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Emc6/4-t Sewing Peripheral Operation Manual Eds/epicor




EDS/Epicor Embroidery System EMC6/4-T Sewing Peripheral ( With Melco Head ) Operation Manual Part Number: 110023-01 Revision: B 1575 West 124th Ave. Denver, Colorado 80234 U.S.A. ALL RIGHTS RESERVED Printed in the United States of America by Melco Industries, Incorporated. No part of this publication may reproduced, stored in a retrieval system, or transmitted by any means(electronic, mechanical, photocopying, recording, or otherwise) without the written approval of Melco Industries. All precautions have been taken to avoid errors, or misrepresentations of facts, equipment, or products. However, Melco Industries does not assume, any liability to any party for loss damage caused by errors or omissions. Rev. B: March 1992 Table of Contents 1. Introduction and Setup Basic Description of the EDS/Epicor Embroidery System 1- 1 The EMC6/4 -T Sewing Peripheral 1- 2 Physical Arrangement 1- 2 Assembly of the EMC6/4 -T 1- 3 Rear Covers 1- 3 Table Tops 1- 6 Safety Center Switch 1- 7 Getting Power To Your System About Electrostatic Discharge 1- 8 1- 8 EMC6/4 -T Network Cable Connections 1 - 10 Configuration of the EMC6/4-T Sewing Peripheral 1 - 11 Configuration Mode 1 - 11 Setting the Machine Program 1 - 11 Selecting the Unit Number 1 - 12 2. Peripheral Operation A Word About Needles 2- 1 Changing Your Needles 2- 2 Threading the Heads 2- 3 Threading The Thread Tree 2- 4 Threading the Primary Tensioner 2- 6 i Threading the Needle 2- 8 Mechanical Jump Stitch 2- 9 Bobbin Tension 2 - 10 Setting The Upper Tensions 2 - 11 Preparing Your Material 2 - 12 Flat Goods Hooping 2 - 12 Loading The Hoop 2 - 15 Loading the Cap Frame 2 - 16 Hat Hooping 2 - 16 Introduction To The Keyboard And Menus 2 - 17 Design Transfer 2 - 18 Menu Descriptions 2 - 19 EMC6/4-T Sewing Peripheral Keyboard 2 - 20 Key Combinations 2 - 22 Menus for the Sewing Peripheral 2 - 23 DESIGN MENU 2 - 24 To Delete A Design 2 - 25 COLOR MENU 2 - 27 COLOR MENU Entry Characters 2 - 28 Change Now Command 2 - 30 RUN DESIGN 2 - 31 FRAME MENU 2 - 34 RETURN TO ORIGIN 2 - 36 ii TRACE MENU 2 - 37 HOME MENU 2 - 39 MOVE MENU 2 - 43 HEAD TIMING MENU 2 - 46 TRIM MENU 2 - 47 RESET MENU 2 - 49 EMC6/4-T Sewing Peripheral Error Message List 3. Operator Maintenance 2 - 50 3- 1 Cleaning Of The EMC6/4-T Sewing Peripheral 3- 1 Cleaning Your Peripheral 3- 1 Cleaning The Table Tops 3- 2 Lubrication Of The EMC6/4-T Sewing Peripheral Lubricating The Sewing Head Sewing Head Synchronization 3- 2 3- 4 3- 6 Head Resync Procedure 3- 7 EMC6/4-T Sewing Head Timing 3 - 10 Replacing Needles 3 - 12 Needle Depth 3 - 12 To Adjust the Needle Depth: 3 - 12 If the Needle Depth needs Adjustment: 3 - 14 Hook Timing 3 - 15 Hook Timing Procedure (Hook already installed on Sewing Head) 3 - 17 iii Retaining Finger Adjustment: 3 - 19 Trimmer Operation And Maintenance 3 - 20 Sequence of Trim Events 3 - 21 Trimmer Maintenance 3 - 22 Trimmer Troubleshooting 3 - 24 iv 1-1 EDS/Epicor Embroidery System EMC6/4 -T (With Melco Head) Sewing Peripheral 1. Introduction and Setup This Operation Manual assumes that the reader has attended a Melco Training Class where the process of computerized embroidery is discussed in detail. This guide describes the operation of the EMC6/4 -T Sewing Peripheral. It does not discuss the general process of computerized embroidery. The EMC6/4 -T, with Automatic Color Change, Thread Break Detection and Automatic Thread Trimmers, is one of eight different Melco EDS/Epicor Embroidery System Sewing Peripherals. The EMC6/4 -T Operation Manual is divided into three sections. The first introduces the reader to the Sewing Peripheral and its assembly. When shipped the peripheral is partially dissembled and requires some simple reassembly before use. The last topic discussed in Section One is the Peripheral Configuration. Before the EMC6/4 -T can embroider, it must be able to communicate with the EDS/Epicor computer. In order to send and receive job data the computer recognizes which of the eight different Melco peripherals its communicating with. Each peripheral has a specific configuration that must be set the first time the peripheral is installed in the EDS/Epicor Network. Section Two describes the basic operation of the Sewing Peripheral, threading the heads and needles, hooping flat goods and caps, the keyboard menus and error messages you may see during operation, and how to correct the error. Section Three presents peripheral maintenance; cleaning and lubrication. Basic Description of the EDS/Epicor Embroidery System The Melco EDS/Epicor Embroidery System combines two basic units. These units are the EDS/Epicor Computer, and the Sewing Peripheral. These two basic components work together as a system to help produce high quality embroidered goods. EMC6/4-T Operation Manual 1-2 The EDS/Epicor computer will control up to sixteen different Melco Sewing Peripherals, in almost any combination. When the peripheral is loaded with a design (job), it can run by itself which frees the computer for other tasks. The EMC6/4 -T Sewing Peripheral The EMC6/4 -T Sewing Peripheral has four, 6 needle sewing heads. It sews both flat goods and caps in a 11"x16" sewing area. It can hold up to sixteen different embroidery jobs in the peripheral’s Design Buffer. The Peripheral can sew the same job as often as needed. It will also sew sixteen different jobs, one after the other in an operator defined sequence. Physical Arrangement The EMC6/4 -T is arranged into five distinct sections: Controller Section - The Controller Section is the left rear area of the peripheral. This section contains the printed circuit boards that control the peripheral and communicate with the EDS/Epicor computer. Sewing Head Section - This section is the central area of the peripheral and has the sewing heads, needle cases, thread tensioners, color change assemblies, thread saddles and the thread trimmers. Keyboard Section - The Keyboard section is the right rear of the peripheral. This section contains a ten button keyboard, and the peripheral display. Carriage Section - This section has the X-Beam, the mechanical drives assemblies, and the X-Carriage. Trimmer Control Section- This section is found under the peripheral’s frame. It contains the Trimmer Cam Box, Actuator Shaft and Trimmer Linkages to the sewing heads. The illustration on the next page identifies these sections of the EMC6/4 -T. Melco Industries, Inc. 1-3 Sewing Head Section Controller Keyboard Section Section Trimmer Control Section Carriage Section The 5 Sections of the Peripheral Assembly of the EMC6/4 -T The EMC6/4 -T is partially disassembled for shipment. This requires the customer preform some simple reassembly upon the receipt of the peripheral. The Read Me First document, helps with the unpacking of the peripheral and separating the Peripheral Parts from Accessories. This portion of Section One describes and illustrates these reassembly procedures. All the tools required for these procedures are provided in the Tool Pouch found in the Operator’s Kit shipped with the machine. The reassembly involves installing the Rear Covers, Table Tops, Safety Center Switch, Thread Tensioners, the Thread Trees and Thread Saddles. Rear Covers There are five (5) Rear Covers on the EMC6/4 -T. These are numbered in the following illustration. Cover# 5 Cover# 4 Cover# 3 Cover# 2 Keyboard Cover# 1 EMC6/4-T Operation Manual 1-4 1. Locate the Rear Covers and the 12 Button Head screws and washers to attach the Covers to the rear of the machine. The Rear Covers are packed in one of the smaller boxes that were packed under the machine. The screws and washers are already in place on the rear of the frame. Remove the screws and washers before installing the Covers. The Keyboard Cover (# 1) is placed inside an anti-static bag to protect the Keyboard from electrostatic discharge during shipping. Remove the Keyboard Cover from the bag. Keep the anti-static bag in case you should need to send a PC board back to the factory for repair. Melco Industries, Inc. 1-5 The covers are installed in the following order; Cover # 1, Cover # 2, Cover # 3, Cover # 5 and Cover # 4 (last). Each Cover has front mounting tabs that snap into position just behind the Table Top mounts. Two screws attach each cover to the rear of the machine’s frame. 2. Begin with the Keyboard/Cover # 1. Remove the two screws from the mounting holes in the back of the frame. The keyboard is connected to the CPU board with a ribbon cable. This cable will be in position on the right side of the Frame (when looking at the front of the machine). The cable is "keyed", so that the cable can only be connected one way. Plug the loose cable end onto the Keyboard connector. 3. Now place cover # 1’s front mounting tabs under the end of the right Y-Channel, shown in the next illustration.. "Rock" the cover back into place, the rear of the cover will now be over the rear edge of the frame and the two holes in the cover should match up with the two holes in the frame. Reinsert the two screws and washers. 4. Rear Cover # 2, overlaps Cover # 1 on the front left side. Cover # 2’s front mounting tabs slip under the Rear Cover Support between Sewing Heads # 1 & # 2, and is screwed to the back of the frame as cover # 1. 5. Rear Cover # 3 fits between Heads # 2 & # 3. Its front mounting tabs slip under the Center Y-Channel as Cover # 1 fit under the Right Y-Channel, and screws to the back of frame in the same manner. 6. Install cover # 5 on the left side of the machine as you did Cover # 1, on the right side. (No cables to attach on this cover.) 7. Cover # 4 (the last cover) overlaps both covers # 3 & # 5. Use the two button head screws to attach the rear of the cover to the back of the machine’s frame. Cover # 4 is the electronics cover, and must be removed to change, add, remove the CPU board, cable etc. All of the rear covers should be secured to the EMC6/4 -T Frame at this time. EMC6/4-T Operation Manual 1-6 Table Tops The Table Tops are the next item to be assembled. First locate the box with the table top pieces inside. You should also find twelve (12) Thumb Screws in a small plastic bag packed in the same box. 1. Sub assembly of the Table Top pieces is done at the factory, all you have to do is place the right and left ends in their correspondong positions and screw in the Thumb Screws under the table top to lock them in place. 2. Place the Center Table Top Section on the center Y-channel. Thread and tighten the Thumb Screws from under the Table Top. 3. Now place the remaining pieces between the center and end pieces and push then into place against the front of the EMC6/4 -T frame. Center Piece Right End Piece Left End Piece Table Tops Melco Industries, Inc. 1-7 Safety Center Switch A safety switch is placed under the Center Section of the Table Top. This switch is not a power switch, but rather will stop the needles from sewing when the Red side of the switch is pressed, and will start the sewing again when the Green side is pressed. The switch is placed in the center of the machine to prevent the necessity of having to reach around the heads when they are sewing, in order to stop the peripheral for any reason. There is a wire harness in the frame where the Center Section of the Table Top attaches. The accompanying illustration identifies which wire connects to which lead on the switch. The switch is already installed in the Center Section of the Table Top, all you need to do is connect the three wires according to the illustration. Red Wire Black Wire Brown Wire Red Side Front Edge of Table Top Green Side Safety Center Switch EMC6/4-T Operation Manual 1-8 Getting Power To Your System All computers are affected by the quality of the power that is supplied to them. Your new EDS/Epicor System Peripheral is no different. The power supplied by your local power company can be adversely affected by electrical storms and by other users in the vicinity of your operation. We suggest that you have a dedicated power line to the outlet(s) that you use for your system. Even with a dedicated line "spikes" or "surges" in the incoming power can damage any computer or peripheral(s). To reduce the possibility of this kind of damage, a "surge protector" should be used to "smooth out" the voltage and give a consistent "clean" power source for your equipment. Each peripheral, as well as the computer, should have surge protection. Most surge protectors (also called line conditioners) have multiple plug outlets so that more then one piece of equipment can be plugged into it. Surge protectors and Line Conditioners are available from your distributor or Melco. See the next page in this manual for an example of a suggested wiring layout for your EDS/Epicor system. About Electrostatic Discharge Electrostatic Discharge (ESD), more commonly called static electricity, is a problem facing anyone using electronic devices. At home when you walk across the carpet, and then reach for the door knob, you may notice a slight shock, see a small spark shoot out between the door knob and your hand; what you experience is an Electrostatic Discharge. This type of electrical "charge" can be generated in the human body in many ways. The most common is walking across a carpet. But an electrostatic charge can be generated by standing outside on a dry windy day, or walking across a concrete floor with leather soles on your shoes. The charge that can be generated in this manner is fatal to electrical devices and components; like your computer, peripherals and the printed circuit boards inside them. You do not have to touch them, just pass your hand over them at a close distance and the damage is done. You may not even feel the discharge but it is there. Typical circuit boards used in our industry today run on 5 to 24 volts of electricity. A typical static charge can be in excess of 2,000 volts, with many being in excess of 20,000 volts. A static discharge of 100 volts can destroy a circuit board in your peripheral, or computer. Protecting your system from ESD is important for trouble free operation. There are any number of good static protection products readily available in most computer stores today. These range from simple to complex schemes. Melco Industries, Inc. 1-9 What scheme you use should depend on where your shop is located. If your EDS/Epicor System is in a residential area you may not need the ESD protection you would if your shop was located in a heavy commercial area. You can reduce static problems by following the suggestions shown below: • Maintain a relative shop humidity between 45 and 75 percent. • Do not place your EDS/Epicor System or Peripherals on carpeting. • If you must use carpeting, use a low pile type. Low pile carpets do not generate as large a static charge as high pile types. • Use a static control mat for the operator to stand