Graco Python XL-DA25 Series, A22608, A22612, A22613, A22614 Instructions And Parts
...
Instructions-Parts
®
Python
XL-DA25
3A6831A
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.
Save all instructions.
EN
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Configuration Number Matrix . . . . . . . . . . . . . . . . . 4
Pump Configuration . . . . . . . . . . . . . . . . . . . . . . 4
Lower 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Relief Procedure . . . . . . . . . . . . . . . . 11
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 11
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 12
Calibrate Chemical Dosage . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance Schedule . . . . . . . . . . 13
Tighten Threaded Connections . . . . . . . . . . . . . 13
Tighten Packings . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Repair - Pump Lower . . . . . . . . . . . . . . . . . . . . . . . 15
Disconnect the Pump Lower . . . . . . . . . . . . . . . 15
Pump Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Reconnect the Pump Lower . . . . . . . . . . . . . . . 18
Repair - Pneumatic Motor . . . . . . . . . . . . . . . . . . . 19
Pneumatic Valve . . . . . . . . . . . . . . . . . . . . . . . . 19
Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 22
Repair Pneumatic Motor . . . . . . . . . . . . . . . . . . 23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Python XL-DA25 Pneumatic Pump . . . . . . . . . . 27
Pump Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pneumatic Motor Parts . . . . . . . . . . . . . . . . . . . 31
Pneumatic Valve Parts . . . . . . . . . . . . . . . . . . . 33
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 35
Pump Lower Models . . . . . . . . . . . . . . . . . . . . . 35
Additional Kits & Accessories . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Python XL-DA25 Pump Dimensions . . . . . . . . . 36
Wall Bracket Mounting Hole Diagram . . . . . . . . 37
Pneumatic Mounting Hole Diagrams . . . . . . . . . 38
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 39
6 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Specifications . . . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42
2 3A6831A
Models
Models
Pneumatic
Plunger Size
3/4 in.
1 in. 3,800 (2.6, 26)
3/4 in.
1 in. 6,100 (42.1, 421)
Motor Size
6.0 in.
7.5 in.
Maximum Working Pressure
psi (MPa, bar)
6,400 (44.1, 441)
10,000 (68.9, 689)
Maximum Pneumatic Inlet Pressure
psi (MPa, bar)
100 (0.69, 6.9)
NOTE: See the Configuration Number Matrix, page 4, to find the plunger and pneumatic motor size for your unit.
Pump Models
Part Number Configuration Code Motor Size Lower Size Lower Coating Seal Material
A22606 PCI-0600-075-113-XC-2-0
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
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
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
A22713 PCI-0750-100-138-XD-2-0 FFKM
A22714 PCI-0750-100-138-XE-2-0 TFE/P
6.0 in.
7.5 in.
3/4 in. Chromex
1 in. Chromex
3/4 in. Chromex
1 in. Chromex
HNBR
HNBR
HNBR
HNBR
3A6831A 3
Configuration Number Matrix
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
PCI 0600 075 113 X C 2 0
Pneumatic
Chemical
Injection
Pump Configuration
Pneumatic
Motor Size
Pump Lower
Primary Seal
Size
Pump Lower
Secondary
Seal Size
Pump Lower
Coating
Seal Material Pump Stroke
Length
Qualifier
Pneumatic
Motor Size
0600 6.0 in. 075 3/4 in. diameter 113 1-1/8 in. diameter X Chromex C HNBR 2 2.5 inch 0 None
0750 7.5 in. 100 1 in. diameter 138 1-3/8 in. diameter DFFKM
Pump Lower
Primary Seal Size
Pump Lower
Secondary Seal Size
Pump Lower
Coating
Seal
Material
ETFE/P
Pump Stroke
Length
Qualifier
4 3A6831A
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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 o n 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.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
• Keep a working fire extingui she r in the wor k ar ea .
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 da ily. Re pla ce worn or dam ag e d pa rt s immed ia tely.
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.
3A6831A 5
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.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacture r.
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. 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.
• Check equipment regularly. Repair or replace worn or d amaged parts immediately with genuine manufacturer’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 re gu la tion s.
6 3A6831A
Installation
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. However, 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 regulations.
Grounding
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.
Pump: ground through electrically conductive pneumatic and fluid lines.
Installation
Required Accessories
Install the following required accessories in the order
shown in F
Pneumatic Line
• 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 pneumatic regulator (E): to control pump
speed and outlet pressure. Locate it close to the
pump.
• Pneumatic line filter (C): removes harmful dirt and
moisture from compressed air/gas supply.
• Second bleed-type pneumatic valve (pneumatic
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.
IG. 1, using adapters as necessary.
pump and located downstream from the pneumatic regulator.
