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
V
Motor
3

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
Yel
Known Value
��
Known Value
+
-
4

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
5

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
6

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.
7

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
8

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.
AC
AC
+
-
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
9

ON/OFF
Switch
Red
Black
Power Cord
Chassis Ground
WhiteWhite
Green
Green
Motor
Black
Fuse
Red
Step 1
110-120 AC
V
--
++
Power switch ON.
Cord plugged in.
Meter on AC Volts
Red
Black
Power Cord
White
White
Black
Fuse
Red
Green
--
Step 2
110-120 AC
V
--
Power switch ON.
Cord plugged in.
Meter on AC Volts
Red
Black
Power Cord
WhiteWhite
Black
Fuse
Red
Green
--
++
Step 3
110-120 AC
V
--
Power switch ON.
Cord plugged in.
Meter on AC Volts
Red
Black
Power Cord
WhiteWhite
Black
Fuse
Red
Green
--
++
NO
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
NO
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
10

Switch
Motor
White Wire
Black Wire
Power Cord
Green Wire (GND)
Switch
Motor
Power Cord
Green Wire (GND)
Step 1
110-120 AC
V
--
++
Power switch ON.
Cord plugged in.
Meter on AC Volts
--
Switch
Motor
Power Cord
Green Wire (GND)
Step 2
110-120 AC
V
--
++
Power switch ON.
Cord plugged in.
Meter on AC Volts
--
NO
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
NO
Black
Black
Black
Black
Green
White
White
Green
Green
White White
Green
Motor will not run.
RTX 900, 1250 and TX 90, 125
11

NO
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.
See pages 00, for the steps.
Replace the
power switch.
NO
See step 4.Do you have
over 100 AC volts? NO
NO
YES
RotoFlex Motor or Compressor motor will not run.
RTX 750 and RTX 1000
See step 3.Do you have
over 100 AC volts?
Repair or
replace Black wire
from power cord to
power switch.
NO
YES
See step 5. Do you have
over 100 AC volts?
Repair or
replace Black
wire or wire splice.
Repair or
replace White
wire or wire splice.
12

CAPACITOR
BLACK
BLACK
BLUE
YELLOW
GROUND
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
BLACK
GREEN
POWER
SWITCH
SELECTOR
SWITCH
AIR COMPRESSOR
POWER
CORD
MOTOR
BLUE
WHITE
WHITE
BLACK
GREEN
POWER
CORD
Step 1
Cord plugged in.
Wires connected.
Meter on AC Volts
110-120 AC
V
--
++
--
WHITE
WHITE
BLACK
GREEN
POWER
CORD
Step 2
Cord plugged in.
Wires connected.
Meter on AC Volts
110-120 AC
V
--
++
--
Step 3
Power switch ON.
Cord plugged in.
Wires connected
to power switch.
Meter on AC Volts
110-120 AC
V
--
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
WHITE
BLACK
POWER
CORD
++
Step 4
Power switch ON.
Cord plugged in.
Wires connected
to power switch.
Meter on AC Volts
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
WHITE
BLACK
POWER
CORD
++
--
Step 5
Power switch ON.
Cord plugged in.
Black Wire unplugged
from Selector switch.
Meter on AC Volts
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK BLUE
WHITE
BLACK
POWER
CORD
++
--
RotoFlex Motor or Compressor motor will not run.
RTX 750 and RTX 1000
13

CAPACITOR
BLACK
BLACK
BLUE
YELLOW
GROUND
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
BLACK
GREEN
POWER
SWITCH
SELECTOR
SWITCH
AIR COMPRESSOR
POWER
CORD
MOTOR
BLUE
RotoFlex Motor motor will not run.
RTX 750 and RTX 1000
Step 1
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
--
WHITE
WHITE
BLACK
GREEN
POWER
CORD
To Motor
Yellow
++
Power switch ON.
Cord plugged in.
Wires connected
to selector switch.
Selector switch ON.
Meter on AC Volts
Step 2
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
--
WHITE
WHITE
BLACK
GREEN
POWER
CORD
To Motor
Yellow
++
Power switch ON.
Cord plugged in.
Wires connected
to selector switch.
Selector switch ON.
Meter on AC Volts
YES
See step 1.
Do you have
over 100 AC volts?
Repair or
replace White
wire or wire splice.
See step 2.
Do you have
over 100 AC volts?
See Capacitor
test. Does the
Capacitor test ok?
Does the
Air Compressor
motor run?
YES
NO See Motors
will not run.
NO
NO
Replace the
Rotoflex Motor.
Repair or
replace Black
wire or wire splice.
NO
Replace the
Capacitor.
YES
YES
14

CAPACITOR
BLACK
BLACK
BLUE
YELLOW
GROUND
GREEN
GREEN
BLACK
BLACK
WHITE
WHITE
BLACK
GREEN
POWER
SWITCH
SELECTOR
SWITCH
AIR COMPRESSOR
POWER
CORD
MOTOR
BLUE
Air Compressor Motor motor will not run.
RTX 750 and RTX 1000
Step 1
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
--
WHITE
WHITE
BLACK
GREEN
POWER
CORD
To Motor
Yellow
++
Power switch ON.
Cord plugged in.
Meter on AC Volts
Step 2
110-120 AC
V
--
POWER
SWITCH
SELECTOR
SWITCH
BLACK
BLUE
--
WHITE
WHITE
BLACK
GREEN
POWER
CORD
To Motor
Yellow
++
Power switch ON.
Cord plugged in.
Meter on AC Volts
YES
See step 1.
Do you have
over 100 AC volts?
Repair or
replace White
wire or wire splice.
See step 2.
Do you have
over 100 AC volts?
Does the
Rotoflex motor
run?
YES
NO See Motors
will not run.
NO
NO
Repair or
replace Black
wire or wire splice.
Replace the
Air Compressor.
YES
15