on. These mats should be connected to common ground with the equipment. • If you choose not to use a static control mat, and must use carpeting, periodically spray your work area with an anti-static spray. Spray more frequently during periods of low humidity. Whatever you choose to do about static electricity, please do something about it. Using the simplest precaution of spraying an anti-static solution on a carpet can prevent an expensive repair, and lost production time. Choosing to protect your EDS/Epicor system from damage by static electricity could be one of the best cost reduction methods you employ. EMC6/4-T Operation Manual 1-10 EMC6/4 -T Network Cable Connections The Network cable connection(s) for the EMC6/4-T are found on the back of machine’s frame just below Cover # 4. These connections allow your EMC6/4 -T to be networked to an existing system or to be the only peripheral on a system. If you already have an Epicor System, decide in where you wish to place the EMC6/4 -T. Using the illustration below connect your new peripheral in its place. CAUTION: DO NOT TURN THE POWER ON TO THE PERIPHERAL BEFORE YOU MAKE THESE CONNECTIONS. Network configurations can be of only one type of peripheral or a mix of different type peripherals, In the figure on this page we present the simplest network configurations. The most important thing to remember about the network is the Terminator. This short piece of cable must be installed in the last machine in the network chain, see the figure on this page. Melco Industries, Inc. 1-11 Configuration of the EMC6/4-T Sewing Peripheral NOTE: For operation the EDS/Epicor Computer must be functional, and the Network Cable installed. The Sewing Peripheral is not a functionally stand alone unit, without the Network installed designs cannot be sent to the peripheral. Configuration Mode There are two items that must be set (configured) by the operator and must set before the peripheral is used for the first time. These are; the Machine Program, and the Unit Number. The Machine Program tells the EDS/Epicor computer which peripheral type it is talking to. The Unit Number allows the computer to send designs to the correct peripheral on the network. The Machine Program and Unit Number are set in the Configuration Mode, and only when turning the peripheral on for the first time. The Machine Program remains the same, you may change the Unit Number at any time using the following directions. Setting the Machine Program 1. To access the Configuration Mode, be sure that the Network Cable is installed. Turn the power on at the peripheral. 2. Go to the Peripheral Keyboard, the Display should be flashing on and off and there maybe a random message displayed. (Disregard this message.) Locate and then press the keys ALT, UP and DOWN ARROW keys simultaneously. The Display will stop flashing and will read: CHECKING RAM This message will last a few seconds and then a new message will appear. Release the three keys. The peripheral is now in the Configuration Mode. 3. The new message should be the name of one of sewing peripherals. All of the peripherals are listed in the message, use the UP or DOWN ARROW keys to scroll through message. Choose EMC6/4M and then press the [ENTER] key. When the Enter key is pressed at this point, the Peripheral is in the Configuration Mode and you have selected the Machine Program. EMC6/4-T Operation Manual 1-12 NOTE: It is most important that you select the correct Peripheral Type when you select the Machine program. Choosing the wrong Peripheral Type can cause serious operational problems when trying to embroider. Selecting the Unit Number The EDS/Epicor Computer must be able to identify each unit independently in order to assign jobs (send designs). So each Peripheral must have a unique UNIT NUMBER. The operator may assign any number between 1 and 16 to any peripheral as long as no one number is repeated. The order of the peripherals on line is not important, so you could have an arrangement like the illustration shown here. After pressing the ENTER key, to set Machine Number (step 3 above), you will see the message "UNIT--" shown on the display. The number that comes up on the display will be random from 1-16. Use the UP or DOWN ARROW keys as before to select the UNIT NUMBER. When you reach the number you want, press the [ENTER] key to set the Unit Number. You may reset the Unit Number any time you wish as long as the peripheral is not sewing. Melco Industries, Inc. 2-1 2. Peripheral Operation In this section of the manual you will learn about using the EMC6/4-T Sewing Peripheral. How to Thread the Sewing Heads, Thread and Bobbin tensions, and how to hoop a garment or a hat. You will also learn about the Peripheral’s Keyboard, the Menus, special features and Error Messages and how to send a design from the Epicor Computer to the Sewing Peripheral. Before we thread the head , you should know a little about Needles ....... A Word About Needles The Needle you use to embroider is perhaps the most important part of the sewing head. The world of sewing needles can be baffling for the beginning embroider. There are about 900 different types and styles of needles commonly used in the embroidery industry today, with about 100 types that are most frequently used. Most machines are designed to use a number of types of needles, some are limited to ceratin styles that can be used. Melco’s Sewing Head is designed to use a specific "SYSTEM NUMBER" series of needle (listed below). This System allows a wide variety of point shapes ( ie; SUK ,SES, etc. )for use with Melco’s sewing heads. The needles supplied with your machine, those that are installed when you received your peripheral and those supplied in the Operator’s Kit, are a mid-range type and are perhaps the most commonly used. System Number 16x257 or 16x231 Canu Number (Catalog Number) See illustration on the next page. 14:25 Nm Number (Number Metric) See illustration on the next page. 80/12 SUK (medium ball point needle) also used 65/9 70/10 75/11 90/14 EMC6/4-T Operation Manual 2-2 Point Shapes vary with the types of material being sewn the most common is SUK (medium ballpoint). NOTE:16x257 is the Schmetz System Number Needle shipped with the Peripheral. 16x231 is an equivalent needle of different manufacture. For more information about needles contact your needle supplier. Changing Your Needles Changing needles is relatively fast and easy. That is why it’s such a good insurance for quality embroidery. The following steps explain how to replace needles on your Melco Sewing Head. The Needle is held in place by the Needle Clamp Needle Clamp Set Screw. See the illustration on this page. You will need a small flat bladed screw driver and the replacement needles. The screw driver is found in the Operator’s Tool Pouch, supplied with your machine. Melco Industries, Inc. 2-3 1. With the screwdriver, loosen the Needle Clamp Set Screw (turn counterclockwise) just enough so you easily slide the needle down and out of the Needle Bar. 2. Take your new needle and with the Scarf pointing towards the rear of the sewing head, push the new needle into the Needle Bar and tighten the Needle Bar Set Screw. Threading the Heads Your EMC6/4-T Sewing Peripheral may come partially threaded from the factory, still, you must know how to thread your machine for future use. While at first, threading the sewing heads will seem a difficult task, it gets easier and quicker with just a little practice. The following instructions and illustrations will guide you through the process. The EMC6/4T has four (4) Sewing Heads, each with six needles that must be threaded to use. There are three areas of the Sewing Head involved in the threading process, they are: A.) The Thread Tree and Saddle Assembly. B.) The Pre-tensioners and the Tensioners. (Both tensioner types combined into one Assembly.) C.) The Needle Case and Needles. Thread each needle, one at a time, through the areas listed above, until all six needles of each head are threaded. EMC6/4-T Operation Manual 2-4 Thread Tree Tensioner Assembly and Saddle Rear Saddle Needle Case Catch Needles General Sewing Head Parts Threading The Thread Tree 1. Threading the Thread Tree is the first step. If you have not already installed your Thread Trees and Saddle Assemblies, do so now. Look at the Thread Tree, notice that it has three small holes along the sides and six larger holes across the front. Place the cones of thread in the sides of the Thread Saddle. 2. Locate thread cone # 1 and pull off about 12 - 18 inches of thread. Bend the "end" of the thread over on itself (when you do this the end of the thread is now called the"Tag") and twist the Tag between your finger tips. Using a single piece of thread and trying to thread the sewing head can be a very frustrating operation. Using the Twisted Tag Method reduces the frustration and speeds the process. 3. Look at the illustrations and locate Thread Position # 1, begin threading at the side of the Thread Tree, and then to the Front. Do this for all Six Needles on all Four Heads. Let the Tag end of the thread drap loosely over the front of the tree, or use a piece of tape to hold the thread down until you thread the Pre-tensioners and Tensioners. Melco Industries, Inc. 2-5 Threading the Pre-tensioners The Pre-tensioners and primary tensioner assembly apply tension to the individual threads. Thread tension requirements can change for many reasons, different fabrics, different threads, density of fills in a design, can affect thread tensions. Deriving appropriate thread tensions comes from practice and experience. In general your thread tension should be tight enough to prevent the bobbin thread from being pulled up through the top material and loose enough to allow smooth thread path movement. A major cause for thread breaks is improper tensioning of the thread. 1. Look at the illustration on this page. The Six Pre-tensioners are at the top of the assembly, above the Primary Tensioners and are numbered left to right 6 through 1. Upper Thread Eyelet Pre-tensioner Rotary Disk Pigtail Tensioner Take Up Spring Lower Thread Eyelet Thread Path Tensioner Assembly EMC6/4-T Operation Manual 2-6 2. Above the pre-tensioner is a row of eyelets, these act as thread guides for individual threads. Thread the tag end of the thread through the eyelet. 3. Pass the thread to the left side of the pre-tensioner, and pull the thread between the pre-tensioner rotary disks. Refer to the Tensioner Assembly Illustration. 4. Turn the Pre-tensioner knob Clockwise to increase tension on the rotary disks, if required. Enough tension on the thread is needed to keep the thread from "jumping"out between the rotary disks during sewing. 5. Loop the thread around and through the Guide Post (also called a "pigtail"). See the Guide Post Illustration on this page. Loop Thread in direction shown. Guide Post (Pigtail) Threading the Primary Tensioner 1. Look at the Tensioner Assembly Illustration on the previous page. Following the thread path, bring the thread down to the tensioner and then wrap the thread 1 and 1/2 times around and between the Tensioners Rotary Disks. 2. Loop the thread through the Take Up Spring, then around the lower pigtail and through the lower eyelet. Pull enough thread through the Tensioner Assembly so that it is not pulled back out of the assemblies’ rotary disks. Let the thread drape down over the Needle Case. Melco Industries, Inc. 2-7 Threading the Needle Case 1. The thread should now be hanging down in front of the Needle Case. Look at the illustration on this page. 2. Thread the tag end through the middle thread guide (A), follow the thread path up to the take up lever (B). 3. Thread the tag through take up lever eyelet from left to right. And then back down to the Middle Thread Guide (A). 4. Follow the thread path down to the lower needle case eyelets (C). Pull enough thread through the needle case keep from pulling the thread out of the take up lever. Let the thread drape over the needle. C A Left Side B Right Side D Needle Case E Thread Path F EMC6/4-T Operation Manual 2-8 Threading the Needle 1. Pass the thread around the Needle Thread Guide. 2. With the Needle’s scarf facing the back of the machine, thread the tag through the eye of the needle from front to back. 3. Continue pulling the thread through the Presser Foot, bring the thread up to the thread holder (a horizontal spring) directly above the Needles. Press the thread against the spring, this will hold the thread until the first stitch of that needle. Leave about 1/2 to 2 inches of thread loose on top of the thread holder. The Sewing Head is now threaded and ready to embroider. Melco Industries, Inc. 2-9 Mechanical Jump Stitch Each sewing head has a Mechanical Jump Stitch Lever, which, when engaged pushes a plunger to prevent the machine from sewing, but still allows the head to rotate. The Lever is located on the left side directly behind the Needle Case. To actuate the Jump Stitch Lever push it up to engage and pull down to disengage. You would use the this feature for example; to disengage one or more sewing heads , or if you only wanted one sewing head to verify a sewout. Note: Do Not use the Mechanical Jump Stitch Lever while the sewing heads are operating. Jump Stitch Soleniod Soleniod Plunger Jump Lever Stitch Lever De-actuated Lever Actuated Front View Parts hidden from view are shown shaded EMC6/4-T Operation Manual 2-10 Bobbin Tension Set the Bobbin Tension by adjusting the set screw through the spring on the Bobbin Case, See the following figure. Once you have set the Bobbin Tension you seldom have to change it again, until you replace the Bobbin, of course. Side Front View View Set the Bobbin Tension as follows: a) Using an appropriately sized screw driver (found in the Tool Kit), adjust the set screw until you feel a slight resistance when you pull the thread from the Bobbin. (You should be able to hold the Bobbin Case by the thread, and no thread will feed through the Bobbin.) b) When you gently "jiggle" your hand, only a slight amount of bobbin thread should feed out of the Bobbin Case. (See the illustration above.) When you load the Bobbin into the Hook Assembly; make certain there is no more than 2 to 4 inches of thread hanging from the Bobbin. Excess bobbin thread has a habit of winding around the back of the Hook Assembly and binding the shaft. Generally, the Hook Assembly must then be removed to clear the obstruction. Melco Industries, Inc. 2-11 Setting The Upper Tensions The Thread Tensions should be set at the factory for most materials you will be sewing on. Shipping and handling of the machine can cause variations. (To check the thread tensions from this point on, you will need your peripheral powered up and networked to the EDS/Epicor Computer.) 1) On the EDS/Epicor computer create a program using the Full Block alphabet. Make it with at least four letters (capital’s work best). 