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

PCI

Pneumatic

Chemical

Injection

125 19 S X

Air Motor Size Plunger Size Pressure Range Plunger Material

A A

Seal Material Qualifier

Air Motor Size Plunger Size Pressure Range Plunger Material

125 1-1/4 inch 13 1/8” Diameter S Standard Pressure

(1/4”, 3/8”, 1/2”, 5/8”,

3/4” plungers)

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

(1/8” & 3/16” plungers)

200 2 inch 25 1/4” Diameter

38 3/8” Diameter

50 1/2” Diameter

63 5/8” Diameter

75 3/4” Diameter

C Ceramic Coated

17-4 PH Stainless

X Chromex Coated

17-4 PH Stainless

Seal

Material

A FKM

B FKMETP

C HNBR

D FFKM

Qualifier

A ATEX

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

3A4386A

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 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.

• 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 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.

3A4386A

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

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 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 damaged 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 regulations.

6 3A4386A

Component Identification

F IG . 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

Timing Valve

3A4386A

Component Identification

Installation

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 air and fluid lines.

Air and fluid lines: use only electrically conductive lines.

Air compressor: follow manufacturer’s recommendations.

Fluid supply container: follow local code.

Required Accessories

Install the following required accessories in the order

shown in F IG . 2, using adapters as necessary. See

Kits and Accessories

starting on page 42.

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 regulator.

• 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 moisture 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 contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See

Flush the Equipment , page 17.

3A4386A

Installation

Typical Installation

J L

F IG . 2: Typical Installation

F IG . 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

F IG . 2 supplied by Graco. All other components are sup-

plied by customer.

Key:

A Main Air Supply Line

B Air Shutoff Valve

C Air Filter

D Bleed-type Master Air Valve

E Air Pressure Regulator

F Pump

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

L Inlet Port

M Outlet Port

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 F IG . 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 42.

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 pointing into the pump. Verify the inlet plumbing is sufficiently strong to support the weight of the pump.

3A4386A 9

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 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 pressure of the pump. The value is the Minimum Gas 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 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 40.) 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 42.

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.

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.

10 3A4386A

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

Outlet Pressure psi (MPa, bar)

Minimum Gas Pressure psi (MPa, bar)

1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor 1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor

0 (0, 0)

250 (1.7, 17.2)

500 (3.4, 34.5)

750 (5.2, 51.7)

1000 (6.9, 68.9)

1250 (8.6, 86.2)

1500 (10.3, 103.4)

1750 (12.1, 120.7)

2000 (13.8, 137.9)

2250 (15.5, 155.1)

2500 (17.2, 172.4)

2750 (19, 189.6)

3000 (20.7, 206.8)

3250 (22.4, 224.1)

3500 (24.1, 241.3)

3750 (25.9, 258.6)

50 (0.34, 3.4)

52 (0.36, 3.6)

55 (0.38, 3.8)

57 (0.39, 3.9)

60 (0.41, 4.1)

62 (0.43, 4.3)

65 (0.45, 4.5)

67 (0.46, 4.6)

70 (0.48, 4.8)

72 (0.50, 5.0)

75 (0.52, 5.2)

77 (0.53, 5.3)

80 (0.55, 5.5)

82 (0.57, 5.7)

85 (0.58, 5.8)

87 (0.60, 6.0)

50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 55 (0.38, 3.8) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 61 (0.42, 4.2) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 67 (0.46, 4.6) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 72 (0.50, 5.0) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 78 (0.54, 5.4) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 83 (0.58, 5.8) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 89 (0.61, 6.1) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 95 (0.65, 6.5) 50 (0.34, 3.4) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 100 (0.69, 6.9) 51 (0.35, 3.5) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 106 (0.73, 7.3) 54 (0.37, 3.7) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 112 (0.77, 7.7) 57 (0.39, 3.9) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 117 (0.81, 8.1) 60 (0.41, 4.1) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 123 (0.85, 8.5) 63 (0.43, 4.3) 50 (0.34, 3.4)

50 (0.34, 3.4) 50 (0.34, 3.4) 128 (0.89, 8.9) 66 (0.45, 4.5) 50 (0.35, 3.5)

50 (0.34, 3.4) 50 (0.34, 3.4) 134 (0.92, 9.2) 68 (0.47, 4.7) 52 (0.36, 3.6)

4000 (27.6, 275.8)

4250 (29.3, 293)

4500 (31, 310.3)

4750 (32.8, 327.5)

90 (0.62, 6.2)

92 (0.64, 6.4)

95 (0.65, 6.5)

97 (0.67, 6.7)

50 (0.34, 3.4) 50 (0.34, 3.4) 140 (0.96, 9.6) 71 (0.49, 4.9) 55 (0.38, 3.8)

50 (0.34, 3.4) 50 (0.34, 3.4) 145 (1.00, 10.0) 74 (0.51, 5.1) 57 (0.39, 3.9)

50 (0.34, 3.4) 50 (0.34, 3.4) 151 (1.04, 10.4) 77 (0.53, 5.3) 59 (0.41, 4.1)

50 (0.34, 3.4) 50 (0.34, 3.4) 157 (1.08, 10.8) 80 (0.55, 5.5) 61 (0.42, 4.2)

5000 (34.5, 344.7) 100 (0.69, 6.9) 51 (0.35, 3.5) 50 (0.34, 3.4) 162 (1.12, 11.2) 83 (0.57, 5.7) 63 (0.44, 4.4)

5250 (36.2, 362) 102 (0.70, 7.0) 52 (0.36, 3.6) 50 (0.34, 3.4) 168 (1.16, 11.6) 86 (0.59, 5.9) 66 (0.45, 4.5)

5500 (37.9, 379.2) 105 (0.72, 7.2) 53 (0.37, 3.7) 50 (0.34, 3.4) 173 (1.20, 12.0) 88 (0.61, 6.1) 68 (0.47, 4.7)

5750 (39.6, 396.4) 107 (0.74, 7.4) 55 (0.38, 3.8) 50 (0.34, 3.4) 179 (1.23, 12.3) 91 (0.63, 6.3) 70 (0.48, 4.8)

6000 (41.4, 413.7) 110 (0.76, 7.6) 56 (0.39, 3.9) 50 (0.34, 3.4) 185 (1.27, 12.7) 94 (0.65, 6.5) 72 (0.50, 5.0)

6250 (43.1, 430.9) 112 (0.77, 7.7) 57 (0.39, 3.9) 50 (0.34, 3.4) 190 (1.31, 13.1) 97 (0.67, 6.7) 74 (0.51, 5.1)

6500 (44.8, 448.2) 115 (0.79, 7.9) 59 (0.40, 4.0) 50 (0.34, 3.4) 196 (1.35, 13.5) 100 (0.69, 6.9) 77 (0.53, 5.3)

6750 (46.5, 465.4) 117 (0.81, 8.1) 60 (0.41, 4.1) 50 (0.34, 3.4) 103 (0.71, 7.1) 79 (0.54, 5.4)

7000 (48.3, 482.6) 120 (0.83, 8.3) 61 (0.42, 4.2) 50 (0.34, 3.4)

7250 (50, 499.9) 122 (0.84, 8.4) 62 (0.43, 4.3) 50 (0.34, 3.4)

7500 (51.7, 517.1) 125 (0.86, 8.6) 64 (0.44, 4.4) 50 (0.34, 3.4)

7750 (53.4, 534.3) 127 (0.88, 8.8) 65 (0.45, 4.5) 50 (0.34, 3.4)

106 (0.73, 7.3)

109 (0.75, 7.5)

111 (0.77, 7.7)

114 (0.79, 7.9)

81 (0.56, 5.6)

83 (0.57, 5.7)

85 (0.59, 5.9)

88 (0.60, 6.0)

8000 (55.2, 551.6) 130 (0.89, 8.9) 66 (0.46, 4.6) 51 (0.35, 3.5)

8250 (56.9, 568.8) 132 (0.91, 9.1) 67 (0.47, 4.7) 52 (0.36, 3.6)

8500 (58.6, 586.1) 135 (0.93, 9.3) 69 (0.47, 4.7) 53 (0.36, 3.6)

8750 (60.3, 603.3) 137 (0.95, 9.5) 70 (0.48, 4.8) 54 (0.37, 3.7)

9000 (62.1, 620.5) 140 (0.96, 9.6) 71 (0.49, 4.9) 55 (0.38, 3.8)

9250 (63.8, 637.8) 142 (0.98, 9.8) 73 (0.50, 5.0) 56 (0.38, 3.8)

9500 (65.5, 655) 145 (1.00, 10.0) 74 (0.51, 5.1) 57 (0.39, 3.9)

9750 (67.2, 672.2) 147 (1.01, 10.1) 75 (0.52, 5.2) 58 (0.40, 4.0)

10000 (68.9, 689.5) 150 (1.03, 10.3) 76 (0.53, 5.3) 58 (0.40, 4.0)

10250 (70.7, 706.7) 152 (1.05, 10.5) 78 (0.54, 5.4) 59 (0.41, 4.1)

10500 (72.4, 723.9) 155 (1.07, 10.7) 79 (0.54, 5.4) 60 (0.42, 4.2)

10750 (74.1, 741.2) 157 (1.08, 10.8) 80 (0.55, 5.5) 61 (0.42, 4.2)

