. Lubricate detent cam (304◆) and install into hous- small round magnet with the pneumatic inlet. ing. -
Page 27: Disconnect The Pneumatic Motor
Repair Disconnect the Pneumatic 9. Take the motor to a work bench. Motor 1. Stop the pump. 2. Flush the pump, if possible (see page 14). Follow Pressure Relief Procedure, page 14. 3. Disconnect the pneumatic line and fluid line and remove the dust guard (10). -
Page 28: Parts
Parts Parts Python XL Pneumatic Pump 3A9514A... - Page 29 Parts Python XL Pump Lower Parts List Ref. Part Description Qty. Ref. Part Description Qty. Packing nut Pneumatic motor, 2.5 in. Fluid Plunger Pneumatic motor, 4.5 in. Table Wall bracket, 2.5 in. 1, pg Wall Bracket, 4.5 in. Motor tie rod Priming bleed valve housing, standard pressure (1/4 in., 3/8 Jam hex nut...
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Page 30: Pneumatic Motor Parts
Parts Pneumatic Motor Parts 2.5 in. (63.5 mm) 3A9514A... -
Page 31: Pneumatic Motor Parts
Parts Pneumatic Motor Parts Ref. Part Description Cover, bottom 202*❖ O-Ring, cover Bearing 204*❖ O-Ring, piston Cylinder, motor 206▲ B32830 2.5 in. cover, cylinder (includes English warning label) B32832 4.5 in. cover, cylinder (includes English warning label) 206▲ 15W719 Label, warning (French and Spanish) (not shown) 207*❖... -
Page 32: Pneumatic Valve Parts
Parts Pneumatic Valve Parts 3A9514A... - Page 33 Parts Pneumatic Valve Parts Complete Pneumatic Valve Replacement Kit 24A351 To replace the complete pneumatic valve, order Pneumatic Valve Replacement Kit 24A351 (2.5 in.) or Kit 24A352 (4.5 in.). The kit includes items 301-312 below, and items 209 and 211 on page 31. Pneumatic Valve Repair Kits Pneumatic valve parts are not sold individually.
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Page 34: Kits And Accessories
Kits and Accessories Kits and Accessories Python XL Pump Lower Table 1: Fluid Plungers (ref. 105) Part Numbers by Fluid Plunger Size Diameter 1/4 in. 3/8 in. 1/2 in. 3/4 in. Qty. Chromex-Coated Fluid Plungers B32254 B32255 B32256 B32258 Table 2: Packing Stacks (ref. 103), including Plunger Bearings (ref. 102) Part Numbers by Fluid Plunger Size Diameter 1/4 in. -
Page 35: Dimensions
Dimensions Dimensions Python XL Pump Dimensions . 19 Python Pump Dimensions Size 24.0 in. 14.5 in. 16.75 in. 19.25 in. 9.94 in. 13.16 in. 9.19 in. (61.0 cm) (36.8 cm) (42.5 cm) (48.9 cm) (25.5 cm) (33.4 cm) (23.3 cm) 3A9514A... -
Page 36: Wall Bracket Mounting Hole Diagram, 4.5 In
Dimensions Wall Bracket Mounting Hole Diagram, 4.5 in. 3A9514A... -
Page 37: Performance Charts
Dimensions Performance Charts 2.5 in. Motors 1/4 in. Plunger (PCI-250-25) . 20 3/8 in. Plunger (PCI-250-38) . 21 3A9514A... - Page 38 Dimensions 1/2 in. Plunger (PCI-250-50) . 22 3/4 in. Plunger (PCI-250-75) . 23 3A9514A...
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Page 39: 4.5 In. Motors
Dimensions 4.5 in. Motors 3/8 in. Plunger (PCI-450-38) . 24 3/4 in. Plunger (PCI-450-75) . 25 3A9514A... -
Page 40: Air/Gas Consumption
Dimensions Air/Gas Consumption The air/gas consumption rate depends on the cycle rate of the pump. To estimate your cycle rate, see the Baseline Chemical Dosage Settings, page 16, and the Performance Charts, starting on page 37. 2.5 in. Motor Air or Gas Consumption SCFM (SM /hr) 15 PSI... -
Page 41: Technical Specifications
Technical Specifications Technical Specifications Python XL Chemical Injection Pump Metric Maximum pneumatic inlet pressure See Models on page 3. Maximum fluid working pressure See Models on page 3. Maximum cycle rate 100 cpm Environmental temperature range -40°–176°F -40°–80°C Noise (dBa) 2.5 in. -
Page 42: 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.
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