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TRC 1000 4.5 Hot cutter, Service Manual, Page: 60 / 67

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TRC 1000 4.5 Hot cutter Service Manual Download Page 60

VCC

F1

FUSE

F2

FUSE

D1

IRL540N/TO

2

1

3

D2

IRL540N/TO

2

1

3

R1

R2

R3

R4

R1

4

6

08X-102/SIP

D3

IRL540N/TO

2

1

3

R1

R2

R3

R4

R2

4

6

08X-102/SIP

D4

IRL540N/TO

2

1

3

D5

IRL540N/TO

2

1

3

D6

IRL540N/TO

2

1

3

D7

IRL540N/TO

2

1

3

D8

IRL540N/TO

2

1

3

D9

MUR420

1

2

D10

MUR420

1

2

D11

MUR420

1

2

D12

MUR420

1

2

D13

MUR420

1

2

D14

MUR420

1

2

D15

MUR420

1

2

D16

MUR420

1

2

MG1

MOTOR 

STEPPER

1

2

3

4

5

6

MG2

MOTOR 

STEPPER

1

2

3

4

5

6

Summary of Contents for 1000 4.5 Hot cutter

Page 1: ...Service Manual for 1000 Series Strip cutters Rev 1 1 6 6 22 ...

Page 2: ...Length 10 Cut Time 11 How Many 11 Operating Screen 12 Stopping the Machine 12 Model CC4 and CC7 Setup 12 Start Up Procedures 13 Keyboard Commands 13 Entering a Program 13 Feed Rate 13 Length 14 Cut Time 15 How Many 15 Stopping the Machine 15 Model HC4 FS Setup 16 Start Up Procedures 16 Periodic Maintenance and Repairs 16 Tools needed 17 Linear Shafts Bearings and Air Cylinder shafts 18 Drive and T...

Page 3: ...r cord and heating element testing 33 Heating Element Replacement 34 Integrated Cutoff Switch Installation Instructions 36 Adjusting LCD Contrast 39 Control Panel Calibration 40 Calibration Method 1 40 Calibration Method 2 40 Replacing Main Fuse 41 Type 1 41 Type 2 43 Replacing Circuit Board Fuse for Drive Rollers 43 Troubleshooting 45 Controller Troubleshooting 45 Cutter Troubleshooting 48 Checki...

Page 4: ...ould be placed on a sturdy table free from wobble or other movement 3 Care should be taken with loose fitting sleeves and long hair when around the cutting unit s feed rollers 4 Unit should be disconnected from the electrical and air supply before any service work is performed 5 Unit should be allowed to cool off for a minimum of 2 hours before any service work is performed 6 Only qualified person...

Page 5: ...tter 14 x 7 x 14 120VAC Single Phase Min 60 PSIG TRC 1000 7 Cold Cutter 14 x 11 x 14 120VAC Single Phase Min 60 PSIG TRC 1000 5 Alternating Angle Cutter 18 x 10 x 14 120VAC Single Phase Min 40 PSIG TRC 1000 Prepuller 11 x 14 x 8 120VAC Single Phase N A TRC 1000 Foot Switch Cutter 18 lbs 12 x 8 5 x 10 120VAC Single Phase Min 40PSIG Control Panel All 10 x 14 x 6 120VAC Single Phase N A 35 lbs 35 lbs...

Page 6: ... a 1000 Series Cold Cutter 4 5 cutter with a Variable Speed Controller Similarly TRC 1000 HC7 CS would identify a 1000 series Hot cutter in 7 cutting capacity with a Constant Speed Control panel It is worth noting that Cutter Heads can be used with either Variable Speed VS Controllers or Constant Speed CS Control Panels Other Identifiers that may be used include the following AA Alternating Angle ...

Page 7: ...stand We will use the terms infeed side and outfeed side as well as motor side throughout this manual Figure 1 The side view of this cold cutter is representative of the HC4 HC7 CC4 and CC7 cutters with some minor differences between the hot and cold cutter models Note the side facing the reader is opposite the motor side of the cutter Outfeed side Infeed side Material Feed Direction Roller Tensio...

Page 8: ...he press to lock fittings Set the air supply pressure at 40 PSI If connected correctly the blade carrier should move to the up stroke position 3 Set the roll stand on the infeed side of the cutter and line it up with the guides Place one plastic disk on the roll stand shaft then feed webbing roll on to shaft so webbing rolls off the top side of the roll Place the other plastic disk on the roll sta...

