Graco RTX-650 Programming manual

WARNING

This manual should only be used

by a qualified Service Technician.

First choice when

quality counts.

Texture Sprayers

Electrical & Mechinical

Troubleshooting Manual

Rev. C 10/11 /07

ti4305a

Table of Contents

Basic meter terminology and testing procedures.................................................................................................3-9

Electric Texture Sprayers

RTX 650 and TX 65:

• Motor will not start.................................................................................................................................. 10

RTX 900,1250 and TX 90,125:

• Motor will not start.................................................................................................................................. 11

RTX 750 and RTX 1000:

• Motors will not start ........................................................................................................................... 12,13

• RotoFlex Motor will not start.................................................................................................................. 14

• Air Compressor Motor will not start ....................................................................................................... 15

RTX 1500:

Operational and troubleshooting:

• Power cord plugged in and Power Switch Off ....................................................................................... 16

• Power cord plugged in and Power Switch ON........................................................................................ 17

• Power cord plugged in and Power Switch ON and IN the PRIME MODE ............................................ 18

• Power cord plugged in and Power Switch ON and Gun Trigger Closed ................................................ 19

• Power cord plugged in and Power Switch ON and Spray Gun Trigger Open......................................... 20

Gas Texture Sprayers

TexSpray 1030 FC:

• Operational Overview ............................................................................................................................. 21

• Pump will not prime................................................................................................................................22

• Pump will not spray................................................................................................................................. 23

GM 1030 TexSpray:

• Operational and troubleshooting ............................................................................................................. 24

BASIC ELECTRICAL TERMINOLOGY

In any discussion of electricity, there are three basic terms you will need to understand.

CURRENT

VOLTAGE

RESISTANCE

CURRENT:

Current is the movement of the electrical charge.

Current Flows through the wires from the power source to the load.

Current is measured in AMPERES (AMPS, A or I). See Figure 1.

NOTE: Meter is only clamped around one wire.

VOLTAGE:

Voltage is the force that causes current to fl ow in a circuit.

Voltage is measured in VOLTS (V or E). See Figure 2.

FIGURE 1

FIGURE 2

ON/OFF

Switch

Ref 58

Power

Plug

Red (+)

White

Black

Green

Black (–)

Black

from Motor

ON/OFF

Switch

Ref 58

Power

Plug

Potentiometer Ref 37

Red (+)

White

Black

Green

Black (–)

Black

120 AC

Motor

BASIC ELECTRICAL TERMINOLOGY

RESISTANCE:

Resistance is anything that causes an opposition to the fl ow of current in a circuit.

Resistance is used to control the amount of voltage and/or amperage in a circuit.

Resistance is measured in OHMS - Ω. See Figure 3.

A common component check would be motor and clutch field windings.

FIGURE 3

��

Black

Red

Yel

Known Value

��

Known Value

CONTINUITY TESTING

Checking “continuity” is one of the most common tests in electrical troubleshooting. Continuity is the ability of a wire or electrical component to

conduct current. When you use a continuity tester, you connect a circuit (the continuity tester) that you know works, to a wire or a component that

may or may not work. The continuity tester will tell you if the wire or component is capable of conducting current.

Continuity testers are available at almost any hardware store.

A volt-ohmmeter or VOM can also be used to check continuity. This meter can be purchased at most electrical or electronic supply stores.

To test a component for continuity:

1 Check the tester by connecting the leads.

* If using a test light the light should turn on.

* If using a digital volt-ohmmeter, the screen should show 00 if OL appears the meter needs to be repaired.

SWITCH TESTING-ROCKER

Common test procedure for a SPST Switch:

0.000

WIRE CONTINUITY TESTING

Continuity testing will “NOT” fi

nd wire fragmentation!!

Example:

120 Vac input static voltage and drops to 119Vac load voltage.

A good piece of wire will carry line and load voltage.

Damaged / Fragmented Wire Damaged / Fragmented Wire

Pinched Wire

120 Vac input static voltage and drops to 76Vac load voltage.

Other causes:

Poor stripping of outer insulation.

Poor crimp.

A defective piece of wire may carry line voltage but will “NOT” carry load voltage

GROUND TESTING

Every corded electric sprayer that comes into your shop for repair should be tested as described below, to make sure that it is properly grounded.

Pull the machine’s plug out of the wall outlet and connect one lead from a DC continuity test light or a VOM to the (round) ground terminal on the

plug.

NOTE:

If the ground terminal is broken off of the plug, install a new plug.

Touch the test light (or VOM) leads to several bare metal surfaces on the body of the machine. If the light (or meter) indicates continuity, the machine

is properly grounded. If the light (or meter) doesn’t indicate continuity trace through the ground (green) wiring on the machine to determine where

the break is.

