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Bravo OS V12 User Interface Manual

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User Interface Manual
Rev 011520

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Summary of Contents for Bravo OS V12

  • Page 1 User Interface Manual Rev 011520...
  • Page 2 Contents Copyright Notice BRAVO OS V12 Version Changes v12.01.XXX Cart Assembly Optional Tray Assembly Unpacking the Machine Setting up the Machine Install the Machine User Interface and X-Beam End Caps Machine Overview Software Activation & Deactivation Lite Product Activation Product Deactivation...
  • Page 3 Bobbin Case Tension Gauge Inserting the Bobbin Case Initial Maintenance User Interface Main Screen Overview Machine Status Loading A Design Resetting a Design Move & Rotate Moving Rotating A Design Move to Color Move to Stitch Laser Alignment (Design Registration) Color Sequence Setting Up the Thread Tree Setting the Color Sequence...
  • Page 4 Advanced Settings Advanced Settings Button Connections Restart in BRAVO OS Advanced Interface Machine Reset Check for Update Deactivate Product Hooping Adjusting the Hoop Tension Hooping the Garment or Fabric Hooping Tips Attaching or Moving the Hoop Support Arms Attaching the Hoop Support Arms...
  • Page 5 Digitizing for Caps Sew Settings for Caps Adjusting the Presser Foot for Caps Centering a Design on a Cap Maintenance Wide Angle Driver Maintenance 5 of 127 Table of Contents...

  • Page 6: Copyright Notice

    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 pri- or 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 organization of such revisions or changes.
  • Page 7 Simplified acti-feed selection by just selecting a product type. For example: if the user is sewing a polo shirt they can just select the t-shirt in product type in the simplified user view in BRAVO OS. • Simplified position screen. User can easily do things like rotate a...
  • Page 8 • Stitches in complex fills will no longer be removed upon rotation in OS. • Corrected machine head up timeout issue. • Corrected an issue that would allow the machine to move X/Y while the needle was in the fabric. •...
  • Page 9 • Added hoops: • Allied Hoops: • 7.0” x 6.5” (17 x 16 cm) • 6.0” x 5.5” (15 x 14 cm) • 3.5” (12 cm) round • 5.9” (15 cm) round • 7.1” (18 cm) round • Mighty Hoops: •...

  • Page 10: Cart Assembly

    Cart Assembly Item Qty. Description Upper Support Shelf (Tabs Up) Lower Support Shelf (Tabs Flat) Cart Leg Swivel Caster Swivel Caster with Lock M5 Button Head Screw M6 Socket Head Screw M6 Split Lock Washer M6 Fender Washer The cart (Melco PN: 34262) consists of the items assembled as shown in the figure to the right.
  • Page 11 Step 1 Place a Cart Leg (Item 3) on a flat surface like a carpet to prevent scratches. Attach the Lower Support shelf (Item 2 with tabs flat) by inserting the two hooks into the cutouts of the cart leg as shown below. Loosely assemble four M5 Button Head Screws (Item 6).
  • Page 12 Step 3 Assemble the Upper Support Shelf (Item 1) to both Cart Legs as shown by inserting the two hooks on each side to the cutouts of both cart legs (Items 3). Loosely assemble eight M5 Button Head Screws (Item 6) and then fully tighten them.
  • Page 13 Step 5 Position the cart behind the machine. Make sure the caster brakes are engaged. Remove the Base Cover from the machine. Carefully lift the machine (two people are required) using the hand-holds. Place the machine in between the four bent up tabs on top of the cart as show to the right.
  • Page 14 Optional Tray Assembly The optional tray assembly (Melco PN: 34272) is available on www. shopmelco.com and contains the following parts. Item # Description Cart Tray Sheet Metal Screw Cart Tray Pad Step 1 Place the tray inside the cart body by rotating or tilting it between the cart legs.

