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Melco EP 1B Technical Manual

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Download this manual See also: Installation, Operation & Maintenance Manual
Technical Manual
for the EP 1B
embroidery machine
Part Number 12616, Revision B
• Single Head, Single Needle
• Easy To Operate
• Low Power Consumption
• High Quality Results

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Summary of Contents for Melco EP 1B

  • Page 1 Technical Manual for the EP 1B embroidery machine • Single Head, Single Needle • Easy To Operate • Low Power Consumption • High Quality Results Part Number 12616, Revision B...
  • Page 2 Melco Embroidery Systems. Melco reserves the right to revise this publication and to make changes in it at any time without obligation of Melco to notify any person or organization of such revisions or changes.

  • Page 3: Table Of Contents

    12. Adjustment of Bobbin Thread Sensor, Solenoid and Thread Breakage Sensor. 13. Replacement of Wire pulley 14. Replacement of X-Y Carriage 15. Replacement of Y(X) Stepping Motor and Y(X) Sensor 16. Replacement of Gear 17. Self-diagnosis Mode EP 1B Technical Manual 06/99...
  • Page 4 Table of Contents 12616, Rev. B Melco Embroidery Systems...

  • Page 5: Setting Method For Adjusting Or Repairing Machine

    1. Setting Method for Adjusting or Repairing Machine 1. Lay the machine on its side, and insert thick books or the like below the machine as shown in Fig.1-1,1-2. 2. Set the machine by adjusting the height of the arm by using a hard book or the like so that baseplate (A) is almost perpendicular to the floor as shown in Fig.1-1,1-2.

  • Page 6: Replacement Of Hook Race (Unit)

    1. Remove the needle by loosening needle setscrew (A), and remove the throat plate by removing setscrew(B) as shown in Fig.2-1. FIGURE 2-1 2. Remove bottom plate (D) by removing 14 bind screws 4x5(C). Fig.2-2. FIGURE 2-2 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 7 2. Replacement of Hook Race (unit) 3. Remove the bed rubber stopper (F). Fig.2-3. 4. Set the needle bar to the lowest position, and loosen the clamp screw at the bed rubber stopper (F) position. FIGURE 2-3 5. After removing the Hook race body cover by removing bind screws 4x6.5(E), remove the bed cover (unit) (H) by removing two bind screws 4x12(G).
  • Page 8 1 direction as shown in Fig.2-6, loosen socket screw(K), and shift the lower shaft gear rightward in the arrow 2 direction. Loosen socket screw (L) next. FIGURE 2-6 8. Loosen socket screw(M) shown in Fig.2-7. FIGURE 2-7 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 9 2. Replacement of Hook Race (unit) 9. Draw out the hook race body(unit) in the arrow 1 direction as shown in Fig.2-8. After removing the hook race body cover and hook body, assemble new hook race body(unit) in the arrow 2 direction. FIGURE 2-8 10.
  • Page 10 Fig.2-13 and lightly press it to the hook shaft gear by shifting it in the arrow 2 direction. Turn the lower shaft front bushing in either direction, and tighten socket screw(K). FIGURE 2-13 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 11 2. Replacement of Hook Race (unit) 14. Mount a dial gauge to the needle bar, and lift the needle bar until it reaches 2.3mm above the lowest position. Fig.2-14-1. FIGURE 2-14-1 Set the hook body tip to the left side race of the needle as shown in Fig.2-14 -2(S).
  • Page 12 Fig.2-17. 17. Mount the set plate by setscrew, and mount the bed cover(unit), base rubber cap, and cover plate. FIGURE 2-17 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 13: Replacement Of Needle Bar (Unit)

    3. Replacement of Needle Bar (unit) 3. Replacement of Needle Bar (unit) This paragraph describes the needle position adjustment, presser foot height adjustment and other work in addition to the replacement of needle bar(unit). 1. Remove the top cover(unit). 2. Remove setscrew(A), two setscrews(B), and snap ring(C), and then, remove front bracket(D).
  • Page 14 FIGURE 3-4 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 15 3. Replacement of Needle Bar (unit) 6. Tighten socket screw(F) lightly as shown in Fig.3-5. FIGURE 3-5 7. Insert the needle into throat plate needle hole(L) while lifting the presser foot as shown in Fig.3-6 ,adjust the needle bar supporter(J) horizontally so that the horizontal gap becomes more then 0.6mm,...
  • Page 16 Fig.3-8, and adjust the height of ring (O) so 1.2 - 2.0 mm that the gap between the presser foot bottom and the upper face of the throat plate becomes 1.2-2.0mm. Fig.3-9. FIGURE 3-9 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 17: Removal Of X-Y Cover