Page 9: ...e webbing through the feed rollers Take the webbing past the rollers an inch or so You can also put the webbing through the rollers by pushing down on the black knob and lifting the rollers and pushing the webbing through Note If your machine is equipped with the optional cutoff switch you must feed material under the trip rod before the guides NEVER ALLOW THE KNIFE TO BECOME RED HOT AS THIS MAY C...

Page 10: ...hen the control panel is turned on the loading screen and version number will be displayed The next series of prompts will be cut settings The first prompt will be for feed rate FEED RATE 5 22 figure 3 will appear on the LCD This will determine how fast the material will feed through the machine in inches While our machines can feed up to 22 inches per second the speed required to run the machine ...

Page 11: ... necessary to get the proper cut time 1 medium weight poly pro webbing will cut in about 75 seconds or 3 4 of a second How Many Figure 6 This is the number of pieces that you want to cut figure 6 After typing in a number and BEFORE you push the Enter key you will want to insert the material through the feed guides pushing it up to the feed rollers Press and hold the FEED JOG button until material ...

Page 12: ...ogram again just push ENTER and it will continue with the program you had entered When you use RESET or the master switch you will lose the program meaning you will have to follow the prompts again and enter the desired program values in again When finished with machine operations simply turn thermostat and master switch off and allow to cool Remove material from machine to prevent material from m...

Page 13: ...rds the rollers Turn master switch to the ON position Feed the webbing through the guides and push it up to the feed rollers and then push the FEED JOG button on the control panel This will take the webbing through the feed rollers Take the webbing past the rollers an inch or so You can also put the webbing through the rollers by pushing down on the black knob and lifting the rollers and pushing t...

Page 14: ...o 22 inches per second the speed required to run the machine successfully will largely be determined by the material being cut We recommend starting somewhere in the middle and working up if necessary Older machines may not have variable speed in which case this prompt will be omitted Type in the desired speed and press ENTER Length Figure 9 The Next prompt will be for length Type in the desired l...

Page 15: ...ton and cut off the webbing This will give you a fresh cut to start with Now with the correct piece count entered in press ENTER and the machine will start cutting When the number of pieces that were entered have been cut the machine will stop If you wish to run the same program again just push ENTER and it will run the same program again while maintain a running count of both program runs Stoppin...

Page 16: ...knob to 3 and allow 10 15 min for the knife to heat up NEVER ALLOW THE KNIFE TO BECOME RED HOT AS THIS MAY CAUSE THE WEBBING TO CATCH ON FIRE Use just enough heat to cut the webbing You will have to experiment with the webbing you are using to find the exact temperature that works best 3 Place material across cutting plate KEEPING HANDS CLEAR OF KNIFE 4 When material is in desired position with HA...

Page 17: ... Wire strippers crimpers Small angle cutting wire cutters Again not everyone who buys a TRC Industries 1000 series cutter will need the items in the second list those who choose to do advanced work on their machines including circuit board repairs should only do so if familiar with circuitry and at their own risk As a note most of the TRC 1000 series strip cutters are made of aluminum While 6061 T...

Page 18: ...ure 12 as well as any strings or pieces of fabric wrapped around the rollers when safe to do so Having foreign materials stuck to your rollers will cause abnormal feed lengths Guide boxes guides should be moved periodically such that material feeds through the machine over different parts of the roller Alternating the contact point of the roller and material will help the rollers last as long as p...

Page 19: ...er part AM4 7a Bottom Top Roller AM4 6a split from heat The heat guards on this machine were removed and heat was left on without machine running leaving the roller to face the heater block on this side until the rubber degraded The top roller can be repaired the bottom one cannot ...

Page 20: ...imum grip of the material without creating excessive drag and premature bearing failure Too little pressure will cause material slippage Finding the right amount of pressure will likely be a matter of trial and error Different types of material as well as different thicknesses may require adjustment to run correctly Figure 13 Side view of the roller tensioner assembly Jam Nut Adjustment nut ...

Page 21: ... sufficient pressure to prevent the pulley from rotating on the shaft The pulleys should also be in line with each other to prevent wear of the sides of the belts The pulley guard should not contact either of the pulley or the belt Figure 14 The pulley guard has been removed from this machine revealing the belt drive and roller pulleys The four motor bolts are also visible now Motor Bolts 4 ...

Page 22: ... for the bolts that connect it to the heater block HC4 3 or HC7 3 This allows for proper alignment of the Hot knife blade so that it lands squarely in the V Shaped groove in the Cutting plate HC4 5 or HC7 5 The Cutting plate can wear out over time and accelerated wear will occur if the blade strikes the edges of the V This can lead to poor cut quality Figure 15 top view of two cutting plates a new...