  • Page 15: Unpacking The Machine

    Unpacking the Machine If your machine was delivered, this may have been completed by the deliv- ery service. It is still recommended that you reconcile your shipment with your packing list. It is important to check the packing list instead of the invoice.
  • Page 16 4. Cut the packing/holding straps securing the machine to the box/ pallet. Remove any additional loose packaging, boxes, and foam spacers. 5. Remove the black base cover from the machine and set it to the side. 6. If not already completed, assemble the cart using the cart instructions.
  • Page 17 8. Depending on which option was purchased, place the machine on the cart or bench-top pad. If the machine is placed on a cart, make sure that it fits within the placement tabs. 9. Replace the black base cover on the machine. 17 of 127 Table of Contents...
  • Page 18 Install the Machine User Interface and X-Beam End Caps 1. Locate the box containing the user in- terface and end caps. The box is labeled with the image to the right. 2. Attach the user interface assembly. Using the two screws and two lock washers that came with the user interface assembly, attach the interface as shown in the image using a 4mm hex wrench.

  • Page 19: Machine Overview

    Machine Overview Thread Tree Thread Feed Rollers Right Side Cover Needle Case Keypad Left Side Cover Network Connection (Back) Hoop Arms Power Connection (Back) Lower Arm Base 19 of 127 Table of Contents...

  • Page 20: Product Activation

    Software Activation & Deactivation BRAVO OS can use a virtual security key as opposed to a physical one. This means that if no physical security key is present when you initially launch your software, you will be prompted to activate the product using the prod- uct serial number.
  • Page 21 • If you are not connected to the Internet, follow the on screen instructions to obtain an activation code through an alternative Internet-enabled device. Product Deactivation To deactivate the software and free the license for use on another device, follow the steps below: 2.

  • Page 22: Machine Connections

    Machine Connections This section will describe how to correctly connect the power and commu- nications cables to the machine and the computer. An Ethernet network connection is required for communication between the computer and the machine. This connection must be established in order to control and send designs to the machine.

  • Page 23: Connecting The Network Cable

    3. Make sure the machine power switch is in the OFF position. Plug the power cable into the inlet. If you are using a line conditioner, as recommended, plug the other end of the cable into the dedicated line conditioner. 4.

  • Page 24: Selecting The Connection

    Selecting The Connection Before a connection can be established, the appropriate connection port must be selected in the software. 1. Launch the software by double tapping the software icon. 2. Tap the Settings button to navigate to the Settings screen. 3.

  • Page 25: Powering Up The Machine

    Powering Up the Machine This section will describe how to correctly power up the machine. Initial Power Up Sequence 1. Make sure that all of the machines are turned off. 2. Make sure the software the software is launched and the Main Screen is being displayed.

  • Page 26: Upper Threading

    Upper Threading The proper thread path from the cone of thread to the eye of the needle is critical in the operation of the machine. Ensuring that the thread moves along the appropriate route will help prevent thread breaks as well as increase efficiency and sew quality.
  • Page 27 Thread Cones or Thread Spools Smaller spools of thread often perform better when seated on a coaster. These coaster help prevent the thread from catching on the bottom of the spool when casting off. Using Thread Clovers Some larger cones of thread have a larger inner diameter than others. If the cones are loose and wobble, using a thread clover can help stabilize the cone.
  • Page 28 Quick Thread Change Changing a cone of thread does not require rethreading the entire thread path. If thread is already in the system, the fastest and easiest way to change a cone of thread is to remove the old cone but leave a good length of the old thread on the machine.
  • Page 29 6. Tie the end of the old thread to the end of new thread using a square knot. 7. Lift the pinch roller and carefully pull the thread from the back of the needle. This will pull the new thread completely through the system.
  • Page 30 Upper Thread Path If the thread comes out of the system, you may need to thread the machine without a starter thread. 1. To start a new cone of thread, push the plastic thread tubes up from behind the thread tree. Place the cone of thread on the thread seat.
  • Page 31 3. Using the black tab just in front, lift the pinch roller. 4. Pull the thread from the hole and place it under the pinch roller. Bring the thread down through the upper thread guide. 5. Pull the thread down to the middle thread guide. Of the three holes, push the thread from the top through the back right hole.
  • Page 32 7. Pull the thread up and through the eye of the take-up lever from right to left. 8. Route the thread straight down through the back left hole in the middle thread guide. 9. Press the thread into the felt restraint and feed it down through the lower thread guide.
  • Page 33 11. Be sure to align the thread with the small v-notch in the thread feed cover. 12. Press the black tab to lower the pinch roller. 13. If desired, the thread can then be held by the retaining spring in front of the lower thread guide or held in place using the grabber.

