TRC 1000 Series Service Manual

Strip cutters

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Service Manual for 1000

Series Strip cutters

Rev 1.1 6/6/22

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Troubleshooting

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Summary of Contents for TRC 1000 Series

Page 1 Service Manual for 1000 Series Strip cutters Rev 1.1 6/6/22...
Page 2: Table Of Contents
Safety Information for TRC-1000 Strip Cutters ..................4 Specifications ............................5 Model Identification ..........................6 Nomenclature ............................. 7 Setting Up and Using your new TRC 1000 Series Strip Cutters ............8 Model HC4 and HC7 Setup ......................8 Start Up Procedures ......................... 8 Keyboard Commands ........................10 Entering A program ........................
Page 3 Hot Knife Cutters: ........................... 22 Hot Knife Blade Adjustment ......................24 Cold Knife Cutters: ......................... 25 Cold Cutter Blade Adjustment ..................... 25 Replacing an air cylinder ......................26 Adjusting the Air Valve ........................27 Feed Roller Replacement ......................29 Top Roller Replacement ........................ 30 Spring Tension Adjustment ......................
Page 4: Safety Information For Trc-1000 Strip Cutters
Safety Information for TRC-1000 Strip Cutters Congratulations on the purchase of your new TRC 1000 Strip cutter. TRC Industries has been manufacturing and servicing the TRC 1000 series strip cutters since 1993. These cutters are solidly built, easy to use machines that will last a lifetime with proper care and maintenance.
Page 5: Specifications
Specifications Model Weight Dimensions Power Requirements Requirements TRC 1000 4.5” 14” x 7” x 14” 120VAC Single Min. 40 PSIG 35 lbs Hot cutter Phase TRC 1000 7” 14” x 11” x 14” 120VAC Single Min. 40 PSIG 40 lbs...
Page 6: Model Identification
All the cutters in our first generation of cutting machines (spanning from 1993 until the time of this publication) are part of the “TRC 1000 Series.” Model numbers beginning with the “HC” designation are Hot Cutters. Models beginning with the “CC” Designation are cold cutters. The following digits, either a “4”...
Page 7: Nomenclature
Nomenclature Throughout this manual we will be referring to sides of the machine as well as its parts. The diagrams below should be used as a reference to help the instructions in this manual easier to understand. We will use the terms “infeed side” and “outfeed side” as well as “motor side” throughout this manual.
Page 8: Setting Up And Using Your New Trc 1000 Series Strip Cutters
Setting Up and Using your new TRC 1000 Series Strip Cutters Model HC4 and HC7 Setup Place control panel and cutter on a flat table with the back of the control panel facing the side of the cutter. Plug the black heater cord cable from the cutter into the control panel.
Page 9 Each cutter comes standard with three sets of guides, as seen here. Figure 2: view from the infeed side of the machine, with feed guides visible. • Turn master switch to the ON position. • Set the temperature control knob to 3 and allow 10 - 15 min. for the knife to heat up. The first few times the machine is heated up, the machine may emit the smell of hot oil.
Page 10: Keyboard Commands
Keyboard Commands FEED JOG Allows you to manually operate the feed rollers KNIFE JOG Allows you to manually operate the knife RE-SET Allows you to clear the machine and start a new program STOP Allows you to stop the machine and save all data in the memory. The STOP function Also allows you to clear a data entry while programming –...
Page 11: Cut Time
The Next prompt will be for length(figure 4). Type in the desired length and press ENTER. For example, 15 inches will be typed in as “15”. For decimal values, use the “*” key. For example, 15.5 inches would be typed as “15*5” Cut Time Figure 5 Next, “Cut Time?”...
Page 12: Operating Screen
Operating Screen Figure 7: screen during operation. The operating screen will be displayed during operation (figure 7). The operating screen displays the following: Top left: Programmed Part length, in inches Top right: Programmed cut time, in seconds Bottom: Running total of programmed parts cut so far Stopping the Machine To stop the machine during operation and not lose the data you have entered, push the STOP button and hold it down until the machine stops.
Page 13: Start Up Procedures
Connect the air regulator to the cutter head via the press to lock fittings. Set the air supply pressure at 60 PSI. If connected correctly the blade carrier should move to the up- stroke position. 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.
Page 14: Length
Figure 8 When 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 " will appear on the LCD. This will determine how fast the material will feed through the machine, in inches.
Page 15: Cut Time
Cut Time Figure 10 Next, “Cut Time?” will appear on the LCD. This is amount of time in seconds the blade will cycle for. The maximum time that most cutters can cut for is 2.4 seconds, but this varies depending on chip version. We recommend starting at 0.5 seconds an increasing as necessary.
Page 16: Model Hc4-Fs Setup
When finished with machine operations, simply turn the master switch off. Model HC4-FS Setup Place cutter on a flat table. Route footswitch to a safe comfortable place on the floor. Foot switch can be secured with carpet tape or similar double-sided tape. Next hook up the air regulator to your air supply and set the pressure at 40 PSI.