2) Transfer the design following the directions in the EDS/Epicor Manual, or see page 2-16 of this manual. 3) Following the instructions in this manual, sew out the design. Remove the hoop and turn the sewout over, to see the underside. Use the illustration below as a guide for determining your tension. (This must be done for each needle of each sewing head.) < 1/3> EMC6/4-T Operation Manual 2-12 If your sewout looks like the left side of the figure on the previous page, then your tensions are correctly set. If your sewout looks like the center or left side, follow the steps below to correct the thread tensions. a) If the sewout like the center of the figure, the top tensions are too loose turn the Upper Tensioners CLOCKWISE. b) If the sewout looks like the right side of the figure , the Top Tensions are too tight - turn the Upper Tensioners COUNTERCLOCKWISE. Repeat these steps for each needle of each head until you are satisfied with the tensions. Remember that tensions change with different threads, needles and base sewing fabrics. Preparing Your Material (Hooping) Whether you are sewing flat goods or caps, you are ready to place your material into an appropriate hoop -- this is called hooping. (Connecting the hoop to the machine is called -- loading.) The EMC6/4-T has the versatility of sewing both flat goods (garments) and caps. Hooping flat goods is the same for all of the sewing peripherals available for the EDS/Epicor system. Hooping flat goods is discussed first. Caps and Cap Frames will be discussed just a little later. If you already have a Melco Sewing Peripheral then you can skip this section. If this is your first peripheral please continue. Flat Goods Hooping Proper hooping of your material can make the difference between a professional looking product or a sloppy piece of work. Whenever you hoop material, make sure that it is straight, fold free and as tight as possible in the hoop. Follow the steps on the following pages as a guide to proper hooping. Melco Industries, Inc. 2-13 Hoop Mounting Bracket Adjusting Screw Outer Hoop Inner Hoop 1.) Obtain an appropriately sized hoop for the design you wish to embroider. The design should fit comfortably within the hoop area, yet not include an abundant amount of extra material (i.e., use the smallest possible hoop for the overall design). NOTE: The Trace Menu discusses how to check for the design fitting into the hoop. See page 2-37 in this section. 2.) Place the outer hoop on a flat, clean and sturdy surface with the hoop’s mounting bracket facing up so it does not touch the surface of the hooping area. ( See illustration on next page. ) 3.) Loosen the adjusting screw on the outer hoop. Turn it counterclockwise. 4.) Place some backing material on the top of the outer hoop. Make sure that you have enough backing to cover the entire hoop area. 5.) Place your material on top of the backing. If you are sewing the actual garment, place a straight pin at the designs center point. Then using the straight pin as a guide, manipulate the material so the design’s center is in the center of the hoop. This reduces the chance that you will run into the edges of the hoop while sewing. NOTE: Many people prefer to make a practice sewout before doing the actual sewout on the garment. Though it is not essential, making a practice EMC6/4-T Operation Manual 2-14 sewout of any design is an excellent way to insure a high quality product, and to counter any unforseen problem that may occur. You only need to run one sewing head, so it would be a time to use the Mechanical Jump Stitch levers (on page 2-7) on three of the heads. Hoop Mounting Bracket Right Way Wrong Way 6.) Press the inner hoop into the outer hoop with the fabric and backing between the hoop. Pull the outside edges of the material to tighten the material inside the hoop so that it is tightly secured and stretched "like a drum." NOTE: When sewing on knits and some jersey materials, do not stretch the inner material so tight. These materials stretch out of shape and the resulting sewout will be distorted. 7.)Turning the adjusting screw clockwise, tighten the screw. For tightly stretched material you may have to tighten and loosen the screw several times to get every thing just right. This is simply a matter of practice. It won’t take long until hooping becomes "second nature." Melco Industries, Inc. 2-15 Loading The Hoop To attach the Hoop to the Peripheral’s Y-Carriage, follow these steps: 1 ) Place the left notch against the carriage stub as shown in the figure below. 2 ) Press the Thumb lever towards the rear of the carriage. Y - Beam X- Carriage Hoop Mounting Thumb Bracket Lever EMC6/4-T Operation Manual 2-16 Loading the Cap Frame To load the cap frame you first remove the Table Top inserts from the peripheral’s sewing area. Then...... 1) Look underneath the cylinder arm and you will see the cap frame mounting bracket. Loosen the thumb screw on the bottom of the bracket. 2) The cap frame driver has a hoop bracket, just like a regular hoop. Pull out the cap frame shaft on the driver out (towards you). Snap the cap frame driver onto the X-Carriage as you would for flat goods sewing. 3) Push the cap frame shaft into the shaft hole in the mounting bracket. Tighten the thumb screw. Hat Hooping Again, proper hooping of your caps and visors can mean the difference between good and bad embroidery. Follow the steps below to hoop a cap or visor. Melco Industries, Inc. 2-17 1) Open the cap frame’s cover with the latch on the cap frame’s left side. 2) Slide the top of your cap around the cap frame. Keep the sides of the hat inside the cap hoop’s outer edges. Push the cap completely onto the cap hoop’s frame as far as possible. NOTE: If you choose to use backing, place it inside the cap before you load the cap onto the frame. 3) Snap the brim holder over the cap’s brim. 4) Close the cap frame’s cover. Remember to try to get the cap as straight, fold free and as tight as possible in the cap frame. Introduction To The Keyboard And Menus While designs are sent to the peripheral from the EDS/Epicor computer, the Sewing Peripheral as a unit is controlled from the Keyboard. It is from the Keyboard that the Menus and Functions of the Sewing Peripheral are accessed. The Keyboard consists of ten keys and a LCD (Liquid Crystal Display). The Menu key, the ALT (Alternate) key, four direction keys UP, DOWN , RIGHT and LEFT,called ARROW keys, an Enter key, a speed key, Fast/Slow, and the Start and Stop keys. Using these keys as described on the following pages will allow you to sew flat goods and caps using any design you choose within the size limits (11"x16" sewing field) of the Sewing Peripheral. A menu in a restaurant is a list of items or choices available for you to buy and eat. A menu in a computer program is just a list of tasks (items) and options (choices) available for that part of the program. The EMC6\ 4-T Sewing Peripheral has ten (10) menus which allow the operator to choose: a) the designs to be sewn, b) the color sequence to sew them in, c) to see that the design fits into the sewing field, d) to allow for correcting sewing errors. The sewing Peripheral can store up to sixteen (16) designs or 120,000 stitches, depending on the individual files. (A typical design is about 20 to EMC6/4-T Operation Manual 2-18 30K in memory size, and runs about 15,000 to 20,000 stitches.) These stored designs can be run over and over as long as you don’t turn the power off. Or you can use the Auto Send feature of the EDS/Epicor Software and have the design deleted automatically. These designs must come from the EDS/Epicor computer via the Network Cable to the Design Buffer in the peripheral. You access the designs (or jobs) in the DESIGN MENU and select color change (color sequence) in the COLOR MENU, and sew jobs using the RUN MENU. These first three menus are described a few pages later on in this section, as well as the other six menus. But first, you must have a design in the peripheral’s Design Buffer. Design Transfer Now that you have your sewing peripheral set up, configured, all the needles are threaded, all the threads tensioned, fabric in the Hoops, and you are ready to sew. But you don’t have a design in the peripheral’s design buffer. To transfer (send) a design from the EDS/Epicor computer to the peripheral you must have both pieces of equipment turned on and configured properly. Then.... 1. Bring up the EDS program on the computer. * We are assuming here that you already have a design ready to send. If not, then prepare one with the computer and save it to the Hard Disk. 2. At the EDS MAIN MENU choose: F10: Peripherals 3. In the Peripherals Menu choose: F2: Send Design 4. Type in the Filename a space and the the Peripheral Numberof the Design you wish to send, for example: LION 1 5. Press the [Enter] key and the design is sent to the peripheral. If you are new to the EDS/Epicor Computer we suggest that you read through Part Ten, Peripherals in the EDS/Epicor Computer Operator’s Manual(part number 11413000). This section of the EDS/Epicor manual explains, in detail, all of the aspects of sending designs from the computer to the peripheral. Melco Industries, Inc. 2-19 Menu Descriptions Before you read these menu descriptions be sure that your peripheral is connected to the EDS/Epicor computer using the network cable. And, that the machine is turned on and is configured correctly for the Sewing Peripheral you are using. In this case for the EMC6/4-T Sewing Peripheral. You sent a design to the peripheral, and now you want to know if the design is in the Design Buffer. This also a good way to learn how the Menus work in the peripheral. 1. At the Keyboard, press the [MENU] key; The display reads: DESIGN MENU 2. Press the [ENTER] key. The display now reads: MELCO 1380 The filename (MELCO) is displayed along with the design "size" in bytes (1380). Each filename (Design or job) will have the design size shown when ever it is displayed. The filename shown here is just an example, the filename you sent from the computer is the one that will be listed here. 3. If you have more than one design in the Design Buffer, and you want to see the other design names, press the one of the ARROW keys. UP ARROW moves "up" through the list. DOWN ARROW moves "down" through the list. Now you have designs in the peripheral. And you also can see how the Menus will be shown, step by step with explanations at each step. First, however, let’s look at an overview of the menus, see what each one does, and then go into detail of how they each work. EMC6/4-T Operation Manual 2-20 EMC6/4-T Sewing Peripheral Keyboard Key Name Key Function MENU Use this key to scroll through the menus. ALT The Alternate key never works by its self. It must always be used in combination with other keys. ENTER When a menu, or any item under the menu is displayed, pressing this key will select the menu or item as the functional option for operation. FAST/SLOW Melco Industries, Inc. Pressing this key toggles the Hoop Carriage speed between fast or slow. 2-21 RIGHT ARROW The main use for this key is to move the needle to the right (hoop moves left). The Right Arrow key is also used as a selector key. LE FT ARROW Using this key moves the needle position to the left of the sewing field (hoop moves to the right). UP ARROW This key moves the needle position back in the sewing field. Also used to scroll up through a menu list. DOWN ARROW This key moves the needle position down in the sewing field, and is used to scroll down a menu list. START This key is used to start the peripheral sewing, to restart after the machine STOP This key when pressed will stop any job on command. It is also used to "Frame Forward" or "Frame Backward" in the FRAME MENU. EMC6/4-T Operation Manual 2-22 Key Combinations Keys Combination Functions [ALT]+ [MENU] From the "idle" state (machine not running), repeated presses of this key combination will display the Menus in REVERSE order. [ALT]+ [ENTER] Pressing the ALT/ENTER combination from any arbitrary position in any menu will take the machine to the "idle" state. [ALT]+ [LEFT ARROW] From the idle state, this key combination will cause the needle case to move 1 needle position to the left. [ALT]+ [RIGHT ARROW] From the idle state, this key combination will cause the needle case to move 1 needle position to the right. [ALT]+ [UP ARROW] Pressing this combination while in the idle state will cause the maximum sewing speed to INCREASE in increments of 50 stitches per minute (spm) to a maximum of 750 spm. [ALT]+ [DOWN ARROW] While in the idle state or running state this key combination will cause the sewing speed to DECREASE in increments of 50 spm, to a minimum of 400 spm. Melco Industries, Inc. 2-23 Menus for the Sewing Peripheral Menus in the order they appear when using the MENU key from the idle state. DESIGN MENU This menu lists all the designs (jobs) that have been loaded (sent by the computer) into the peripheral’s memory, in the order that they were sent. The menu also allows the operator to select the design to send to the Run Buffer, and also provides a way to Delete a design from the Design Buffer. COLOR MENU The operator sets the Color Sequence from this menu. RUN DESIGN This menu puts the selected design and color sequence into the Run Buffer, requires the operator to SET HOME before sewing the first job after turning on the machine. This menu also allows the design to sew. FRAME MENU The Frame Menu permits the operator to move "forward" or "backward" through adesign to correct sewing errors. With this menu it is possible to make precise corrections. TRACE MENU Allows the operator to Trace a designs outline to be sure that fits in the sewing area and hoop selected. HOME MENU The Home Menu allows the setting of the "HOME POSITION", selecting hoop sizes for preset sewing areas and for POWER FAIL RESCUE functions. MOVE MENU Allows the operator to move the needle a precise distance within the sewing field. HEAD TIMING MENU This is a maintenance menu that enables the operator to set, correct or adjust the Needle Depth and Hook Timing of the peripheral. EMC6/4-T Operation Manual 2-24 TRIM MENU All Trim Commands are found in this menu. RESET MENU Allows for the "clearing" of stitch counts, clearing the run buffer without turn off the machine. YOU DO NOT DELETE A JOB FROM THIS MENU. DESIGN MENU The first menu you see from the idle state after you press the MENU key, is the DESIGN MENU. When the machine is not running it is in the "idle" state. When the peripheral is turned on for the first time the Design Buffer is empty. Once you send designs from the EDS/Epicor computer, the peripheral will store those designs, in memory until you delete the design from memory. IDLE STATE The Peripheral is powered, properly configured and a design has been placed in the Design Buffer. MENU 1. Press the MENU key on the peripheral’s keyboard. This displays the "Top Level" Menus available for the peripheral, for example; DESIGN MENU, COLOR MENU and the RUN MENU are Top Level menus. DESIGN MENU 2. The first Top Level menu is the DESIGN MENU. Here you will find listed all the designs that are in the peripheral’s memory. Think of these menus as a roll- a-dex, on your desk. Each roll-a-dex card has a name on it (the filename of your designs). When you find the index (Top Level menu) you can flip through the roll-a-dex and then find the specific information you were looking for (the filename). ENTER 3. Press the ENTER key on the keyboard. This allows you to enter the roll-a-dex (called a SUB-MENU or SUB-DIRECTORY). MELCO1 1380 is Melco Industries, Inc. 4. When you press the ENTER key the first filename 2-25 displayed along with the size (in bytes) of the design. Designs are listed in the order they were received from the computer. UP ARROW LION1 2245 ENTER 5. Use the ARROW keys to scroll up or down through the list of designs. 