Graco EM5 Series Datasheet

308–487
Rev. A
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Standard
EM5Electronic Metered
Dispense Valves
1000 psi (69 bar) Maximum Working Pressure
Maximum Flow Rate 5 gpm (18.9 lpm)
Unit of Measurement: Quarts
Model 238–451 75 Bend 3/8-in. Rigid T ube
Model 238–452 3/8-in Coupled Flexible Hose
Model 238–453 15 Bend 3/8-in. Gear Lube T ube with 90  Elbow
Unit of Measurement: Liters
Model 238–454 75 Bend 3/8-in. Rigid T ube
Model 238–455 3/8-in Coupled Flexible Hose
Model 238–456 15 Bend 3/8-in. Gear Lube T ube with 90  Elbow
 These dispense valves are designed to
dispense petroleum-based lubricants and
antifreeze only .

These dispense valves are designed for indoor
use only . If used outdoors, they must be
sheltered from the rain.
CAUTION
EXIA
Intrinsically safe
Class I,
Division 1,
Groups C, D
Hazardous Locations
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Model 238–451 shown


 
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 20. . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol

This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol

This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury .

This equipment is for professional use only .
 Read all instruction manuals, tags, and labels before you operate this equipment.
 Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor .

Do not alter or modify this equipment.
 Check equipment daily . Repair or replace worn or damaged parts immediately .

Do not exceed the maximum working pressure of the lowest rated system component. See the
T echnical Data on page 18 for the maximum working pressure of this component.
 Use fluids and solvents that are compatible with the equipment wetted parts. See the Technical
Data
section of all equipment manuals. Read the fluid and solvent manufacturer ’ s warnings.
 Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180 F (82 C) or below –40 F (–40 C).
 Comply with all applicable local, state, and national fire, electrical, and safety regulations.
 Do not point the dispense valve at anyone or at any part of the body .

Do not put your hand or fingers over the end of the dispense valve.
 Do not stop or deflect leaks with your hand, body , glove, or rag.
 Use only extensions and no-drip tips that are designed for use with your dispense valve.
 Follow the Pressure Relief Procedure on page 4 before you clean, check, or service this
equipment.
T
ighten all fluid connections before you operate this equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.




 
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury
.
 Be sure the entire fluid system is properly grounded. Refer to your pump instruction manual for
complete details. See Grounding on page 6.
 If there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
 Keep the dispensing area free of debris, including solvent, rags, and spilled gasoline.
 Do not smoke while dispensing flammable fluids.
Y ou must use one of the battery types as specified in Replacing the Battery on page 14. Use of
any other batteries than those specified could af fect the intrinsic safety of this unit.



4 308-487
Installation
Typical Installations
Fig. 1 shows a typical hose reel installation.
Additionally , these dispense valves can be installed on
a console, as shown in Fig. 2.
Do not use this electronic metered dispense
valve on non-Graco consoles. Such use could
result in the trigger becoming inadvertently
pressed while the dispense valve is stowed.
CAUTION
Fig. 1
L
M
K
N
J
06174
KEY DESCRIPTION
J Fluid shut-of f valve
K Hose
L Hose reel fluid inlet hose
M Hose reel
N Metered dispense valve
The typical installation shown in Fig. 1 is only a guide.
The components shown are typical; however , it is not a
complete system design. Contact your Graco
distributor for assistance in designing a system to suit
your particular needs.
Mounting Brackets
Mounting brackets are available for hanging an EM5
dispense valve on a hose reel or on a console. To
order mounting brackets, see the list below:
191–155 V alve bracket for mounting on console
191–156 V alve bracket for mounting on hose reel
valve bracke
191-155
Fig. 2 06228
PRESSURIZED EQUIPMENT HAZARD
The equipment stays pressurized until pressure is
manually relieved. To reduce the risk of serious
injury from pressurized fluid, accidental spray from
the dispenser or splashing fluid, follow the
Pressure Relief Procedure when you:
 Are instructed to relieve pressure
 Stop dispensing
 Check, clean, or service any system equipment
 Install or clean fluid nozzles
WARNING
Pressure Relief Procedure
1. Turn of f the power supply to the pump.
2. T rigger the dispense valve into a waste container
to relieve pressure.
3. Open any bleed-type master air valves and fluid
drain valves in the system.
4. Leave the drain valve open until you are ready to
pressurize the system.
FIRE AND EXPLOSION HAZARD
The movement of fluids through the
dispensing system generates static
electricity . The static electricity can
cause volatile fumes to ignite, resulting in explosion
and fire. The dispensing system must grounded.
See Grounding on page 6.
WARNING

 
Installation
Pre-Installation Procedure
1. Relieve the pressure.

