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Melco EMT 1 Technical Manual

Embroidery peripheral
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Technical Manual for
the EMT 1
embroidery peripheral
Part Number 110344-01, Revision B
•
Single Head, One Needle
•
Tubular Goods Hooping
•

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Summary of Contents for Melco EMT 1

  • Page 1 Technical Manual for the EMT 1 embroidery peripheral • Single Head, One Needle • Tubular Goods Hooping • Part Number 110344-01, 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 Configuring the EMT 1 ........
  • Page 4 Hook Timing Adjustments Only ....... 3 - 27 110344-01, Revision B EMT 1 Technical Manual...
  • Page 5 Cap Frame ..........4 - 4 EMT 1 Technical Manual...
  • Page 6 Table of Contents This page intentionally left blank 110344-01, Revision B EMT 1 Technical Manual...

  • Page 7: Scope Of Manual

    1 - 1 1. Introduction Scope Of Manual The EMT 1 Embroidery Peripheral Technical Manual is a guide for performing repairs and adjustments which go beyond routine operator maintenance. Although these procedures are best understood and performed by professional service technicians in conjunction with specific factory technical training, much of the information in this manual may be useful reference for others who might possess appropriate technical aptitude and skills.

  • Page 8: Glossary Of Terms

    Maintenance Philosophy The maintenance philosophy used in this manual, and practiced at Melco, is to isolate potential problems within the system to a "practical" replacement assembly. Therefore, components are typically not repaired, but rather, a circuit board or mechanical "assembly"...

  • Page 9: Good Maintenance Practice

    Static Electricity As with all computerized equipment, the EMT 1 Embroidery Peripheral is sensitive to static electricity. Any time work is performed inside covered areas of the embroidery peripheral, the person performing the work MUST be using a static grounding strap.

  • Page 10: Electrical Grounding

    System, electrical failures may result. Functional Arrangement The EMT 1 is functionally arranged into several sections including the electronics, a power supply section, the keyboard and disk drive, the Embroidery Head, and the Carriage section. Figure 1-1 shows the general locations of these and other functional parts of the embroidery peripheral.

  • Page 11: Configuring The Emt 1

    NOTICE: Re-configuring your EMT 1 will clear the power fail rescue function for the current situation. There are two items that must be set in each EMT 1 Embroidery Peripheral before it is used in the Melco system for the first time.

  • Page 12: Troubleshooting Leds And Test Points

    Troubleshooting LEDs and Test Points Troubleshooting LEDs and Test Points At the front of the EMT 1 is a metal cover plate over a variety of indicator LED lights and a series of test points for checking certain voltages with a multimeter. This area is provided for observing various machine conditions, especially while troubleshooting problems that may occasionally occur.
  • Page 13 1) Estop Engaged 2) Light Fuse Blown 3) Bobbin Fuse Blown 4) Disregard, ISO RET (Isolated GND) Not Used with EMT 1 5) Disregard, +6 VDC ISO * Not Used with EMT 1 6) Z Motor Current Limit Error +36 VDC *...

  • Page 14: Various Technical Specifications

    Various Technical Specifications Various Technical Specifications The following is a list of various tension and force specifications for the EMT 1 (All specifications to be within plus or minus 10% unless otherwise indicated): X Drive Belt Tension........25 pounds Y Drive Belt Tensions .

  • Page 15: General

    Drive Belt Tensions 2 - 1 2. Service Maintenance (except embroidery head ) General This section of the manual provides parts replacement procedures and various adjustments required during parts replacement or other service repairs of all areas of the machine except the embroidery head. Embroidery head service maintenance information is located in Section 3 of this manual.

  • Page 16: Keyboard Section

    Section Figure 2 - 1 1. Turn OFF the power switch to the EMT 1 and remove the power cord from the power source electrical outlet and the rear of the machine. 2. Remove the cable cover from the base plate at the rear of the keyboard/display assembly.

  • Page 17: Display Screen Intensity

    4th screw and that when the screws are tightened the buttons do not stick in the cover holes when pressed. Display Screen Intensity During the adjustment of the display intensity the EMT 1 must be turned on so the result of the adjustment may be observed.