6. When you find the design you want using the ARROW keys, stop. Press the ENTER key once again to select the design. This will also put you into the next Top Level Menu. The next Top Level Menu after the DESIGN MENU is the COLOR MENU. To Delete A Design The following description is the only way to delete a design manually from the Peripheral Keyboard. You can delete a design in the peripheral’s design list from the EDS/Epicor computer, by using the AUTODELETE function. This automatically deletes the design after the job has been sewn once. You may also delete a design from the computer by using the Peripheral Extended Status Screen, in the Peripheral Menu of EDS/Epicor. To Delete a Design from the Peripheral’s Keyboard MENU 1. Press the [MENU] key. DESIGN MENU 2. If the DESIGN MENU does not come up, and another MENU is displayed, use the [UP or DOWN ARROW] keys to scroll through the Top Level Menu until you come to the DESIGN MENU. ENTER 3. Press the [ENTER] key to list the designs in the Design Buffer. EMC6/4-T Operation Manual 2-26 MELCO1 1380 LION1 2245 LION2 2260 LION1 4. If the design you wish to delete is not shown first, use the [Up or DOWN ARROW] keys to scroll through the design list. 2245 [ALT]+ [DOWN ARROW] keys, 5. When you reach the design you wish to delete, stop. 6. Press the [ALT and DOWN ARROW] simultaneously one time. This action then causes the display to read: KILL LION1? KILL LION1? [Y] 7. Use the [UP ARROW] to choose YES or the [DOWN ARROW] to choose NO [N]. KILL LION1? Y ENTER Melco Industries, Inc. 8. If you chose YES, press the [ENTER] key and the design is deleted. 9. If you chose NO, press the [ENTER ]key and you are returned to the last menu DESIGN MENU. 2-27 COLOR MENU The COLOR MENU is the next in sequence from the Design Menu. From the Idel State press the MENU key twice to get to the COLOR MENU, or press the MENU key as many times as necessary to scroll to the COLOR MENU. COLOR MENU ENTER 1. Press the [ENTER] one time after reaching the COLOR MENU. COLOR 1:123456 2. Your display now reads: COLOR 1:123456. Notice that in the display the numural 1 after the colon sign has a small black line under it. This is called a cursor. The cursor can be moved left or right using the LEFT or RIGHT ARROW keys. The display shown here is the default display for the COLOR MENU. If you don’t have a color sequence on mind or if there are no color sequences in the design, the machine will either sew Needle # 1 throughout the design; or if there are color changes the machine will sew them in the order that is shown here. RIGHT ARROW 3. Press the [RIGHT ARROW] key one time. Now COLOR 2:123456 the display now reads COLOR 2:123456. Besides moving the cursor one place to the right, the COLOR number has changed from 1 to 2. Fine and dandy, but we want Color # 2 to be Needle # 4. To change these, keep the cursor [UP ARROW]+ under the number you wish to change. Then [DOWN ARROW]press the UP ARROW to increase the value, and the DOWN ARROW to decrease the value. The display should now read; COLOR 2:143456 EMC6/4-T Operation Manual 2-28 4. Now the second color is needle # 4. The peripheral will sew the color on needle# 1 and then when the color change is seen the EMC6/4-T will pause, move to needle # 4 and begin sewing again with the new color. COLOR MENU Entry Characters The Color Menu has ten characters and a "Blank Space" that can be inserted into the Color Sequence, at the cursor, while you are creating the sequence; or later on after you have gone to another menu and find that you need to come back to the Color Menu. • Press the [UP ARROW] to cycle through the Entry Characters, they are; P, -, 0, "Blank Space", and numeruals 1 to 6. • Enter the P at the beginning of the sequence and the EMC6/4-T will pause between color changes to allow for manual thread trimming. Press the [START] key to continue sewing. (If you have a design already punched with trim commands for the peripheral , you will not need to include the Character P, unless you want to pause for some other reason during the sewing.) • Enter a (-) into the sequence to continue sewing the previous color, for example: the color sequence could look like this, 426-12. The peripheral would sew needle # 4, then change to needle # 2, and then to needle # 6, however it would ignore needle # 1 and continue sewing needle # 6 until the (-) is removed from the sequence. • Enter (0) between needles and the peripheral will stop at color changes to allow for changing threadcones (colors). This is for designs using more then six colors. • The "Blank Space" allows repeating of a sequence within a design. An example is the Athletic Fill Alphabet. Each letter has 2 colors. The order of sewing is the 1st letter fill then the 1st letter border, 2nd letter fill and 2nd letter border and so on. Th color sequence for this would be two needles followed by "Blank Spaces". Blanks, do not show on the display. Press [ALT]+ [DOWN ARROW] for "Blank Spaces". • The numerals 1-6 repersent the needle positions. • The maximum number of characters in a Color Sequence is 24 characters. Melco Industries, Inc. 2-29 • The maximum number of characters shown the display is 16 characters. • When the color sequence is full of characters, an Error Message is displayed: COLOR LIST FULL NOTE: A complete list of error messages of the Sewing Peripheral are shown and discussed at the end of this section of the Manual. With the Entry Character P in the front of the sequence the EMC6/4M will pause at each color change for hand trimming of the thread. Placing the P at the begining of sequence will cause the machine to pause at each color change. It would not be necessary to place the P at each needle location of the display. After the pause remember to press the [START] key to continue sewing. When the sequence is what you want, press the [ENTER] key one time. This combines the color sequence with the design selected from the Design Menu and puts you into the next Top Level Menu, the RUN MENU. If when you need to change the color sequence, for any reason later on, you do not have to change the entire sequence. Use the cursor and the Arrow keys to select the position and characters you need. And remember that as long as the peripheral is sewing you may change the sequence for the NEXT design to be sewn, but NOT for the current design being sewn out. The machine will retain the last color sequence that ran unless the power is turned OFF. A Power Fail Rescue Function, discussed in the HOME MENU, will allow the machine to finish the current design, and then you must re-enter the color sequence before you begin sewing after the PFR. EMC6/4-T Operation Manual 2-30 Change Now Command The Change Now command is found in the Color Menu. The command allows the operator to change the Color Sequence of the CURRENT design being sewn or of the next job queued in the Run Buffer. COLOR MENU ENTER 1. While the machine is sewing the current design, access the Color Menu by scrolling with the [MENU[ key and stopping at the Color Menu. 2. Press the [ENTER] key. COLOR 2:P152-3 3. The display changes to show the current color sequence or the last sequence enter to run. ARROW Keys 4. COLOR 1:12P546 5. Now the "new" color sequence is displayed. ENTER Use the Right and Left Arrow keys to move the cursor, and the Up and Down Arrow keys to insert,or delete, new entry characters in the color sequence. 6. If you are done making changes to the color sequence press the [ENTER] key. At this point you are telling the peripheral, no more changes. CHANGE NOW? 7. When you press the [ENTER] key in the step above, you were saying that you had no more changes to make. Now the peripheral is asking you, if you wish to make the changes now to the current design? [ALT]+ [ARROW] 8. If you wish the changes to be made to the current design, press the [ALT]+ [UP ARROW] keys for YES. If you wish the NEXT DESIGN to have these changes, press the [ALT]+ [DOWN ARROW] keys for NO. Melco Industries, Inc. 2-31 ENTER 9. This is the most important step. Press the [ENTER] key here and one of two actions RUN DESIGN will occur; 1) if you said YES to "Change Now?" the new color sequence will queue up on the current running job, when you press the START key. Or, 2) if you said NO to "Change Now?" the peripheral will ignore the change for the current job, but will change the color sequence for the NEXT job in the Run Buffer. • In either case, you MUST press the ENTER key at this point. Failure to do so will cause the Run Buffer to fill up with unused color changes and will reduce space for Designs in the Run Buffer. START 10. Press the [START] key to make the changes, either YES or NO. RUN DESIGN The RUN DESIGN menu holds the Design, and the Color Sequence in a "Job Que", to permit sewing the design. An important feature of the EDS/Epicor Sewing Peripherals is called SET HOME. Unless this function is set, the machine will not sew. You MUST SET HOME before you can sew a single stitch. The Set Home function and the Power Fail Rescue function are tied together. Set Home provides the ability for the sewing peripheral to recover the last location of the last stitch before loss of power. This function will not work unless it has a beginning position, called SET HOME. If this function has not been set, please go to the HOME MENU and set the HOME POSITION before continuing with the RUN DESIGN menu. RUN DESIGN ENTER SET HOME NOW? 1. Scroll through the Top Level Menus, or press the [MENU] key three times from the Idle State to reach the RUN DESIGN menu. 2. Press the [ENTER] key, one time. 3. You must set the HOME POSITION before you can sew. At this time you may press the Menu EMC6/4-T Operation Manual 2-32 key to scroll to the HOME MENU. Set the HOME POSITION, and the return to the Run Menu. Start with step 1 and continue. IF YOU HAVE ALREADY SET THE HOME POSITION THIS MESSAGE WILL NOT BE SHOWN IN THE RUN MENU. MELCO1 600 START you 4. When the Set Home function is done you see the design name, and to the right of the display you now see the Sewing Speed. 5. Press the [START] key to begin sewing. If have not set the HOME POSITION an ERROR MESSAGE will be displayed: HOME NOT SET. Press the [ENTER] key and allow for the HOME POSITION to set before trying to sew. END OF DESIGN Melco Industries, Inc. 6. When the Design is finished this message is displayed. If you want to sew the same design again, install a new hoop(s) and press the [ START] key. 2-33 The Following Menus The Design, Color, and RUN Design menus are the basic menus you need to sew out designs (jobs) with the Peripheral. The next menus discussed allow the operator to: • Trace a design’s outline to see if it will fit in the sewing area. • Correct errors in the sew out. • Set the HOME POSITION. • Clear the stitch counts and the Run Buffer. • Move a design’s location in the sewing field in both axis. • Enable the operator to correct, adjust or reset the needle depth, and set the timing of the needle and hook assemblies. • Reset the machine to a "cleared memory". The following six menus will not be used every time you sew out a design, but can help to make the sewing out of your designs easier, more flexible, and can help assure a quality sewout. EMC6/4-T Operation Manual 2-34 FRAME MENU The next menu after the RUN DESIGN menu is the FRAME MENU. The Frame Menu allows the operator to "frame up through a design" without sewing or "framing back through a design" without sewing. If all you want to do is to go back to a point in the design and sew over what you have sewn before, then just press the STOP key on the peripheral’s keyboard and hold it down for a few seconds. The Beam will reverse and "backup" through the design until you release the STOP key or the beginning of the design is reached. The Frame Menu is really a toggle that allows you to choose which direction the Framing movements progress. Framing Back through a design (the default setting), or Framing Forward through a design. All Framing movements a done without sewing. After you have Framed through a design to the point you wish to start sewing again, press the START key to begin. A sub-menu of the Frame Menu is RTO or Return To Origin. Choosing RTO will return you to the designs "point of origin." Depending on who punched the design or where you purchased the design, the Point Of Origin may or may not be the first stitch. FRAME MENU ENTER FRAME BACK 1. Reach the [FRAME MENU] by scrolling with the MENU key. 2. Press the [ENTER] key. 3. The display changes to read: FRAME BACK Press the STOP key, one time and the Beam and carriage will move "back" one stitch. Continue pressing the STOP key for a few seconds and the Neam Carriage move back through the design until it reaches the first stitch. Pressing the STOP key during this Backwards movement will stop the Frame back function. Melco Industries, Inc. 2-35 RIGHT/LEFT ARROW FRAME FORWARD (STOP) [ALT]+ [ENTER] combination 4. Pressing Right Arrow or Left Arrow keys will toggle the display to read: FRAME FORWARD or FRAME BACK 5. Frame Forward works the same as FRAME BACK, only the Beam and Carriage move "Forward" through the design. Press the STOP key to stop the forward movement. 6. Press the [ALT]+ [ENTER] key to display the design name. Press the [ENTER] key to display the Design Name and stitch count. The Stitch Count will increase or decrease depending on which Frame Function you select. This allows you to know exactly where in the design to begin sewing again. For example; using Frameback, the stitch count will decrease as the beam moves back through the design. Then when you select Frame Forward to go back to the original stopping point, the Stitch Count increases until you reach the original stopping point in the design. EMC6/4-T Operation Manual 2-36 RETURN TO ORIGIN Return To Origin (RTO) is a sub-menu of the Frame Menu. This option allows the operator to go back to the origin (beginning) of a design. FRAME MENU 1. DOWN ARROW display 2. Reach the Frame Menu by scrolling with the MENU key. Press the [DOWN ARROW] key. The RETURN TO ORIGIN now reads: RETURN TO ORIGIN ENTER 3. Press the [ENTER] key. START 4. Press the [START] key. The Beam and Carriage will move back to the origin of the design and stop. • If for some reason you must stop the beam movement press the [ STOP] key. FRAME FORWARD Melco Industries, Inc. 5. When the Beam reaches the first stitch (origin point) the display changes to read: FRAME FORWORD Use Frame Forward to get back to your original stopping point. 