Graco EM5 Series Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2000, Graco Inc. is registered to I.S. EN ISO 9001
STANDARD
EM5tElectronic
Metered Dispense Valves
1000 psi (7 MPa, 69 bar) Maximum Working Pressure
5 gpm (18.9 lpm) Maximum Flow Rate
Factory-Set to Measure in Quarts
Model 238461 75bend 3/8-in. rigid tube
Model 238462 3/8-in. coupled flexible hose
Model 238463 15bend 3/8-in. gear lube tube, 90elbow
Factory-Set to Measure in Liters
Model 238464 75bend 3/8-in. rigid tube
Model 238465 3/8-in. coupled flexible hose
Model 238466 15 bend 3/8-in. gear lube tube, 90elbow
Model 238467* 75bend 3/8-in. rigid tube
Model 238468* 3/8-in. coupled flexible hose
Model 238469* 15 bend 3/8-in. gear lube tube, 90elbow
* Canadian Weights & Measures approved
Patent Nos.
4,883,199 DE3834454C2
D382,500 1025804
6,047,906
309142D
Read warnings and instructions.
See page 2 for Table of Contents.
This dispense valve is designed to dispense
petroleum-based lubricants and antifreeze only.
Do not dispense windshield washer solvent with
this dispense valve.
This dispense valve is designed for indoor use
only.
This dispense valve is not designed for in-line
installation. Do not install with a shutoff valve on
the outlet side of the meter. Such installation
could result in damage to the meter housing
cover.
CAUTION
TI0267
Parts

2 309142
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calibration 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Drawing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Change Summary 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Information 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
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. Use only genuine Graco parts and accessories.
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
Technical Data on page 20 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 nozzles that are designed for use with your dispense valve.
Follow the Pressure Relief Procedure on page 5 before you clean, check, or service this
equipment.
Tighten 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.
WARNING
WARNING
INSTRUCTIONS

309142 3
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 7.
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 flammable fluids or fumes are in the dispensing area.
WARNING
WARNING

4 309142
Installation
Typical Installations
Fig. 1 shows a typical hose reel installation. Fig. 2
shows how these dispense valves can be installed on
a console.
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
H
TI0268
KEY DESCRIPTION
HThermal relief kit (required) Part No. 235998
Install downstream from pump.
JFluid shut-off valve
K Hose
LHose reel fluid inlet hose
MHose reel
NMetered dispense valve
The typical installation shown in Fig. 1 is only a guide;
it is not a complete system design. Contact your
Graco distributor for assistance in designing a system
to suit your particular needs.
This dispense valve is not designed for in-line
installation. Do not install with a shut-off valve
on the outlet side of the meter. Such installation
could result in damage to the meter housing
cover.
CAUTION
Mounting Bracket
Mounting bracket 196471 is available for resting an
EM5 dispense valve on a console. See Fig. 2.
Do not obstruct the trigger of this dispense
valve, and do not set the unit down resting on its
trigger, or it might not stop dispensing.
CAUTION
Fi
g
. 2
mounting
bracket
196471
NOTE: When using the EM5 with the rigid oil
extension on a dispense console, the rigid tube (5a)
should be oriented with the 75bend closest to the
nozzle, as shown below. This prevents interference
when used with a dispense console.
5a
5a
TI0274

309142 5
Installation
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 dispense valve, or splashing fluid, follow the
Pressure Relief Procedure when you
Are instructed to relieve pressure
Check, clean, or service any system equipment
Install or clean fluid nozzles or filter
WARNING
Pressure Relief Procedure
1. Turn off the power supply to the pump.
2. Trigger 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.
Pre-Installation Procedure
1. Install the battery. See Replacing the Battery on
page 16.
2. Relieve the pressure.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure above.
3. Close the shut-off valve (item J in Fig. 1).
4. Ground the hose and reel or console. See
Grounding on page 7.
NOTE: Do not use 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 fluid in the
lines is contaminated, flush the lines before you
install the metered valve. Contaminated lines
could cause the valve to leak.
CAUTION
1. If this is an existing installation, go to step 7.
Steps 2 through 6 are the Flushing Procedure.
2. Close the fluid shut-off 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-off 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.
WARNING
To reduce the risk of serious injury, whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure at left.
8. Slide the swivel cover (4) of the EM5 onto the
hose, small end first. See Fig. 3.
9. Apply thread sealant to the male threads of the
hose fitting, thread the hose fitting into the
swivel (3) of the EM5, and tighten firmly. See
Fig. 3.
NOTE: Make sure you let the sealant cure to the
manufacturer’s recommendations before you let
fluid into the system.
3
hose fitting
Slide onto
hose before
connecting.
Fig. 3
4
TI0269
PTFE