Motor/Air
Compressor
Cylinder Valve
Coil 15D560
N/O Main
Power Switch
117693
N/C Primer Switch 119064
Open in
Prime Mode
The Switch will remain closed
until air flow is present. The
Gun being triggered or a Air
Leak will cause the ball to lift up
and open the circuit.
Main Valve Coil
287326
N/C Air Flow
Sensor Switch
287326
15D559
Valve
assembly
RTX 1500 Electrical and Air Ladder Diagram
Power cord plugged in and Power Switch Off .
120V
Load Blk Neutral Wht
M
Grnd
Air Flow
Air Flow
Air
Compressor
Sensor Switch
Coil
45psi
Exhausted
Air
Air Cooler
Exhausted
Air
Air
Regulator
Air
Coil
Cylinder Valve 15D560:With
Coil Voltage Applied. This will allow air
to be exhausted and the weight of the
motor to push the cylinder rod in and
remove tension on the Roto Flex Hose.
15D559
Valve assembly
Cylinder Valve
Gun Valve
KEY
Air Flow
Electrical Switching Circuit
Exhausted
Air
16

Motor/Air
Compressor
Cylinder Valve
Coil 15D560
N/O Main
Power Switch
117693
N/C Primer Switch 119064
Open in
Prime Mode
The Switch will remain closed
until air flow is present. The
Gun being triggered or a Air
Leak will cause the ball to lift up
and open the circuit.
Main Valve Coil
287326
N/C Air Flow
Sensor Switch
287326
15D559
Valve
assembly
120V
Load Blk Neutral Wht
M
Grnd
Air Flow
Air Flow
Air
Compressor
Coil
45psi
Exhausted
Air
Exhausted
Air
Air Cooler
Exhausted
Air
Air
Regulator
Air
Coil
Cylinder Valve 15D560:
With Coil Voltage Applied. This will
allow air to be exhausted and the weight of the
motor to push the cylinder rod in and remove
tension on the Roto Flex Hose.
15D559
Valve assembly
Gun Valve
RTX 1500 Electrical and Air Ladder Diagram
Power cord plugged in and Power Switch ON
KEY
Air Flow
Electrical Load Circuit
Sensor Switch
17

Motor/Air
Compressor
Cylinder Valve
Coil 15D560
N/O Main
Power Switch
117693
N/C Primer Switch 119064
Open in
Prime Mode
The Switch will remain closed
until air flow is present. The
Gun being triggered or a Air
Leak will cause the ball to lift up
and open the circuit.
Main Valve Coil
287326
N/C Air Flow
Sensor Switch
287326
15D559
Valve
assembly
120V
Load Blk Neutral Wht
M
Grnd
Air Flow
Air Flow
Air
Compressor
Coil
45psi
Exhausted
Air
Exhausted
Air
Air Cooler
Exhausted
Air
Air
Regulator
Air
Coil
Cylinder Valve 15D560 : With
No Coil
Voltage.This will allow air to enter the
cylinder and push the cylinder rod out and put
tension on the Roto Flex Hose.
15D559
Valve assembly
Gun Valve
KEY
Air Flow
RTX 1500 Electrical and Air Ladder Diagram
Power cord plugged in and Power Switch ON and IN the PRIME MODE
Electrical Switching Circuit
Sensor Switch
18

Motor/Air
Compressor
Cylinder Valve
Coil 15D560
N/O Main
Power Switch
117693
N/C Primer Switch 119064
Open in
Prime Mode
The Switch will remain closed
until air flow is present. The
Gun being triggered or a Air
Leak will cause the ball to lift up
and open the circuit.
Main Valve Coil
287326
N/C Air Flow
Sensor Switch
287326
15D559
Valve
assembly
120V
Load Blk Neutral Wht
M
Grnd
Air Flow
Air Flow
Air
Compressor
Coil
45psi
Exhausted
Air
Exhausted
Air
Air Cooler
Exhausted
Air
Air
Regulator
Air
Coil
Cylinder Valve 15D560:
With Coil Voltage Applied. This will allow
air to be exhausted and the weight of the
motor to push the cylinder rod in and remove
tension on the Roto Flex Hose.
15D559
Valve assembly
Gun Valve
RTX 1500 Electrical and Air Ladder Diagram
Power cord plugged in and Power Switch ON and Gun Trigger Closed
KEY
Air Flow
Electrical Switching Circuit
Sensor Switch
19

Motor/Air
Compressor
Cylinder Valve
Coil 15D560
N/O Main
Power Switch
117693
N/C Primer Switch 119064
Open in
Prime Mode
The Switch will remain closed
until air flow is present. The
Gun being triggered or a Air
Leak will cause the ball to lift up
and open the circuit.
Main Valve Coil
287326
N/C Air Flow
Sensor Switch
287326
15D559
Valve
assembly
120V
Load Blk Neutral Wht
M
Grnd
Air Flow
Air Flow
Air
Compressor
Coil
45psi
Exhausted
Air
Exhausted
Air
Air Cooler
Exhausted
Air
Air
Regulator
Air
Coil
Cylinder Valve 15D560 :
With No Coil Voltage.This will allow air
to enter the cylinder and push the cylinder rod
out and put tension on the Roto Flex Hose.
15D559
Valve assembly
Gun Valve
KEY
Air Flow
RTX 1500 Electrical and Air Ladder Diagram
Power cord plugged in and Power Switch ON and Spray Gun Trigger Open .
Electrical Switching Circuit
Sensor Switch
20