Page 17: Tools Needed
As a note, most of the TRC-1000 series strip cutters are made of aluminum. While 6061-T6 is a superb material for manufacturing rugged machines, it has its limitations. Use caution when tightening screws and bolts, to avoid stripping the threaded holes.
Page 18: Linear Shafts/Bearings And Air Cylinder Shafts
Linear Shafts/Bearings and Air Cylinder shafts: keep clean of dust, lint and other foreign substances. These points should also be lubricated periodically with a light weight oil, such as sewing machine oil. Oil linear bearings here Drive and Tension Rollers : Remove any melted materials stuck onto rollers (figure 12), as well as any strings or pieces of fabric wrapped around the rollers when safe to do so.
Page 19 Figure 12: Rollers in poor condition. Top: melted plastic stuck onto bottom roller (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;...
Page 20: Springs
Springs: Depending on the model of TRC 1000 that you are operating, there will be springs to tension to top roller as well as the knife blades. Proper tension on the top roller will allow optimum grip of the material without creating excessive drag and premature bearing failure.
Page 21: Drive Belt And Pulleys
Drive Belt and Pulleys: Periodically the drive belt cover should be removed. Underneath there are two pulleys. These should be checked to make sure the set screws that hold them in place have 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.
Page 22: Cutting Blades And Cutting Plates
Cutting Blades and Cutting Plates Hot Knife Cutters: The Cutting Blade (HC4-4 or HC7-4) and Groove on the Cutting Plate should be scraped clean. Periodically check all screws for loosening. On hot knife models, the Hot Knife Blade Carrier (HC4-2 or HC7-2) has slotted holes for the bolts that connect it to the heater block (HC4-3 or HC7-3).
Page 23 Figure 16: Hot cutter blade 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: Hot Knife Blade Adjustment
Hot Knife Blade Adjustment Figure 17: An outfeed side view of the hot knife assembly, with parts labeled Hot knife blades should be checked often for proper alignment. Misalignment will cause damage to the blade and cutting plate and result in poor cut quality. Hot knife blades should be adjusted only after the machine has been allowed to cool down to prevent contact with hot surfaces.
Page 25: Cold Knife Cutters
This problem is encountered mostly after removal of side plates to replace drive roller. Cold Knife Cutters: The TRC 1000 series cold cutter features durable A2 steel blades, ground to a fine apex on precision grinding machines. These blades can dull, and should be sent back to TRC Industries for sharpening.
Page 26: Replacing An Air Cylinder
Use the adjusting screws in the top blade carrier to tilt blade in or out. Tilting the top left corner of the blade out, will pull the trailing edge of the blade in. Only slight adjustments are required to make a noticeable difference. Too much angle adjustment can cause premature blade wear.
Page 27: Adjusting The Air Valve
This is especially important for TRC 1000 hot knife models, as the knife slamming against the cutting plate (HC4-5) will can cause wear to the alignment groove as well as premature rounding of the blade edge.
Page 28 Air Valve adjustme nt screws Figure 19: top view of machine from figure 17. The base plate has been hinged open for better access to the air valve. The two brass adjustment screws are visible. Note this particular machine is a cold cutter. •...
Page 29: Feed Roller Replacement
Feed Roller Replacement Worn rollers can affect machine accuracy and feeding of material. Top rollers on all TRC 1000 series cutters can be resurfaced several times by contacting TRC Industries. Bottom rollers cannot be resurfaced, because their diameter and the precise movement of the stepper motors create accurate material lengths.
Page 30: Top Roller Replacement
With the Spring Arm removed, the top roller can be pulled horizontally out the side of the machine. Top rollers can be resurfaced many times. To have your top roller resurfaced, contact TRC Industries. • The new or resurfaced top roller can be put inserted back into the machine through the side plate hole.
Page 31: Drive Belt Adjustment
• Turn the adjustment nut to either increase or decrease the amount of threaded bolt protruding from the spring block. The more bolt that is protruding, the more compressed the spring will be, resulting in higher load on the rollers. •...
Page 32: Drive Motor Replacement
Once satisfactory, the guard should be reattached. Drive Motor Replacement Drive motors should last years if spring tension is adequate but not excessive. Replacement drive motors can be purchased from TRC Industries wired and ready to install. To replace a drive motor: •...
Page 33: Thermostat, Heater Cord And Heating Element Testing
• 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 bolts, simply loosen them to allow the motor to move freely back and forth in its milled slots.
Page 34: Heating Element Replacement
• Performing the above test at the terminal block on cutting head with heater cord plugged into control panel will aid in determining the condition of the heater cord. • If voltages are correct at these points and machine doesn't heat up then the heating element is bad.
Page 35 Figure 21: The bottom bolts on the linear motion block have been removed, and the top ones loosened. This allows the entire assembly to be rotated to access the heater element. • Loosen Set screw(s) on side of the Heating Block and remove Heating Element. It may be necessary to drive the Heating Element out of the Heating Block.