Page 23: ...de assembly removed from machine for better visualization of proper blade alignment in blade groove Note it is possible to install this plate upside down only one side the top has a blade groove so make sure to install correctly ...

Page 24: ...ck is cool to the touch remove air and disconnect controller from power To adjust for misalignment Lower blade and heater block assembly so that it rests on the cutting plate Determine which side of the blade is lowest Loosen the upper nuts Raise the lower nut of the low side so that it is level with the higher side Make sure the knife blade edge is seated firmly in the cutting plate groove from e...

Page 25: ...should be sent back to TRC Industries for sharpening Attempting to sharpen the front of the bevel as one would with a typical knife blade will result in a secondary bevel and poor cut quality This also may cause the blades to be impossible to resharpen For this reason it is recommended that blades in need of sharpening be sent back to TRC Industries The alignment of these blades is also very impor...

Page 26: ...lower elbows AM 13C from air cylinder with a wrench Loosen jam nut at blade carrier Remove air cylinder mounting nut Unscrew air cylinder shaft from blade carrier and remove Screw new air cylinder shaft into blade carrier and tighten jam nut NOTE During installation of shaft into blade carrier be careful not to nick shaft as this will ruin the air cylinder seal Align bottom port of air cylinder to...

Page 27: ...the machine to cool to prevent contact with hot surfaces Using the top roller tensioner handle tilt the machine 90 degrees figure 17 up onto the outfeed side of the machine to gain access to air valve The air valve is located just right of stepper motor It may be helpful to loosen the top two button head bolts that hold the base plate in so the plate can hinge open Figure 18 Machine set upright on...

Page 28: ...achine is a cold cutter Some adjustment to close the set screws on the air valve may be necessary depending on air pressure Blades should not slam up or down Ideally the blade makes a smooth down stroke followed by a smooth return The screw on the left side of the air valve is for cylinder retraction up The screw on the right is for cylinder extension down Air Valve adjustme nt screws ...

Page 29: ...pring arm bolt and remove spring arm from motor side AM 1R Remove all screws securing side plate to center plates There are between 12 and 14 depending on the model of cutter Separate side plate from the cutter chassis being careful not to pull the cable from the motor to the DB 15 connector at the infeed side of the machine Do not pull out any of the wires With the motor side plate of the machine...

Page 30: ... or resurfaced top roller can be put inserted back into the machine through the side plate hole Make sure the roller shaft engages the bearing in the Spring Arm opposite the side plate hole the roller was removed from Replace the Spring Arm making sure to engage the shaft in the bearing correctly Replace the Spring Block by pressing the spring AM 2 onto the Spring arm stud with the Spring block st...

Page 31: ...to be sufficient tighten the jam nut against the spring block locking the adjustment in place Figure 20 Parts of the Spring Tension Adjustment Drive Belt adjustment Disconnect the machine from power Remove the two screws securing pulley guard and remove the pulley guard Inspect the inside of the guard for signs of contact with the pulleys Loosen the four bolts securing motor Do not remove the bolt...

Page 32: ...y power to the machine and test the roller jog function Care must be taken to keep hands and fingers out of the belt line Belts should not slip during operation and pulleys should not slip on the roller or motor shaft If slip is detected the pulleys will need to have shaft set screws tightened Once satisfactory the guard should be reattached Drive Motor Replacement Drive motors should last years i...

Page 33: ...rnating Current so wire orientation is not important We recommend installing the DB 15 connector first using the jack screws and nuts Reinstall spade terminals to cutoff switch if so equipped Cutoff switches have three terminals Common normally open and normally closed The wires should be connected to common and normally open These are the bottom two terminal connections After connecting the air v...

Page 34: ... to circuit board Disconnect power and air to machine Allow machine to cool down sufficiently to avoid contact with hot machine parts Remove the four outfeed side guard plate screws and guard plate Using a flat blade screw driver disconnect heating element from terminal block 7 hot cutters will have two heater elements these will both need disconnected in the same manner Remove the bottom screw se...

Page 35: ...nd secure Set Screw s ensuring the element is centered in the heater block for HC4 models and with heater ends pushed in up to the wires on HC7 models Lead wires should be pointed up toward the terminal block connection Set screws should be hand tightened only Over tightening of these screws is the single most common cause of element failure Bend the leads of the Heating Element s toward Terminal ...

