Melco EMT16X User manual

EMT16X Technical Manual
Rev 113020

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Contents
Copyright Notice 9
About This Manual 10
Scope of Manual 11
Standard Conventions and Denition of Terms 12
Regulatory Notices 13
Best Maintenance Repair Practices 14
Maintenance Philosophy: 14
Grounding and Static Electricity 17
Machine Orientation 19
Safety Issues 20
Warranty Considerations 21
Explanation of Machine Symbols 22
Keypad Operations 23
Head Timing Keypad Functions 26
Keypad Buttons 28
Trace Button 28
Arrow Up Key (Y-Axis Back) 28
Color Change/Needle Case 28
Arrow Left Key (X-Axis Left) 28
Arrow Right Key (X-Axis Left) 29
Center Key 29
Adjustment Key 29
Arrow Down Key (Y-Axis Forward) 29
Hoop Key 30
Step Back Key 30
Step Forward Key 30
Laser Key 30
Start Button 30
Stop Button 31
Emergency Stop Button 31
LED Indicator 32
Specications 33
Technical Specications 35
Torque Specications 36
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Software Maintenance Menus 38
Special Tools and Fixtures 39
General Maintenance 40
Cleaning 40
Lubrication Schedule and Specications 42
Maintenance Schedule 42
Daily Maintenance 44
Weekly Maintenance 46
Monthly Maintenance 52
Quarterly Maintenance 58
Head Up Position Adjustment 68
Mechanical Head-Up Position 68
Adjusting Head-Up (Z-Home) Position: 69
Hook Timing Inspection/Adjustment 70
Rotational Hook Timing Inspection Procedure 71
Needle To Hook Gap Inspection Procedure 72
Adjustment Procedure 73
Trimmer Replacement 76
NPT Printed Circuit Board Assembly Replacement 76
NPT Sensor Replacement 77
NPT Motor Replacement 81
Centering The Needle Plate 90
Laser Light - Adjustment 91
Needle Depth 93
Setting the Needle Depth by Eye 93
Presser Foot Height 94
X/Y Home Adjustment 95
Home Adjustment Procedures: 95
X-Cable Tension 98
Determining if an X-Cable is Set to Required Specications 98
Adjusting an X-Cable that is Tensioned Outside the Required Specications 99
Y-Axis Timing Belt Tensioning 101
Y-Axis Belt Tension Inspection 101
Y-Axis Belt Tension Adjustment 102
When Belt Tensions are Correct 102
Y-Motor Timing Belt Tensioning 103
Inspection and Adjustment 103
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Z-TIMING: Bottom Center & Head-Up 104
Bottom Center (Z Timing) 104
Z-Drive Belt Tensioning 109
Inspection and Adjustment 109
Z-Home Adjustment 111
Procedure to Identify the Closest Needle 112
Needle Case Calibration 115
Fine calibration procedure: 115
Rough Calibration Process: 116
Rotary Hook Support Adjustment 118
Inspection Procedure 118
Adjustment Procedure 120
Color Change, Take-Up, Feeder Housing Assembly 122
Replacement Procedure for Entire Color Change/Take-Up/Feeder Assembly: 122
Color Change Linear Actuator Replacement 124
Replacement Procedures: 124
Thread Feeder Gear Replacement 127
Replacement Procedures: 127
Thread Feeder Optical Sensor PCB Replacement 129
Replacement Procedure: 129
Thread Feeder Radial Bearing Replacement 130
Replacement Procedures: 130
Thread Feeder Stepper Motor Assembly 131
Replacement Procedure: 131
Laser Pointer Assembly 133
Replacing the laser assembly: 133
LED Cluster PCB Replacement 135
Presser Foot Assembly Replacement 136
Reciprocator 139
Replacement Procedure 139
Take-Up Lever Cam Replacement 141
Replacement Procedure 141
Z-Drive Repair and Adjustment 144
Z-Drive Belt Replacement and Tensioning 144
Z-Home Sensor PCB Replacement 146
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Z-Belt Idler Assembly Replacement 148
Z-Motor Assembly 149
Clearing Thread from Thread Feeder Roller 152
Color Change Spindle Mounting Bracket Replacement 154
Grabber Blade Replacement 156
Needle Case Removal 159
Needlecase Installation 161
Grabber Stepper Motor Replacement 163
Take Up Lever Replacement 164
Thread Feeder (replacement and adjustment) 166
Thread Sensor Assembly Replacement 169
Bobbin Shaft Overhaul 171
Rotary Hook Replacement 173
Main PCB 175
Power Input Assembly Replacement 178
Power Input Assembly & Inline Coupler Replacement: 179
Power Input Assembly Component Replacement: 181
Power Input Assembly Installation: 186