  • Page 34: Removing The Bobbin Case

    Bobbin Threading and Tensioning The proper bobbin tension and installation also play an integral role in the quality and efficiency of an embroidery sewout. What Type of Bobbin? For the best results with your machine, use Style L continuous polyester filament bobbins.
  • Page 35 Inserting a New Bobbin in the Bobbin Case & Checking the Tension 1. Hold the bobbin case with the front facing down and the open end facing up. 2. Hold the new bobbin with the thread coming over the top and to the right in a clockwise fash- ion.
  • Page 36 Bobbin Case Tension Gauge Overview 1. Indicator 2. Second Pulley 3. First Pulley 4. Bobbin Case Set Position 5. Thread Cutter 6. Thread Take-up 36 of 127 Table of Contents...
  • Page 37 Using the Gauge 1. Clean and thread the bob- bin case as you normally would. 2. Pull the thread through the tension spring, but do not pull the thread through the pigtail. 3. Insert the threaded bobbin Step 3 case into the tension gauge with the extended portion of the latch falling into the guide as shown in red.

  • Page 38: Other Instructions

    Adjusting Bobbin Tension 1. To adjust the tension, access the adjustment screw (larger of the two) on the tension spring from the recessed corner of the gauge. 2. Using a small flat blade screw driver, turn the adjustment screw in small increments between testing.

  • Page 39: Inserting The Bobbin Case

    Inserting the Bobbin Case CAUTION: Never attempt to remove or insert the bobbin while the machine is in operation. 1. Insert the bobbin and case in the machine with the pigtail facing up. Push on the bobbin case until it snaps into place. 2.

  • Page 40: Initial Maintenance

    Initial Maintenance The first time the machine is powered on, it is highly recommended that an initial maintenance be performed. To step through this maintenance, Press the Settings buttons to access maintenance. Press the Maintenance button to go to the maintenance menu in the software and perform the following maintenance procedures.

  • Page 41: User Interface

    User Interface In the following sections, you will become more familiar with the operating software for your machine. The next sections will walk you through the loading of a design and how to set machine settings such as color sequence. Main Screen Overview The Main Screen is divided into three sections.

  • Page 42: Machine Status

    Machine Status The status bar can indicate machine status. The various status colors and their meanings are listed below. Silver - indicates that the machine is in a load-ready state. This is the only state from which you can load a design to the machine.

  • Page 43: Loading A Design

    Loading A Design To load a design, press the Load Design button. Note that this button will only be available if the selected machine is in a load-ready state. If it is in the middle of a design, the button will give you the option to reset the design.
  • Page 44 Confirm Selection Press the Confirm button to confirm your selection, exit the load design screen, and load the file to the machine. Double-tapping the file will also confirm and load the file to the machine. Cancel Load Design Press the Cancel button to exit the load design screen without loading a new design to the machine.
  • Page 45 Search The Search Bar allows you to search for a file name within the current fold- er. Typing in this bar will automatically begin to filter the results. Pressing the Clear button on the right side of the bar will clear the Search Bar and return all files from the folder or drive to the window.
  • Page 46 Resetting a Design After a design has started sewing, the Load Design button will be replaced with a Reset Design button. Press this button to move to stitch zero and reset the design com- pletely. After a design has been reset, a new design can be loaded, or the same design can be sewn again from stitch zero.
  • Page 47 Move & Rotate To move or rotate a design in the hoop or move to a specific stitch or color, press the move button. This button will be unavailable when the machine is sewing. Moving Moving Around the Hoop Pressing any of the arrow keys will move the hoop on the machine and result in the design moving within the hoop in the direction the arrow was pressed.