Page 36: ...Reconnect Air Hoses and check for proper knife operation Test Unit to for proper heating Replace Guard Plate before operating machine Integrated Cutoff Switch Installation Instructions The Integrated Cutoff Switch is designed to stop the machine when material supply is exhausted This feature can be purchased on any new TRC 1000 series machine or added on to any existing 1000 series machine The add...

Page 37: ...s Re install heat shrink tubing Heat the top portion first closest to connector and secure with zip tie Heat shrink lower part and trim Re install DB 15 connector in back plate and secure with jack screws and nuts Re orient the machine so it is sitting in its normal configuration with bottom plate down Looking at the infeed side through the hole where the guide plate was two small 6 32 threaded ho...

Page 38: ...ide of the shaft tighten set screw Locate and install the 3 16 trip rod into the side arm installed in the last step Tighten set screw to secure With these two rods and side arm installed the trip lever can be located correctly on the pivot shaft Move the trip arm over the switch and set to actuate micro switch when trip rod is resting in notches of side plates Be sure to leave a small gap between...

Page 39: ...pply power and test cutting unit for proper operation Unit should stop when trip rod is down An OUT OF MATERIAL message will appear when cutoff switch is activated To continue cutting replenish machine with material Be sure to remove any remaining partial sections of material from machine before resuming cutting operations Use the feed jog once material is inserted into the rollers to advance mate...

Page 40: ...made via one of the two methods below Calibration Method 1 Turn the power switch to the on position Hold down the key and continue holding through the start screens until Steps in appears The default calibration factor for these machines is 4300 That is 43 00 steps per inch If your material is cutting short increase the number by typing in a value more than 4300 Since there are 43 steps per inch e...

Page 41: ...latile memory therefore once the machine is powered off the calibration factor will reset If the calibration factor was noted it can be reprogrammed upon starting the machine Newer circuit boards Version 2 4 and up can have nonvolatile memory added so calibration factors will be saved even after the machine is shut off and will resume at the last programmed calibration factor once powered up again...

Page 42: ... accessible The fuse can be tested for continuity while in tray A small screwdriver can be used to pry the fuse out Note that fuses may appear intact so a continuity test is the only way to determine if the fuse is operational There should only be one fuse in the tray Most machines with this tray type use an 8 amp slow blow fuse These are not typically found in automotive or hardware stores anymor...

Page 43: ...The second fuse on the TRC 1000 series strip cutters is on the circuit board This fuse or set of fuses in the case of the TRC 1000 Alternating Angle Cutter is mounted directly to the board and can only be accessed by opening the control panel Whether they are on top of or on the underside of the board depends on the version To replace newer bottom of circuit board fuses Disconnect control panel po...

Page 44: ...om cutter head Locate the DB15 connector at the back of the control panel There are two jack screws holding this connector in place Loosen and remove them Remove the panel screws located around the lower perimeter of the control panel Open the lid of the control panel The lid may need to be propped up on it side next to the controller lower housing There are four wires from the main wiring harness...

Page 45: ...er electronics yourself can be very rewarding saving both time and money there are inherent risks involved These risks include the risk of electrocution fire burns and damage to equipment If you are uncomfortable or unsure of your ability to successfully work on your TRC 1000 please contact us to schedule repairs We will be happy to fix your machine or at least help you rule out any easy to fix is...

Page 46: ... for repairs 2 Check to make sure circuit board power connections are secure 3 Carefully remove EEPROM 40 pin chip Replace chip and reassemble controller to verify EEPROM chip reset If unsuccessful contact TRC Industries for repair 4 Contact TRC Industries for repair Control Panel accepts information but will not run or continue a program 1 Optional cutoff switch faulty 2 Optional cutoff switch st...

Page 47: ...heck to see if material is wound around rollers or otherwise causing jam Clear any jams 4 Reduce spring pressure Spring pressure adjustment can be found in Spring Tension Adjustment section 5 Check control cable for damage and make sure it is plugged in and connector screws tightened 6 Replace motor 7 Contact TRC Industries to replace FET driver Main fuse in power receptacle blows as soon as power...

Page 48: ...al wandering back and forth on rollers 2 Material hanging up on guide strips or guide box 3 Material curved 4 Rollers worn 5 Too little spring tension on top roller 1 Adjust feed guides to more closely guide material into rollers 2 Check guide box for burrs or misaligned guides and adjust as necessary 3 Straighten material as best as possible and try cutting again 4 Check rollers for wear and if p...