User Interface Assembly Replacement 187
Harnesses 190
Color Change Motor Harness 191
Ethernet Harness 194
Grabber/Threadfeed Motor Harness 196
Grabber/Threadfeed/CC Home Harness 200
Laser Harness 203
LED Cluster Harness 205
Replacement Procedures: 205
Thread Break Harness 209
Z Home Harness 212
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User Interface Harness 215
X/Y Home Harness 218
Bearing Block Assemblies 221
X-Beam Assembly 223
X-Carriage Assembly 225
X-Drive Cable Removal 227
X-Drive Cable Installation 229
X-Drive Motor Replacement 233
X-Home Optical Switch Assembly Replacement 236
X/Y Home PCB Replacement 238
Y-Drive Belt Replacement 240
Y-Motor Assembly 242
Troubleshooting 244
Grabber Function Test 245
Final Functional Tests 247
Optical Sensors Test 249
Power Supply Test 250
Servo Motor Resistance Test 252
Stepper Motor Resistance Test 253
Servo Motor Resistance Test 254
Test Designs 255
Thread Tension Test 256
Belt Tension Test 256
Long Stitch Test 257
Looping Test 257
Orientation Test 258
Registration Test 258
Small Alphabet Test 258
Thread Break Sensor Test 259
Thread Break Test 259
Trimmer Test 260
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Electrical Failures 261
Color Change Failures 261
LED Cluster Assembly Failures 262
Mechanical Failures 263
False Thread Breaks 263
Loose/Looping Stitches 263
Needle Breaks 263
Skipped Stitches 264
Thread Breaks 265
Miss-Starts 269
Cap Frame Issues 269
Miscellaneous Problems 270
X-Axis Failures 271
Y-Axis Failures 272
Z-Axis Failures 273
Software Error Messages 274
DSP Command Errors 275
Can’t Initialize Stepper Motors 275
No Trace Data 275
XY Home Not Set 275
Goto Func Error 276
Hoop Center Error 276
Stepper Motor Time Out and Index Errors 276
E-Stop Engaged 277
Servo Motor Errors (Move Time Out, Tracking, and Over Current Errors) 278
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Critical Measurements 280
Introduction 280
Needle Drive Stud to Reciprocator Fit 281
Hook Timing 281
Upper Arm to Lower Bed Alignment 281
Needle to Hook Gap 282
Hook to Rotary Support Gap 282
Take-Up Lever Stroke 282
Take-Up Lever Fit to Shaft 283
Take-Up Lever Endplay 283
Cam Follower Preload 283
Pull Force on Take-Up Lever 284
Color Change Lead Screw 284
Color Change Housing Location 285
Bobbin Tension 285
Presser Foot Adjustment at Bottom Dead Center 286
Thread Feed Forward 200 287
Needles 287
Thread Clean Thread Path 288
Z-Belt Tension 288
X-Cable Tension 289
Y-Axis Timing Belt Tension 289
Proper Lubrication of Moving Parts 289
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Copyright Notice
© Copyright Melco, 2020
ALL RIGHTS RESERVED. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise)
without prior written approval from the author. The author reserves the right to revise this publication
and to make changes in it at any time without obligation of the author to notify any person or organiza-
tion of such revisions or changes.
All precautions have been taken to avoid errors or misrepresentations of facts, equipment, or products.
However, the manufacturer does not assume any liability to any party for loss or damage caused by errors
or omissions.
The machine technology is protected by - but not limited to - the following patents:
• Pat. US 6,445,970 B1
• Pat. US 6,736,077 B2
• Pat. US 6,732,668 B2
• Pat. US 6,823,807
• Pat. US 6,871,905
• Pat. US 6,983,182 B2
• Pat. US 7,513,202
• Pat. US 7,308,333 B2
• Pat. US D474,785 S
• Pat. CH 693569 A5
• Pat. US 8,851,001 B2
• Other patents pending
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About This Manual
This manual contains instructions on repairs and adjustments to the embroidery machine, in addition to
other technical information.
If you do not fully understand any information in this manual, you are advised to contact your local au-
thorized technical support provider for assistance.
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Scope of Manual
This technical manual is a guide to performing repairs and adjustments that go beyond routine operator
maintenance.