Pneumatic and fluid lines: use only electrically conductive lines.
Air compressor: follow manufacturer’s recommendations.
Fluid supply container: follow local code.
3A6831A 7
• 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 contaminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipm en t. See
Flush the Equipment, page 11.
Installation
A
C
E
D
R
F
J
K
H
G
L
M
N
H
P
S
B
Typical Installation
FIG. 1:
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
pneumatic needle valve (B) are the only components in
IG. 1 supplied by Graco. All other components a re sup-
F
plied by customer.
Key:
A Main Pneumatic Supply Line
B Secondary Pneumatic Bleed-Type 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 Fluid Inlet Line
LInlet Port
MOutlet Port
N Pneumatic Lubricator
P Fluid Outlet Line
R Speed Control Valve
S Lift Ring (for lifting the pump only)
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 F
for assistance.
NOTE: A y-strainer (G) or chemical filter is required
before the pump inlet. This will keep any debris from the
IG. 1, please contact your Graco distributor
tank from reaching the pump seals. Fluid filter s ar e
available from Graco.
1. Mount the pump (F) and connect the fluid inlet
line (K).
8 3A6831A
Installation
Connect Pneumatic Supply
1. Install the pneumatic regulator (E) and gauge to
control the inlet pressure. See Models on page 3 for
your model’s maximum pneumatic pressure.
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 finding the table that corresponds to the plunger size (see
Minimum Pneumatic Pressures by Fluid Plunger
Size and Outlet Pressures on page 10). Next, using
the column that corresponds to the pneumatic motor
size, find the row equal to or slightly greater than the
outlet pressure of the pump. The value is the Minimum
Pneumatic Pressure 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 needle valve (B) closed at this point to
keep the pump from operating without fluid, which minimizes seal wear.
Connect Chemical Outlet
1. Connect a fluid line from the pump outlet port (M) to
the injection point.
2. Install a fluid 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 th e
inlet side of the pump. See Kits and Accessories on
page 35.
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 maximum working pressure of the pump.
3. Set the pressure relief valve at or below the maximum working pressure of the pump.
3. Attach a pneumatic line to th e 1/ 4 in. fe ma le NPT
port on the needle valve (B).
Route Exhaust to Remote
Location
Replace the muffler (18) with a pneumatic line to route
exhaust to a remote location.
NOTICE
Due to the operational design of the pneumatic valve,
a small amount of the exhaust is not recoverable, a nd
will vent to atmosphere. However, a 100% Exhaust
Capture Kit, B32651, is available.
3A6831A 9
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, starting on page 39, for maximum flows at any given pressure.
0600 (6.0 in) Pneumatic Motor Minimum Gas Pressure
psi (MPa, bar)
Outlet Pressure psi
(MPa, bar)
0 (0, 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)
1000 (6.9, 68.9) 15.6 (0.1, 1.1) 26.3 (0.2, 1.8)
1500 (10.3, 103.4) 23.4 (0.2, 1.6) 39.5 (0.3, 2.7)
2000 (13.8, 137.9) 31.3 (0.2, 2.2) 52.6 (0.4, 3.6)
2500 (17.2, 172.4) 39.1 (0.3, 2.7) 65.8 (0.5, 4.5)
3000 (20.7, 206.8) 46.9 (0.3, 3.2) 79.0 (0.5, 5.4)
3500 (24.1, 241.3) 54.7 (0.4, 3.8) 92.1 (0.6, 6.4)
4000 (27.6, 275.8) 62.5 (0.4, 4.3)
4500 (31.0, 310.3) 70.3 (0.5, 4.8)
5000 (34.5, 344.7) 78.1 (0.5, 5.4)
5500 (37.9, 379.2) 85.9 (0.6, 5.9)
6000 (41.4, 413.7) 93.8 (0.6, 6.5)
6400 (44.1, 441.3) 100.0 (0.7, 6.9)
3/4 Inch
Fluid Plunger
1 Inch
Fluid Plunger
0750 (7.5 in) Pneumatic Motor Minimum Gas Pressure
psi (MPa, bar)
Outlet Pressure psi
(MPa, bar)
0 (0, 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)
1000 (6.9, 68.9) 15.0 (0.1, 1.0) 16.4 (0.1, 1.1)
1500 (10.3, 103.4) 15.0 (0.1, 1.0) 24.6 (0.2, 1.7)
2000 (13.8, 137.9) 20.0 (0.1, 1.4) 32.8 (0.2, 2.3)
2500 (17.2, 172.4) 25.0 (0.2, 1.7) 41.0 (0.3, 2.8)
3000 (20.7, 206.8) 30.0 (0.2, 2.1) 49.2 (0.3, 3.4)
3500 (24.1, 241.3) 35.0 (0.2, 2.4) 57.4 (0.4, 4.0)
4000 (27.6, 275.8) 40.0 (0.3, 2.8) 65.6 (0.5, 4.5)
4500 (31.0, 310.3) 45.0 (0.3, 3.1) 73.8 (0.5, 5.1)
5000 (34.5, 344.7) 50.0 (0.3, 3.4) 82.0 (0.6, 5.7)
5500 (37.9, 379.2) 55.0 (0.4, 3.8) 90.2 (0.6, 6.2)
6000 (41.4, 413.7) 60.0 (0.4, 4.1) 98.4 (0.7, 6.8)
6500 (44.8, 448.2) 65.0 (0.4, 4.5)
7000 (48.3, 482.6) 70.0 (0.5, 4.8)
7500 (51.7, 517.1) 75.0 (0.5, 5.2)
8000 (55.2, 551.6) 80.0 (0.6, 5.5)
8500 (58.6, 586.1) 85.0 (0.6, 5.9)
9000 (62.1, 620.5) 90.0 (0.6, 6.2)
9500 (65.5, 655.0) 95.0 (0.7, 6.6)
10,000 (68.9, 689.5) 100.0 (0.7, 6.9)
3/4 Inch
Fluid Plunger
1 Inch
Fluid Plunger
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).