  • Page 18: Disk Drive

    The bulb case must be removed by rotating it counter-clockwise off the base to access the lamp. Lamp Assembly Figure 2 - 4 EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 19: Bobbin Winder

    The built in bobbin winder receives its power from the EMT 1 12 V source. Winding starts by moving the actuator lever to the start position. The winding...

  • Page 20: E-Stop Switch Replacement

    5. Remove the switch block by depressing the tab on the assembly body through the opening in the switch block and sliding the switch block off the end of the assembly body. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 21 Display Screen Intensity 2 - 7 6. Remove the locking collar the rest of the way off the assembly and remove the remainder of the e-stop switch assembly. 7. Install a new e-stop switch assembly by reversing the switch pole previous steps for removing markings switch...

  • Page 22: Power Distribution Section

    In addition to the three harnesses entering the top and the power switch harness at the side, there is a ground wire attached to a stud near the rear left corner of the power distribution section that must be removed. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 23 Module Replacement 2 - 9 the two left side screws at three harnesses the base of the entering at the top distribution section (loosen screws ONLY) the two right side screws at the base of the ground distribution wire section (remove completely) four screws at...
  • Page 24 NOTE: When a new power distribution module is installed, there is no requirement for adjusting any voltages. 13. Reinstall the left rear table top (with optional bobbin winder assembly). 14. Reattach the power cord to the peripheral voltage source. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 25: Electronics Section

    Remove Card Cage Cover screws 1. Turn OFF the power switch to the EMT 1 and remove the power cord from the power source electrical Card Cage outlet and the rear of the machine.

  • Page 26: Card Cage Components

    The CPU PCB is the first PCB located to the front of the card cage as shown in Figure 2-11. Refer to the following procedure for replacing the CPU PCB. 1. Turn OFF the power switch to the EMT 1. 2. Remove the card cage cover and install a static grounding strap between the working surface and the personnel performing this procedure.

  • Page 27: Ethernet Network Pcb

    Interface PCB as Figure 2-11 shows. (Not required with standalone peripherals that are initiated by a "boot-disk" in the disk drive.) Refer to the following for replacing. 1. Turn OFF the power switch to the EMT 1. 2. Remove the card cage cover and install a static grounding strap between the working surface and the personnel performing this procedure.

  • Page 28: Interface Pcb

    Low Voltage Driver PCB as shown in Figure 2-11. Refer to the following procedure for replacing the Interface PCB. 1. Turn OFF the power switch to the EMT 1. 2. Remove the card cage cover and install a static grounding strap between the working surface and the personnel performing this procedure.

  • Page 29: Xyz Motor Driver Amplifiers

    Low Voltage Driver PCB and is the last PCB to the rear (see Figure 2-11). Refer to the following procedure for replacement. 1. Turn OFF the power switch to the EMT 1. 2. Remove the card cage cover and install a static grounding strap between the working surface and the personnel performing this procedure.
  • Page 30 13. Reinstall all the upright printed circuit boards as earlier described. 14. Remove the static grounding strap and replace the card cage cover. 15. Reinstall the right rear table top. Figure 2 - 13 EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 31: X Beam Assembly

    This procedure requires a specific Melco force gauge (p/n 995585-01) for proper belt adjustment after replacing the motor. 1. Turn OFF the power switch to the EMT 1 and remove the power cord from the power source electrical outlet and the rear of the machine.
  • Page 32 X harness interface PCB. 13. Carefully tuck the two X motor harnesses between the motor and harness interface PCB and reconnect the cover over the top of the X harness interface PCB. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 33: X Drive Belt

    Refer to the following procedure to replace the X drive belt: 1. Turn OFF the power switch to the EMT 1 and remove the power cord from the power source electrical outlet and the rear of the machine.

  • Page 34: Belt Tension

    4. Move the X carriage all the way to the left of the beam until it mechanically stops. 5. Orient the Melco force gauge (p/n 995585-01) vertically with the ’push end’ down. Place the finger of the ’push end’ against the top of the lower loop of the belt and mid-way between the two pulleys at the belt ends (see Figure 2-16).