Although these procedures are best understood and performed by professional service technicians in
conjunction with specic factory technical training, much of the information in this manual is a useful
reference for others who might possess appropriate technical aptitude and skills.
•
Note: This manual is written for individuals with adequate knowledge, Melco certied training
or equivalent and experience in the use of tools required. No attempt is made to explain how
to use tools required to make repairs to the machine other than graphical depictions within the
procedures involved.
This technical manual species that certain functions are to be performed only by authorized service tech-
nicians. This is because specialized training and/or special tools or xtures are required in order to per-
form the function correctly. Performing repairs to the machine may result in damaged components, poor
machine performance, and potential injury to the technician or operator.
If you do not fully understand any information in this manual, contact technical support for assistance
before performing the procedure. The technical support staff are professional service technicians trained
on this equipment. They have acquired technical expertise through experience and technical training.
Additionally, certied equipment technicians routinely receive up to date servicing information to further
enhance their product knowledge.
This technical manual is presented in six sections:
1. Introduction to the manual and various service requirements
2. General information and specications containing all of the engineering settings and specications
you need to know when adjusting the machine
3. Lubrication schedules and procedures
4. Service and repair - detailed instructions to service and repair the machine
5. Options - maintenance and repair of optional equipment
6. Troubleshooting - a troubleshooting guide for problems commonly encountered with the machine.
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Standard Conventions and Denition of Terms
Throughout this manual abbreviations and specic terms may be used. When abbreviations or techni-
cal terms are used, they are dened through the use of pop-up hot spots, which opens a dialog box to
explain their meaning. Hot spot text is green and underlined. To access a pop-up hot spot simply click the
underlined word to read its explanation.
Certain procedures in the manual require actions such as pressing a certain key, or typing some letters on
the computer keyboard. The following is a list of some of the more commonly used conventions found in
this manual:
• To indicate a key on the computer keyboard, the key in question is enclosed in brackets, for exam-
ple: Press the [Enter] key to initiate the application.
• A key on the interface keyboard is represented by a picture of that key.
Attention Styles:
Occasionally in the manual, special attention is required. In these situations, certain images and text styles
are used to attract your attention to a particular message. The following styles are used to denote certain
types of messages.
•
WARNING!! Situations which may result in personal injury if not performed correctly.
•
CAUTION!! Situations that might result in damage to equipment or property but is not likely to
result in personal injury.
•
IMPORTANT: Situations critical to correct machine operation that is not likely to result in damage
to the machine or personal injury.
•
NOTE: Important information that is signicant, but not likely to result in interference to correct
machine operation.
•
TIP: Helpful information that might make a procedure easier or more efcient.
When a reference to a part description is in bold type, that reference is the actual part description as
listed in the machine parts manual. The parts manuals are unique for each machine depending on serial
number and date of build. For part numbers, pictures, and assembly diagrams, refer to the parts manual
issued for that particular machine.
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Regulatory Notices
(U.S.) The FCC (Federal Communications Commission) mandates that if a user makes changes or modi-
cations to the machine not expressly approved by the manufacturer, the user’s authority to operate the
machine may be voided.
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Best Maintenance Repair Practices
The procedures presented in this manual are to be considered best maintenance repair practices. These
procedures are intended to optimize the performance and durability of your machine. Best maintenance
repair practices are to be performed using the correct tools and xtures while adhering to all safety pre-
cautions appropriate for each job.
•
WARNING!! Personal injury may result if proper precautions are not observed. Remove rings,
watches, and any other metallic objects from hands and wrists before servicing the machine.
Remove metallic articles from shirt pockets to prevent them from falling into the machine. Do
not allow loose clothing or long hair contact moving parts of the machine. Under certain con-
ditions of machine failure, the moving parts of the machine may not be controllable by normal
means. At these times, the machine may operate without notice.
•
CAUTION!! Use extreme care not to drop metallic objects, tools, or other conductive material on
the main Printed Circuit Board (PCB) when you have the base cover removed. If you drop such
objects on the main PCB, it can severely damage the electronics which will be very expensive to
repair.
Maintenance Philosophy:
The maintenance philosophy used in this manual is to isolate potential problems within the system to the
smallest practical replacement assembly. Therefore, components are typically not repaired, but rather, a
circuit board or mechanical subassembly may be replaced.
In the process of isolating problems in the machine, the person performing the troubleshooting must also
practice good troubleshooting techniques. Good troubleshooting techniques include, but are not limited
to, guarding against static electricity that can result in further damage to machine components, and only
replacing one part at a time to enable identication of the defective part after the machine is repaired.