11000 (75.8, 758.4) 160 (1.10, 11.0) 81 (0.56, 5.6) 62 (0.43, 4.3)

11250 (77.6, 775.7) 162 (1.12, 11.2) 83 (0.57, 5.7) 63 (0.44, 4.4)

11500 (79.3, 792.9) 165 (1.14, 11.4) 84 (0.58, 5.8) 64 (0.44, 4.4)

12000 (82.7, 827.4) 170 (1.17, 11.7) 87 (0.60, 6.0) 66 (0.46, 4.6)

117 (0.81, 8.1) 90 (0.62, 6.2)

120 (0.83, 8.3) 92 (0.63, 6.3)

123 (0.85, 8.5) 94 (0.65, 6.5)

126 (0.87, 8.7) 96 (0.66, 6.6)

129 (0.89, 8.9) 99 (0.68, 6.8)

132 (0.91, 9.1) 101 (0.69, 6.9)

134 (0.93, 9.3) 103 (0.71, 7.1)

137 (0.95, 9.5) 105 (0.72, 7.2)

140 (0.97, 9.7) 107 (0.74, 7.4)

143 (0.99, 9.9) 110 (0.76, 7.6)

146 (1.01, 10.1) 112 (0.77, 7.7)

149 (1.03, 10.3) 114 (0.79, 7.9)

152 (1.05, 10.5) 116 (0.80, 8.0)

155 (1.07, 10.7) 118 (0.82, 8.2)

157 (1.09, 10.9) 120 (0.83, 8.3)

163 (1.12, 11.2) 125 (0.86, 8.6)

3A4386A 11

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)

250 (1.7, 17.2)

500 (3.4, 34.5)

750 (5.2, 51.7)

1000 (6.9, 68.9)

1250 (8.6, 86.2)

50 (0.34, 3.4)

60 (0.41, 4.1)

70 (0.48, 4.8)

80 (0.55, 5.5)

90 (0.62, 6.2)

100 (0.69, 6.9)

50 (0.34, 3.4)

51 (0.35, 3.5)

1500 (10.3, 103.4) 110 (0.76, 7.6)

1750 (12.1, 120.7) 120 (0.83, 8.3)

2000 (13.8, 137.9) 130 (0.89, 8.9)

2250 (15.5, 155.1) 140 (0.96, 9.6)

56 (0.39, 3.9)

61 (0.42, 4.2)

66 (0.46, 4.6)

71 (0.49, 4.9)

2500 (17.2, 172.4) 150 (1.03, 10.3) 76 (0.53, 5.3)

2750 (19, 189.6) 160 (1.10, 11.0) 81 (0.56, 5.6)

3000 (20.7, 206.8) 170 (1.17, 11.7) 87 (0.60, 6.0)

3250 (22.4, 224.1) 180 (1.24, 12.4) 92 (0.63, 6.3)

50 (0.34, 3.4)

51 (0.35, 3.5)

55 (0.38, 3.8)

58 (0.40, 4.0)

62 (0.43, 4.3)

66 (0.46, 4.6)

70 (0.48, 4.8)

3500 (24.1, 241.3) 190 (1.31, 13.1) 97 (0.67, 6.7)

3750 (25.9, 258.6) 200 (1.38, 13.8) 102 (0.70, 7.0)

4000 (27.6, 275.8)

4250 (29.3, 293)

107 (0.74, 7.4)

112 (0.77, 7.7)

4500 (31, 310.3)

4750 (32.8, 327.5)

5000 (34.5, 344.7)

5250 (36.2, 362)

117 (0.81, 8.1)

122 (0.84, 8.4)

74 (0.51, 5.1)

78 (0.54, 5.4)

82 (0.56, 5.6)

86 (0.59, 5.9)

90 (0.62, 6.2)

94 (0.65, 6.5)

127 (0.88, 8.8) 98 (0.67, 6.7)

133 (0.91, 9.1) 101 (0.70, 7.0)

5500 (37.9, 379.2)

5750 (39.6, 396.4)

6000 (41.4, 413.7)

6250 (43.1, 430.9)

6500 (44.8, 448.2)

6750 (46.5, 465.4)

7000 (48.3, 482.6)

7250 (50, 499.9)

138 (0.95, 9.5)

143 (0.98, 9.8)

148 (1.02, 10.2)

153 (1.05, 10.5)

158 (1.09, 10.9)

163 (1.12, 11.2)

168 (1.16, 11.6)

173 (1.19, 11.9)

105 (0.73, 7.3)

109 (0.75, 7.5)

113 (0.78, 7.8)

117 (0.81, 8.1)

121 (0.83, 8.3)

125 (0.86, 8.6)

129 (0.89, 8.9)

133 (0.91, 9.1)

7500 (51.7, 517.1)

7750 (53.4, 534.3)

8000 (55.2, 551.6)

8250 (56.9, 568.8)

8500 (58.6, 586.1)

8750 (60.3, 603.3)

9000 (62.1, 620.5)

9250 (63.8, 637.8)

9500 (65.5, 655)

178 (1.23, 12.3) 137 (0.94, 9.4)

184 (1.27, 12.7) 141 (0.97, 9.7)

189 (1.30, 13.0) 144 (1.00, 10.0)

194 (1.34, 13.4) 148 (1.02, 10.2)

199 (1.37, 13.7) 152 (1.05, 10.5)

156 (1.08, 10.8)

160 (1.10, 11.0)

164 (1.13, 11.3)

168 (1.16, 11.6)

12 3A4386A

Installation

3/8 in. Fluid Plunger Pumps

Outlet Pressure psi (MPa, bar)

0 (0, 0)

150 (1, 10.3)

300 (2.1, 20.7)

450 (3.1, 31)

600 (4.1, 41.4)

750 (5.2, 51.7)

900 (6.2, 62.1)

1050 (7.2, 72.4)

1200 (8.3, 82.7)

1350 (9.3, 93.1)

Minimum Gas Pressure psi (MPa, bar)

1.25 in. Air Motor 1.75 in. Air Motor

50 (0.34, 3.4) 50 (0.34, 3.4)

63 (0.44, 4.4) 50 (0.34, 3.4)

77 (0.53, 5.3)

90 (0.62, 6.2)

104 (0.72, 7.2)

117 (0.81, 8.1)

50 (0.34, 3.4)

46 (0.32, 3.2)

53 (0.36, 3.6)

60 (0.41, 4.1)

131 (0.90, 9.0)

144 (0.99, 9.9)

67 (0.46, 4.6)

74 (0.51, 5.1)

158 (1.09, 10.9) 80 (0.55, 5.5)

171 (1.18, 11.8) 87 (0.60, 6.0)

1500 (10.3, 103.4) 185 (1.27, 12.7) 94 (0.65, 6.5)

1650 (11.4, 113.8) 198 (1.37, 13.7) 101 (0.70, 7.0)

1800 (12.4, 124.1)

1950 (13.4, 134.4) -

108 (0.74, 7.4)

115 (0.79, 7.9)

2 in. Air Motor

50 (0.34, 3.4)

41 (0.28, 2.8)

46 (0.32, 3.2)

51 (0.35, 3.5)

56 (0.39, 3.9)

62 (0.42, 4.2)

67 (0.46, 4.6)

72 (0.50, 5.0)

77 (0.53, 5.3)

83 (0.57, 5.7)

88 (0.61, 6.1)

2100 (14.5, 144.8)

2250 (15.5, 155.1)

2400 (16.5, 165.5)

2550 (17.6, 175.8)

2700 (18.6, 186.2)

2850 (19.7, 196.5)

3000 (20.7, 206.8)

3150 (21.7, 217.2)

3300 (22.8, 227.5)

3450 (23.8, 237.9)

3600 (24.8, 248.2)

122 (0.84, 8.4)

129 (0.89, 8.9)

93 (0.64, 6.4)

99 (0.68, 6.8)

136 (0.93, 9.3) 104 (0.72, 7.2)

142 (0.98, 9.8) 109 (0.75, 7.5)

149 (1.03, 10.3) 114 (0.79, 7.9)

156 (1.08, 10.8) 120 (0.82, 8.2)

163 (1.12, 11.2) 125 (0.86, 8.6)

170 (1.17, 11.7) 130 (0.90, 9.0)

177 (1.22, 12.2)

184 (1.27, 12.7)

135 (0.93, 9.3)

141 (0.97, 9.7)

191 (1.31, 13.1) 146 (1.01, 10.1)

3750 (25.9, 258.6)

3900 (26.9, 268.9)

4050 (27.9, 279.2)

4200 (29.0, 289.6)

4350 (30.0, 299.9)

4500 (31.0, 310.3)

4650 (32.1, 320.6)

4800 (33.1, 330.9)

4950 (34.1, 341.3)

5100 (35.2, 351.6)

198 (1.36, 13.6) 151 (1.04, 10.4)

157 (1.08, 10.8)

162 (1.12, 11.2)

167 (1.15, 11.5)

172 (1.19, 11.9)

178 (1.22, 12.2)

183 (1.26, 12.6)

188 (1.30, 13.0)

193 (1.33, 13.3)

199 (1.37, 13.7)

3A4386A 13

Installation

Outlet Pressure psi (MPa, bar)

0 (0, 0)

100 (0.7, 6.9)

200 (1.4, 13.8)

300 (2.1, 20.7)

400 (2.8, 27.6)