  • Page 48: Move To Stitch

    Rotating A Design Pressing the 90° button will rotate the design 90° clockwise. Pressing the 180° button will rotate the design 180° clockwise. To rotate the design by specific degrees, enter the desired rotation into the field. Pressing the Negative button will rotate the design by the specified amount counter-clockwise.
  • Page 49 Laser Alignment (Design Registration) The Laser Alignment feature allows you to line up an embroidery design to a mark, such as a stripe, on a garment. Perform the following steps to use the Laser Alignment feature: 1. Use the Hoop and Arrow key to move the laser to your first refer- ence point (for example, the top of the stripe on the left side).
  • Page 50 Desired Alignment Keypad Commands Design in the Center of the Line: 1. Laser + Left: 2. Laser + Left: 3. Laser + Center: Design to Right of the Line: 1. Laser + Right: 2. Laser + Left: 3. Laser + Center: 50 of 127 Table of Contents...

  • Page 51: Color Sequence

    Color Sequence From the Main Screen, the Color button will display the needle that the machine is currently on. Pressing the Color Sequence button will allow you to set or edit a color sequence. This button will only be able to be pressed when the machine is stopped.
  • Page 52 Setting Up the Thread Tree When the software is first loaded, the thread tree will be displayed in grey. To assign appropriate colors to the tree, double-tap on the thread cone to be changed. This will bring up the thread cone assignment screen. Thread Cone Assignment Screen The thread cone assignment screen shows the same representation of the thread tree and preview of the design as the previous screen.
  • Page 53 2. Select the thread catalog that contains the desired thread color. Scroll by pressing the up or down arrow. You can skip to an area by pressing on the desired section of the alphabet between the arrows. Once located, press the thread catalog to select it. 3.
  • Page 54 Setting the Color Sequence With the thread tree appropriately colorized, setting the color sequence will be easier and far more representative of the final sew-out. The color sequence displays two colors for every color block. The lower sliver of color is a representation of the color information stored in the embroidery file.
  • Page 55 4. Continue in the same manner by first selecting the color block you wish to assign to a cone/needle and then selecting the cone/needle. Use the arrow buttons to move forward and back through the sequence. Confirm Color Sequence XXXXXXXXXXXXXXX Press the Confirm button to confirm the color sequence, exit the Color Sequence Screen, and return to the Main Screen.
  • Page 56 Adding Machine Commands to the Sequence Machine commands can be added to the color sequence to make designs a bit easier to sew. For example, on an especially stitch-heavy design, a Pause command may be placed in the middle to have the machine stop and wait for the embroiderer to change the bobbin.
  • Page 57 Pause A Pause command can be inserted between color blocks in a color sequence. This will cause the machine to stop and wait to be restarted, but it will not move the hoop forward. To place a Pause command into the sequence: 1.

  • Page 58: Hoop Selection

    Hoop Selection From the Main Screen, the Hoop button will display the hoop that is cur- rently selected. Pressing the Hoop button will allow you to select a differ- ent hoop. This button will only be able to be clicked or tapped when the machine is stopped.
  • Page 59 Confirm Hoop XXXXXXXXXXXXXXX Press the Confirm button to confirm the hoop, exit the hoop selection screen, and return to the Main Screen. Cancel Hoop Press the Cancel button to return to the Main Screen without saving the new hoop. Choosing the Appropriate Hoop for the Job Hooping a garment properly and selecting the right hoop for the job is essential to quality embroidery production.
  • Page 60 Choosing the Appropriate Hoop Size The ideal hoop for an embroidery design is one that just fits. The design should fall just within the hoop limits. This removes the influence of excess material from around the design and can help with registration (lining up), puckering, and overall stitch quality.