Improper installation or alteration of grounding plug could results in risk of electric shock, fire or explosion that could cause serious injury or death.

The other function of the grounding plug is to protect the control board from static build up. If the plug is missing this could cause permanent damage

to the control board.

CAPACITOR TESTING:

A capacitor is an electrical component that stores electricity. Capacitors are usually used to help start a motor or make a motor run more eff

The following instructions can be used to test any capacitor.

WARNING!

A CAPACITOR CAN SHOCK YOU EVEN WHEN A MACHINE IS UNPLUGGED. NEVER TOUCH CAPACITOR TERMINALS WITH

YOUR FINGERS. ALWAYS USE TOOLS WITH INSULATED HANDLES. NEVER DISCHARGE A CAPACITOR NEAR FLAMMABLE

LIQUIDS OR VAPORS.

1 Visually inspect the capacitor for leaks, mechanically damage or loose terminals. Replace it if any of these problems exist.

2 Unplug the machine and remove the capacitor(s).

If capacitor(s) are attached to the control board the test can not be perormed.

3 “SEE ABOVE WARNING” Using a screwdriver with

insulated handles, hold so that the blade contacts the

capacitor terminals as shown in Fig. A. This will

“discharge” the capacitor.

4 Put a volt-Ohm meter on the R X 100 scale.

5 While watching the meter, connect the 2 leads to the 2 terminals on the capacitor.

If the capacitor is good, the meter needle will go to the right (toward 0 resistance) (Fig. 1), then to the left (toward - maximum resistance)

If the meter needle goes all the way to the right and stays there, the capacitor is defective.(Fig.2)

If the meter needle stays all the way to the left (doesn't move at all when connected to the capacitor), the capacitor is defective.(Fig. 3)

FIG. A

Capacitor

GOOD BAD BAD

RECTIFIER

(See Fig. 1) Now we come to the most popular application of the diode: rectifcation. Simply rectifcation is the conversion of alternating

current (AC) to direct current (DC). This almost always involves the use of some device that only allows one-way fl ow of electrons.

As we have seen, this is exactly what a diode does.

RECTIFIER TESTING:

The following instructions can be used to test any bridge rectifer.

Use a DC continuity test light or a VOM (on the R x 100 scale) for all tests.

Disconnect all wires from the rectifer.

FIG. 1

1 Connect test leads as shown in Figure A. If the meter beeps, the rectifer is

defective. If the meter does not beep, go to the next step.

2 Connect test leads as shown in Figure B. If the meter does not beep, the

rectifer is defective. If the meter beeps, go to the next step.

3 Connect test leads as shown in Figure C. If the meter beeps, the rectifer is

defective. If the meter does not beep, go to the next step.

4 Connect test leads as shown in Figure D. If the meter does not beep, the

rectifer is defective. If the meter beeps, go to the next step.

5 Connect test leads as shown in Figure E. If the meter beeps, the rectifer is

defective. If the meter does not beep, go to the next step.

6 Connect test leads as shown in Figure F. If the meter does not beep, the rectifer is defective. If the meter beeps, go to the next step.

7 Connect test leads as shown in Figure G. If the meter beeps, the rectifer is defective. If the meter does not beep, go to the next step.

8 Connect test leads as shown in Figure H. If the meter does not beep, the rectife r is defective. If the meter beeps, the rectifer is good.

0.000

OL OL 0.000

0.000

OL OL 0.000

FIG. A FIG. B FIG. C FIG. D

FIG. E FIG. F FIG. G FIG. H

DC DC

ON/OFF

Switch

Red

Black

Power Cord

Chassis Ground

WhiteWhite

Green

Motor

Black

Fuse

Red

Step 1

110-120 AC

Power switch ON.

Cord plugged in.

Meter on AC Volts

Red

Black

Power Cord

White

Black

Fuse

Red

Green

Step 2

110-120 AC

Power switch ON.

Cord plugged in.

Meter on AC Volts

Red

Black

Power Cord

WhiteWhite

Black

Fuse

Red

Green

Step 3

110-120 AC

Power switch ON.

Cord plugged in.

Meter on AC Volts

Red

Black

Power Cord

WhiteWhite

Black

Fuse

Red

Green

See step 2. Do you have

over 100 AC volts?

YES

See step 1.Do you have

over 100 AC volts?

YES

Repair or

replace the

power Cord.

Replace the

power switch.

Replace Motor

See step 3.Do you have

over 100 AC volts? NO

YES

Check the 3amp

Fuse, if ok repalce

fuse holder.

Motor will not run.

RTX 650 and TX 65

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