Page 49: ...alibration section Erratic feed roller operation or intermittent reversal 1 Bad control cable or loose connection 2 Blown FET or drive board 3 Bad motor 4 Loose pulleys 5 Worn Drive belt 6 Older circuit board program needs updated 1 Check control cable for damage and continuity Make sure connections are secured with cable screws 2 Contact TRC Industries for replacement FET 3 Contact TRC Industries...

Page 50: ...ulty terminal block connections 3 Bad thermostat 1 Check heater element with multimeter for continuity and resistance 2 Check terminal block wire connections to make sure they are solidly connected 3 Replace thermostat Knife does not jog or move 1 Gummed up shafts or linear bushing 2 No air pressure to knife air cylinder 3 Bad air cylinder 4 Air valve needs adjusted 5 Bad triac or driver on circui...

Page 51: ...procedure found in Hot Knife Blade Adjustment Section 4 Contact TRC Industries for more cutting options 5 Check regulator for minimum of 40 PSIG Check air connections for leaks Checking for Electrical problems Unplug power cord heater cord and control cable from the back of the control panel Open Control panel by removing the case screws and lifting the top up and back Visually check for loose wir...

Page 52: ... of the way Loosen the 4 terminal strip screws Loosen each of the terminal screws with a small flat blade screwdriver Remove the four wires red black white and purple Remove the 4 screws securing the board to the bottom of the panel top Lift circuit board out terminal block side first Handle with care Note Be careful not to scrape the circuit board with any sharp or pointed objects such as a screw...

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Page 60: ...3 R1 R2 R3 R4 R2 4608X 102 SIP D4 IRL540N TO 2 1 3 D5 IRL540N TO 2 1 3 D6 IRL540N TO 2 1 3 D7 IRL540N TO 2 1 3 D8 IRL540N TO 2 1 3 D9 MUR420 1 2 D10 MUR420 1 2 D11 MUR420 1 2 D12 MUR420 1 2 D13 MUR420 1 2 D14 MUR420 1 2 D15 MUR420 1 2 D16 MUR420 1 2 MG1 MOTOR STEPPER 1 2 3 4 5 6 MG2 MOTOR STEPPER 1 2 3 4 5 6 ...

Page 61: ...en pins To the left is a drawing showing the pin numbers and locations Using a digital ohm meter set on the lowest resistance range measure between pins 1 and 3 1 2 ohms 2 and 3 1 2 ohms 1 and 2 2 3 ohms 6 and 8 1 2 ohms 7 and 8 1 2 ohms 6 and 7 2 3 ohms Readings may be slightly higher or lower depending on your meter calibration A reading of 0 ohms indicates that the winding in shorted A reading ...

Page 62: ... 3 ohms 9 and 11 1 2 ohms 10 and 11 1 2 ohms 9 and 10 2 3 ohms Readings may be slightly higher or lower depending on your meter calibration A reading of 0 ohms indicates that the winding in shorted A reading of infinity indicates the winding is open In either case the motor is no good and must be replaced Operation of a defective motor can lead to burned out transitors on the drive board ...

Page 63: ...nge Blue Brown Grey Green Red Black White Purple Yellow Orange Grey Green Red Blue Black P1 CONNECTOR DB15 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1 P2 CONNECTOR DB15 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1 P3 CONNECTOR DB9 5 9 4 8 3 7 2 6 1 P4 CONNECTOR DB9 5 9 4 8 3 7 2 6 1 ...

Page 64: ...ses when angle head reaches home position Cutoff Switch Knife Solenoid TRC 1000 Main Feed Motor TRC 1000 Angle Motor Oriental PK268 03B P1 CONNECTOR DB15 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1 P2 CONNECTOR DB9 5 9 4 8 3 7 2 6 1 MG1 MOTOR STEPPER 1 2 3 4 5 6 MG2 MOTOR STEPPER 1 2 3 4 5 6 SW1 SW SPST 1 2 SW2 SW SPST 1 2 ...

Page 65: ... shorted if it is melted The screws that secure the transistors to the heat sink should be fairly tight The insulating strip underneath of the transistors should not have any holes in it besides the screw hole Pins Condition 1 2 Open 2 3 Open 1 3 Open 2 Metal Tab Closed 3 GND Closed Open equals infinite resistance Closed equals zero resistance ...

Page 66: ...Drive Transistor Test ...

Page 67: ...rs Over the last 29 years TRC has made countless changes and improvements to 1000 series lineup If the answers you are looking for are not to be found in this manual give us a call or send us an email and we will do our best to help you We appreciate your business and look forward to serving your cutting needs in the future We would like to thank Ray Foster for his service and dedication to TRC In...

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