  • Page 35: Lint Wiper

    Refer to the following procedure to replace the Y motor: NOTE: This procedure requires a specific Melco force gauge (p/n 995585-01), for proper belt adjustment after replacing the motor. 1. Turn OFF the power switch to the EMT 10T and remove the power cord from the power source electrical outlet and the rear of the machine.
  • Page 36 11. Slide the motor out of the Y shaft bearing support bracket far enough to note the orientation of the encoder connector on the motor, then disconnect the motor encoder harness and remove the motor the rest of the way. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 37: Y Motor Belt

    To adjust the Y motor belt tension after replacing the belt or a Y drive motor, refer to the following procedure: NOTE: This procedure requires a specific Melco force gauge (p/n 995585-01), for proper belt adjustment after replacing the motor. 110344-01, Rev B...
  • Page 38 1. Refer to the procedure for removing the left rear table top (with optional bobbin winder assembly) and remove the table top. 2. Refer to Figure 2-18 and check the Y motor belt tension using the Melco force gauge (p/n 995585-01) and the steps that follow:...

  • Page 39: Y Drive Belt

    13. Repeat this procedure until the proper tension is attained. Y Drive Belt There are two Y drive belts used on the the EMT 1: one associated with each of the Y carriage assemblies at either side of the peripheral.
  • Page 40 11. Place a new belt into position around the pulleys and attach the belt to the under side of the Y carriage block by reversing the previous steps for removing the belt and mounting clamp. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 41 Y Drive Belt 2 - 27 Y carriage block Y drive belt cap head screws for adjusting belt belt tension mounting clamp and screws access holes Figure 2 - 20 12. Be certain the teeth on the new belt are positioned in the proper location in the rear pulley to maintain the parallelism between the X beam and Y carriages.

  • Page 42: Belt Tension Adjustment

    3. When the adjustment in the previous step is complete, move the X beam to the rear until it mechanically stops. 4. Refer to Figure 2-21 and check the Y drive belt tension with the Melco force gauge (p/n 995585-01) by the following steps.
  • Page 43 Y Drive Belt 2 - 29 7. Release the downward force on the gauge plunger and allow the finger to apply an upward force to the bottom of the top loop of the belt. 8. Read the scale on the force gauge. The reading should be 2 +/- 0.25 pounds.
  • Page 44 2 - 30 X Beam Assembly This page intentionally left blank EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 45: General

    Removal 3 - 1 3. Embroidery Head Maintenance General This section of the manual provides parts replacement procedures and various adjustments required during repair maintenance of the embroidery head only. Information for service maintenance on the rest of the machine is located in Section 2 of this manual.

  • Page 46: Z Motor Replacement

    Figure 3 - 2 Z Motor Replacement Note: This procedure requires a Gates 5M Tensiometer (Melco p/n 992165-01) for proper belt adjustment after replacing the motor. 1. Turn the main power Off, and remove the power cord from power source.

  • Page 47: Belt Tension

    13. Tighten both Z drive pulley set screws. Belt Tension Note: This procedure requires a Gates 5M Tensiometer (Melco p/n 992165-01) for proper belt adjustment. 14. Apply downward pressure on the motor to establish a belt tension of 7 pounds (+/- 1 pound) measured with the Gates Tensiometer.

  • Page 48: Z Shaft Encoder

    The careful application of the Z encoder procedures by a factory trained technician will result in a machine that will operate correctly and reliably. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 49: Inspection

    Inspection 3 - 5 Inspection This procedure is a guide for determining the condition of the encoder. Inspect the Z shaft encoder following the steps below. If the requirements of this process are not met, replace the encoder by following the Shaft Encoder Installation procedure.

  • Page 50: Installation

    3 - 6 Z Shaft Encoder Installation The Melco EMT 1 Embroidery Peripheral uses a shaft encoder on the rear of the head to provide the information required by the CPU. Note: This procedure leads to a calibration which requires the use of a special service tool: the Melco head up alignment pin tool (995338-01) or the Melco 10 needle head up fixture (p/n 995673-01).