2-37 TRACE MENU Once you have a garment hooped, it is very difficult to rehoop and have the same exact center. The Trace Menu allows the operator to trace the outline of a design within the hoop, and provides an opportunity to replace the with a larger, or smaller hoop size before sewing. Using the Trace Menu before sewing can prevent the extra handling of hoops and materials. TRACE MENU 1. Reach the TRACE MENU by scrolling through the Top Level Menus with the[MENU] key. ENTER 2. CENTERING OFF 3. With Centering ON, the Beam and Carriage will stop at the calculated center of the traced design. With Centering OFF the design outline is traced and the Beam and carriage stop at the designs point of origin. [RIGHT ARROW] OFF [LEFT ARROW] ON Press the [ENTER] key. The display changes to read: CENTERING OFF 4. Use the RIGHT or LEFT ARROW keys to toggle Centering ON or OFF. ENTER 5. Press the [ENTER] key. The display changes to read: CALCULATING..... CALCULATING..... The designs "center" is now being calculated. This message may be displayed for a few seconds, then the display will change to read: TRACE OUTLINE The Beam and Carriage will not move. TRACE OUTLINE EMC6/4-T Operation Manual 2-38 START 6. Press the [START] key and the outline will change to read,: TRACE (function name) XXX (the design name). TRACE LION2 START ENTER START Melco Industries, Inc. 7. With Centering ON, you may now change the starting needle by using the Left or Right ARROW keys to move the needle case one needle position at a time. After the Beam and Carriage Assembly stop moving, the display will continue to read the function name and the design name. If you need to change your hoop size, now is the time to it. Remember that too large a hoop for the design can be a contributing factor to poor quality sew outs. Try to use a hoop that is not too small for the design, but not too big for it either. When you are ready with a new hoop size install the hoop and press the [START] key. The peripheral will trace the design again, or as many times as you need. 8. Press the [ENTER] key when you are ready to sew the design. This puts you into directly into the Run Menu. Press the [START] key to begin sewing. 2-39 HOME MENU The next menu in order from the Trace Menu is the HOME MENU. This menu allows the operator to Set Home Position, preselect hoop limits (or sizes) and allows for recovering from a power loss Normally this would be the first menu you select after turning the power ON. If you have just powered up your machine and have tried sewing by pressing the START key in the Run Menu; then you already seen one of the most important features of the Sewing Peripherals. The SET HOME function. The machine WILL NOT RUN without the Home Position being set. HOME POSITION (or just HOME) is a point defined as (0,0). This is the upper left hand corner of the sewing field. The peripheral must have a defined Home Position to make any X or Y movements. Once Home is set you do not have reset unless you lose power or turn the machine OFF. Following is a complete description of the HOME MENU. HOME MENU ENTER 1. Use the [MENU] key to scroll to the ; HOME MENU 2. Press the[ ENTER] key, the display will now read: SET HOME 3. Press the [ENTER] key to set the Home position. SET HOME ENTER The Set Home position of the EMC6/4M is the Center of the Cap Frame sewing field. The Beam will move to location from any point when the HOME POSITION is set, or when the GO TO HOME command is used. GO TO HOME After Home is set the display shows: GO TO HOME EMC6/4-T Operation Manual 2-40 UP ARROW DOWN ARROW You may now reach the other sub-menus in order by using the [DOWN ARROW] key, or in reverse order with the [UP ARROW] key. The rest of this menu description will use the DOWN ARROW key to access the sub-menus. If you have, already Set Home and try a second time, the Error message, MACHINE RUNNING is displayed. To continue after this error message, press the MENU to move to the next Top Level Menu, then use the [ALT]+ [MENU] key combination to return to the HOME MENU. Use the Arrow keys as described above to move to the next sub-menu. GO TO HOME 4. Pressing the [ENTER] key when GO TO HOME is displayed will move the Beam to the HOME position from any point in the sewing field. 5. Press the [DOWN ARROW] key one time from GO TO HOME to reach POWER FAIL RESCUE function. ENTER DOWN ARROW POWER FAIL RESCUE 6. If you have power loss during sewing or if the operator turns OFF during sewing, follow these steps to recover the last design and finish the last sewout. 6.1) Turn the main power switch for the peripheral to OFF. When power is returned to the dedicated line, turn the peripheral back ON at the rear of the peripheral. Melco Industries, Inc. 2-41 6.2) If the EDS/Epicor computer also lost power, be sure to turn it OFF as well. Turn it back on after power is restored. The EDS/ Epicor computer will automatically reload the last design after regaining power. This should take only a few seconds, if the peripheral only, had a power loss, and may take 30 -45 seconds if the computer lost power also. HOME MENU SET HOME 6.3) After the design has been reloaded, press the [MENU] key to scroll to the HOME MENU, press the [ENTER] key. The display will read: SET HOME DOWN ARROW DOWN ARROW Press the [DOWN ARROW] key two times. This brings you to POWER FAIL RESCUE. POWER FAIL RESCUE 6.4) When you reach POWER FAIL RESCUE ENTER press the [ENTER] key.The Beam will move to the center of the Cap Frame Field and then to the second to last stitch before power loss. START 6.5) Press the [START] key to continue sewing from the second to last stitch before the power loss.) POWER FAIL RESCUE should only be used after a power loss. This function will not work without a loss of power. DOWN ARROW SELECT HOOP ENTER ALL FIELD SEWING 7. 8. Press the [DOWN ARROW] key one time from POWER FAIL RESCUE and SELECT HOOP is displayed. Press the [ENTER] key one time, the display changes to: ALL FIELD SEWING EMC6/4-T Operation Manual 2-42 This selection has no set limits other than peripheral’s full sewing field of 11/2" x 16 1/2". (ENTER) If this is the selection you wish, press the [ENTER] key. Or press the [DOWN ARROW] key to view the other selections. DOWN ARROW CAP FRAME SEWING 9. The next selection is: CAP FRAME SEWING This is the selection that MUST BE CHOSEN if you are going to sew a cap. DOWN ARROW 10. 3 in Circle 5x9 in Circle 5 in Circle 6 in Circle 8 in Circle 10 in Circle 11x16 in Oval 8 x13 in Oval ENTER HOOP LIMITS ON Press the [DOWN ARROW] key again, the first of the preset hoop limits is displayed. These are shown in English dimensions of inches. For Metric dimensions, you must select F4: DESIGN PARAMETERS Menu from the EDS/Epicor computer, and change the "Units". Scroll through the list with the [DOWN ARROW] key until you come to the selection you wish. 11. Press the [ENTER] key when you have the selection you wish. The display will read: HOOP LIMITS ON The Beam moves to the center of the chosen Hoop size. The peripheral will now sew only in the selected hoop limits. To turn the limits OFF, press the[LEFT ARROW] key. This will deselect the chosen hoop size in the SELECT HOOP sub-menu. Melco Industries, Inc. 2-43 MOVE MENU The MOVE MENU is the next menu in sequence after the Home Menu. As its name implies, the MOVE MENU allows the operator to make precise movements of the Beam and Carriage Assembly, in order to place a design in a specific location within the sewing field. You can move the Beam and Carriage, using the Arrow keys while in the Idle State, but the movements are not governed by a distance measurement. The Move Menu however, is governed by precise distance measurements that the operator inputs from the peripheral’s keyboard. This menu allows for complicated designs, for example: the finished design when loaded into the peripheral is too large for memory, dividing the design into two or more sub-designs is a convenient method for accomplishing very large designs. In the figure below, the machine has already sewn a three letter monogram on the lower left side of the center of the sewing field. The dashed lines show the center of the sewing field, and the box with the three small plus signs (+ ) represent where we wish to sew the same design again. (It doesn’t have to be EMC6/4-T Operation Manual 2-44 the same design, any design in the Design Buffer can also be sewn as long as it fits in the sewing field.) You can see from the illustration, that the sewing field is divided into 4 quadrants, with the design already sewn in the lower left quadrant, and the place we wish to sew the design again in the upper right quadrant. END OF DESIGN After the first design is finished sewing, the message on the display is: END OF DESIGN MOVE MENU MOVE 1. Press the [MENU] key to scroll to the MENU. ENTER MOVE X + 00.00 in 2. Press the [ENTER] key one time. The display now reads: MOVE X + 00.00 in The X-Beam moves from side to side, the right side is positive (+ ), the left side is negative (-) This side to side movement is called the X direction. RIGHT ARROW 3. Press the [RIGHT ARROW] key, this make the value positive (+ ), if the value is not already positive. UP ARROW 4. Press the [UP ARROW], until the value shown on the display reads + 2.00in.Pressing the UP, or DOWN ARROWs once and the value shown on the display will increase (UP) or decrease (DOWN) by 0.01 in. with each pressing. If you hold down either key not letting it up the values will change very rapidly. This takes a little practice to keep from over shooting your mark. The display should now read: MOVE X + 2.00 in MOVE X + 2.00 in Melco Industries, Inc. 2-45 ENTER 5. Press the [ENTER] key to access the Y movement. The display now reads: MOVE Y + 00.00 in MOVE Y + 00.00 in The Y direction moves the Beam towards the rear (back) and to the front of the sewing area. The move towards the rear is positive (+ ) and the move towards the front is negative (-). RIGHT ARROW UP ARROW MOVE Y + 02.50 in 6. Press the [RIGHT ARROW] to make the value positive, if it is not positive already. 7. Press the [UP ARROW] key and hold it down until the display reads: MOVE Y + 02.50 in ENTER 8. START 9. Press the [ENTER] key. Press the [START] key, and the machine will make the X and Y moves to reposition the hoop under the needle. After the X and Y moves have been made you can you use the Trace Menu to see if the design will fit in your sewing field. If this job is the only one in the Run Buffer, you can sew it again and again. However, the Move Menu must be used each time a design’s location needs to be repositioned. NOTE: If the message "MACHINE RUNNING" is displayed, either a job has been run or is in progress and must be canceled before the next job is run, or a move has been entered, but not executed with the START key. EMC6/4-T Operation Manual 2-46 Head Timing Menu The Head Timing Menu is a "maintenance" menu, and allows the operator to make adjustments to the Sewing Peripheral’s Head Timing. This menu can only be used when the sewing head is stopped. Here we present the Head Timing Menu’s sub-menus and keystrokes. A complete discussion on using the Head Timing Menu is found in Section 3, Maintenance , Sewing Head Timing on page 3-10. MENU 1. Use the [Menu] key to scroll to the Head Timing Menu. HEAD TIMING ENTER HEAD TIMING ON UP ARROW DOWN ARROW RIGHT ARROW LEFT ARROW ALT + UP ARROW ALT + LEFT ARROW ALT + DOWN ARROW ALT + RIGHT ARROW Melco Industries, Inc. 2. Press the [ENTER] key. The display reads: HEAD TIMING ON 1 STEP Forward 1 STEP Back 10 STEPS Forward 10 STEPS Back Go TO Head UP ONE Revolution Needle Depth Hook Timing 2-47 TRIM MENU This menu is for the Trimmer option commands, all commands related to Trimming are presented here. TRIM MENU ENTER 1. Press the [MENU] key to scroll to the to the TRIM MENU. 2. Press the [ENTER] key. ENABLE 3. If the Trimmers are Disabled press LEFT ARROW (Enable) the [LEFT ARROW] key to ENABLE the RIGHT ARROW (Disable) function. The right and left arrow keys toggle between enable and disable. DOWN ARROW Press the [DOWN ARROW] to move "down" through the menu. The Display now RIGHT ARROW (SHORT) reads: SHORT TAIL or LONG TAIL LEFT ARROW (LONG) depending on which was chosen. Toggle between Short and Long Tail with the Left or Right Arrow keys. DOWN ARROW TRIM IMMEDIATE DOWN ARROW JUMP COUNT 6 4. 5. Press the Down Arrow key to display TRIM IMMEDIATE. This menu item should be used only when the Sewing Head is stopped. Pressing the [ENTER] now will active the Trim Immediate command. 6. Press the [DOWN ARROW] and the display reads: JUMP COUNT 6. RIGHT ARROW (Increases) LEFT ARROW (Decreases) 7. Press the Left Arrow the Jump Count increases by 1 digit. Each you press the Right Arrow key the count will EMC6/4-T Operation Manual 2-48 increase by one. Press the Left Arrow key and the count will decrease by one. The Jump Count default is 6 the maximum number is 15, the minimum is 0. Using zero as the Jump Count will disable the Jump Count function. DOWN ARROW CAM TIMING Melco Industries, Inc. 8. Press the Down Arrow key to move to the CAM TIMING function. This is a service function and if it should be necessary to reset the Trimmer Cam, see page 3-20 in the Maintenance Section, or call your Service representative. Pressing the [ENTER] key will active the function. This should be done only when the sewing heads are not moving. 