500 (3.4, 34.5)

600 (4.1, 41.4)

700 (4.8, 48.3)

800 (5.5, 55.2)

900 (6.2, 62.1)

1000 (6.9, 68.9)

1100 (7.6, 75.8)

1200 (8.3, 82.7)

1300 (9, 89.6)

1400 (9.7, 96.5)

1500 (10.3, 103.4)

1600 (11, 110.3)

1700 (11.7, 117.2)

1800 (12.4, 124.1)

1900 (13.1, 131)

2000 (13.8, 137.9)

2100 (14.5, 144.8)

2200 (15.2, 151.7)

2300 (15.9, 158.6)

2400 (16.5, 165.5)

2500 (17.2, 172.4)

2600 (17.9, 179.3)

2700 (18.6, 186.2)

2800 (19.3, 193.1)

1/2 in. Fluid Plunger Pumps

Minimum Gas Pressure psi (MPa, bar)

1.25 in. Air Motor 1.75 in. Air Motor

50 (0.34, 3.4) 50 (0.34, 3.4)

66 (0.45, 4.5) 50 (0.34, 3.4)

2 in. Air Motor

50 (0.34, 3.4)

82 (0.56, 5.6)

98 (0.67, 6.7)

114 (0.78, 7.8)

130 (0.89, 8.9)

50 (0.34, 3.4)

58 (0.40, 4.0)

66 (0.46, 4.6)

50 (0.34, 3.4)

51 (0.35, 3.5)

146 (1.00, 10.0) 74 (0.51, 5.1)

162 (1.11, 11.1) 83 (0.57, 5.7)

178 (1.23, 12.3) 91 (0.63, 6.3)

194 (1.34, 13.4) 99 (0.68, 6.8)

107 (0.74, 7.4)

115 (0.79, 7.9)

57 (0.39, 3.9)

63 (0.44, 4.4)

69 (0.48, 4.8)

76 (0.52, 5.2)

82 (0.56, 5.6)

88 (0.61, 6.1)

123 (0.85, 8.5) 94 (0.65, 6.5)

131 (0.91, 9.1) 101 (0.69, 6.9)

140 (0.96, 9.6) 107 (0.74, 7.4)

148 (1.02, 10.2) 113 (0.78, 7.8)

156 (1.08, 10.8) 119 (0.82, 8.2)

164 (1.13, 11.3) 126 (0.87, 8.7)

172 (1.19, 11.9) 132 (0.91, 9.1)

180 (1.24, 12.4) 138 (0.95, 9.5)

189 (1.30, 13.0) 144 (1.00, 10.0)

197 (1.36, 13.6) 151 (1.04, 10.4)

157 (1.08, 10.8)

163 (1.12, 11.2)

169 (1.17, 11.7)

176 (1.21, 12.1)

182 (1.25, 12.5)

188 (1.30, 13.0)

194 (1.34, 13.4)

14 3A4386A

Outlet Pressure psi (MPa, bar)

0 (0, 0)

75 (0.5, 5.2)

150 (1, 10.3)

225 (1.6, 15.5)

300 (2.1, 20.7)

375 (2.6, 25.9)

450 (3.1, 31)

525 (3.6, 36.2)

600 (4.1, 41.4)

675 (4.7, 46.5)

750 (5.2, 51.7)

825 (5.7, 56.9)

900 (6.2, 62.1)

975 (6.7, 67.2)

1050 (7.2, 72.4)

1125 (7.8, 77.6)

1200 (8.3, 82.7)

1275 (8.8, 87.9)

1350 (9.3, 93.1)

1425 (9.8, 98.3)

1500 (10.3, 103.4)

1575 (10.9, 108.6)

1650 (11.4, 113.8)

1725 (11.9, 118.9)

1800 (12.4, 124.1)

5/8 in. Fluid Plunger Pumps

Minimum Gas Pressure psi (MPa, bar)

1.25 in. Air Motor 1.75 in. Air Motor

50 (0.34, 3.4) 50 (0.34, 3.4)

68 (0.47, 4.7) 50 (0.34, 3.4)

2 in. Air Motor

50 (0.34, 3.4)

87 (0.60, 6.0)

106 (0.73, 7.3)

125 (0.86, 8.6)

143 (0.99, 9.9)

50 (0.34, 3.4)

54 (0.37, 3.7)

64 (0.44, 4.4)

73 (0.50, 5.0)

50 (0.34, 3.4)

56 (0.39, 3.9)

162 (1.12, 11.2) 83 (0.57, 5.7)

181 (1.25, 12.5) 92 (0.64, 6.4)

200 (1.38, 13.8) 102 (0.70, 7.0)

111 (0.77, 7.7)

121 (0.83, 8.3)

63 (0.44, 4.4)

71 (0.49, 4.9)

78 (0.54, 5.4)

85 (0.59, 5.9)

93 (0.64, 6.4)

131 (0.90, 9.0) 100 (0.69, 6.9)

140 (0.97, 9.7) 107 (0.74, 7.4)

150 (1.03, 10.3) 115 (0.79, 7.9)

159 (1.10, 11.0) 122 (0.84, 8.4)

169 (1.16, 11.6) 129 (0.89, 8.9)

178 (1.23, 12.3) 137 (0.94, 9.4)

188 (1.30, 13.0) 144 (0.99, 9.9)

198 (1.36, 13.6) 151 (1.04, 10.4)

159 (1.09, 10.9)

166 (1.14, 11.4)

173 (1.19, 11.9)

181 (1.24, 12.4)

188 (1.30, 13.0)

195 (1.35, 13.5)

Installation

3A4386A 15

Installation

3/4 in. Fluid Plunger Pumps

Outlet Pressure psi (MPa, bar)

Minimum Gas Pressure psi (MPa, bar)

1.25 in. Air Motor 1.75 in. Air Motor 2 in. Air Motor

0 (0, 0)

50 (0.3, 3.4)

50 (0.34, 3.4)

68 (0.47, 4.7)

100 (0.7, 6.9)

150 (1, 10.3)

86 (0.59, 5.9)

104 (0.72, 7.2)

200 (1.4, 13.8) 122 (0.84, 8.4)

250 (1.7, 17.2) 140 (0.96, 9.6)

50 (0.34, 3.4)

44 (0.30, 3.0)

53 (0.36, 3.6)

62 (0.43, 4.3)

71 (0.49, 4.9)

50 (0.34, 3.4)

41 (0.28, 2.8)

48 (0.33, 3.3)

55 (0.38, 3.8)

300 (2.1, 20.7) 158 (1.09, 10.9) 80 (0.55, 5.5)

350 (2.4, 24.1) 176 (1.21, 12.1) 90 (0.62, 6.2)

400 (2.8, 27.6) 194 (1.34, 13.4) 99 (0.68, 6.8)

450 (3.1, 31) 108 (0.74, 7.4)

500 (3.4, 34.5)

550 (3.8, 37.9)

600 (4.1, 41.4)

650 (4.5, 44.8)

117 (0.81, 8.1)

126 (0.87, 8.7)

62 (0.42, 4.2)

69 (0.47, 4.7)

76 (0.52, 5.2)

83 (0.57, 5.7)

90 (0.62, 6.2)

97 (0.67, 6.7)

136 (0.93, 9.3) 104 (0.72, 7.2)

145 (1.00, 10.0) 111 (0.76, 7.6)

700 (4.8, 48.3)

750 (5.2, 51.7)

800 (5.5, 55.2)

850 (5.9, 58.6)

900 (6.2, 62.1)

950 (6.6, 65.5)

1000 (6.9, 68.9)

1050 (7.2, 72.4)

1100 (7.6, 75.8)

1150 (7.9, 79.3)

1200 (8.3, 82.7)

1250 (8.6, 86.2)

154 (1.06, 10.6) 118 (0.81, 8.1)

163 (1.12, 11.2) 125 (0.86, 8.6)

172 (1.19, 11.9) 132 (0.91, 9.1)

181 (1.25, 12.5) 139 (0.96, 9.6)

191 (1.31, 13.1) 146 (1.01, 10.1)

200 (1.38, 13.8) 153 (1.05, 10.5)

160 (1.10, 11.0)

167 (1.15, 11.5)

174 (1.20, 12.0)

181 (1.25, 12.5)

188 (1.30, 13.0)

195 (1.35, 13.5)

16 3A4386A

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

sure. (Use a hex wrench for PCI-xxx-xxH pumps.

See

Configuration Number Matrix , page 4.)

5. Slowly disconnect fluid lines (K & P) from check valves (L & M).

6. Reconnect timing valve (22).

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 air lines (A, K, & P) using shutoff valves (H).

2. Disconnect air supply lines (A).

3. Disconnect timing valve (22) to vent internal trapped pressure.

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 inlet to the supply source of the flushing fluid.

3. Connect outlet to a waste reservoir.

4. Run the pump until the dispensed fluid is predominately flushing fluid.

5. Follow the Pressure Relief Procedure .

F IG . 3 Disconnect timing valve

4. Use a flathead screwdriver to turn the prime/bleed valve (20) slowly counter-clockwise to relieve pres-

3A4386A 17

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 Configuration Number Matrix , page 4.

3. Turn the timing valve knob (122) located on the timing valve (22) counter-clockwise slowly. This will turn the pneumatic supply on to the pump and begin cycling.