  • Page 51: Calibration

    Note: This procedure leads to a calibration which requires the use of a special service tool: the Melco head up alignment pin tool (995338-01) or the Melco 10 needle head up fixture (p/n 995673-01). 1. Install the Z shaft encoder as described previously.
  • Page 52 3 - 8 Z Shaft Encoder 5. Position the Melco head up alignment pin tool (995338-01) or the Melco 10 needle head up fixture (p/n 995673-01) into the head up alignment hole in the top of the head as shown in Figure 3-6.

  • Page 53: Needle Case

    Thread Tensioner Assembly Replacement 3 - 9 Needle Case Thread Tensioner Assembly Replacement 1. To access the rear of the thread tensioner assembly to disconnect harnessing, you must first remove the thread saddle. 2. Refer to Figure 3-8 to locate and remove the in-line thread break wire and pin from the rear of the thread tensioner post.

  • Page 54: Thread Check Spring Replacement

    6. After inserting the thread tensioner into the tensioner bracket, perform the thread tensioner check spring adjustment. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 55: Thread Check Spring Adjustment

    Thread Check Spring Adjustment 3 - 11 Thread Check Spring Adjustment After replacing a thread check spring, reinstall the tensioner assembly into the needle case. You must then adjust the tension of the check spring against the thread break contact post. To set this tension: 1.

  • Page 56: Replacing The Needle Bar / Presser Foot / Associated Parts

    To replace the needle bar, presser foot or other associated parts, refer to the steps below. Then turn to the Hook Timing procedure later in this chapter of the manual. 1. Turn ON the EMT 1 and bring the embroidery head to the HEAD UP position.
  • Page 57 Replacing The Needle Bar / Presser Foot / Associated Parts 3 - 13 9. Carefully capture and retain the various parts that become released as you remove the needle bar upward and out the top of the needle case. 10. If replacing the needle bar, transfer the screw from the top of the old needle bar to the top of the new needle bar.

  • Page 58: Needle Case Removal

    1. Turn ON the EMT 1 and bring the embroidery head to the HEAD UP position. 2. Turn OFF the EMT 1 and disconnect the power cord from its power source.
  • Page 59 Needle Case Removal 3 - 15 7. Slide the needle case cover plate out of the needle case cover and remove the 4 screws and needle case cover (see Figure 3-10). 8. Next, hold onto the needle case as you remove the 4 screws that hold the needle case to the front of the embroidery head (see Figure 3-15).

  • Page 60: Jump Stitch Solenoid Replacement

    6. Refer to Figure 3-17 and remove the top and bottom screws ONLY of the jump stitch solenoid bracket and then remove the solenoid and the solenoid bracket as one piece. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 61: Jump Stitch Solenoid Adjustment

    Jump Stitch Solenoid Adjustment 3 - 17 FRONT VIEW SIDE VIEW Jump Stitch Solenoid Bracket screws (top and bottom) Jump Stitch NOTE: You DO NOT Solenoid need to remove the locking nut inner two screws of the solenoid bracket. Figure 3 - 17 NOTICE: Before you remove the solenoid from the bracket, record the number of threads of the solenoid that are showing beyond the solenoid bracket (or measure the distance the end of the solenoid...

  • Page 62: Bracket Positioning

    This may cause premature failure of the reciprocator mechanism. The solenoid and bracket assembly must not be so far backward that it contacts the Bracket Position 3 embroidery head connecting rod during its mechanical motion. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 63 Jump Stitch Solenoid Adjustment 3 - 19 To position the solenoid and bracket: 1. Put the new solenoid and bracket assembly in place and push it to the back of the cutout in the side of the head. 2. Attach it to the head with the 2 screws removed earlier, then check the alignment to be within the above 3 positions.