10 3A6831A
Operation
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection and splashing
fluid, follow the Pressure Relief Procedure when
you stop dispensing and before cleaning, checking, or
servicing the equipment.
NOTE: Always discharge fluid into an approved container or location.
1. Shut off all fluid and pneumatic lines (A, K, & P)
using the two fluid shutoff valves (H) and the pneumatic needle valve (B).
2. Slowly loosen the fluid lines to (K & P) at the pump
outlets (L & M) to bleed off any residual pressure.
3. Disconnect the fluid lines (K & P) from pump outlets
(L & M).
Flush the Equipment
To avoid fire and explosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest possible pressure.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Follow the Pressure Relief Procedure.
2. Connect the inlet port to the flushing fluid supply
source.
3. Connect the outlet port to the waste reservoir.
4. Run the pump until the dispensed fluid is predominately flushing fluid.
5. Follow the Pressure Relief Procedure.
3A6831A 11
Operation
Prime the Pump
1. Verify all connections and fluid lines are tight.
NOTE: The pressure regulator (E) and inlet pneumatic
needle valve (B) both effect the pump cycle rate. After
inlet pressure is set, the needle valve can serve as a
speed control.
2. Adjust pneumatic regulator (E) to desired pressure.
3. Open bleed-type pn eu m at ic valv e (D) . Slowly turn
pump needle valve (B) counter-clockwise, increasing air/gas flow to the pump.
NOTICE
Pump runaway may occur if the needle valve (B) is
opened too far for pressure settings, causing damage
to the packing sets (102 and 107).
4. Keep the pump cycle rate less than 1 cycle every 3
seconds only while priming the pump.
Calibrate Chemical Dosage
1. Set the pump to an estimated setting of the flow
rate.
2. Follow the instructions provided with your calibration
gauge.
3. Adjust the cycle rate with the inlet pneumatic needle
valve (B) and/or the pressure regulator (E).
4. Repeat the steps 2 and 3 to verify your changes.
Repeat as necessary until the desired flow rate is
achieved.
Baseline Chemical Dosage Settings
See Performance Charts, starting on page 39, for maximum flows at any given pressure.
Plunger Pumps
CPM
10
20
30
40
50
60
3/4 in. Fluid
GPD LPD GPD LPD
180 680 269 1017
359 1360 537 2033
539 2041 806 3050
719 2721 1074 4066
899 3401 1343 5083
1078 4081 1611 6100
1 in. Fluid
Plunger Pumps
NOTE: Maximum cycle rate is 60 CPM (cycles per min-
ute), and the minimum cycle rate is 10 CPM. All values
are at 0 psi back pressure. Cycle rates over 60 may
cause excess wear and premature seal failure.
12 3A6831A
Maintenance
Preventive Maintenance
Schedule
The operating conditions of your particular pump determines 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.
Tighten Packings
Maintenance
The packings included in your pump have the ability to
be adjusted to stop leaks that develop when the seals
are worn. If a leak develops in the pump’s fluid section,
tighten the packing nut clockwise by 1/16 of a turn, or
lower, until the leak is eliminated. The life of the packing
can be affected by over-tightening the packings. If the
packing nut needs to be tightened repeatedly after short
intervals, replace the packing.
Storage
If the pump is going to be stored for long periods, it is
recommended that the pump be flushed with a
light-weight oil or rust prohibiter to protect pump components. Store the pump with protective fluid inside whenever possible.
3A6831A 13
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