4. Keep the pump cycle rate less than 1 cycle every 3 seconds. The pump is primed when discharge from the prime valve (20) has transitioned from air, to bubbly liquid chemical, to pure liquid chemical.

5. Close the prime valve (20) tightly and verify that fluid has stopped draining from the port.

NOTE: PCI-xxx-xxH pumps feature a one-piece valve

(19) that requires a hex wrench turn.

18 3A4386A

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 gallons per day (GPD) and liters per day (LPD).

122

Full (1”, 25 mm)

1/2 stroke

(1/2”, 13 mm)

3/4 stroke

(3/4”, 19 mm)

1/4 stroke

(1/4”, 6 mm)

F IG . 4 Calibrate Chemical Dosage

2. Follow the instructions provided with your calibration gauge in conjunction with the

Baseline Chemical

Dosage Settings on page 20.

3. Adjust the timing valve (22) accordingly after the test is performed. Turning the knob (122) counter-clockwise will increase the pump flow rate, while turning the knob clockwise will decrease the flow.

4. Repeat the test procedure to verify your changes.

Repeat as necessary until the desired flow rate is achieved.

F IG . 5 Stroke adjustment settings

• To increase the stroke length, turn the stroke adjustment knob (21) counter-clockwise.

• To decrease the stroke length, turn the stroke adjustment knob (21) clockwise.

3A4386A 19

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)

CPM Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke

0.3 (1.1)

0.6 (2.2)

0.9 (3.3)

1.1 (4.3)

1.4 (5.4)

1.7 (6.5)

2.0 (7.6)

2.3 (8.7)

2.6 (9.8)

50 2.9 (10.9)

55 3.2 (11.9)

60 3.4 (13.0)

0.2 (0.8)

0.4 (1.6)

0.6 (2.4)

0.9 (3.3)

1.1 (4.1)

1.3 (4.9)

1.5 (5.7)

1.7 (6.5)

1.9 (7.3)

2.2 (8.1)

2.4 (9.0)

2.6 (9.8)

0.1 (0.5)

0.3 (1.1)

0.4 (1.6)

0.6 (2.2)

0.7 (2.7)

0.9 (3.3)

1.0 (3.8)

1.1 (4.3)

1.3 (4.9)

1.4 (5.4)

1.6 (6.0)

1.7 (6.5)

0.1 (0.3)

0.1 (0.5)

0.2 (0.8)

0.3 (1.1)

0.4 (1.4)

0.4 (1.6)

0.5 (1.9)

0.6 (2.2)

0.6 (2.4)

0.7 (2.7)

0.8 (3.0)

0.9 (3.3)

0.6 (2.4)

1.3 (4.9)

1.9 (7.3)

2.6 (9.8)

3.2 (12.2)

3.9 (14.7)

4.5 (17.1)

5.2 (19.5)

5.8 (22.0)

6.5 (24.4)

7.1 (26.9)

7.7 (29.3)

0.5 (1.8)

1.0 (3.7)

1.5 (5.5)

1.9 (7.3)

2.4 (9.2)

2.9 (11)

3.4 (12.8)

3.9 (14.7)

4.4 (16.5)

4.8 (18.3)

5.3 (20.2)

5.8 (22.0)

0.3 (1.2)

0.6 (2.4)

1.0 (3.7)

1.3 (4.9)

1.6 (6.1)

1.9 (7.3)

2.3 (8.6)

2.6 (9.8)

2.9 (11.0)

3.2 (12.2)

3.6 (13.4)

3.9 (14.7)

0.2 (0.6)

0.3 (1.2)

0.5 (1.8)

0.6 (2.4)

0.8 (3.1)

1.0 (3.7)

1.1 (4.3)

1.3 (4.9)

1.5 (5.5)

1.6 (6.1)

1.8 (6.7)

1.9 (7.3)

1/4 in. Fluid Plunger Pumps 3/8 in. Fluid Plunger Pumps

GPD (LPD) GPD (LPD)

CPM Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke

5 1.4 (5.3)

10 2.8 (10.7)

1.1 (4.0)

2.1 (8.0)

0.7 (2.7)

1.4 (5.3)

15 4.2 (16.0) 3.2 (12.0) 2.1 (8.0)

20 5.6 (21.3) 4.2 (16.0) 2.8 (10.7)

0.4 (1.3)

0.7 (2.7)

1.1 (4.0)

1.4 (5.3)

3.2 (12.2)

6.5 (24.5)

9.7 (36.7)

2.4 (9.2)

4.9 (18.4)

7.3 (27.6)

12.9 (49.0) 9.7 (36.7)

1.6 (6.1)

3.2 (12.2)

4.9 (18.4)

6.5 (24.5)

0.8 (3.1)

1.6 (6.1)

2.4 (9.2)

3.2 (12.2)

25 7.0 (26.6) 5.3 (20.0) 3.5 (13.3)

30 8.4 (32.0) 6.3 (24.0) 4.2 (16.0)

1.8 (6.7)

2.1 (8.0)

16.2 (61.2) 12.1 (45.9) 8.1 (30.6)

19.4 (73.5) 14.6 (55.1) 9.7 (36.7)

4.0 (15.3)

4.9 (18.4)

35 9.9 (37.3) 7.4 (28.0) 4.9 (18.6) 2.5 (9.3) 22.7 (85.7) 17.0 (64.3) 11.3 (42.9) 5.7 (21.4)

40 11.3 (42.6) 8.4 (32.0) 5.6 (21.3) 2.8 (10.7) 25.9 (98.0) 19.4 (73.5) 12.9 (49.0) 6.5 (24.5)

45 12.7 (48.0) 9.5 (36.0) 6.3 (24.0) 3.2 (12.0) 29.1 (110.2) 21.8 (82.7) 14.6 (55.1) 7.3 (27.6)

50 14.1 (53.3) 10.6 (40.0) 7.0 (26.6) 3.5 (13.3) 32.4 (122.5) 24.3 (91.9) 16.2 (61.2) 8.1 (30.6)

55 15.5 (58.6) 11.6 (44.0) 7.7 (29.3) 3.9 (14.7) 35.6 (134.7) 26.7 (101.1) 17.8 (67.4) 8.9 (33.7)

60 16.9 (63.9) 12.7 (48.0) 8.4 (32.0) 4.2 (16.0) 38.8 (147.0) 29.1 (110.2) 19.4 (73.5) 9.7 (36.7)

20 3A4386A

1/2 in. Fluid Plunger Pumps 5/8 in. Fluid Plunger Pumps

GPD (LPD) GPD (LPD)

CPM 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)

9.8 (37.1) 7.3 (27.8) 4.9 (18.5)

1.2 (4.6) 7.6 (29.0) 5.7 (21.7) 3.8 (14.5)

2.4 (9.3) 15.3 (57.9) 11.5 (43.4) 7.6 (29.0)

1.9 (7.2)

3.8 (14.5)

15 14.7 (55.6) 11.0 (41.7) 7.3 (27.8) 3.7 (13.9) 22.9 (86.9) 17.2 (65.2) 11.5 (43.4) 5.7 (21.7)

20 19.6 (74.1) 14.7 (55.6) 9.8 (37.1) 4.9 (18.5) 30.6 (115.8) 22.9 (86.9) 15.3 (57.9) 7.6 (29.0)

25 24.5 (92.7) 18.4 (69.5) 12.2 (46.3) 6.1 (23.2) 38.2 (144.8) 28.7 (108.6) 19.1 (72.4) 9.6 (36.2)

30 29.4 (111.2) 22.0 (83.4) 14.7 (55.6) 7.3 (27.8) 45.9 (173.7) 34.4 (130.3) 22.9 (86.9) 11.5 (43.4)

35 34.3 (129.7) 25.7 (97.3) 17.1 (64.9) 8.6 (32.4) 53.5 (202.7) 40.2 (152.0) 26.8 (101.4) 13.4 (50.7)

40 39.2 (148.3) 29.4 (111.2) 19.6 (74.1) 9.8 (37.1) 61.2 (231.7) 45.9 (173.7) 30.6 (115.8) 15.3 (57.9)

45 44.1 (166.8) 33.0 (125.1) 22.0 (83.4) 11.0 (41.7) 68.8 (260.6) 51.6 (195.5) 34.4 (130.3) 17.2 (65.2)

50 49.0 (185.3) 36.7 (139.0) 24.5 (92.7) 12.2 (46.3) 76.5 (289.6) 57.4 (217.2) 38.2 (144.8) 19.1 (72.4)

55 53.9 (203.9) 40.4 (152.9) 26.9 (101.9) 13.5 (51.0) 84.1 (318.5) 63.1 (238.9) 42.1 (159.3) 21.0 (79.6)

60 58.8 (222.4) 44.1 (166.8) 29.4 (111.2) 14.7 (55.6) 91.8 (347.5) 68.8 (260.6) 45.9 (173.7) 22.9 (86.9)

3/4 in. Fluid Plunger Pumps

GPD (LPD)

CPM Full Stroke 3/4 Stroke 1/2 Stroke 1/4 Stroke

5 11.7 (44.3) 8.8 (33.2) 5.9 (22.2) 2.9 (11.1)

10 23.4 (88.6) 17.6 (66.5) 11.7 (44.3) 5.9 (22.2)

15 35.1 (132.9) 26.3 (99.7) 17.6 (66.5) 8.8 (33.2)

20 46.8 (177.2) 35.1 (132.9) 23.4 (88.6) 11.7 (44.3)

25 58.5 (221.5) 43.9 (166.1) 29.3 (110.8) 14.6 (55.4)

30 70.2 (265.8) 52.7 (199.4) 35.1 (132.9) 17.6 (66.5)

35 81.9 (310.1) 61.4 (232.6) 41.0 (155.1) 20.5 (77.5)

40 93.6 (354.4) 70.2 (265.8) 46.8 (177.2) 23.4 (88.6)

45 105.3 (398.8) 79.0 (299.1) 52.7 (199.4) 26.3 (99.7)

50 117.0 (443.1) 87.8 (332.3) 58.5 (221.5) 29.3 (110.8)

55 128.7 (487.4) 96.6 (365.5) 64.4 (243.7) 32.2 (121.8)

60 140.5 (531.7)105.3 (398.8) 70.2 (265.8) 35.1 (132.9)

Operation

3A4386A 21

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

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 1/16th 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.

