Graco 25T478 Parts list manual

3A7681A

Instructions-Parts

Medium Pressure Back

Pressure Regulators

The back pressure regulator (BPR) controls fluid pressure and flow in circulation systems.

For professional use only.

See page 2 for model information, including maximum

working pressure and approvals.

Important Safety Instructions

Read all warnings and instructions in this

manualbeforeusingtheequipment.Save

these instructions.

Optional gauges are shown.

Related Manuals

23A7681A

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Install the Back Pressure Regulator. . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure Relief Procedure. . . . . . . . . . . . . . . . . . 7

Adjusting the BPR . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flush the Equipment. . . . . . . . . . . . . . . . . . . . . . . 8

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Technical Specifications . . . . . . . . . . . . . . . . . . . . 14

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 14

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 16

Related Manuals

Models

* Regulated range is 250–1000 psi (1.7–7 MPa, 17–70 bar) above 3 gpm (11 lpm).

Manual in English Description

3A4030 Intelligent Paint Kitchen

3A7709 Pneumatic Pump Control Module

Part Description Flow

Range Regulated Fluid

Pressure Max. Fluid

Inlet Pressure

Max. Air

Working

Pressure Approvals

25T478

Back pressure

regulator (BPR),

low flow, medium

press, pneumatic 0–5 gpm,

0–19 lpm

100–1000 psi

(0.7–7MPa,7-70

bar)*

3000 psi

(20.7 MPa,

207 bar)

100 psi

(0.7 MPa, 7.0

bar)

25T477 250–2000 psi

(1.7–13.8 MPa,

17-138 bar)

25R490 250–3000 psi

(1.7–20.7 MPa,

17–207 bar)

25R491

Back pressure

regulator (BPR),

low flow, medium

pressure,

mechanical with

locking nut

250–3000 psi

(1.7–20.7 MPa,

17–207 bar) ------

Ex h IIB T6 Gb

0°C to 50°C

NOTE: Type of

Protection“h”applied

is constructional

safety “c.”

Warnings

3A7681A 3

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent

flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well-ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static sparking).

• Ground all equipment in the work area. See Grounding instructions.

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes

are present.

•Stop operation immediately ifstaticsparkingoccursoryoufeelashock.Donotuseequipmentuntil

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, 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 spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying 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.

Warnings

43A7681A

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) from distributor or

retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine

manufacturer’s replacement parts only.

• Do not alter ormodify 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.

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 Sheets (SDSs) 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.

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.

Installation

3A7681A 5

Installation

The Typical Installation shown in Fig. 1 is only a guide to

design a system. For assistance in designing a system

to meet your needs, contact your Graco distributor.

Install the Back Pressure

Regulator

1. Install the back pressure regulator (BPR) (A) in the

Fluid Return Line (D) or circulation loop return line.

See FIG. 1. Verify that the BPR is securely installed

in a rigid piping system. If flexible fluid lines are

used, the two 1/4 - 20 tapped mounting holes on the

side of the regulator should be used to securely

mount the regulator.

2. The BPR (A) has one 3/8 inch inlet port and one 1/4

inch gauge port. (The gauge port can be used as an

optional inlet port for low flow applications.) The two

outlet ports are 3/8 inch npt.

Connect fluid lines to the inlet and outlet ports that

are convenient for your installation. Make sure the

fluid flow agrees with the IN and OUT markings on

the BPR housing.

3. Install an accessory gauge, if used, in the 1/4 inch

gauge port. Install plugs in the unused inlets and

outlets.

4. If more than one spray station is used, install the

BPR (A) in the Fluid Return Line (D) after the last

spray station to maintain proper system pressures.

5. Install an air line to the top fitting on the BPR (A) for

air piloted models. The Air Line (G) needs an Air

Regulator (H) and Air Filter (not shown) to allow for

the adjustment of the fluid pressure. The Air Filter is

required to remove harmful dirt and moisture from

theair supply.Installa BleedTypeShut OffValve (J)

upstream of the air regulator.

Grounding

Do not use PTFE tape on pipe threads. Such use

could cause a loss of grounded continuity, which

could lead to a fire or explosion caused by static. Also,

if pieces of the tape break off, the function of the BPR

could be affected.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Install the BPR into piping that is

properly grounded. Grounding provides an escape

wire for the electric current.

Installation

63A7681A

Key:

A Back Pressure Regulator (BPR)

B Air Filter/Regulator

C Fluid Supply Line

D Fluid Return Line

E Fluid Regulator

F Air-Assisted Airless Spray Gun

G Air Line

H Air Regulator (Pilot Air) (Air Filter not shown)

J Bleed Type Shut Off Valve (Air)*

K Shut Off Valve (Fluid)

L Drain Valve (not shown)*

* Required in your system.

FIG. 1: Typical Installation: Single Circulating Spray Station

Operation

3A7681A 7

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Engage trigger lock.

2. Follow the recommendedshut down procedure from

the respective pump manual.