T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure above.
2. Close the shut-of f valve (item J in Fig. 1).
3. Ground the hose and reel or console. See
Grounding on page 6. Do not use T eflon tape
on the pipe joints; it may cause a loss of ground
across the pipe joint.
Installation Procedure

If this is a new installation, or if the oil in the
lines is contaminated, flush the lines before you
install the metered valve.
1. If this is an existing installation, go to step 7.
Steps 2 through 6 are the Flushing Procedure .
2. Close the fluid shut-of f valve (J) at each dispense
position.
3.
Make sure the main fluid outlet valve at the pump
is closed, the air pressure to the pump motor is
adjusted, and the air valve is open. Slowly open
main fluid valve.
4. Place the hose end (with no dispense valve
connected) into a container for waste oil. Secure
the hose in the container so it will not come out
during flushing. If you have multiple dispense
positions, first flush the dispense position farthest
from the pump, and work your way toward the
pump.
5.
Slowly open the shut-of f valve (J) at the dispense
position. Flush out a sufficient amount of oil to
ensure that the entire system is clean, and close
the valve.
6. Repeat step 5 at all other dispense positions.
7. Relieve the pressure.

T o reduce the risk of serious injury , whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4.
8. Loosen and disconnect the hose from the old
dispense valve (the one that you are replacing).
9. Slide the swivel cover (4) onto the hose, small end
first. See Fig. 3.
10. Apply thread sealant to the the male threads of the
hose fitting, thread the hose fitting into the swivel
(3) of the EM5, and tighten firmly . See Fig. 3.
11. Thread the extension (5a, 6a, or 7a) into the outlet
of the EM5, and tighten firmly . For rigid
extensions, thread the extension in at least
three full turns, position the extension for
proper alignment, and tighten the sealing
nut (5c or 7c).
See Fig. 4.
12. Thread the new dripless nozzle (5b, 6b, or 7b)
onto the extension, and, with an open-end
adjustable wrench on the flats of the nozzle,
tighten firmly . See Fig. 4.

Do not use the old non-drip nozzle (Part No.
203–655) or any other manual shut-of f nozzle on
the EM5 extension. Y ou must use the new nozzle
that is provided with the EM5. The old nozzle
could rupture under pressure, and the EM5 could
be damaged.
13. Open all dispense position shut-of f valves, and
start the pump to pressurize the system. See the
Operation section for proper operation of meters.
14. T o ensure dispensing accuracy , purge all air from
the fluid lines and dispense valves before you use
them. Set the system flow to the desired flow rate,
which is typically 1.5 gpm. Flow rates in excess of
5 gpm may cause metering errors.
3
hose fitting
Slide onto
hose before
connecting.
06187
Fig. 3
4

 
Installation
hose

5c
4
5a
5b
Model shown has
a 75 bend rigid
extension (5).
Fig. 4
Grounding
Proper grounding is an essential part of maintaining a
safe system.
T o reduce the risk of static sparking, ground all system
components per local and national electrical codes.
Refer to the user manuals for the pump and other
system components to ground the following:
1. Pump: Follow manufacturer ’ s recommendations.
2. Air and Fluid hoses: Use only grounded hoses.
3. Air compressor: Follow manufacturer ’s
recommendations.
4.
Fluid supply container: Follow your local code.
5. T o maintain grounding continuity when flushing or
relieving pressure, always hold a metal part of the
valve firmly to the side of a grounded metal pail,
then trigger the valve.
Operation
Terms
The following list contains explanations for the terms that are shown on the display and/or used in this section.
 R-TOT AL: resettable total
Displayed to show the amount dispensed, and it can be reset––typically before each dispense cycle.
 TOT AL: non-resettable total
Displayed to show the cumulative amount that the dispense valve has ever dispensed, and it cannot be reset.
 PRESET
A user-entered amount to be dispensed, in which the display can be set to count up from zero or down from the
entered amount. The unit beeps to indicate that the preset amount has been dispensed. It does not
automatically stop dispensing.
Selecting Dispensing Options
NOTE: If the display is blank, press any button on the
keypad to “wake up” the display .
This is the procedure for setting or changing the
resettable total, the units of measurement, and the
auto preset amount, and for turning the auto reset
function on and of f.
In this procedure, if a display item is blinking, that
means you can change the value.
NOTE: The numbers that are blinking on the display
when you leave each mode and advance to the next
mode are the values at which the unit gets set.
1. Hold down the Auto and Reset buttons.
The display enters the first of four option modes, in
which R–TOTAL blinks, and the current resettable
total is shown on the display , as shown at right.

00008R-TOTAL
GAL

 
Operation
2. If you do not want to reset the total, skip this step
by pressing the Auto button. If you want to reset
the total, press the Reset button.
A resettable total of 00000 GAL or 00000 LITERS
is shown on the display .
If you press the Reset button again, the display
returns to the previous total. Whatever is
displayed is locked in when you press the Auto
button.
3.
Press the Auto button.
The presently selected units of measurement
blinks. It will be one of the following:
QTS , GAL , LITERS, or PTS , as shown below .
QTS

LITERS
PTS
GAL
4. If you do not want to change the unit of
measurement, skip this step by pressing the Auto
button. If you want to change the unit of
measurement, press the Reset button.
Each time you press the Reset button, the display
scrolls to the next unit of measurement.
NOTE: Y ou do not need to change the calibration
for the different units of measurement.
5. Press the Auto button with your choice of the units
of measurement blinking.
The auto preset amount blinks, and the unit of
measurement quits blinking.
6. If you do not want to change the auto preset
amount, skip this step by pressing the Auto button.
If you want to change the auto preset amount, do
the following:
6a. Press the Reset button.
The amount shown on the display is cleared.
6b. Press the 10 button to change the 10s digit,
press the 1.0 button to change the 1s digit,
and press the 0.1 button the change the first
decimal digit.
In the figure below , the arrows point from the
numbered buttons on the keypad to the
corresponding digits in the display .