Page 36: Integrated Cutoff Switch Installation Instructions
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.
Page 37 • (2) Plastic Spacers • (1) Trip Lever • (5) 6-32 set screws • (2) connection wires with spade connectors • (1) section of heat shrink tubing for the DB-15 Connection • (2) zip ties • Disconnect machine from power and allow to cool to prevent contact with hot machine parts.
Page 38 Groove in side plate for trip Pivot Rod hole Threaded cutoff Switch holes Figure 23: Pivot rod switch visible here, as well as threaded holes for the switch itself. Note this machine has the guide plate installed with groove facing down. •...
Page 39: Adjusting Lcd Contrast
removed, the assembly should move so the trip rod falls down into the notches on the side plates, actuating the switch. Some adjustment may be necessary to get this to work correctly. • Machines that were purchased without cutoff switch will have the guide plate installed with the trip rod groove facing down.
Page 40: Control Panel Calibration
• Remove control panel screws • Open lid of control panel. Inside you will see the underside of the circuit board (pictured above). • A variable resistor, shown in the photo, can be turned with a screwdriver. Turn about a quarter turn clockwise.
Page 41: Replacing Main Fuse
Once the desired calibration factor has been determined for the part being cut, it is recommended to note this factor. Older TRC 1000 machines were not equipped with nonvolatile memory; therefore, once the machine is powered off, the calibration factor will reset.
Page 42 It can be accessed by prying the tray open with a small flat blade screwdriver. The two-part tray will come out. To separate the two parts of the inner tray, lift up on the black clip, shown in the photo below, and pull out on the inner section of the tray. Lift tab, Pull tray With the inner section of the fuse tray removed, the fuse is now accessible.
Page 43: Type 2
Replacing Circuit Board Fuse for Drive Rollers 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.
Page 44 Fuse located here Figure 26: View of control panel with lid open, revealing bottom of circuit board. • Using a pair of pliers or flat blade screwdriver, the fuse can be removed and inspected. On newer boards this is a 6.25 amp slow blow fuse. DO NOT use 8A fuses on the circuit board, as this can lead to excessive heat and board damage.
Page 45: Troubleshooting
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 issues (fuse replacements and the like) before you send in for repairs.
Page 46 Contrast”. 2. Replace LCD Driver, then replace LCD if Driver alone does not fix Control Program Resets 1. LCD Bezel 1. Contact TRC unexpectedly grounding to Industries for repairs. control panel 2. Check to make sure 2. Faulty circuit board...
Page 47 4. Replace control cable 5. Remove circuit board 40 Pin chip and replace Circuit board fuses for feed 1. Older program chip 1. Contact TRC rollers keep blowing that needs to be Industries to obtain updated a newer chip 2. Excessive load...
Page 48: Cutter Troubleshooting
4. Check rollers for wear, and if possible, adjust material to feed through different section of rollers without wear. Rollers can be sent back to TRC Industries for re- grinding 5. See “Spring Tension Adjustment” section to adjust roller tension...
Page 49 Make sure 3. Bad motor connections are 4. Loose pulleys secured with cable 5. Worn Drive belt screws 6. Older circuit 2. Contact TRC board/program Industries for needs updated replacement FET 3. Contact TRC Industries for replacement motor. See section titled “Drive Motor...
Page 50 3. See section “Replacing Circuit board fuse for Drive Rollers” 4. Check cable for damage and continuity with a multimeter. 5. Contact TRC Industries for repair 6. Refer to “Drive Motor Replacement” Section Hot knife does not get hot 1. Heater element 1.
Page 51: Checking For Electrical Problems
5. Contact TRC Industries for repairs 6. See section “Replacing Circuit board fuse for Drive Rollers” and attempt to operate machine again Hot Knife does not cut all 1. Dwell time to short 1. Increase dwell time the way through material 2.
Page 52: Circuit Board Removal
The red and black wires are DC voltage. Purple, white, orange and blue are AC voltage. Green is ground and transformer secondary AC voltage. Voltage should be tested at the circuit board terminal. Circuit board removal • Unplug the control panel from both the cutter head and from power. DO NOT ATTEMPT TO REMOVE CIRCUIT BOARD WHILE ENERGIZED! •...
Page 61 Control cable test The cutter head depends on clear, uninterrupted signal from the controller in order to work. Damage to cable ends can cause poor connection, leading to many problems. If after troubleshooting the cause of a problem is still not evident, it is worth checking the continuity between corresponding pin numbers of the cable.
Page 62 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 9 and 11 = 1.2 ohms 10 and 11 = 1.2 ohms 9 and 10 = 2.3 ohms...
Page 65 Drive Transistor Test Test each of the transistors Q1-Q4 or Q1-Q8. The plastic screw insulator is usually a good indicator that the transistor is 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.
Page 66 Drive Transistor Test...
Page 67 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 Industries, and for passing on much of the knowledge that never made it to pen and paper.

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