    4. Removal of X-Y Cover 4. Removal of X-Y Cover 1. Remove the carriage cover(B) by removing three bind screws 3x10(A). Fig.4-11. FIGURE 4-1 2. Remove X-guide bar(F) and carriage(unit) (E) by removing two countersunk screws 4x5(D). Fig.4-2. FIGURE 4-2 12616, Rev.
  • Page 18 Fig.4-4. 6. Remove bind screw 3x4 and small plain washer(K). 7. After loosening two bind screws 3x4 and small plain washers(C), shift cover(L) in the arrow direction. Fig.4-4. FIGURE 4-4 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 19 4. Removal of X-Y Cover 8. Remove bind screw 3x8 and toothed lock washer 3.5 (M). Fig.4-7. 9. Remove ten bind screws 3x4 and finished plain washers 3 (N). Fig.4-5,6,7. FIGURE 4-5 FIGURE 4-6 FIGURE 4-7 12616, Rev. B...

  • Page 20: Replacement Of A Board, Lan Board, Power Supply Unit 24V And Power Supply Unit 5V

    2. (a) Replacement of A board. (C) FIGURE 5-2 I. Remove the connectors. Fig.5-3 II.Replace A board with a new one by removing fore bind screws 3x6. III.Assemble it in the reverse order. EP 1B Technical Manual Melco Embroidery Systems...
  • Page 21 5. Replacement of A Board, LAN Board, Power Supply Unit 24V and Power Supply Unit 5V (b) Replacement of AT board and LAN board.(D) I. Remove 3 connectors. Fig.5-3 II.Replace AT board and LANboard with a new one by removing 4 bind screws 3x25. III.Insert plastic spacer firmly.

  • Page 22: Replacement Of K Board And Display Tube (Vfd)

    2. Remove a connector from the A board. 3. Remove the top cover and the belt cover. Fig.6-1 FIGURE 6-1 4. Remove the front cover by removing 3 bind screws 4x8(A) and 1 bind screw4x10(B). Fig.6-2,6-3 FIGURE 6-3 FIGURE 6-2 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 23 6. Replacement of K Board and Display Tube (VFD) 5. (a) Replacement of K board I. Remove the insulating paper(C) from the front panel by removing 4 bind taptight screws 3x8. Fig.6- II. Remove the flexible cord(D) for VFD from the connector. III.

  • Page 24: Replacement Of Power Supply Switch, Inlet And Connector Fixing Plate

    I. Replace the inlet by removing 2 countersunk head screws.(C) Fig.7-1,7-2 FIGURE 7-2 (c) Replacement of Connector fixing plate.(D) I. Replace the connector fixing plate by removing 2 bind screws 4x6.5 (E) Fig.7-3 FIGURE 7-3 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 25: Replacement Of X-Y Mechanism

    8. Replacement of X-Y Mechanism 8. Replacement of X-Y Mechanism 1. Remove the bottom plate by removing 14 bind screws 4x5. Fig.8-1 FIGURE 8-1 2. Remove the connectors(A) from A board. Fig 8-2. 3. Remove the X-Y cover. par.4 FIGURE 8-2 4.
  • Page 26 FIGURE 8-5 8. After connecting EP 1B and PC, start up both of them and initialize the X-Y mechanism. 9. Adjust the X-Y mechanism while moving it so that the needle is inserted into the hole of jig (E) as shown in Fig.8-5, and tighten setscrews (B).

  • Page 27: Removal Of Machine

    9. Removal of Machine 9. Removal of Machine 1. Remove the bottom plate by removing 14 bind screws 4x5. Fig.9-1 FIGURE 9-1 2. Disconnect the connectors of cords (A),(B),(C),(D),(E),(F) and (G) from A board. Fig.9-2 FIGURE 9-2 3. After loosening bind screw 4x10 (H), remove pan head screw 6x35 (I).

  • Page 28: Replacement Of Thread Breakage Sensor, S Board(Unit), Upper Shaft Sensor And Solenoid