  • Page 64: Replacing Reciprocator / Needle Bar Guide Shaft

    7. Install the new reciprocator into the head. Be certain it is oriented properly and insert the connecting stud onto the connecting rod. 8. Add two drops of machine oil onto the needle bar guide shaft (or new guide shaft if replacing). EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 65 Replacing Reciprocator / Needle Bar Guide Shaft 3 - 21 9. Install the needle bar guide shaft as follows (see Figure 3-19): a) Insert the guide shaft down through the hole in the top of the head. b) Insert the guide shaft through the reciprocator. c) Insert the guide shaft down through the roller bearing.

  • Page 66: Rotary Hook

    9. Remove the two screws holding the inner basket retaining finger and FRONT VIEW OF HOOK ASSEMBLY remove the finger (see Figure 3-21). Figure 3 - 21 * May not be exactly the degrees indicated. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 67 Hook Replacement 3 - 23 10. Remove the rotary hook assembly for cleaning and If the hook If the hook point reinstallation, or for replacing point does extends beyond with a new one. not extend to the needle, it is the needle, it referred to as is referred to...

  • Page 68: Needle Depth

    LCD displays HEAD TIMING ON. 4. Press keys. The head rotates to the ‘‘Head Up’’ position and the LCD displays GO TO HEADUP 110.0*. * May not be exactly the degrees indicated. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 69 Hook Replacement 3 - 25 5. Next press . The head rotates one revolution. The LCD displays ONE REVOLUTION 110.0. The needle bar should be down with the presser foot about 1/4 inch from the needle plate. NOTE: If the needle does not come down the upper dead stop clamp may need adjustment as described later in this procedure.
  • Page 70 16. Replace the lower needle case cover. 17. Replace the needle plate, both rotary hook covers, and the bobbin case; and return the machine to its operational state. * May not be exactly the degrees indicated. EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 71: Hook Timing Adjustments Only

    Hook Timing Adjustments Only 3 - 27 Hook Timing Adjustments Only This procedure is for checking and setting hook timing adjustments when the hook assembly is not being replaced. If you are replacing the hook assembly, refer to the preceding section in this chapter. If you suspect your peripheral has gone out of timing due to hitting a hoop, bird nesting, or some other reason, follow these steps: 1.
  • Page 72 19. Grasp the needle bar clamp and pull Figure 3 - 29 down until the needle goes into the slot in the bobbin basket and the needle bar catches securely. * May not be exactly the degrees indicated. EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 73 Hook Timing Adjustments Only 3 - 29 20. Position the POINT of the HOOK directly behind the SCARF of the needle. Leave a THREAD distance between the POINT of the hook and the needle. 21. Tighten the colored hook screw and check that the setting is correct as shown in Figures 3-27 and 3-28.
  • Page 74 3 - 30 Rotary Hook This page intentionally left blank EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 75: Wide Angle Cap Frame

    Cap Supports 4 - 1 4. Accessory Adjustments Wide Angle Cap Frame The Wide Angle Cap Frame (also referred to as "WACF") has several adjustable components. Refer to this section for instructions on how to properly adjust these components. Cap Supports supports If you are experiencing registration or sew quality problems in parts of...

  • Page 76: Cap Support Pads

    Figure 4 - 5 Caution! Do not over-compress the coils or you may cause excessive wear to the cable terminal. Figure 4-6 shows an over-compressed coil. Figure 4 - 6 EMT 1 Technical Manual Melco Embroidery Systems...

  • Page 77: Spindles On The Clamps

    Clip Posts 4 - 3 Spindles On The Clamps The clamps form a positive lock on the frame when it is installed on the driver. The clamps press the spindles against the rollers on the driver to form this lock. If the frame can move when it is installed on the driver, you should adjust the spindles.

  • Page 78: Cap Frame

    2 screws shown in Figure 4-11. Move the latch to the inner-most screw holes as shown in Figure 4-12 and secure the latch with the same screws and nuts. Figure 4 - 12 EMT 1 Technical Manual Melco Embroidery Systems...
  • Page 79 Maintenance Philosophy ....1 - 2 Configuring the EMT 1....1 - 5 Configuration Procedure .
  • Page 80 Installation ..... . 3 - 6 Calibration ..... . 3 - 7 110344-01, Revision B EMT 1 Technical Manual...

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