3. Close the Bleed Type Shut Off Valve (J) on the Air

Regulator (H) to the pneumatic BPR to reduce fluid

pressure to zero. Turn the adjusting screw on the

mechanical BPR counterclockwise to reduce the

fluid pressure to zero.

4. Disengage trigger lock.

5. Hold a metal part of the gun firmly to the side of a

grounded metal pail, and trigger the gun to relieve

pressure.

6. Engage trigger lock.

7. Open the Drain Valve (L) (required in your system).

Have a container ready to catch the drainage.

8. Leave the drain valve open until you are ready to

spray again.

9. If you suspect the spray tip or hose is clogged or

that pressure has not been fully relieved:

a. VERY SLOWLY loosen the tip guard retaining

nut or the hose end coupling to relieve pressure

gradually.

b. Loosen the nut or the coupling completely.

c. Clear the obstruction in the hose or tip.

Adjusting the BPR

The BPR controls pressure upstream from the BPR.

Adjust the pump fluid pressure and the BPR for the best

spraying combination and proper circulation of the fluid.

• The pneumatic pilot operated BPR fluid pressure is

adjusted by increasing or decreasing the pilot air

pressure. The fluid to air pressure ratio ranges from

10:1 to 30:1 depending on the model chosen for the

application. See Technical Specifications, page

14.

• The mechanical operated BPR fluid pressure is

adjusted by rotating the adjusting screw clockwise

to increase fluid pressure and counterclockwise to

decrease fluid pressure.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief

Procedure when you stop spraying and before

cleaning, checking, or servicing the equipment.

Maintenance

83A7681A

Maintenance

Flush the Equipment

Flush the BPR whenever the rest of the system is

flushed. Before flushing, fully open the BPR by reducing

pilot air pressure to zero or turning the adjusting screw

counterclockwise to reduce pressure to zero.

NOTE: Do not allow paint or solvent to remain in the

system for a long time. Fluid could dry on the piston,

causing leakage at the piston packing. If leakage

occurs, disassemble and clean the BPR.

Cleaning

Regular cleaning and inspection, and lubrication of the

BPR are necessary to keep the BPR working properly.

1. Follow the Pressure Relief Procedure on page 7.

2. Remove the BPR from the system.

3. Disassemble the BPR, referring to the parts

drawings on pages 9 and 11. Clean and inspect all

parts.

To reduce the risk of serious bodily injury, including

fluid injection or splashing in the eyes or on the skin,

always follow the Pressure Relief Procedure before

adjusting, cleaning, repairing, or removing the BPR

from the system.

Never completely remove the adjusting screw when

system pressure is present.

NOTICE

Use special care when handling the hard carbide por-

tions of the piston (3) and seat (4). Damage causes

poor operation and leakage.

Parts

3A7681A 9

Parts

25R490, 25T477, 25T478 Lower Flow Medium Pressure BPR, Pneumatic

FIG. 2: Lower Flow Medium Pressure BPR, Pneumatic (25R490 shown)

Apply NLGI Grade 2 grease (Chevron SRI).

Torque to 175–200 in-lbs (20–23 N•m).

Apply metal assembly paste to threads

(Molykote®G-N paste).

Apply thread sealant.

Torque to 60–70 ft-lbs (81–95 N•m).

Parts

10 3A7681A

Ref. Part Description Qty.

1 19Y871 (25R490) CYLINDER,

REGULATOR, BP, MEDIUM

PRESS, 30:1

19B727 (25T477) CYLINDER,

REGULATOR, BP, MEDIUM

PRESS, 20:1

19B728 (25T478) CYLINDER,

REGULATOR, BP, MEDIUM

PRESS, 10:1

2 19Y873 HOUSING, REGULATOR, BP,

MEDIUM PRESS 1

3 238932 PISTON, VALVE 1

4 238933 SEAT, VALVE 1

5 113751 RING, RETAINING, INTERNAL 1

6 19Y810 (25R490) PISTON, AIR,

ACTUATOR, REGULATOR, BP 1

19B729 (25T477) PISTON, AIR,

ACTUATOR, REGULATOR, BP,

20:1

19B730 (25T478) PISTON, AIR,

ACTUATOR, REGULATOR, BP,

10:1

7 189817 GASKET 1

8 111796 SEAL, U-CUP 1

9 171885 WASHER 1

10 166985 PACKING, O-RING 1

11 19B484 (25R490) SEAL, U-CUP,

SYMETRIC, BEVEL, LITE 1

113249 (25T477) PACKING, U-CUP 1

112181 (25T478) SPACKING, U-CUP 1

12 101748 PLUG, PIPE SST 1

13 19Y872 (25R490)COVER,REGULATOR,

BP, AIR, UPPER, MP 1

19B731 (25T477, 25T478) COVER,

REGULATOR, BP, AIR, MED

PRESS

14 109458 (25R490) PACKING, O-RING 1

156594 (25T477, 25T478) PACKING,

O-RING 1

18 101970 PLUG, PIPE, HDLS, optional if

gauge is not used (not shown) 1

Ref. Part Description Qty.

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