  • Page 61: Material Thickness

    Material Thickness Choosing the relative thickness of the material being sewn will help im- prove sew quality. The Material Thickness setting is shown just below the Material Thickness button. Selecting a Material Thickness To choose the Material Thickness, press the Material Thickness button.
  • Page 62 Adjusting Material Thickness Adjustments to the material thickness can be made by clicking or tapping on either the plus or minus button to either side of the material thickness setting. Finding just the right settings for your material thickness is not always nec- essary, but it can make a marked improvement in sew quality and machine performance.
  • Page 63 Increase Material Thickness When... When not enough thread is being fed into the design, you need to increase the material thickness value. If you experience any of the following prob- lems, you may need to perform this adjustment. • Satin stitches - You are encountering thread breaks and you can see bobbin thread on the top of the design.

  • Page 64: Machine Speed

    Machine Speed The machine speed is displayed on the Main Screen. This reflects the maxi- mum speed that the machine will run. The machine may automatically slow for longer stitch movements in X, Y, or now Z. Longer stitches, as well as higher thread feed values, may affect speed.
  • Page 65 Machine Speed Suggestions While the embroidery machines have extremely fast sew speeds, these speeds may need to be changed depending on the products or designs you are planning to embroider. When the machines start to sew, they will begin slowly and then rapidly speed up after the thread has had a couple of stitches to catch.
  • Page 66 Settings Pressing the Settings button on the Main screen will bring up the Settings screen. From here machine settings may be set or sub- menus may be accessed. Bobbin Detect This settings determines if the machine will detect bobbin breaks or not. Certain applications may be prone to disrupting the thread sensor and producing false breaks.

  • Page 67: Presser Foot Adjustment

    Presser Foot Adjustment The Presser Foot Adjustment button will lower and raise the nee- dle to allow for easier adjustment of the presser foot. For more in- formation on the adjustment of the presser foot, see that section. Maintenance The Maintenance button opens the maintenance screen. The main- tenance screen will also open when maintenance is due.

  • Page 68: Advanced Settings Button

    Restart in BRAVO OS Advanced Interface The BRAVO OS Restart button will close the user interface screen and reopen in a more advanced interface. If you would like to return to the sim- plified user interface, go to Tools>Restart in Bravo...

  • Page 69: Machine Reset

    Machine Reset The Machine Reset button will prompt you to cycle the power on your machine. When the machine reconnects with the software, the software will push a fresh set of run files to the machine. This will essentially reset your machine. This function is usually only used when prompted by customer support.
  • Page 70 Hooping Hooping the fabric or garment securely is important to the quality of the embroidery. This section will walk you through the adjustment of the hoop tension as well as the hooping process. Adjusting the Hoop Tension You will need to adjust the tension of the hoop any time you change to a drastically different material.
  • Page 71 9. Reach inside the garment and tighten the outer hoop by turning the adjustment screw clockwise. Tighten the hoop to finger-tight. 10. Now, without loosening the screw, remove the hoop from the garment. 11. Tighten the adjustment screw a turn or two more. 12.
  • Page 72 Hooping the Garment or Fabric With the hoop properly adjusted, the garment can be hooped. 1. Start with a clean flat working surface. Remove clutter from the area. Do not hoop on an uneven surface or stack of shirts. 2. Use an appropriate hoop for your design. For more information, read the section on choosing an appropriate hoop.
  • Page 73 • Try to hoop in a smooth motion. If the hoop rocks back and forth, extra material will move into the hoop and diminish the quality of the embroidery. • Do not overstretch the material. Stretching the material will stretch and distort the sew-out.
  • Page 74 Hooping Tips Round hoops give the most even tension of all the hoop shapes. Wooden hoops will have registration marks on them. These help maintain the shape and hold of the hoop. Many wooden hoops are double-high, meaning their sides are twice as tall as normal hoops.
  • Page 75 Attaching or Moving the Hoop Support Arms Depending on the hoop you plan on using, the hoop support arms on the machine will need to be in the inner position, outer position, or removed completely if using a clamp or the wide angle driver. This section will walk you through attaching and removing the support arms properly as well as adjusting the spring clips.
  • Page 76 4. Install a hoop by sliding the side brackets of the hoop underneath the spring clips on the support arms. Slide the hoop towards the rear of the machine until it snaps into place and the brackets are fully seated beneath the spring clips. Make sure that the slotted bracket is to the right as you are facing the machine.
  • Page 77 Removing the Hoop Support Arms 1. Use a 6mm hex wrench to loosen each of the two thumb screws attaching each arm to the x-carriage. 2. Using your fingers, fully loosen the thumb screws. 3. Remove the support arms from the x-carriage. Adjusting the Spring Clips When you have a hoop installed, you should make sure both spring clips are attached securely to the arms.
  • Page 78 Loading a Hoop onto the Machine 1. Install a hoop by sliding the side brackets of the hoop underneath the spring clips on the support arms. Make sure that the slotted bracket is to the right as you are facing the machine. 2.