2-49 RESET MENU The RESET MENU is the last menu in sequence from the idle state. This menu allows the operator to reset parameters to the beginning of the current job, or to rest to default parameters (those seen at power up). Using this menu DOES NOT clear the Sewing Peripheral’s memory, it will however, clear the RUN DESIGN menu, TRACE MENU, HOME and MOVE Menus. TYPES OF RESETS System Reset clears: RUN BUFFER, only keeps the current job but must be restarted each time. Hard Reset clears: All parameters entered from the peripheral keyboard. Restores power up or default values. RESET MENU ENTER SYSTEM RESET UP ARROW 1. Use the [MENU] key to scroll to the RESET MENU. 2. Press the [ENTER] key. 3. The display now reads: SYSTEM RESET Use the ARROW keys to choose the type of Reset. DOWN ARROW HARD RESET ENTER ENTER 4. After you choose the type of Reset you want, press the [ENTER] key two times to execute the command. EMC6/4-T Operation Manual 2-50 EMC6/4-T Sewing Peripheral Error Message List An Error Message is a prompt used to alert the operator that a problem exists with the peripheral. There are 36 Error Messages programmed into the sewing peripheral’s operating software. An Error Message is displayed if you press the start key before a design is loaded into Run Buffer. This message is a reminder that you must have a design loaded before the peripheral will start sewing. Other messages tell you that something mechanical has occurred, such as the X-Beam has reached its limits but the design has not finished. This may, for example, mean: that you selected too small a hoop size for the design you want to sew. Hoop limits are chosen from the Select Hoop sub-menu in the Top Level HOME MENU. Here we list, alphabetically, all 36 Error Messages that could be displayed when the peripheral stops sewing during a job, and how to recover. APPLCIATION RUN The sewing peripheral did not recive all the design data sent by the computer. Correct by cycling the periphheral power on and off. You might see this error message when you power up first thing in the morning, or perhaps after a power failure. If this error happends frequentaly, call your service rerpresentative, there may a serious problem with your computer or peripheral. BAD CC ENCODER This is a message that you should never see. If you do, call your service representative for help. It means that the EMC6/4-T can not read color changes due to a bad Color Change Encoder (a part of the Color Change Assembly). It will have to be replaced. Call your Melco Service Representitve for help. BAD DESIGN NAME The machine could not find the design name when the Start key was pressed. If you are running with Auto Delete ON, the design was automatically deleted when the End Of Design message was shown on the display. Or with Auto Delete OFF, this message means the operator has deleted the designs in the Melco Industries, Inc. 2-51 Design Menu and not replaced them before pressing the Start key. Reload the design from the EDS/Epicor computer and continue. BAD KEYBOARD CODE This could be either a software or a hardware problem. For some reason the peripheral was unable to read the keyboard code. (Computers use a specific code to recognize each key of the keyboard.) Use the Reset Menu to reset the machine and try again. Or, recycle the peripheral’s power by turning off at the rear of the machine waiting ten-fiveteen seconds and turning the power back on. If that fails call your service representative for help. BAD PFR PTR When you set the Power Fail Rescue (PFR) function on the peripheral, a marker (called a pointer or PTR) is inserted into the design program. Pointers allow the PFR function to "see" where, in the design, the last stitch was made, so that the operator can recover the design without starting over from the beginning. This message means the software detected a power failure while the peripheral was saving the pointer to the design while the machine was sewing. (This doesn’t happen very often.) To correct this problem, you should first try a Return To Origin, and frame through the design to the stopping point. Press the Start Key. If that doesn’t work; then you must recycle power to the peripheral. If this happends ferquently check your buildings power or check with your local power company. If you can find no problems with your power supply, then call your service representative. BAD Z CREEP FUNC This is a software error and means that Z axis command in the Head Timing Menu was slow in getting to the CPU. Wait a few seconds and try again. EMC6/4-T Operation Manual 2-52 COLOR CHANGE The EMC6/4-T will stop at allow manual thread trimming at color changes when the entry character P, is placed in the beginning of the color sequence. See Color Menu Entery Characters page 2-28. CC HEAD UP ERROR Trying to a color change when the sewing head is not at Head Up position. Scroll to the Head Timing Menu function, GO TO HEAD UP to cycle the sewing head back to Head Up and press the Start Key. If this hapeends ferquently it could be a Head Up Encoder problem requiring replacement of the encoder. Call your service representative for instructions and help. COLOR LIST FULL You are trying to add too many color changes to the design. While the display will show up to 16 characters, you may have as many as 24 characters in a color sequence. Trying to add more then 24 will result in this error message as a reminder. CC TIME OUT The peripheral’s software has a built in 15 second delay for a color change, this message is displayed when the peripheral "sees" more than a 15 second delay and no color change is made. This indicates a problem with color change function, call your service representative for advice or help. DELETE FAILED The machine was unable to delete the design due to the same design currently running or another design is being downloaded. Wait 20 seconds and try again. Melco Industries, Inc. 2-53 FOUND END OF DESIGN The software found an End Of Design message before the true EOD. Sorry, but you must start over, once the EOD is "seen" by the computer the design is stopped. Reload the design from the computer. This is a message you might see after a power failure. If this message is displayed frequently call your service representative, there may be a problem with the CPU. GRABBER NOT HOME This message means the Upper Thread Grabber is not in its home (fully retracted) position. This message can be seen at any time the machine is running. When the machine senses that the Grabber is not at home software stops the machine. To recover, see Section 3, Maintenance page 3-20. HOME NOT SET Trying to do a GO TO HOME function without the HOME POSITION being set. Set Home and continue. HOME WAS NOT SET Home Position was not set by the Set Home command in the Home Menu. Remember that the Home position must be set before sewing for the first time, even if you do not use any other Home function. Go to the Home Menu, Set Home and continue. ILLEGAL SEQUENCE In the Color Menu, you must have at least one valid needle number in the Color Change Sequence. These needle numbers are 1-6 and Zero. This message will come up if at least one valid needle number is not in the Color Change Sequence. The operator can not exit from the Color Menu without EMC6/4-T Operation Manual 2-54 correcting the sequence. See the Color Menu and Change Now Commands page 2-27 and 2-30. JOB BUFFER FULL Means that no more information may be stored in the peripheral’s job queue. This will be seen in the Run Menu most often, but can also be seen in the Color Menu when "Change Now?" is used too many times without using the Enter key to complete the change. If you are running with Auto Send ON; then you clear the entire Job Buffer in the Reset Menu. Remember that after you use the Reset Menu you must go back and "redo" any job perameters, ie; move commands, color change sequences, etc., before you continue sewing. LOADING TRY AGAIN Trying to do a Power Fail Recovery but the design has not been completely loaded from the computer. Wait a few seconds and try again. MACHINE RUNNING The operator has tried to Trace, Move or do Head Timing with the machine sewing. The sewing head must be at full stop and at Head Up when these functions are used. MC BUFFER FULL The Motor Command Buffer, on the CPU (Central Processing Unit) printed circuit board, is filled up with too many commands. This could be caused by too many Move commands with no presses of the Start key. May also be too many Head Timing Commands too quickly. This message may also indicate a more serious error in the CPU. To clear the MC Buffer you must cycle power to machine. Turn the power OFF at the rear power switch, wait 10 - 15 seconds, and then turn the power back on. If you running with Auto Send ON the computer will reload the Design Buffer after a few seconds. Melco Industries, Inc. 2-55 If you are running with Auto Send OFF you must reload the design from the EDS/Epicor computer. If cycling the power does not clear the screen message then call your service representative for help, there may a problem with the CPU. MISSED HEADUP The Z axis controller chip did not "see" a Head Up signal. Software waits for another 150 degrees of rotation and if the signal still hasn’t been seen stops the machine. Use the Head Timing Menu function GO TO HEADUP to cycle the head back to Headup and continue sewing. If this happens frequently call your service representative for help. If you are running with Auto Send OFF, you delete designs one at a time in the Design Menu; or the computer’s Extended Status screen in the EDS/Epicor program. NOT AT HEADUP Trying to do a Power Fail Recovery, but the sewing head is not at Head Up, or trying to jog (move the beam) in the X or Y axis without the sewing head at headup. Moves of the sewing Beam and Carriage assembly are not allowed unless the head is at Head Up. Cycle the head to the Head Up position with the Head Timing Menu function GO TO HEADUP. NO DESIGNS FOUND This message, found in the Design Menu, means that the designs have been automactically deleted using the EDS/Epicor Autosend function, and no designs have been sent to replace them. Or the designs were deleted manually from the peripherals keyboard. Send designs to peripheral from the computer. EMC6/4-T Operation Manual 2-56 NO DESIGN QUEUED Trying to do a Power Fail Recovery (PFR) but with no design in the Run Buffer. Select the design from the Design Menu and try again. OFF COLOR INDEX Tried to do a Head Timing function but the color change was off its index. Use the ALT, LEFT or RIGHT ARROWS to index the color change correctly. If the Keys don’t work it may neseccary to remove the Thread Saddle and manually reset the color index, call your service representative for instructions and help. PR JOB ERROR Trying to do a Power Fail Recovery but the design was already finished. Select a new design to sewout. RACK LIMIT??? The X or Y motion is not within the sewing field limits when the machine is running the peripheral will stop and give this error. If you are doing Frame forward or Frame Back functions this Error Message will be displayed when you reach the limits of rack movement, but the frame function can continue. If not in the Frame Menu, then go to the Home Menu and check the Hoop Limits sub-menu. You may be using a hoop size that is too small for the design. Try selecting a larger hoop size, and start over. Melco Industries, Inc. 2-57 RELOAD An error was detected by software as the computer was reloading a design while running in Auto Send. Check the Design Menu, if the design is still there, delete the design at the peripheral and reload it from the EDS/Epicor computer. Frequent occurrences indicate a system memory problem, or a bad link in the network. Check the terminator cable to be sure that it is plugged in all the way or not missing. If this does not fix the problem call your service representative for help. RUN JOB ERROR Means that no design was selected before pressing the ENTER key in the RUN DESIGN Menu to begin sewing. Select a design in the Design Menu before going to the RUN DESIGN Menu before pressing the Start key. THREAD BREAK The Threadbreak Sensor(s) detected a broken thread or Thread Tensions were too loose. Check the Thread Path for obstuctions. Check upper and lower thread tensions and the bobbin tension. Check the needle, presser feet and needle plate for nicks and burrs. Press Start to continue. TRIM INACTIVE The operator tried to do a TRIM IMMEDIATE command with the Trimmers Disabled (turned off). EMC6/4-T Operation Manual 2-58 TRIMMER NOT HOME This error message means the cutting blades are not fully retracted (home). This message is displayed when the machine is ready to run after a trim but the blades are not home. To recover, see Trimmer Troubleshooting, Section 3, Maintenance page 3-20. X RACK NOT DONE Y RACK NOT DONE This means that the needle is about to enter the cloth before the X or Y motion was done. This is generally caused by trying to run with a fill, in the design, that is too dense. The needle must be completely out of the fabric and at Head Up before an X or Y move can be made. With very dense fills it is best to reduce the sewing speed, this will allow the needle to clear the fabric before any moves of the Beam and Carriage assembly. Reducing sewing speed will also prevent broken needles and damaged fabric when sewing dense fills. Z COMMAND ERROR This error message is software related, and means that an invalid "read" or "write" command sequence was detected in the Z controller software functions. This can be caused by sewing a design with dense fills at too high a sewing speed. Reduce the speed and continue or go to the Head Timing Menu and choose GO TO HEADUP command. Then press the Start key to continue. Z TIMEOUT ERROR This error message is also software related, and means that, in the sewing mode it took longer than 1.5 seconds between Head Up commands. And in the Head Timing Menu this means that the Z axis (Sewing Head) was commanded to move and didn’t complete the move in the allowed time. Turn the machine OFF, check the rotary hook for obstructions, thread, execss dirt, etc. Turn the machine ON, go to the Head Timing Menu and select GO TO HEAD UP. If you get this error message more than two times and you can find nothing wrong, i.e. jamed hook, call your Melco Service Repersentitive for help. Melco Industries, Inc. 3-1 3. Operator Maintenance Cleaning Of The EMC6/4-T Sewing Peripheral The proper cleaning and lubrication of your EMC6/4-T Sewing Peripheral will reduce wear on parts and reduce your down time due to mechanical problems. In this section you will learn how to properly lubricate your sewing heads and other mechanical assemblies. Follow the lubrication schedules and cleaning instructions presented in this section and your machine(s) will give you many hours of productive sewing. Cleaning Your Peripheral Cleaning of the plastic surfaces while not important to the machines operation, is an aesthetic consideration for the looks of the equipment. DO NOT use strong detergents such as, powered cleaners or "all purpose cleaners," for cleaning the plastic parts of your machine. You may use cleaners like "Fantasik Spray Cleaner" or a 3% solution (mild) laundry soaps like "Tide" or "Ivory Liquid." Use a soft, clean cloth to wipe the plastic parts. Wring out the cloth before using. DO NOT USE ANY FLUIDS ON MACHINE WHILE RUNNING. If an accident happens mop up the excess fluid with a clean dry cloth, and allow the machine to dry before turning the power on at the peripheral. Should the fluid get inside the plastic covers, it will require removing the covers to enter the interior. THEN CONTACT YOUR MELCO SERVICE REPRESENTATIVE FOR RECOMMENDATIONS. NOTE: NEVER REMOVE COVERS OR PLACE HANDS OR FINGERS INSIDE THE MACHINE WITHOUT TURNING THE POWER OFF FIRST AND REMOVING THE POWER CORD FROM THE POWER SOURCE(OUTLET). EMC6/4M Operation Manual 3-2 Cleaning The Table Tops Clean the table tops with a mild detergent and water. Use a "damp" cloth, and avoid getting water or detergent inside the machine. DO NOT ATTEMPT TO CLEAN ANY ELECTRICAL PARTS AT ANY TIME. Lubrication Of The EMC6/4-T Sewing Peripheral When you unpacked your Sewing Peripheral you found an Operator’s Kit, and inside the Kit you found a set of tools in a pouch. These tools are all that are necessary to maintain your machine. You also found two tubes of lubricants. One tube is clear and contains a light duty sewing machine oil, for lubricating parts of the sewing head. The other is a tube of medium duty ball bearing grease. This is used to lubricate the reciprocator cam and the Trimmer Cam. Using these lubricants as directed, will prolong the life and productivity of your machine. These lubricants should be used sparingly, over lubricating can cause mechanical and quality problems, for example; over lubricating the Needle Bars or the Needle Case can cause oil to drip onto the fabric you are sewing on, if you are sewing on silk it would be a spot that you can never get out. Over lubricating the Rotary Hook Assembly can cause oil to be deposited on the bobbin thread and then transferred to the base fabric. Or, it can cause a build up of dust and lint that can bind the Hook shaft. Refer to the Sewing Head Lubrication Schedule on the next page for when lubrication points should be lubricated. Melco Industries, Inc. 3-3 Rotary Hook Needle Bars Needle Bar Driver Connecting Rod (upper hole) Connecting Rod (lower hole) Take Up Lever Cam Trimmer Cam Trimmer Knife Arm Pins Trimmer Picker Pins Every Every Every Every Every Every Every Every Every 4 Operating Hours 40 Operating Hours 40 Operating Hours 40-80 Operating Hours 200 Operating Hours 6 Months 6 Months 40 Operating Hours 40 Operating Hours Sewing Sewing Sewing Sewing Sewing Grease Grease Sewing Sewing Frequency Lubrication Point Machine Machine Machine Machine Machine Oil Oil Oil Oil Oil Machine Oil Machine Oil Lubricant EMC6/4-T Lubrication Schedule 2. Pull down Hook Cover. 