22 3A4386A

Troubleshooting

1. Follow Pressure Relief Procedure , page 17,

before checking or repairing pump.

2. Check all possible problems and causes before disassembling pump.

Problem

Air bubbles in fluid

Timing valve not cycling

Timing valve cycling, but pump not stroking

Fluid leaking

Pump stroking, but no fluid moving

Cause Solution

Suction line is loose

Debris in timing valve

Worn timing valve seals

Fluid back pressure too high

Tighten

Clean or rebuild timing valve

Rebuild timing valve

Verify pump is sized to back pressure. Check inlet gas pressure.

Packings too tight

Loose fittings

Worn seals

Loosen or replace packing

Tighten fittings

Adjust packing (if leak persists, replace packing)

Air in pump Prime pump

Worn or damaged check valve seals Rebuild inlet and outlet check valves

3A4386A 23

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

Disconnect Pump

1. Follow the Pressure Relief Procedure , page 17.

2. Expose the packing nut (16) by rotating the dust shield (12) as you pull downward.

4. Remove the fluid cylinder (13) from the middle sec-

tion. See F IG . 7

F IG . 6 Expose and loosen packing nut

3. Loosen, but do not remove, the packing nut (16).

F IG . 7 Remove fluid cylinder

5. Carefully slide the fluid cylinder (13) away from the air motor housing (1), taking great care to keep the fluid plunger (5) from contacting any metal surfaces.

The fluid plunger (5) will stay attached to the air

motor during repair. See F IG

. 7 and F IG . 8.

24 3A4386A

Repair

Pump Repair

1. Remove packing nut (16) from fluid cylinder (13).

2. Carefully remove bearings (14) and packing (15) from the fluid cylinder (13).

3. Replace packing (15) and bearings (14), if necessary. Lubricate prior to reassembly.

Tan

Seal lips facing down

F IG . 8 Remove parts from fluid cylinder

Gray

Black

Tan

F IG . 9 Packing (15) detailed view

4. Reinsert the packing nut (16), packing (15), and bearings (14) into the fluid cylinder (13). Tighten hand tight and back off ½ of a turn to prevent damage to packing (15) during reassembly.

3A4386A 25

Repair

Reconnect Fluid Cylinder

1. Carefully guide the fluid plunger (5) into the packing nut (16) and through the packing (15) as the threads on the fluid cylinder (13) are brought closer to the air motor housing (1).

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 torque of 5 in-lbs (0.6 N•m).

F IG . 10 Reconnect fluid cylinder

2. Tighten fluid cylinder (13) to 30 ft-lbs (40 N•m).

F IG . 11 Tighten packing nut

NOTE: If a torque wrench is not present in the field, an alternative method is to tighten the packing nut (16) finger tight through the window, then use a small punch or hex wrench to further tighten by approximately 10 degrees.

NOTE: If the packing nut (16) is over-tightened, the pump may not complete a full stroke and seal life will be compromised.

26 3A4386A

Repair

Remove Air Piston and Fluid Plunger

Assembly

1. Follow the

Pressure Relief Procedure , page 17.

2. Expose the packing nut (16) by rotating the dust shield (12) as you pull downward.

NOTE: The upper air motor is under light spring tension; therefore, it is necessary to hold downward pressure on the air piston cylinder (8) as the set screws (10) are loosened.

F IG . 12 Expose and loosen packing nut

3. Loosen, but do not remove, the packing nut (16).

4. Remove the air piston cylinder (8) from the air motor housing (1) by loosening the three set screws (10) so they are almost completely removed.

F IG . 13 Remove air piston cylinder and components

5. Carefully slide the air piston cylinder (8) away from the air motor housing (1), taking great care to keep the fluid plunger (5) from contacting any metal surfaces. The fluid plunger (5) may come out with the air cylinder (8) during removal and can stay connected to the air piston (6) during repair.

6. Remove the pump piston (6) and plunger (5) assembly from the air cylinder (8).

7. Inspect the air piston seal, fluid plunger surfaces, and return spring (4), and replace as necessary.

See

Replace Air Motor Seal on page 28.

3A4386A 27

Repair

Replace Air Motor Seal

1. Remove the air piston o-ring (7) with a plastic pick from the air piston (6), taking great care not to scratch any of the groove surfaces on the piston.

Air Piston, Fluid Plunger, and Upper

Cylinder Reassembly

1. Ensure that all parts are cleaned before reassembly.

2. Apply a thin coat of grease to the inside of the air piston cylinder (8) and piston o-ring (7), and insert the piston (6) and plunger (5) assembly.

Wrench Flats

F IG . 14 Air piston and fluid plunger

2. Clean any debris or buildup from the piston (6) and plunger (5) assembly, as well as the air piston cylinder (8) and return spring (4).

3. Apply a liberal amount of assembly grease to the new air piston o-ring (7), and slide it over the piston

(6) and into the groove.

Fluid Plunger Replacement

1. Use the wrench flats (see F IG . 14) located on the

piston (6) and plunger (5) to loosen and remove the plunger from the piston.

2. Clean the dried thread locker from the internal threads of the piston (6) as much as possible.

3. Apply a thin bead of high strength thread locker to the external threads of the new plunger (5).

4. Install the new plunger and tighten to 75 in-lbs

(8.5 N•m).

5. Allow thread locker to dry for 60 minutes before operating the pump.

F IG . 15 Reassemble air piston

3. Apply a light coat of assembly grease to the end of the plunger (5), making certain the tip is fully coated.

4. Place the return spring (4) inside the piston stop (2).

5. Reconnect the air piston cylinder (8) to the air motor housing (1). Carefully guide the fluid plunger (5) into the packing nut (16) and through the packing as the air piston cylinder is brought closer to the air motor housing. Light pressure is required to keep the air piston cylinder in place. Ensure the cylinder (8) is

28 3A4386A

Repair pushed down to the hard stop so that the set screws

(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

(1.7 N•m), then loosen and tighten again it to a final torque of 5 in-lbs (0.6 N•m).

NOTE: If a torque wrench is not present in the field, an alternative method is to tighten the nut finger tight through the window, then use a small punch or hex wrench to further tighten by approximately 10 degrees.

Check Valves

Inlet Check Valve Repair (all models except

PCI-xxx-xxH)

1. Follow the Pressure Relief Procedure , page 17.

2. Remove the inlet check valve assembly (17).

16 17a

17b

17c

F IG . 16 Tighten packing nut

NOTE: If the packing nut (16) is over-tightened, the pump may not complete a full stroke and seal life will be compromised.

F IG . 17 Inlet check valve assembly

3. Remove the retaining nut (17a) and piston (17b).

4. Remove the piston o-ring (17c).

5. Inspect parts for wear, replace as needed.

6. Install the piston o-ring (17c), piston (17b), and retaining nut (17a).

7. Reconnect the inlet check valve assembly (17).

3A4386A 29

Repair

Inlet Check Valve Repair (models

PCI-xxx-xxH only)

1. Follow the Pressure Relief Procedure , page 17.

2. Remove the inlet check valve assembly (17).

Outlet Check Valve Repair (all models except PCI-xxx-xxH)

1. Follow the

Pressure Relief Procedure , page 17.

2. Remove the outlet check valve assembly (18).

18a

18b

18c

18d

17b

17c

17d

17e

F IG . 18 Inlet check valve assembly

3. Separate the front housing (17d) from the back housing (17e).

4. Remove the piston (17b) and the piston o-ring (17c).

5. Inspect parts for wear, replace as needed.

6. Install the piston o-ring (17c) and piston (17b) in the back housing (17e).

7. Reattach the front housing (17d) to the back housing (17e).

8. Reconnect the inlet check valve assembly (17).

F IG . 19 Outlet check valve assembly

3. Remove the retaining nut (18a), spring (18b), and piston (18c).

4. Remove the piston o-ring (18d).

5. Inspect parts for wear, replace as needed.

6. Install the piston o-ring (18d), piston (18c), spring (18b), and retaining nut (18a).

7. Reconnect the outlet check valve assembly (18).

30 3A4386A

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).