•
WARNING!! Failure to practice Best Maintenance Repair Practices may result in injury to person-
nel performing the work and/or damage to the equipment. The warranty is exclusive of, and
may be VOID if poor maintenance practices have caused damage to the equipment.
Dust:
As with any electronics, the worst source for contamination for the PCBs and the Control PCB is dust.
Although great care has been made during the design of the electronics in the machine, dust accumula-
tion may cause failure of the machine if it is allowed to accumulate.
•
CAUTION!! DO NOT use solvents of any type on the printed circuit boards (PCBs) or sensors.
Solvents will damage the electronic components. Use only compressed air to clean these items.
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Using compressed air, blow the dust away from sensors and off the PCB’s in the machine. In addition,
minimize dust accumulation cleaned on all exposed surfaces. Excessive dust will reduce the useful life
span of the machine.
Sensors should be cleaned with dry, compressed air during each of the lubrication cycles. Dust accumula-
tion in the base around the control PCB should be blown out every month or whenever the base cover is
removed for any type of maintenance.
Liquid Cleaning Compounds:
Never spray liquid cleaning compounds directly onto the machine, especially if it is turned on or connect-
ed to an electrical supply outlet. Always spray cleaning compounds onto a rag and wipe the machine
clean. Liquid cleaners can, if sprayed directly on the machine, get onto electrical components and short
them out. Optical sensors are very sensitive and may be damaged by liquid cleaning compounds.
Obstructions:
Obstructions of machine movements can cause severe damage. Obstructions include things like fabric
getting caught in the gears, loose hardware left inside the machine, thread accumulation around the
grabber blade, Velcro, and anything that hinders the machine’s moving parts. It is very important to clear
obstructions from any subsystem immediately before damage or excessive wear occurs.
Use Proper Parts For The Job
It is very important that you use the proper parts for the job, especially needles. Refer to the Operator
Manual for information on needle selection. Using the wrong needle will increase the frequency of frays
and thread breaks and will decrease performance of the machine.
Avoid using substandard substitute parts on the machine. Always use manufacturer distributed parts or
better to ensure superior quality output of your machine. When considering buying substitute parts, i.e.,
hardware, it is strongly recommended that you consult Technical Support and obtain the specications to
ensure that you get the equivalent grade or better parts.
Use The Correct Tools When Making Repairs
Always use the correct tools when making repairs or performing maintenance on the machine. No at-
tempt has been made in this Manual to explain what tools to use. It is assumed that the person who
makes repairs or performs maintenance on the machine has the proper technical aptitude and training to
allow them to do so. Using tools incorrectly or using the wrong tools can cause damage to the machine
and result in personal injury.
The use of poor quality tools such as multimeters and mechanical measuring devices can produce unpre-
dictable and often unsatisfactory results. Always purchase tools for repair or maintenance on the machine
that are of standard design and professional quality. You may if desired, consult Technical Support for
assistance in recommending such tools as multimeters and measuring devices before you purchase them.
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Drive Belt Tensions:
•
CAUTION! Damage to the machine may result if belt tensions are improperly adjusted. All drive
belts require special procedures and tools for setting the proper tensions. If the tension adjust-
ments are made without using the proper procedures and tools (and without training in some
cases), poor performance, excessive wear, damaged components, personal injury, and voided
warranty may result.
Scheduled Maintenance:
Scheduled maintenance is lubrication, cleaning, measurements, and inspections that are specied on a
periodic schedule.
Scheduled maintenance is prescribed in the operator manual for the machine. Failure to perform sched-
uled maintenance will result in poor performance and eventual failure of the machine. In addition, failure
to perform the maintenance prescribed in the operator manual can affect warranty protections.
Lubrication:
Lubrication should be done whenever a part is replaced or repaired and as prescribed according to the
Lubrication Specications. When applying lubricants to any parts, use only the approved lubricants and
application methods specied in the Lubrication Specications.
•
CAUTION! Damage to the machine will result if inadequate or excessive lubrication is applied
to machine parts. Failure to adhere to lubrication specications will result in premature wear,
poor performance, and potential warranty issues.
Torque Measurements:
Apply proper torque to all screws, bolts, and nuts or similar parts used in the machine. Torque speci-
cations are provided for a reason. They have been developed from years of experience with the parts
involved. Avoid guessing at the torque applied to a part and measure it, especially where measurement is
specied.
•
CAUTION!! Inadequate torque can result in premature failure of the part involved, usually
causing it to come loose. Excessive torque usually results in stress to the part that will not al-
ways be detectable. The part can fail later during machine operation and can cause catastroph-
ic machine failure.