1. Remove the Needle Plate. Hook Needle Cover Plate 3. Pull Bobbin Case and Bobbin straight out of Hook Assembly. Oiler Tube Rotary Hook Assembly 4. Place one drop of oil on the Race ( groove). Bobbin Case Every 4 Operating Hrs. Rotary Hook Lubrication EMC6/4M Operation Manual 3-4 Lubricating The Sewing Head Other than the reciprocator, the sewing head reqiures no operator lubrication. The Needle Case does reqiure lubrication at the Needle Bars, and the Needle Bar Driver. While part of the Trimmer Assembly is located in the Bed Assembly and the Arm Assembly, these are addressed under their own topic. See page 3-22 , Trimmer Maintenance Infromation. Color Change Guide Shaft 1-2 drops of Sewing Machine Oil every 40-80 Operating Hours each side. Needle Bars, 1-2 drops of Sewing Machine Oil on pads, for each Needle Bar. EMC6/4-T Sewing Head Lubrication Melco Industries, Inc. 3-5 Index the sewing head to Needle # 1. Place 3-5 drops of sewing machine oil in the puddle slot. Needle Bar Driver Lubrication Connecting Rod Upper Hole Connecting Rod Lower Hole Place 1-3 drops of sewing machine oil at each location. Connecting Rod Lubrication EMC6/4M Operation Manual 3-6 Grease Every 6 Months. Take Up Lever Cam Lubrication Sewing Head Synchronization An area of Sewing Head Timing that can become misadjusted after hitting a hoop is Head Synchronization. That is, all four sewing heads being aligned with each other. NOTE: Should all the Sewing Heads become misadjusted away from the "Head Up"position, a special tool and a dial indicator (in addition to resetting the Z Motor Encoder) are required for making the proper "Head Up"adjustment. If adjustment of all four heads is thought to be needed, contact the Melco Service Department and schedule a service call. The following steps provide a procedure to "resync" a Sewing Head if one (1) head becomes improperly aligned with the other sewing heads. Melco Industries, Inc. 3-7 Head Resync Procedure 1. Turn OFF the EMC6/4-T Sewing Peripheral. 2. Locate the Mechanical Jump Stitch Lever on each Sewing Head, and be sure that each lever is disengaged. This insures that each sewing head is in "SEW MODE". 3. Locate the Head Position Indicator Disk attached to the end of the Z -Drive Shaft at the right side of the located on the far right (just above the Keyboard area). On this disk you will find four (4) markings: O, HU, N, and H. 4. Insert a 5mm hex wrench into the Cap Head screw that is in the center of the Head Position Indicator Disk, and rotate the Z Shaft one complete revolution CLOCKWISE, stopping when the HU position on the disk is aligned with the scribe mark on the Head Casting (straight up or at "12 o’clock"). 5. At this point the Take Up Levers of each head should be all in a line. (See Figure on the next page.) EMC6/4M Operation Manual 3-8 6. If this is not the case with all four sewing heads, most likely the head that is not in line is the Head that is out of "sync". 7. On both a properly adjusted Sewing Head and the improperly adjusted Sewing Head, you must remove the top, rear covers of the Sewing Heads (see below) to gain access to the drive gears from the Z Drive Shaft to the top, Horizontal Sewing Head Shaft. 8. Notice the locking collar on the Sewing Head top horizontal shaft of the properly adjusted Sewing Head. It has a large Cap Head Screw that is positioned very close to straight up. CAUTION: Use care not to allow the Z Drive Shaft locking collar to "drift away" from the gear it is attaching. If this happens, the cylindrical shroud over the Z Drive Shaft, will need to be removed to gain access to the locking collar. The ONLY way to install a new locking collar, is to remove the Z Drive Shaft, which is not desirable, since this is a factory procedure only. Melco Industries, Inc. 3-9 Drive Shaft Cover Tube Locking Collar Z Drive Shaft Left Rear View of Sewing Head 9. Loosen the locking collar on the improperly adjusted Sewing Head that secures the drive gear attached to the Z Drive Shaft. 10. With this collar loosened, you can now rotate the improperly adjusted Sewing Head so that the large cap head screw on the locking collar of the Sewing Head top horizontal shaft is positioned very close to straight up (the same position as the properly adjusted heads). 11. When the Sewing Head is mechanically synchronized with the other heads, make sure that there is no excessive gear play between the 2 drive gears at the Z Drive Shaft, then tighten the Z Drive Shaft locking collar. In this case excessive gear play would be an excess of 1/16" movement between the gear teeth before contact of the mating teeth. NOTE: N1. If the grease is cleaned from the body of the Z Drive Shaft gear, you will observe a red mark on the gear. For proper attaching function, the slot in the locking collar must be closely positioned directly in line with this red mark before tightening the locking collar. N2. Excessive gear play, in this instance, would be more than 5 degrees of rotational movement before the gears totally engage. This translates to approximately 1/16th of an inch movement of the gears. Conversely, having no rotational movement (gear play) is not recommended. While it seems that it would good idea to have no movement between the gears, this can cause binding of the head at start up, and possibly damaging the gear teeth. 12. After you have successfully completed checking the Sewing Head rotation, insure the position of each Mechanical Jump Stitch Lever is in the disengaged position. Rotate the Z Shaft one revolution stopping at "HU" (head up) on the Head Up Indicator Disk. EMC6/4M Operation Manual 3-10 13.The Take Up Levers of all four heads should be all in a line. All the needle bars of each head should be all in a line in the fully retracted position. See the figure below. EMC6/4-T Sewing Head Timing This topic describes the use of the HEAD TIMING MENU from page 2-46. Sewing Head Timing is comprised of a number of different, but interrelated topics. First and perhaps most importantly, is Head Up (1). The sewing Head must be correctly set to the Head Up Position, both mechanically and electronically, before you can accurately set Needle Depth (2), Hook Timing (3), and the Hook Gap (4). Note: Head Up is a "Factory Setting" and should not be changed or adjusted unless the Head Up Encoder has been replaced, then once the Head Up position is set with the new encoder it should not have to set again. Check with your Melco representative for advice if you think there is a problem with the Head Up position on your sewing head before you attempt any changes to Head Up. Melco Industries, Inc. 3-11 Needle Depth, unlike the Head Up Position, may change during the course of operating the sewing head. Hitting the hoop with the needle (called Spiking), changing needle sizes and type or brand of needle, can necessitate readjusting Needle Depth. Changing the type of sewing thread can also require that you reset the Hook Gap of the Rotary Hook as well. Generally speaking, if you use the correct System Number needle you should not have needle depth problems. Additional movements or operations such as programmed Jump Stitches, Color Changes and Trim commands are important for the design, but are not directly related to sewing a stitch. Proper timing of your sewing head will increase the opportunity for quality sewing. Timing alone will not produce a quality product, this requires a well punched design, choosing the proper backing material,choosing the proper thread and needle combination for the base material you will be sewing on, sewing speed, and experience as well as a properly "timed" sewing head. It is extremely difficult for the machine go "out of timing." But, just because something is difficult does not mean its impossible. There are two major events that can cause this to happen: 1) "Spiking the Hoop" with the needle during operation. Spiking is imbedding the Needle in the wooden hoop, this will sometimes break the needle and surprisingly often will not. Spiking the hoop will dull the needle. In fact this kind of event, breaking or dulling the needle, is more of a problem then knocking the head out of timing. 2) Hitting the Hoop with Presser Foot (but not with the Needle) during operation. This can bend the Presser Foot and depending on the severity of the "bend" can cause the needle or thread to rub the inner portion of the presser Foot, instead of passing through it as it should, and thus causing thread breaks. Even if these two things happen it does not automatically mean the head is out of timing. As a general rule you should replace the needle and "check" the timing after an event like spiking the hoop or presser foot. EMC6/4M Operation Manual 3-12 Replacing Needles Replacing or changing needles is relatively fast and easy. The needles are held in place by the Needle Clamp and the Needle Clamp Set Screw, see page 2-2 for specific needle replacement information. Needle Depth How well the sewing Head makes a stitch is dependant on the correct needle/hook relationship. Look at the illustration on page 3-15, Hook Timing. This illustration shows how the sewing head makes a single stitch (called the Stitch cycle). Understanding the stitch cycle and the proper timing of the sewing head will go a long way in helping you produce quality embroidery. When you "Time" your Sewing Head(s), you perform four specific procedures: 1) Adjust the Needle Depth - The correct Needle Depth is that point where the needle reaches the lowest point in its cycle and the eye of the needle is below the Hook point of the Rotary Hook. 2) Set the Hook Position - The Hook Position is correct when the hook reaches the point where it lies just behind the needle, above the eye, and a specific horizontal distance from the needle. 3) Adjusting the Retaining Finger - At all times the during sewing, the Restraining Finger must be at a specific distance, both vertically and horizontally, from the Hook Assembly. 4) Checking your Adjustments - Because timing is so critical, you should always visually check your adjustments, as a double check before you begin sewing. To Adjust the Needle Depth: Tools: All the tools required to preform this procedure are supplied in the Operator’s Kit shipped with each Peripheral. The tools you will need are: *Needle Gage *Needle Dowel (These two items are packaged as a "kit" in a small clear plastic bag and can be found in the Operator’s Kit.) *Flat-bladed screw driver, medium. *Flat-bladed screwdriver, small. Melco Industries, Inc. 3-13 Procedure: 1. Unthread the Needle(s). 2. Turn the power ON. 3. Using the [ALT][LEFT ARROW] keys move the needle case to needle # 1. 4. Remove the table insert from the around the Cylinder Arm. 5. Remove the Needle Plate. 6. Remove the Bobbin Case. 7. Remove the Needle from the Needle Clamp. 8. Insert the Needle Dowel by turning the cutout toward the BACK of the Machine and pushing UP as far as possible. EMC6/4M Operation Manual 3-14 9. Reach the HEAD TIMING MENU by scrolling with the [MENU] key. Press the [ENTER] key. The Display now reads HEAD TIMING ON. 10. Press the [ALT][LEFT ARROW] keys; the head will make one revolution and deenergize the jump stitch solenoid. 11. Press the [ALT][DOWN ARROW] keys. The display now reads NEEDLE DEPTH, and the Needle (dowel) will move to its lowest point. 12. Press the [ALT][RIGHT ARROW] keys, the display now reads HOOK POSITION. 13. Place the Needle Gage on the Bobbin Shaft Post where the Bobbin usually sits. If you can’t slide the Needle Gage under the Needle Dowel, the needle depth is too low. If the when you insert the Needle Gage the Needle Dowel does not just touch the surface of the Needle Gage, then the Needle Depth is too high. • When you insert the Needle gage the Needle dowel should just touch the gage’s surface. This indicates that you have correct needle depth and the sewing head needs no adjustment for needle depth. 14. If your needle depth does not need adjustment, press the [ALT][UP ARROW] keys to bring the head to HEAD UP and to reset the Jump Stitch Solenoid. If the Needle Depth needs Adjustment: Adjusting the Needle Depth requires adjusting the Needle Bar. To adjust the Needle Bar: 1. Remove the Needle Case Cover. 