  • Page 79: Adjusting The Presser Foot

    Adjusting the Presser Foot The machine has an adjustable presser foot that can be set from 0.5mm to 3.5mm above the needle plate. The presser foot height should be changed when the thickness of the material you are sewing changes dramatically. To adjust the presser foot height, the software must be open, and your ma- chine must be on and communicating with it.
  • Page 80 Setting the Presser Foot for Different Materials The presser foot will need to be adjusted whenever you drastically change the thickness of material that you are sewing on. For example, if you sew a sweatshirt and then sew a T-shirt, the presser foot would need to be adjusted.

  • Page 81: Keypad Operations

    Keypad Operations The machine keypad controls not only the starting and stopping of the machine, but it also provides access to change hoop position, sew speed, as well as the active needle. Many of these functions require the pressing of just a single button. Other functions require pressing multiple buttons simultaneously.

  • Page 82: Key Combinations

    Center Press for 1 second to change the focus of the OS to this ma- chine. This only matters when multiple machines are present. Key Combinations Center Hoop Hoop + Center: Centers the currently selected hoop on the machine. Move Hoop Hoop + Up Arrow: Moves the hoop so the needle will sew higher in the hoop.
  • Page 83 Adjustment + Up Arrow: Increases sew speed by 50 s.p.m. Adjustment + Down Arrow: Decreases sew speed by 50 s.p.m. 83 of 127 Table of Contents...
  • Page 84 Change Active Needle Needle Case + Left Arrow: Changes the active needle by moving the needle case to the left. Needle Case + Right Arrow: Changes the active needle by moving the needle case to the tight. Trim Immediate Adjustment + Needle Case: Performs a trim command.