18f

18b

18c

18d

18e

F IG . 20 Outlet check valve assembly

3. Separate the front housing (18e) from the back housing (18f).

4. Remove the spring (18b), piston (18c), and piston o-ring (18d).

5. Inspect parts for wear, replace as needed.

6. Install the piston o-ring (18d), piston (18c), and spring (18b).

7. Reattach the back housing (18f) to the front housing (18e)

8. Reconnect the outlet check valve assembly (18).

3A4386A 31

Repair

Timing Valve

Timing Valve Repair

1. Follow the Pressure Relief Procedure , page 17.

2. Remove the spring retainer (112) from the bottom of the timing valve. Inspect the sealing o-ring (114) and replace as necessary.

110

106

5. Pull the spool (103) out of the lower housing (101).

Inspect and replace as necessary.

103

125

102

130

102

130

101

115

114

111

112

F IG . 21 Separate upper and lower housings

3. Remove the spool return spring (115), inspect and replace if necessary.

4. Remove the two screws (111) to separate the two halves of the timing valve (101 & 110). Inspect the three face seal o-rings (106) and replace as necessary.

F IG . 22 Remove timing valve spool

6. Remove all of the seal cartridge components by hooking the radial ports with a plastic pick. Take care not to scratch or damage any of the metal or plastic parts. Sealing can be compromised.

32 3A4386A

Repair

7. The stack of seal cartridge components includes four sets of seals (105) and o-rings (124). Inspect and replace these as necessary. The repair parts from Graco come as a piston assembly with the seals factory installed.

124

105

102

105

124

F IG . 23 Seal cartridge

8. Remove the drive piston (107) from the upper housing (110) with a needle-nose pliers.

NOTE: Keep the seal (108) and piston (107) together.

10. Remove the control knob (122) by loosening the two hex set screws (123) with a 1/16” hex key wrench.

123

122

120

119

110

117

118

110

108

107

F IG . 24 Remove timing valve piston

9. Inspect the seal (108) and piston (107), and replace if necessary. The repair parts from Graco come as a piston assembly with the seals factory installed.

F IG . 25 Remove timing valve knob assembly

11. Remove the knob control spring (120) and the retaining ring (119).

12. Remove the needle valve (117) by unscrewing it from the housing (110). Inspect the sealing o-ring

(118) and replace as necessary.

13. Clean and inspect all parts before reassembly.

14. Apply a thin coat of grease to the o-ring (118) and reinstall the needle valve (117). Tighten needle finger tight.

15. Install the retaining ring (119) and knob control spring (120).

3A4386A 33

Repair

16. Place the timing valve knob (122) over the needle valve (117), with the “0” lined up with the marker on the label (121). Tighten the hex set screws (123).

121

Marker the housing lead-in (130) to ease installation and ensure that the seals are not damaged.

103

Lead-in

125

102 (w/105 & 124)

122 130

F IG . 26 Align timing valve knob with label

17. Reinstall the drive piston (107) in the bottom of the upper housing (110).

NOTE: Do not apply grease to the dynamic seals (105 &

108). They are designed to operate without grease.

18. Reinstall the seal cartridges (see F IG . 23 for the

order of the seals (105) and o-rings (124)) into the lower housing (101). Apply a thin coat of grease on

F IG . 27 Reinstall seal cartridges and spool

19. Reinstall the spool (103) carefully through the seal cartridge components.

34 3A4386A

Repair

20. Connect the upper and lower housings by lining up the dowel pins (113) in lower housing (101) with the receiving holes in the upper housing (110). Tighten the screws (111).

Final Reassembly

1. After all inspections and repairs are completed, reconnect all fluid lines.

2. Reconnect the timing valve (22) onto the pump assembly.

110

106

113

115

114

101

111

112

F IG . 28 Reconnect upper and lower housings

21. Insert the spring (115) in the bottom of the lower housing (101) and reinstall the spring retainer (112).

F IG . 29 Reconnect timing valve

3. Reconnect all pneumatic lines.

Prime the Pump , on page 18.

Calibrate Chemical Dosage , on page 19, to test for

proper pump operation. The calibration test will ensure the desired pump stroke is achieved, as well as, verify proper operation of the check valves.

6. Compare results from calibration test with previous notes or the recommended pump settings in

Stroke

Adjustment , on page 19.

3A4386A 35

Parts

Python Pneumatic Pump

PCI-200-13S-SA-A shown

25 

2 18

13 20

27 

3A4386A

Parts

Python Pneumatic Pump Parts List

Ref. Part Description

B32163 Air motor housing, for 1/2” and smaller fluid plungers

B32164 Air motor housing, for 5/8” and larger fluid plungers

B32165 Air piston stop, for 1.25” air piston

B32166 Air piston stop, for 1.75” and

2.0” air pistons

See

Table 1,

pg 38

See

Table 1,

pg 38

Fluid plunger wiper, included with fluid plunger spring (ref. 4)

Fluid plunger spring

See

Table 2,

pg 38

Fluid plunger

B32172 Air piston, 1.25”

B32173 Air piston, 1.75”

B32174 Air piston, 2.0”

B32034 O-ring packing, 1.25”, included with air piston (ref. 6)

B32035 O-ring packing, 1.75”, included with air piston (ref. 6)

B32036 O-ring packing, 2.0”, included with air piston (ref. 6)

B32205 Air piston cylinder, 1.25”

B32206 Air piston cylinder, 1.75”

B32207 Air piston cylinder, 2.00”

B32163 Retaining ring, included with air motor housing (ref. 1)

10 B32175 Set screw, included with air motor housing (ref. 1)

11 B32176 O-ring packing, for 1/2” and smaller fluid plungers; included with dust shield (ref. 12)

B32177 O-ring packing, for 5/8” and larger fluid plungers; included with dust shield (ref. 12)

12 B32178 Dust shield, for 1/2” and smaller fluid plungers

B32179 Dust shield, for 5/8” and larger fluid plungers

Qty.

Ref. Part Description

13 See

Table 3,

pg 38

14 See

Table 4,

pg 38

15 See

Table 4,

pg 38

16 See

Table 5,

pg 39

Fluid cylinder

Plunger bearings, included with packing (ref. 15)

Packing

Packing nut

17 See

Table 6,

pg 39

18 See

Table 7,

pg 39

Inlet valve check

Outlet valve check

19 B32191 Priming bleed valve housing, standard pressure (1/4”, 3/8”,

1/2”, 5/8”, & 3/4” plungers)

B32250 Priming bleed valve housing, high pressure (1/8” & 3/16” plungers)

20* B32192 Priming bleed valve; included with priming bleed valve housing (ref. 19)

21 B32192 Pump stroke adjuster

22 B32069

Spool timing valve, see pg 41

25  17G319 Warning label, hanging

27  17G320 Warning label, adhesive

33 -Cap plug

Qty.

 Replacement Danger and Warning labels, tags, and cards are available at no cost.

* Not included with PCI-xxx-xxH configurations.

3A4386A 37

Parts

Table 1: Fluid Plunger Springs (ref. 4), including Plunger Wipers (ref. 3)

Ref

1/8 in.

B32167

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32167 B32167 B32168 B32169 B32170

Table 2: Fluid Plungers (ref. 5)

Ref

1/8 in.

B32066

B32139

B32241

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32067

B32140

B32242

17-4 Stainless Steel Fluid Plungers

B32068 B32135 B32136

Chromex-Coated Fluid Plungers

B32141 B32142 B32143

Ceramic-Coated Fluid Plungers

B32243 B32244 B32245

B32137

B32144

B32246

Table 3: Fluid Cylinders (ref. 16)

Ref

1/8 in.

B32180

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32181 B32182 B32183 B32184 B32185

Table 4: Packing Stacks (ref. 15), including Plunger Bearings (ref. 14)

Ref

1/8 in.

B32115

B32116

B32117

B32118

B32033

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32119

B32120

B32121

B32122

B32041

B32094

B32095

B32096

B32097

B32042

FKM

B32098

FKMETP

B32099

HNBR

B32100

FFKM

B32101

AFLAS

B32043

B32102

B32103

B32104

B32105

B32044

B32123

B32124

B32125

B32126

B32085

3/4 in.

B32171

Qty.

3/4 in.

B32138

Qty.

B32145

B32247

3/4 in.

B32180

Qty.

3/4 in.

B32127

Qty.

B32128 1

B32129 1

B32130

B32086

38 3A4386A

Parts

Table 5: Packing Nuts (ref. 16)

Ref

1/8 in.

B32187

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32187 B32187 B32188 B32203 B32190

Table 6: Inlet Valve Check (ref. 17)

Ref

1/8 in.

B32226

B32228

B32230

B32232

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32226

B32228

B32230

B32232

B32216

B32218

B32220

B32222

FKM

B32024

FKMETP

B32026

HNBR

B32113

FFKM

B32028

B32024

B32026

B32113

B32028

B32024

B32026

B32113

B32028

Table 7: Outlet Valve Check (ref. 18)

Ref

1/8 in.

B32227

B32229

B32231

B32233

3/16 in.

Part Numbers by Fluid Plunger Size Diameter

1/4 in. 3/8 in.

1/2 in.

5/8 in.

B32227

B32229

B32231

B32233

B32217

B32219

B32221

B32223

FKM

B32025

FKMETP

B32027

HNBR

B32114

FFKM

B32029

B32025

B32027

B32114

B32029

B32025

B32027

B32114

B32029

3/4 in.

B32190

Qty.

3/4 in.

Qty.

B32024

B32026

B32113

B32028

3/4 in.

Qty.