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Grounding and Static Electricity
•
WARNING!! It is very important that the power cord is plugged into a properly wired electri-
cal outlet. Failure to have a properly wired outlet may result in damage to the equipment and
personal injury. It is recommended that a licensed electrician be consulted to ensure that the
electrical outlet is properly wired and grounded. If a properly wired electrical outlet is not used
for the source supply voltage to the system, electrical failures may result.
Static Electricity:
As with all computerized equipment, your machine is sensitive to static electricity. Any time work is
performed inside covered areas of the embroidery machine, the person performing the work must use
a static grounding strap or take adequate steps to dissipate static build-up prior to touching electronic
components.
•
WARNING!! Failure to use a grounding strap, or failure to practice other good maintenance/
repair techniques may cause damage to the machine and possible personal injury.
•
CAUTION!! Unless otherwise specied within these procedures, DO NOT disconnect the
electrical supply input cord from the machine or the electrical input source outlet. Doing so will
remove the ground connection needed to dissipate the electrical static build-up prior to work-
ing on the internal components in the machine. Always make contact with the exterior metal
portion of the machine for about one minute to dissipate any electrical static build-up in your
body before touching any electronic component of the machine, especially the main board.
Grounding Strap Use:
A grounding strap should be connected properly to ensure that static charge on the person’s body is neu-
tralized to the chassis ground of the embroidery machine when working in the electronic areas under the
covers. Proper connection is provided at any bare (unpainted) metal surface or any other surface (such as
a ground screw head) that is known to be an earth ground. If a ground strap is not used or is not avail-
able, touch the chassis for about a minute to dissipate any static build-up before you touch any electronic
component inside the machine (with the machine turned off and the power input cord connected to an
electrical outlet).
•
WARNING!! DO NOT attempt to use any grounding strap that is not specically designed for
static use. A “straight-wire” grounding device (one without built-in resistance) will place the
operator in danger of exposure to dangerous voltages. It is recommended that the static strap
be checked during daily use for proper resistance protection.
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•
CAUTION !! Use extreme care not to damage the cable and protective coating during assem-
bly. If the protective coating is damaged, the cable will wear out very fast impacting the quality
of the sew outs.
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Machine Orientation
The references in the manual to certain sections of the machine are oriented as if you were facing the
front of the machine as shown below. Example: The “left” arm cover is on the left side of the machine
when you face it from the front, but is on the right side if you face it from the rear. The part however, is
called the “left” arm cover since it is installed on the left side, oriented as you face the machine from the
front.
Left Side Right Side
The left and right sides of the machine are oriented just as if you were facing it from the front side of the
machine directly.
The rear of the machine refers to the entire back side of the machine.
The front part of the machine refers to the entire front section of the machine.
The upper arm assembly, lower arm assembly, needlecase, user interface, and thread tree refer to the
entire individual assembly and associated components.
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Safety Issues
Voltages
•
WARNING!! Lethal voltages exist inside the power supply unit, at the back side of the electrical
supply input connector, and in the wires between the two. If you plan to do any work with any
of these components, turn the power switch off and disconnect the electrical input supply cord
from the machine.
•
WARNING!! DO NOT disassemble the power supply unit. It contains no customer or eld ser-
viceable parts. The internal components in the power supply unit may contain dangerous volt-
ages even when the power is disconnected. Disassembling the power supply can cause severe
injury resulting from electrical shock, and may void the warranty.
•
WARNING!! DO NOT operate the machine with the lower rear cover removed, except when
indicated by the instructions in this manual. Operating the machine without the covers creates
a risk of severe electrical related injury.
Hazardous Material Notices:
•
WARNING!! The lubricants specied in this Manual contain known carcinogens. Do not allow
lubricants to come into contact with your eyes, mouth, or nose. Always wash your hands thor-
oughly after performing lubrication procedures.
•
WARNING!! When using solvents to clean components in the machine, always ensure adequate
ventilation. Allow all solvents to completely evaporate before turning the machine back on to
prevent shorting out electrical components. Vapors from most solvents are both toxic and am-
mable. Dispose of rags soaked with solvent properly.
Moving Parts:
•
WARNING!! Do not operate the machine without the covers being installed. Moving parts can
cause crushing and pinching injuries. In addition, fabric and other materials can get caught in
the moving belts and gears and damage the machine.
•
WARNING!! Do not attempt to pull on or trim threads near moving needles. This can result in
painful injury.
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