Fig. 4 8241C
6c
6a
6b
5a
5c
5b 6d
7a
7c
7c 7c
7d
7b
7b
7a
7c
This flexible extension
can also be threaded
directly into the meter outlet
without the street elbow
(6d) or sealing nut (6c).
meter
outlet
7d
nozzle bushing
nozzle bushing
Either end of this rigid
tube can be threaded into
the meter outlet. This is
the best orientation for use
with a dispense console.
6 309142
Installation
10. Models 238461, 238464, and 238467
See Fig. 4.
a. Thread the sealing nut (5c) onto the
extension (5a) with the side facing
out.
b. Thread the extension (5a) into the meter outlet
at least three full turns, position it for proper
alignment, and tighten the sealing nut against
the meter outlet.
Models 238462, 238465, and 238468
See See Fig. 4.
a. Thread the sealing nut (6c) onto the elbow (6d)
with the side facing out.
b. Thread the elbow (6d) into the meter outlet at
least three full turns, position it for proper
alignment, and tighten the sealing nut (6c)
against the meter outlet.
c. Thread the flexible hose (6a) into the elbow,
and tighten it.
NOTE: The flexible hose (6a) can also be
threaded directly into the meter outlet without
the elbow or sealing nut.
Models 238463, 238466, and 238469
This nozzle assembly can be configured two ways.
See See Fig. 4.
a. Thread a sealing nut (7c) onto the tube (7a)
with the side facing out.
b. Thread the tube (7a) into the meter outlet at
lease three full turns, position it for proper
alignment, and tighten the sealing nut (7c)
against the meter outlet.
c. Thread the other sealing nut (7c) onto the
other end of the tube (7a) with the 
side facing out.
d. Thread the elbow (7d) onto the end of the tube
(7a) at least full turns, position it for proper
alignment, and tighten the sealing nut (7c)
against the elbow.
OR
a. Thread a sealing nut (7c) onto the elbow (7d)
with the side facing out.
b. Thread the elbow (7d) into the meter outlet at
lease three full turns, position it for proper
alignment, and tighten the sealing nut (7c)
against the meter outlet.
c. Thread the other sealing nut (7c) onto the
tube (7a) with the side facing out.
d. Thread the tube (7a) into the elbow (7d) at
least three full turns, position it for proper
alignment, and tighten the sealing nut (7c)
against the elbow (7d).
PTFE
PTFE
PTFE
PTFE
PTFE
PTFE

309142 7
Installation
11. Thread the new nozzle (5b, 6b, or 7b) onto the
extension, and, with an open-end adjustable
wrench, tighten it firmly. See Fig. 4.
NOTE: On Models with automatic nozzle
239829 (5b or 6b), tighten the nozzle with the
wrench on the flats of the nozzle bushing. Do not
disassemble the nozzle bushing from the
nozzle. Disassembly will affect the performance
of the nozzle.
Do not use Graco’s old nozzle (Part No. 203655) or
any other manual shut-off nozzle on the EM5
extension. You must use the nozzle that is
provided with the EM5, or the meter could be
damaged. Do not use any sealant material.
CAUTION
12. Open all dispense position shut-off valves, and
start the pump to pressurize the system. See the
Operation section for proper operation of the
EM5.
13. To ensure dispensing accuracy, purge all air from
the fluid lines and dispense valve before you use
it. Set the system flow to the desired flow rate,
which is typically 1.5 gpm. Do not exceed a 5-gpm
flow rate.
Grounding
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.
WARNING
Proper grounding is an essential part of maintaining a
safe system.
To 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:
Pump: Follow manufacturer’s recommendations.
Air and Fluid hoses: Use only grounded hoses.
Air compressor: Follow the manufacturer’s
recommendations.
Fluid supply container: Follow the local code.
To 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.