  • Page 85: Led Indicator

    LED Indicator The Status Indicator LED is illuminated when the machine is turned ON. The LED color and whether it is blinking indicates the machine status or if it has a fault. Status Light Condition Definition Action to Take Green (blinking) Machine is on, but no Start software, check RSA files loaded yet...
  • Page 86 Needle Types and Replacements Embroidery quality can be greatly affected by your choice of needles. You will need to find what works best with your applications. The following information should help. Replacing a Needle Sew conditions and material properties will affect the life of a needle, but eventually, needles will need to be changed.
  • Page 87 Common Reasons to Change the Needle • The needle breaks or is bent. • The thread will consistently fray - this usually means there is a bur on the needle causing it to fray a part of the thread. • The needle is dull.
  • Page 88 Size Benefit Drawback 60/8 Used for the thinnest threads Thinner needle blade is more and finest detail work. prone to needle deflection and breakage. Uncommon needle size and can be difficult to source and purchase. 65/9 Smallest of the more com- Thinner needle blade is more mon needles.
  • Page 89 Needle Points Needle points also come in a variety of options. The main two are sharp and ball point. Sharp point needles are generally better at cutting through materials and are usually used on tightly woven or non-woven. Ball point needles are most often used on knit materials. They tend to move the threads of the material to the side of the needle as they sew.
  • Page 90 Sewing Caps Sewing caps will require a little more setup than sewing a flat product. For sewing caps, you will need to do the following. 1. Select the appropriate hoop in software 2. Load the Wide Angle Driver (this may need adjustment the first time) 3.
  • Page 91 Installing & Removing the Wide Angle Driver Both the cap frames and the micro clamps utilize the Wide Angle Driver. The Red Wide Angle Driver consists of two pieces: • The (red) cap frame driver ring • The lower arm bracket You must ALWAYS select the proper cap frame hoop in the software when sewing with cap frames.
  • Page 92 5. Remove the hook guard: Using a 2mm hex wrench, loosen the two button head screws securing the hook guard and slide it away from the machine. 6. Loosen the knobs of the lower shaft support until the top of screws are flush with the t-nut.
  • Page 93 11. Slide the red driver assembly onto the lower arm and support shaft. This may be easier if the grabber bar of the machine is closed. To close the bar, simultaneously press the “Adjustment” and “Center” keys on the keypad of the machine. Then, slide the red driver assembly onto the lower arm and support shaft.
  • Page 94 Red Wide Angle Driver Removal 1. Starting with a 6mm Allen wrench, remove the thumbscrews at- taching the red driver assembly to the x-carriage. 2. Slide the red driver assembly toward you and off of the lower arm and support shaft. This may be easier if the grabber bar of the machine is closed.
  • Page 95 6. The wide angle driver is now removed. Hoop arms can be reat- tached to sew with standard hoops. Red Wide Angle Driver Cap Support Wings (Option) The cap support wings of the wide angle driver will need to be removed to use the driver with the Conventional Cap Frame (CCF) or any of the Micro Clamps.
  • Page 96 5. Assemble the 4 nuts onto the threaded posts by hand. Allow them to stay slightly loose. This will enable the adjustment of the support wing assembly to the machine. 6. With the cap support wing assembly loosely installed on the wide angle driver, install the driver onto the machine.
  • Page 97 8. Move the driver and carriage back until the cap support wing as- sembly fully covers the needle plate. 9. Place a business card between the cap support wings and the needle plate. 10. Adjust one side of the cap support until it makes contact with the business card and needle plate.
  • Page 98 12. Tighten the two phillips head screws on the connecting bracket. 13. Remove the business card and check that there is a gap between the cap support wings and the needle plate. Repeat the steps above if required to achieve a slight gap. Removal of the Cap Support Wing Assembly (Option) 1.
  • Page 99 3. Remove the four nuts on the back of the driver. A 7mm hex driver or wrench will be needed. 4. Remove the cap support wing assembly. Slightly pivot the assembly from left to right and back again while removing it. This will help to ease each leg around the roller.
  • Page 100 Adjusting the Red Wide Angle Driver This procedure may need to be performed if the Red Wide Angle Driver was purchased separately from your machine, the driver has been dropped or mishandled, if the initial installation of the driver shows the adjustment to be off, or if prompted by technical support.
  • Page 101 Adjustment Procedure 1. Begin by loosening the two bearing block hex screws and the two interface bracket screws using the 4mm hex screwdriver. 2. Install the Red Wide Angle Driver on your machine. See the installa- tion section of the document for details. 3.