15.000
AUTO
GAL
NOTE: If you press and hold the 10, 1.0, or
0.1 buttons, the digits advance rapidly .

 
Operation
7. Press the Auto button.
The reset-to-zero indicator (clock icon) is shown
on the display , along with either On or OFF , as
shown below . On means that the unit will
automatically reset to zero after two minutes of
inactivity . OFF means that the unit will remain at
the current total indefinitely
, or until the Reset
button is pushed.
OFF
06044
8. T oggle between On and OFF by pressing the
Reset button, then press the Auto button.
The unit returns to the Normal dispensing mode.
Locking and Unlocking the Trigger
The trigger (15) on this electronic metered dispense
valve has a locking mechanism. The trigger does
not automatically unlock; you must unlock it
manually.
To lock the trigger,
press on the part of the trigger
that has the textured grip (see below) until you feel it
click into the locked position.
press here
to lock
06227
press here
to unlock
Fluid continues to flow until you unlock the trigger .
To unlock the trigger,
press on the smooth part of
the trigger (see above) until you feel it click out of the
locked position. Then release the trigger .
Fluid flow stops.
Dispensing Fluid
These are the procedures for dispensing fluid in
Standard mode and Preset mode.
Standard Mode
1. Press the Reset button.
0.000 is shown on the display .
NOTE:
Also while you press the Reset button, the
Segment Check is shown on the display very
briefly , which allows you to check for burned out
segments in the display . Press the Reset button
repeatedly to get a good look at each segment in
the display . The Segment Check should show all
of the segments shown below .
8.8.8.88 QTS
06044
LITERS
PTS
GAL
R-TOTALAUTO CAL
,,,
Before you squeeze the trigger , make sure you
have read Locking and Unlocking the Trigger
at left.

2. Squeeze the trigger .
Fluid begins to flow , and the amount shown on the
display counts up from zero.
3. Release the trigger when you have dispensed the
desired amount of fluid.
Fluid flow stops, and the amount you have
dispensed is shown on the display .

 
Operation
Preset Mode
NOTE: All buttons are disabled while fluid is being
dispensed.
1.
Press the Auto button.
The stored preset dispense amount is shown on
the display if an amount is stored.
2. If you do not want to change the preset dispense
amount shown on the display , skip this step. If you
want to change the amount, do the following:
Press the 10 button to change the 10s digit, press
the 1.0 button to change the 1s digit, and press the
0.1 button the change the first decimal digit.
3. Pull the trigger back.
Fluid begins to flow , and the amount shown on the
display counts down from the preset amount if the
unit is in UPOFF mode. The amount counts up
from zero if the unit is in UP ON mode.
The unit makes three short audible beeps shortly
before it dispenses the preset amount. Then it
makes one long audible beep when the preset
amount of fluid is dispensed.
NOTE: The three short beeps occur within a
certain volume of the preset amount, as follows:
QTS: Unit beeps within 0.4 quarts of preset
amount.
PTS: Unit beeps within 0.5 pints of preset amount.
GAL or LITERS: Unit beeps within 0.1 gallons or
liters of preset amount.
4. Let go of the trigger .
The amount dispensed is shown on the display .
The trigger does not unlock when the preset
amount is dispensed. Y ou must manually
unlock the trigger . See Locking and Unlock-
ing the Trigger
on page 8.

5. If you want to resume dispensing the preset
amount, go to step 3. If you want to restart
dispensing from zero, press the Reset button.
Viewing Totals and the Calibration Factor
This is the procedure for viewing the non-resettable
and resettable totals in the current units and for
viewing the calibration factor .
1.
If the display is blank, press the T otal button to
wake it up. If the display is already awake, go to
step 2.
The Normal mode display is shown, as shown
below.

0.000 GAL
2. Press the T otal button.
The non-resettable total amount is shown on the
display in the current units, as shown below .

00010 GAL
TOTAL

 
Operation
3. Press the T otal button again.
The resettable total amount is shown on the
display in the current units, as shown below .

00000 R-TOTAL
GAL
4. Press the T otal button again.
The calibration factor is shown on the display , as
shown below .

06815
CAL
5. Press the Reset button.
The unit returns to Normal mode, and the Normal
mode display is shown.
Error Codes
If, after a dispensing cycle, you see an error code on
the display, as shown below , see the Error Codes
section of the Troubleshooting chart on page 13. If
an error code is shown on the display, you can press
the Reset button to clear the error code and see the
dispensed amount. Even in an error condition, the unit
keeps track of the amount dispensed.

Err 1