8 309142
Setup
Terms
The following terms are shown on the display and/or
used often in this instruction manual.
R–TOTAL: Resettable Total
Displayed to show the cumulative amount that the
dispense valve has dispensed. It can be reset to
zero.
TOTAL: Non-Resettable Total
Displayed to show the cumulative amount that the
dispense valve has dispensed for the history of the
unit. It cannot be reset.
Standard Dispense Mode
The dispense mode in which the display always
counts up from zero or from where it recently
stopped in Standard dispense mode. There are no
warning beeps for predetermined dispense
amounts.
Asleep / Awake
Asleep is a battery-saving mode in which the
display goes blank after 45 seconds of inactivity.
The display comes awake from sleep mode when
you press any button on the keypad or when you
squeeze the trigger to dispense fluid.
Keypad Buttons
The buttons on the keypad and their functions are as
follows (see the figure below):
TOTAL
Used to see the resettable total, non-resettable
total, and calibration factor.
RESET *
Used to reset the displayed amount to zero and to
enter the Standard dispense mode.
*The Reset and Total buttons are used together
(pressed simultaneously) to access the setup
menus, in which you select dispensing options.
NOTE: All buttons are disabled while fluid is being
dispensed.
TI0272
GAL

309142 9
Setup
Selecting Dispensing Options
This is the procedure for setting or changing the resettable total and the units of measurement.
1. If the display is asleep, wake it up by pressing any button on the keypad.
2. To enter the dispensing options menus, press and hold the Reset and Total buttons simultaneously for
five (5) seconds.
The first menu is the Resettable Total menu, which is described in the first subsection below. You can move
through the menus by pressing the Reset button. The value that is displayed when you leave each menu is the
value that gets stored.
Resettable Total
In this menu, you can reset the resettable total to zero
or leave it unchanged. The resettable total
accumulates until the next time it is manually reset.
1. If you have not already entered the dispensing
options menus, do steps 1 and 2 in Selecting
Dispensing Options above.
2. With R–TOTAL blinking and the current resettable
total displayed, as shown in Fig. 5, do ONE of the
following two options:
Press the Total button.
The resettable total is set to zero, and 00000
GAL or 00000 LITERS is displayed.
You can press the Total button again to toggle
between zero and the previously displayed
resettable total. To lock in the displayed value
and advance to the Units of Measurement
menu, press the Reset button.
OR
Press the Reset button.
The currently displayed value is stored, and
the display advances to the Units of
Measurement menu.
R-TOTAL
GAL
TI0272
Fig. 5
Units of Measurement
In this menu, you can set the units of measurement to
quarts, gallons, pints, or liters.
1. If you have not already entered the dispensing
options menus, do steps 1 and 2 in Selecting
Dispensing Options above.
2. Press the Reset button. QTS, GAL, LITERS, or
PTS will blink to indicate that you are in the
Units-of Measurement menu.
3. With QTS, GAL, LITERS, or PTS blinking, as
shown in Fig. 6, do ONE of the following two
options:
Press the Total button.
Each time you press the Total button, the
display scrolls to the next unit of
measurement. To lock in the new unit of
measurement, press the Reset button, and the
display advances to the dispense mode.
OR
Press the Reset button.
The displayed unit of measurement is retained,
and the display advances to the dispense
mode.
GAL
TI0272
Fig. 6

10 309142
Calibration
NOTE: This unit has been calibrated at the factory to
dispense lubricating oils; it should not require
additional calibration during installation. If this unit will
be used to dispense antifreeze, and accuracy must be
greater than plus or minus 2 percent, it is
recommended that you use a calibration factor of 368
quarts or 389 liters.
You must ground yourself to a true earth ground
while calibrating the meter. You must keep
yourself constantly grounded when you touch
any electronic components inside the cover of
the dispense valve. To order a grounding wrist
strap, order Part No. 112190.
CAUTION
This is the procedure for calibrating the meter.
1. Remove the six screws (21) (see the Parts
Drawing on page 18) that hold the two halves of
the cover together, open the unit, and remove the
fluid section to gain access to the Calibration
button.
2. Press the RESET button.
NOTE: You have four minutes to complete the
calibration procedure.
3. Press the calibration button inside the unit, shown
in Fig. 7. The “CAL”indication should show on the
display (see Fig. 8).
Note location of battery wire to prevent damage
during reassembly
CAUTION
calibration
button
Fig. 7
4. Reassemble the two halves of cover using
screws (21).
NOTE: Number displayed on unit after assembly may
be 001 or greater.
5. Press the Total button. Output should be 000 as
shown in Fig. 8.
QTS (or LITERS)
TI0272
Fig. 8
CAL
6. If the unit of measure is liters, dispense exactly
one liter of fluid into a calibrated one liter container.
For proper calibration, you must dispense the
exact amount per the markings on the container.
7. If the unit of measure is gallons, pints, or quarts,
dispense exactly one quart of fluid into a calibrated
one quart container. For proper calibration, you
must dispense the exact amount per the markings
on the container.
NOTE: If an error has been made, pressing the
TOTAL button will zero the display. This will allow you
to perform the calibration dispense again. Pressing the
RESET button with display at zero will return the unit
to its previous calibration factor.