2. Use the large flat bladed screw driver to loosen the Needle Bar Connecting Stud, so you can move the Needle Bar up or down. 3. Lower, or raise the Needle Bar, until the Needle Dowel just touches the Needle gage. 4. Hold the Needle Bar in place and tighten the Needle Bar Connecting Stud. 5. Remove the Needle Bar Gage from the center post, and rotate the head to HEAD UP. Melco Industries, Inc. 3-15 6. Remove the Needle Dowel, and replace the Needle making sure that the needle’s scarf, or cutout area, is facing the back of the peripheral. Be sure that the needle is inserted completely up in the Needle Bar. With the Needle Gage removed follow setps 9-12 and then look at the following illustration. If the eye of the needle is within the limits shown in the figure then your Needle Bar is coorect. Lower Limit Ideal Upper Limit Hook Timing When a sewing quality problem is encountered, hook timing should only be suspected as one of the possible causes. Check the following in addition to checking the hook timing: EMC6/4M Operation Manual 3-16 *Sewing Heads out of sync with each other. *Tension settings (upper and lower). *Needle condition, size, and type of point. *Lubrication of hook assembly and head. *Nicks in presser foot or needle plate. *Presser foot height. *Stitch density. *Proper sewing technique for the material being used (i.e. backing material, type and size of thread). *Material improperly hooped. *Needle Bar depth too low or too high. To check for proper hook timing, refer to the iullstration on the preceding page, showing the stitch cycle relationship. Study the drawing and look carefully at the relationship between the needle and the hook. The hook point must pass through the needle scarf area approximately 1/8 inch (3.175 mm) above the eye, when the needle has risen 3/32 inch (2.38 mm). To check this relationship between the needle eye and the hook point, first replace the existing needle with a new one and remove the needle plate so the hook area can be readily seen. Then select the "Head Timing Menu" from the EMC6/4M Peripheral Keyboard. 1. Press the [ALT] and [Left Arrow] keys. The Head cycles one revolution, and comes to Head Up without engaging the Jump Stitch Solenoid. 2. Next Press the [ALT] and [Down Arrow] keys to bring the Head to full needle down position. 3. Then press the [ALT] and [Right Arrow] keys to cycle the head to the "hook" position. At this time in the stitch cycle, the hook should be behind the needle scarf and approximately 1/8 inch (3.175 mm) above the eye. If this is not the case, the Needle Bar Depth and/or the Hook Timing must be adjusted. After the Needle Bar Depth has been set then you may adjust the Hook Timing and Needle Gap. Melco Industries, Inc. 3-17 Caution: You should never adjust hook timing before checking needle bar depth. With the needle bar depth incorrect and misadjusted hook timing, replacing broken needles will make for a lot of down time. So be careful, and don’t be afraid to check adjustments on a regular basis. Hook Timing Procedure (Hook already installed on Sewing Head) In this procedure, it is understood that the Hook Assembly is installed on the Sewing Head and in the approximate position for sewing. The fine adjustments for Hook Rotational Position and Needle Gap remain to be set. 1. Turn "ON" the Sewing Peripheral and select the "HEAD TIMING MENU" from the Keyboard. 2. Press the [ALT] and [LEFT ARROW] keys to cycle the head one revolution (the machine will go to Head Up without engaging the Jump Stitch Solenoid). 3. Next press the [ALT] and [DOWN ARROW] keys (full needle down). 4. Then the [ALT] and [RIGHT ARROW] keys to cycle the head to the "hook" position. The Sewing Head is now in the position for making the fine adjustments for Hook Rotational Position and Needle Gap. EMC6/4M Operation Manual 3-18 Refer to the figure on the preciding page to identify parts mentioned in the following steps. 1. Check the hook position and the needle gap at this time. The hook point should be in the a position directly behind the needle and the gap between the hook point and needle should be approximately the thickness of the thread being used. If necessary, reposition the hook point so it will be directly behind the needle when the key sequence in step 1 is performed. 2. To set the rotational position of the hook point, first loosen (DO NOT REMOVE) the two (2) hook assembly mounting screws that are not accessible from the top when the hook point is directly behind the needle. To access these screws, press the [RIGHT ARROW] and/or the [LEFT ARROW] keys to rotate the hook in small steps of rotation to align the screws, one at a time, to accessible from the Left side. Then perform the ENTIRE head movement key sequence in step 1 to cycle the head to the hook position again. 3. Now loosen the third mounting screw (it is now accessible from the top), and position the hook directly behind the needle. Slightly tighten the third mounting screw to prevent the hook assembly from rotating, and to hold the position. The gap between the hook point and the needle must be approximately the thickness of the thread being used. The "Gap" can be checked by positioning a 1 foot (30cm) length of the sewing thread behind the needle, under the gap. If the thread is lifted slowly, at each end, it should pass through the gap behind the needle just slightly touching the needle and the hook point but without catching the hook point or deflecting the needle.Check the gap and refer to the next step to adjust if necessary. 4. Keeping the rotational position directly behind the needle, loosen the mounting screw and slide the Hook Assembly toward or away from the needle to increase or decrease the gap as necessary. Again check the gap as described in step 4; and readjust the hook until the proper gap is achieved. Securely tighten the mounting screw to fasten the hook to the shaft. 5. Press the [RIGHT or LEFT ARROW] key to rotate the Hook Assembly in small steps of rotation to gain access to the two remaining mounting screws, and tighten each in turn. 6. Perform the key sequence in step 1 to cycle the Sewing head to the "Hook" position again to check for the proper gap. Melco Industries, Inc. 3-19 Retaining Finger Adjustment: The rotational hook point location and needle gap adjustments are completed. The adjustment for the inner basket retaining finger must now be performed. a) Insure the retaining finger tab is positioned into the retaining finger groove of the inner basket, as shown below. b) Loosen the attaching screws for the retaining finger; and align the tab so that it is centered in front of the needle. c) Insure that a gap is present between the retaining finger tab and the inner basket retaining finger groove. This gap must be large enough to allow thread to pass through it, but close enough to restrain the inner basket from rotating. d) Retighten the retaining finger mounting screws when the adjustments are completed. Hook Timing is now complete. EMC6/4M Operation Manual 3-20 Trimmer Operation And Maintenance The EMC6/4-T Sewing Peripheral includes an Automatic Thread Trimming Function. This function will work automatically when "Enabled" (turned on) in the Head Timing Menu, see pg 2-46. The function may be turned off (disabled) and thread trimming done manually. When your design was first punched (digitized) and if color changes were required, they were inserted in the design during the digitizing process. The Melco Trimmers will "see" this and automatically trim the thread at the color change. The EMC6/4-T Sewing Peripheral will not trim thread on its own, it must see the command in the design program while the peripheral is sewing. You may use the Trim Immediate command from the peripheral’s keyboard, only when in the HEAD TIMING MENU and only when the machine is stopped (Z axis is not moving). When the peripheral sees a trim command or color change, the machine will slow down to 100rpm/Z Rotation, all trimming is done within this "window." The cutters (under the Needle Plate) cut the thread, while simultaneously the grabber reaches out from behind the needle case to "grab" the tail of thread below the needle and pulls the tail back and up into the lower thread wiper (holder). Immediately after the trimmers actuate, the Beam makes a two part move before the machine starts sewing again. This move clears the bobbin thread remaining under the Needle Plate, to prevent that thread from wrapping around the rotary hook assembly and causing a thread jam. The Beam may move either forward/backward, or backward/forward, depending on where the Beam position is at the time of the Trim. The Trimmer function will operate under the following conditions: 1. Upon reaching a Color Change, defined in the design, which consists of X-Y move followed by a Color Change function. 2. 3. Upon reaching a Trim Dataset (an X-Y move followed by a Trim function). This dataset is inserted during digitizing of the design. At the End Of The Design. 4. If the Peripheral finds "x" number of consecutive Jump Stitches, where "x" is user definable. See Frame Menu, page xx.(The definable range is 1-15, 6 is default. A zero(0) disables this function.) Melco Industries, Inc. 3-21 5. Upon selection of the user definable Trim Immediate function. See Head Timing Menu, page 2-46. Sequence of Trim Events 1. As the machine sews the EMC6/4-T program software detects a Color Change, a Trim command, 1-15 consecutive Jump Stitches, or the End of Design dataset. 2. The program software slows the sewing heads to 100 spm (stitches per minute), this is the window for trimming. 3. The Picker, engages into the Bobbin and catches the thread loop, this makes the remaining thread the correct length to start sewing again. 4. The Moving Cutter, directly below the Needle Plate, initially separates the two top threads and the bobbin thread. It then cuts the bobbin thread and one of the top threads, when it retracts to its "home position". 5. The X-Beam now makes two moves, that clears the top thread, now called a Tail,out of the cloth. 6. At the same time as the Cutters cut thread and the X-Beam makes its moves, the Grabber reaches out from behind the Needle Case and "grabs" the Tail pulling it up and back into the Thread Wiper. The length of the tail (Long or Short) is user selectable in the Head Timing Menu. One Trim event takes 4.5-5 seconds to accomplish. 7. When the Trim is complete, the peripheral begins sewing and ramps up to the original sewing speed chosen by the operator at the out set of the sewing session. EMC6/4M Operation Manual 3-22 Trimmer Maintenance Lubrication of the Trimmer Option consists of greasing the Cam located under the Frame of the EMC6/4-T. And lubricating the Knife Arm Pin and Trimmer Picker Pivot See page 3-3 for lubrication frequencies. 1. Remove the Cam Box Cover shown in the illustration at the bottom of this page. 2. Smear the Cam Follower Groove with medium ball bearing grease provided in the EMC6/4-T Tool Kit. Do Not use sewing machine oil for this lubrication. Refer to the Trimmer Cam Illustration. 3. Lubricate the Knife Arm Pin, and the Trimmer Picker Pivot, shown in the illustration on the next page. Z-Drive Shaft Z-Drive Motor Table Top Bed Assemblies Trim Linkage Trimmer Cam Box Left Front View Melco Industries, Inc. 3-23 Trimmer Cam Trimmer Knife Arm Pins Top View Side View Trimmer Picker Pivots Front View EMC6/4M Operation Manual 3-24 Trimmer Troubleshooting During the course of trimmer operation problems may occur. Problems like the cutters not picking up the threads, or the thread coming out of needle when the machine begins to sew after a trim. While things like this will not happen often, they will happen. When they do its an indication that some adjustment is necessary. Most of the major adjustments should be made by factory trained service representatives. Some adjustments however can be accomplished by the operator. There is a EMC6/4-T Technical Manual available that covers all mechanical aspects of the sewing peripheral and the Trimmers. Contact your Melco Service Representative about the Technical Manual. Here we present a troubleshooting guide to help you track down problems you are likely to encounter, with a probable cause and suggested corrective action. Problem: The upper thread is not cut. Probable Cause and Corrective Action 1. The moving cutter does not pickup the thread. a. Cam timing is not correct. • Adjust cam timing referring to Timing Chart. b. Cutter linkage may have slipped. • Reset cutter linkage referring to technical manual. 2. Moving cutter doesn’t travel far enough by fixed cutter to cut the thread. a. Cutter linkage may have slipped. • Reset the linkage referring to technical manual. 3. Fixed to moving cutter relationship out of adjustment. • Adjust relationship referring to technical manual. Melco Industries, Inc. 3-25 Problem: The thread comes out of the needle at trimming. Probable Cause and Corrective Action 1. Trimming timing of the moving cutter is too early. a. Cam timing is not correct. • Reference technical manual. 2. Check spring on the tensioner is too tight. a. Adjust check spring per technical manual. Problem: Thread comes off the needle when starting. Probable Cause and Corrective Action 1. The upper thread is too short. a. Anything in the upper thread handling area makes the tension of the upper thread too tight for trimming. • Check the thread path for obstructions. b. Pre- Tension disc too tight. c. Picker does not move in enough. • Adjust Picker clearance to bobbin. (1.5mm) See technical manual. d. The moving cutter is damaged. • Replace. See technical manual. 2. The under thread (bobbin) is too short. a. Bobbin tension is too tight and thread breaks. b. Bobbin thread is not being held. • Check bobbin thread holding spring. c. Bobbin is wrong type for job. • Change bobbin thread. EMC6/4M Operation Manual 3-26 Problem: Upper thread is not pulled under at start. Probable Cause and Corrective Action 1. Upper thread is too long after trim. a. Pre-Tension is too tight. b. Picker is not fully retracting. • Check picker function. c. Picker not going in at startup. • Check picker function. Problem: Thread on inactive needles are not being stored and are getting sewed down. Probable Cause and Corrective Action 1. Grabber not grabbing thread. a. Grabber not going out far enough to catch thread. • Check Grabber function. b. Grabber wire broken. • Replace assembly. See technical manual. Problem: Error Message "TRIMMER NOT HOME" Probable Cause and Corrective Action 1. Something is preventing the cutters from returning to their home position. • Check picker function, look for "birdsnest" of thread wrapped around picker,cutters, or rotary hook. a. Movable knives out of adjustment. • Check and adjust. See Technical Manual. b. Bobbin Thread Holding Spring, damaged by cutters. • Replace damaged holding spring. Melco Industries, Inc. 3-27 • Move cutters home by grasping the Cutter Actuating Shaft under the frame and push it as far left as it will go. Problem: Error Message "GRABBER NOT HOME" Probable Cause and Corrective Action 1. One of the Grabbers under the sewing head is not fully retracted. • Rotate the Motor Stop Lever on the left side of head # 2, down, or press the Start Key. • If the message comes back, check the grabber function on each head to find a cause for the message. EMC6/4M Operation Manual