B32025

B32027

B32114

B32029

3A4386A 39

Parts

Python Timing Valve Assembly

B32069

122

123‡

120

119

117

118

110

108*

107*

104*

103*

125*

105*

124*

102*

105*

124*

130*

105*

124*

102*

105*

124*

129*

113

106*

101

109

114

115

112

111 ‡

116

40 3A4386A

Parts

Timing Valve Assembly (B32069) Parts List

Ref.

Part Description

101 B32193 Lower Housing

102* -Seal Cartridge

103* --

104* --

Spool

Ball, 316 stainless steel; included with lower and upper housing (ref. 101 & 110)

105* --

106* --

Seal, Spool

O-ring; included with lower housing (ref. 101)

107*

108*

109

Piston

Seal, Piston

Pin; included with spring retainer (ref. 112)

110 B32194 Upper Housing

111‡ -Screw, 316 SST, 1/4-20

112 B32196 Spring Retainer

113 -Dowel Pin; included with lower housing (ref. 101)

114 -O-ring; included with spring retainer (ref. 112)

115 B32197 Spool Return Spring

116 -Nipple Fitting, 1/8 NPT; included with lower housing

(ref. 101)

117 B32199 Timing Valve Needle

118 -O-ring; included with timing valve needle (ref. 117)

Qty.

Ref.

119

120

122

Part

123‡ --

Description

Internal Ring, Stainless Steel; included with timing valve needle (ref. 117)

Knob Spring; included with timing valve needle (ref. 117)

Needle Knob; included with timing valve needle (ref. 117)

Set Screw; included with timing valve needle (ref. 117)

O-ring

Seal Cartridge Retainer

Grease Lubricant (not shown)

Pipe Sealant (not shown)

Bottom Seal Retainer

Cartridge Spacer

Qty.

124* --

125* --

126 --

127 --

129* --

130* --

* Parts included in Kit B32153 (purchase separately).

‡ Parts included in Kit B32195 (purchase separately).

3A4386A 41

Kits and Accessories

Additional Kits & Accessories

Part No.

Description

B32045 225-750 PSI Pressure Relief Valve Kit

(Adjustable)

B32046 750-1500 PSI Pressure Relief Valve Kit

(Adjustable)

B32047 1500-2250 PSI Pressure Relief Valve Kit

(Adjustable)

B32048 2250-3000 PSI Pressure Relief Valve Kit

(Adjustable)

B32049 3000-4000 PSI Pressure Relief Valve Kit

(Adjustable)

B32050 4000-5000 PSI Pressure Relief Valve Kit

(Adjustable)

B32051 5000-6000 PSI Pressure Relief Valve Kit

(Adjustable)

B32088 SST Calibration Column Kit

B32089 SST Manifold Assembly Kit

B32157 316 SST Ball Valve Kit, 3/4” NPT(F)

B32158 Fluid Filter 6000 PSI

B32159 Fluid Filter 10000 PSI

B32160 Float Switch

B32162 1/4" NPT(F) X 1/4" NPT(F) Check Kit

B32038 FKM Large (3/8” - 3/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32039 FKM ETP Large (3/8” - 3/4”) Inlet and Outlet Check Valve Repair Kit (includes a spring and piston o-rings)

B32040 FFKM Large (3/8” - 3/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32111 HNBR Large (3/8” - 3/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32224 FKM Small (1/8” - 1/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32225 FKM ETP Small (1/8” - 1/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32235 FFKM Small (1/8” - 1/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32234 HNBR Small (1/8” - 1/4”) Inlet and Outlet

Check Valve Repair Kit (includes a spring and piston o-rings)

B32240 HF4 to 1/4” NPT(F) Adapter; 10,000 psi

(1/8” - 3/16” plungers)

42 3A4386A

Dimensions

Python Pump Dimensions

Dimensions

F IG . 30 Python Pump Dimensions

13.26 in.

(33.7 cm)

5.3 in.

(13.5 cm)

2.34 in.

(5.9 cm)

2.3 in.

(5.8 cm)

9.125 in.

(23.2 cm)

3A4386A 43

Performance Charts

1 1/4” Air Motors (PCI-125)

1/8” Plunger (PCI-125-13)

GPD

(LPD)

4.5

(17.0)

4.0

(15.1)

3.5

(13.3)

3.0

(11.4)

2.5

(9.5)

2.0

(7.6)

1.5

(5.7)

1.0

(3.8)

0.5

(1.9)

A B C D

2000

(13.79)

(137.9)

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

8000

(55.16)

(551.6)

Outlet Pressure - PSI (MPa, Bar)

10000

(68.95)

(689.5)

F IG . 31

12000

(82.74)

(827.4)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

44 3A4386A

Performance Charts

3/16” Plunger (PCI-125-19)

(45.4)

(37.9)

GPD

(LPD)

(30.3)

(22.7)

(15.2)

(7.6)

1000

(6.89)

(68.9)

B C D

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

2000

(13.79)

(137.9)

3000

(20.68)

(206.8)

4000

(27.58)

(275.8)

5000

(34.47)

(344.7)

Outlet Pressure - PSI (MPa, Bar)

6000

(41.37)

(413.7)

7000

(48.26)

(482.6)

F IG . 32

1/4” Plunger (PCI-125-25)

GPD

(LPD)

(68.1)

(60.6)

(53.0)

(45.4)

(37.9)

(30.3)

(22.7)

(15.2)

(7.6)

500

(3.45)

(34.5)

B C D

1000

(6.89)

(68.9)

1500

(10.34)

(103.4)

2000

(13.79)

(137.9)

2500

(17.24)

(172.4)

Outlet Pressure - PSI (MPa, Bar)

3000

(20.68)

(206.8)

3500

(24.13)

(241.3)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

F IG . 33

3A4386A 45

Performance Charts

3/8” Plunger (PCI-125-38)

GPD

(LPD)

(170)

(151)

(133)

(114)

(95)

(76)

(57)

(38)

(19)

A B C D

F IG . 34

1/2” Plunger (PCI-125-50)

200

(1.38)

(13.8)

400

(2.76)

(27.6)

600

(4.14)

(41.4)

800

(5.52)

(55.2)

1000

(6.90)

(69.0)

1200

(8.27)

(82.7)

Outlet Pressure - PSI (MPa, Bar)

1400

(9.65)

(96.5)

1600

(11.03)

(110.3)

1800

(12.41)

(124.1)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

(303)

(265)

(227)

GPD

(LPD)

(189)

(151)

(114)

(76)

(38)

A B C D

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

100

(0.69)

(6.9)

200

(1.38)

(13.8)

300

(2.07)

(20.7)

400

(2.76)

(27.6)

500

(3.45)

(34.5)

600

(4.14)

(41.4)

Outlet Pressure - PSI (MPa, Bar)

700

(4.83)

(48.3)

800

(5.52)

(55.2)

900

(6.21)

(62.1)

F IG . 35

46 3A4386A

Performance Charts

5/8” Plunger (PCI-125-63)

120

(454)

100

(379)

GPD

(LPD)

(303)

(227)

(151)

(76)

A B C D

100

(0.69)

(6.9)

200

(1.38)

(13.8)

300

(2.07)

(20.7)

400

(2.76)

(27.6)

Outlet Pressure - PSI (MPa, Bar)

500

(3.45)

(34.5)

F IG . 36

3/4” Plunger (PCI-125-75)

GPD

(LPD)

180

(681)

160

(606)

140

(530)

120

(454)

100

(379)

(303)

(227)

(151)

(76)

A B C D

(0.35)

(3.5)

100

(0.69)

(6.9)

150

(1.03)

(10.3)

200

(1.38)

(13.8)

Outlet Pressure - PSI (MPa, Bar)

250

(1.72)

(17.2)

F IG . 37

600

(4.14)

(41.4)

300

(2.07)

(20.7)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

3A4386A 47

Performance Charts

1 3/4” Air Motors (PCI-175)

1/8” Plunger (PCI-175-13)

4.0

(15.1)

GPD

(LPD)

3.5

(13.3)

3.0

(11.4)

2.5

(9.5)

2.0

(7.6)

1.5

(5.7)

1.0

(3.8)

0.5

(1.9)

0 2000

(13.79)

(137.9)

A B

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

8000

(55.16)

(551.6)

10000

(68.95)

(689.5)

Outlet Pressure - PSI (MPa, Bar)

12000

(82.74)

(827.4)

F IG . 38

3/16” Plunger (PCI-175-19)

(30.3)

(26.5)

(22.7)

GPD

(LPD)

(19.0)

(15.2)

(11.4)

(7.6)

(3.8)

A B C D

2000

(13.79)

(137.9)

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

8000

(55.16)

(551.6)

Outlet Pressure - PSI (MPa, Bar)

10000

(68.95)

(689.5)

F IG . 39

14000

(96.53)

(965.3)

12000

(82.74)

(827.4)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

48 3A4386A

Performance Charts

1/4” Plunger (PCI-175-25)

GPD

(LPD)

(68.1)

(60.6)

(53.0)

(45.4)

(37.9)

(30.3)

(22.7)

(15.2)

(7.6)

A B C D

1000

(6.89)

(68.9)

2000

(13.79)

(137.9)

3000

(20.68)

(206.8)

4000

(27.58)

(275.8)

5000

(34.47)

(344.7)

6000

(41.37)

(413.7)