    IV.Remove 2 bind screws 3x4, and thread breakage sensor plate (2) (C). V.Remove a countersink head screw 2x8(D), and replace magnet sensor. Fig.10-5. VI.Assemble them in the reverse order. VII.After replacing, adjust the tension. Par.12-3. FIGURE 10-3 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 29 10. Replacement of Thread Breakage Sensor, S Board(unit), Upper Shaft Sensor and Solenoid. (b) Replacing Upper thread tension unit (upper thread tension spring and magnet). FIGURE 10-4 I. Remove 2 bind screws 4x8(E), and replace upper thread tension unit(F). Fig.10-5. II.After replacing, adjust the tension.
  • Page 30 2 pan head screws(L), and replace S board. Fig 10-8. VI.After replacing, assemble them in the reverse order. VII.Adjust the sensitivity and tension. par.12-1. 3. Replacement of Upper Shaft Sensor and Solenoid. FIGURE 10-8 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 31 10. Replacement of Thread Breakage Sensor, S Board(unit), Upper Shaft Sensor and Solenoid. I. For replacing the solenoid, remove the solenoid from the set plate by removing setscrews (M) and setscrews (P) shown in Fig.10-9. FIGURE 10-9 II.Remove snap ring on thread tension release rod(N), and pull thread tension release rod and plunger of solenoid.
  • Page 32 10. Replacement of Thread Breakage Sensor, S Board(unit), Upper Shaft Sensor and Solenoid. III. After removing set plate by removing screws(M) ,replacing the upper shaft sensor by pressing hook of the sensor. FIGURE 10-11 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 33: Mounting Of Machine

    11. Mounting of Machine 11. Mounting of Machine 1. Mount the machine to the baseplate by using 3 machine mounting screws (A) and 3 finished plain washers. Fig.11-1. FIGURE 11-1 2. Fix bind screws 4x5(B) after positioning the horizontal position of the machine by + pan head screws 6x35(C).

  • Page 34: Adjustment Of Bobbin Thread Sensor, Solenoid And Thread Breakage Sensor

    0 - 1.5mm. IV.Turn handwheel to set the thread take-up lever at the highest position. 0 - 1.5 mm FIGURE 12-2 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 35 12. Adjustment of Bobbin Thread Sensor, Solenoid and Thread Breakage Sensor. V.Turn on power switch. Turn volume VR2(C) until the green LED starts blinking goes on and off. (dust sensor adjustment). VI.Set thread wound bobbin (9m) in a bobbin case. Embroider a suitable design, which is transferred from EDS3.
  • Page 36 "off" position. Fig.12-7. IV.Confirm that faceplate does not touch the sensor when closed. V.Confirm that magnet does not touch sensor and LED is blinking while embroidering. FIGURE 12-7 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 37: Replacement Of Wire Pulley

    13. Replacement of Wire pulley 13. Replacement of Wire pulley 1. Remove the X-Y cover and then, remove the X-Y mechanism from the baseplate. 2. Draw the bushing (A) out of the X-Y mechanism, and draw out cushion (B) sideways. FIGURE 13-1 3.
  • Page 38 9. Remove bolts (D) and nut (E) from the X-Y mechanism, and set cushion (B) and bushing (A). 10. Fix the X-Y mechanism to the baseplate, while adjusting the needle position. 11. Mount the X-Y cover and carriage. FIGURE 13-6 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 39: Replacement Of X-Y Carriage

    14. Replacement of X-Y Carriage 14. Replacement of X-Y Carriage 1. Perform steps (1)-(3) in par.13. 2. Fix the wire (C) to pulley (A) securely by using grip band (B) as shown in Fig.14-1. Loosen setscrews (D), and disconnect wire (C) from wire pulley (E).
  • Page 40 (F) in the arrow 1 direction as shown in Fig.14-5. 10. Set new Y-carriage (F) to carriage (R). (Set the stitch frame of the carriage to be opposite to the nut side of Y-carriage (F).) FIGURE 14-5 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 41 14. Replacement of X-Y Carriage 11. Loosen nut (U) slightly, and adjust the Y-carriage by turning the eccentric pin (S), to which V-bearing (Q) is mounted, so that the Y-carriage functions smoothly without any play to guide rails (T). 12. Tighten nut (U), and make sure that the Y-carriage (F) functions without any play.
  • Page 42 20. Turn pulley (A) clockwise and counterclockwise several times by hand, and check the wire (C) for normal tension. If the wire (C) tension is not suitable, pull the wire pulley (E) again. 21. Perform the same operation as described in 9.- 11. in par.13. EP 1B Technical Manual Melco Embroidery Systems...

  • Page 43: Replacement Of Y(X) Stepping Motor And Y(X) Sensor

    15. Replacement of Y(X) Stepping Motor and Y(X) Sensor 15. Replacement of Y(X) Stepping Motor and Y(X) Sensor 1. Perform steps 1. - 3. in par.13. 2. After removing motor cord (unit) from stepping motor, remove the stepping motor by removing setscrews (A) shown in Fig.15-1.
  • Page 44 Remove Y(X) motor cord connector and Y(X) sensor connector(E) from A board. Fig.15-5. FIGURE 15-5 7. Pass the removed connectors under the base and remove clip band(F). Fig.15-6. FIGURE 15-6 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 45 15. Replacement of Y(X) Stepping Motor and Y(X) Sensor 8. Remove stepping motor connector and 1 bind screw 3x6(G). Then replace Y(X) motor cord unit (Y(X) sensor). Fig.15-7. FIGURE 15-7 9. Assemble new one in the reverse order. 10. Turn on power switch of main unit and PC. Keep the condition in which the carriage can be moved.