Outlet Pressure - PSI (MPa, Bar)

7000

(48.26)

(482.6)

8000

(55.16)

(551.6)

F IG . 40

3/8” Plunger (PCI-175-38)

GPD

(LPD)

(95)

(76)

(57)

(38)

(19)

(170)

(151)

(133)

(114)

0 500

(3.45)

(34.5)

A B C D

1000

(6.89)

(68.9)

1500

(10.34)

(103.4)

2000

(13.79)

(137.9)

2500

(17.24)

(172.4)

Outlet Pressure - PSI (MPa, Bar)

F IG . 41

3000

(20.68)

(206.8)

3500

(24.13)

(241.3)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

3A4386A 49

Performance Charts

1/2” Plunger (PCI-175-50)

GPD

(LPD)

(303)

(265)

(227)

(189)

(151)

(114)

(76)

(38)

A B C D

500

(3.45)

(34.5)

1000

(6.90)

(69.0)

Outlet Pressure - PSI (MPa, Bar)

1500

(10.34)

(103.4)

F IG . 42

5/8” Plunger (PCI-175-63)

120

(454)

100

(379)

GPD

(LPD)

(303)

(227)

(151)

(76)

A B C D

200

(1.38)

(13.8)

400

(2.76)

(27.6)

600

(4.14)

(41.4)

Outlet Pressure - PSI (MPa, Bar)

800

(5.52)

(55.2)

F IG . 43

2000

(13.79)

(137.9)

1000

(6.90)

(69.0)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

50 3A4386A

Performance Charts

3/4” Plunger (PCI-175-75)

GPD

(LPD)

180

(681)

160

(606)

140

(530)

120

(454)

100

(379)

(303)

(227)

(151)

(76)

A B C D

100

(0.69)

(6.9)

200

(1.38)

(13.8)

300

(2.07)

(20.7)

400

(2.76)

(27.6)

Outlet Pressure - PSI (MPa, Bar)

500

(3.45)

(34.5)

F IG . 44

600

(4.14)

(41.4)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

2” Air Motors (PCI-200)

1/8” Plunger (PCI-200-13)

GPD

(LPD)

4.0

(15.1)

3.5

(13.3)

3.0

(11.4)

2.5

(9.5)

2.0

(7.6)

1.5

(5.7)

1.0

(3.8)

0.5

(1.9)

0 2000

(13.79)

(137.9)

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

8000

(55.16)

(551.6)

10000

(68.95)

(689.5)

Outlet Pressure - PSI (MPa, Bar)

F IG . 45

12000

(82.74)

(827.4)

14000

(96.53)

(965.3)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-65 (0.45, 4.5)

3A4386A 51

Performance Charts

3/16” Plunger (PCI-200-19)

GPD

(LPD)

(30.3)

(26.5)

(22.7)

(19.0)

(15.2)

(11.4)

(7.6)

(3.8)

0 2000

(13.79)

(137.9)

A B C

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

8000

(55.16)

(551.6)

10000

(68.95)

(689.5)

Outlet Pressure - PSI (MPa, Bar)

F IG . 46

1/4” Plunger (PCI-200-25)

GPD

(LPD)

(68.1)

(60.6)

(53.0)

(45.4)

(37.9)

(30.3)

(22.7)

(15.2)

(7.6)

A B C D

12000

(82.74)

(827.4)

2000

(13.79)

(137.9)

4000

(27.58)

(275.8)

6000

(41.37)

(413.7)

Outlet Pressure - PSI (MPa, Bar)

8000

(55.16)

(551.6)

F IG . 47

14000

(96.53)

(965.3)

10000

(68.95)

(689.5)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

52 3A4386A

Performance Charts

3/8” Plunger (PCI-200-38)

GPD

(LPD)

(95)

(76)

(57)

(38)

(19)

(170)

(151)

(133)

(114)

A B C D

500

(3.45)

(34.5)

1000

(6.89)

(68.9)

1500

(10.34)

(103.4)

2000

(13.79)

(137.9)

2500

(17.24)

(172.4)

3000

(20.68)

(206.8)

Outlet Pressure - PSI (MPa, Bar)

3500

(24.13)

(241.3)

4000

(27.58)

(275.8)

4500

(31.03)

(310.3)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

F IG . 48

1/2” Plunger (PCI-200-50)

(265)

(227)

(189)

GPD

(LPD)

(151)

(114)

(76)

(38)

A B C D

500

(3.45)

(34.5)

1000

(6.90)

(69.0)

1500

(10.34)

(103.4)

Outlet Pressure - PSI (MPa, Bar)

2000

(13.79)

(137.9)

2500

(17.24)

(172.4)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

F IG . 49

3A4386A 53

Performance Charts

5/8” Plunger (PCI-200-63)

120

(454)

100

(379)

GPD

(LPD)

(303)

(227)

(151)

(76)

0 200

(1.38)

(13.8)

A B C D

400

(2.76)

(27.6)

600

(4.14)

(41.4)

800

(5.52)

(55.2)

1000

(6.90)

(69.0)

Outlet Pressure - PSI (MPa, Bar)

F IG . 50

3/4” Plunger (PCI-200-75)

GPD

(LPD)

180

(681)

160

(606)

140

(530)

120

(454)

100

(379)

(303)

(227)

(151)

(76)

0 100

(0.69)

(6.9)

A B C D

200

(1.38)

(13.8)

300

(2.07)

(20.7)

400

(2.76)

(27.6)

500

(3.45)

(34.5)

600

(4.14)

(41.4)

Outlet Pressure - PSI (MPa, Bar)

F IG . 51

1200

(8.27)

(82.7)

700

(4.83)

(48.3)

1400

(9.65)

(96.5)

800

(5.52)

(55.2)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

Inlet Pressure - PSI

(MPa, Bar)

A-50 (0.35, 3.5)

B-100 (0.69, 6.9)

C-150 (1.03, 10.3)

D-200 (1.38, 13.8)

54 3A4386A

Technical Data

Python Chemical Injection Pump

Maximum air inlet pressure

Maximum fluid working pressure

Environmental temperature range

Noise (dBa)

Maximum sound pressure

Inlet/Outlet Sizes

Fluid inlet size

Fluid outlet size (1/4”, 3/8”, 1/2”, 5/8”, & 3/4” plungers only)

Fluid outlet size (1/8” & 3/16” plungers only)

Prime/bleed size (1/4”, 3/8”, 1/2”, 5/8”, & 3/4” plungers only)

Prime/bleed size (1/8” & 3/16” plungers only)

Pneumatic inlet size

Pneumatic outlet size (exhaust recovery)

Materials of Construction

Pump/Check Valve Seal Material

Wetted Parts

See

-40°–176°F

Models on page 3.

See Models on page 3.

1/16 in. npt(f)

1/8 in. npt(f) (1/4 npt(f) adapter included)

1/8 in. npt(f)

Metric

-40°–80°C

<70 dBa with included muffler installed.

1/4 in. npt(f) (1/4 npt(m) adapter included)

1/4 in. npt(f)

HiP HF4

10-32 UNF

See Configuration Chart

on page 4 for seal material. All

other packing materials are PEEK and PTFE unless otherwise noted.

See Configuration Chart

on page 4 for plunger material. All

other materials are 316 stainless steel unless otherwise noted.

Weight

All models 8-11 lbs.

3.6-4.9 kg

3A4386A 55

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE .

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO . These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com

For patent information, see www.graco.com/patents .

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 3A4386

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

www.graco.com

Revision A , August 2016

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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.

Important Safety Instructions

II 2 G c T6

Contents

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

Models

Configuration Number Matrix

Key Points

Warnings

Component Identification

Installation

Grounding

Required Accessories

Air Line

Fluid Line

Flush Before Using Equipment

Typical Installation

Mount the Pump and Connect

Chemical Supply

Connect Pneumatic Supply

Connect Chemical Outlet

Minimum Gas Pressures by Fluid Plunger Size and Outlet Pressures

Operation

Pressure Relief Procedure

Flush the Equipment

Prime the Pump

Calibrate Chemical Dosage

Stroke Adjustment

Baseline Chemical Dosage Settings

Maintenance

Preventive Maintenance

Schedule

Tighten Threaded Connections

Tighten Packings

Storage

Troubleshooting

Repair

Pump

Disconnect Pump

Pump Repair

Reconnect Fluid Cylinder

Remove Air Piston and Fluid Plunger

Assembly

Replace Air Motor Seal

Air Piston, Fluid Plunger, and Upper

Cylinder Reassembly

Fluid Plunger Replacement

Check Valves

Inlet Check Valve Repair (all models except

PCI-xxx-xxH)

Inlet Check Valve Repair (models

PCI-xxx-xxH only)

Outlet Check Valve Repair (all models except PCI-xxx-xxH)

Outlet Check Valve Repair (models

PCI-xxx-xxH only)

Timing Valve

Timing Valve Repair

Final Reassembly

Parts

Python Pneumatic Pump

PCI-200-13S-SA-A shown

Python Pneumatic Pump Parts List

Python Timing Valve Assembly

B32069

Timing Valve Assembly (B32069) Parts List

Kits and Accessories

Additional Kits & Accessories

Dimensions

Python Pump Dimensions

Performance Charts

1 1/4” Air Motors (PCI-125)

1/8” Plunger (PCI-125-13)

3/16” Plunger (PCI-125-19)