  • Page 46: Replacement Of Gear

    4. Remove the opposite wire in the same way as in step 3. FIGURE 16-1 5. Loosen setscrews (J) shown in Fig.16-2, and separate the wire and the X-carriage from each other. FIGURE 16-2 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 47 16. Replacement of Gear 6. Draw pulley (F) on the sensor (L) side shown in Fig.16-6 after loosening socket screws (K)(K*). (K screw is a WP screw.) Fig.16-3. FIGURE 16-3 7. Remove ring (N) by removing setscrew (M) shown in Fig.16-4. 8.
  • Page 48 (P) of the pulley as shown in Fig.16- 6, and tighten socket screws (K)(K*), so that the concaved face of pulley (F*) and shaft end face (B) are positioned face to face. FIGURE 16-6 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 49 16. Replacement of Gear 11. Put ball (R) mounted at the wire tip into the spot-faced hole which is the same phase as cut (P*) as shown in Fig.16- 7. Set the protrusion of the wire holder (I) to meet the other spot-faced hole, and fix the wire holder (I) by...
  • Page 50 A (S), tighten setscrews (J) to FIGURE 16-10 connect the wire (H) and X-carriage (R) to each other. 18. Connect the opposite wire and X-carriage to each other by setscrews (J). EP 1B Technical Manual Melco Embroidery Systems...
  • Page 51 16. Replacement of Gear 19. Remove work bolts and nuts, set the cushion (T) to the side bracket (S) in the arrow 1 direction as shown in Fig.16- 11,and set the bushing (U) in the arrow 2 direction. 20. Connect the X-Y mechanism to the baseplate (irrespective of the relationship with the needle) and turn on the...
  • Page 52 Fig.16-12, loosen setscrews (Z) of the Y-sensor and shift the Y-sensor backward (or leftward in case of Fig.16-14). 23. Position the X-Y mechanism, and mount the X-Y cover and carriage according to steps 5. - 8. in par.8. FIGURE 16-14 EP 1B Technical Manual Melco Embroidery Systems...

  • Page 53: Self-Diagnosis Mode

    17. Self-diagnosis Mode 17. Self-diagnosis Mode (1) Diagnosis for keys (1) Press [ALT+ ] keys to turn on the power switch. After the message [Diagnose Mode] appears, [START KEY] will indicate that diagnosis mode has started. [START KEY (2) When START key is pressed, the screen will say [START KEY [OK]] and then change to [STOP KEY].
  • Page 54 START key, the DC driving motor for the upper shaft starts to rotate. When the STOP key is pressed, the rotation of the motor stops. When key is pressed, the rotation speed will increase. [SPEED=200 EP 1B Technical Manual Melco Embroidery Systems...
  • Page 55 17. Self-diagnosis Mode (2) Following the above steps, in every 10 seconds, the machine rotates at the speed of 300 rpm, 400 rpm, 500 rpm, 600 rpm and 700 rpm respectively and then the machine stops. [RESULT ? (3) When the rotation speed is correct, press the key and when it is not good (NG), press the key.
  • Page 56 START key. When the driving motor for the upper shaft rotates 4 cycles and stops at the top position, [DUSTY] is displayed. (3) When all steps are confirmed according to the above described procedure, press the key. [SUMMERY of TEST EP 1B Technical Manual Melco Embroidery Systems...
  • Page 57 17. Self-diagnosis Mode (13)Display of the test results (1) When [SUMMERY of TEST] is displayed, press the ENTER key to see all the diagnosis results. [* KEY PANEL:OK (2) NC means No Check. An item which have not been diagnosed are indicated by the following message.
  • Page 58 (2) Press the ENTER key. [INPUT CIPHER (3) Press the , , keys in this order. [Right CLEARD (4) Select the data confirmation of EEPROM. Make sure the display is showing FFFFH. [FFFFFFFFFFFFFFFF] EP 1B Technical Manual Melco Embroidery Systems...
  • Page 59 17. Self-diagnosis Mode 12616, Rev. B...
  • Page 60 17. Self-diagnosis Mode EP 1B Technical Manual Melco Embroidery Systems...

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