  • Page 102 5. Making sure the edges of the two black brackets are aligned, tight- en one of the upper screws. 6. Tighten the opposite screw securing the bearing mounting block. 7. Tighten the second upper screw securing the bracket and then the second lower screw securing the bearing mounting bracket.
  • Page 103 Hooping a Cap on the Conventional Cap Frame The process for hooping a cap on the CCF is the same for almost any type of cap you are hooping. Prepare the Cap Preparing the cap before it is hooped will help the sew quality and ease the hooping process.
  • Page 104 3. Pull the sweatband to the outside of the cap. Near the back of the cap, the sweatband may be sewn into the cap. At this point, it may need to be folded a bit to fit in the frame. 4.
  • Page 105 2. Unlatch the cap frame and swing the frame open and to the right. Do this by pulling the tab away from the frame. Then, press down on the edge of the frame to free the latch from the hook. Swing the frame open.
  • Page 106 4. Slide the prepared cap onto the cap frame with the visor pointing up and the frame going inside the cap. Make sure that the sweat- band is flipped to the outside of the cap. The sweatband may not touch the vertical ridge of the frame. That’s okay.
  • Page 107 • Push down on the middle top of the cap frame strap to seat it around the sweat band. 10. While holding the cap frame strap down around the sweat band, release the back of the cap and attach the strap latch over the hook on the support.
  • Page 108 Hooping a Cap on the Wide Angle Cap Frame The process for hooping a cap on the WACF is the same for almost any type of cap or visor you are hooping. Prepare the Cap Preparing the cap before it is hooped will help the sew quality and ease the hooping process.
  • Page 109 3. Pull the sweatband to the outside of the cap. Near the back of the cap, the sweatband may be sewn into the cap. At this point, it may need to be folded a bit to fit in the frame. 4.
  • Page 110 3. Place an appropriate backing over the gauge and the teeth of the cap frame. Make sure that the backing is long enough to support the full embroidery area. It may be easiest to use backing long enough to reach the posts on the bottom of the cap frame. Some people find it easier to use the binder clips to hold the backing while they are hooping the cap.
  • Page 111 4. Slide the prepared cap onto the cap frame with the visor pointing up and the frame going inside the cap. The bill should be pushed against the bill-stop on the frame. The bill should also be relatively centered on the frame. The centering mark on the bill-stop can be used for reference.
  • Page 112 7. Pull the side of the sweatband toward the cap frame and down. Smooth any bunching of the cap sides or sweatband. You may eventually need to fold the sweatband a bit to avoid the latch- ing hook. But this will help with the placement of the cap on the frame.
  • Page 113 10. Bring the strap down the other side of the cap. Make sure the teeth of the strap fall just above the stitching attaching the sweat band. This will help ensure a level sewout. 11. Hook the latch on the strap into the hook on the latch post. You may need to fold or adjust the sweatband of the cap slightly to accommodate the hook and latch.
  • Page 114 • Then, push the strap down against the cap brim moving from the latch toward the wing nuts so that it is very snug to the cap. • Slide the strap toward the wing nut to remove the excess. • Tighten the wing nuts while holding the strap tight against the cap.
  • Page 115 14. If clips were used to secure the backing while hooping, remove them now. 15. If sewing on the sides of the cap, smooth the cap material back- ward and over the clip posts on the both sides. Indent the cap material along the clip posts.
  • Page 116 • To do this, place the palms of your hands on the gauge and place your fingers on the frame. • Pull your fingers toward your palms until the cap frame release from the gauge. • Inspect the hooping. Look at the inside of the cap to ensure that the backing is not bunched and that it is caught in the teeth of the frame.
  • Page 117 Loading/Removing a Hoop with the Wide Angle Driver Loading a Hoop To load a hooped cap onto the installed wide angle driver, use the following steps. 1. Rotate the hooped cap so the bill 90° to allow the bill to pass un- der the needle case.
  • Page 118 4. With the frame aligned, press the frame toward the driver until the three (3) spring loaded locking clamps snap into place. It may be helpful to grasp the back of the driver and close your grip to push the cap into place as pictured. Removing a Hoop To remove a hooped cap from the installed Red Wide Angle Driver, use the following steps.
  • Page 119 3. Rotate the hooped cap 90° so the bill can pass under the needle case. The hoop can now be removed from the machine. Digitizing for Caps Setting up designs for caps requires a few considerations. Make sure that the design is of an appropriate size for the profile of the cap and ensure that the sew path will not create ripples, thread breaks, needle breaks, or registration issues.
  • Page 120 1. Measure from the bill to where the cap really starts to curve over the head of the potential wearer. This will require a little bit of judgment. 2. Subtract one inch from that measurement to find a fairly safe de- sign height.
  • Page 121 In embroidery, it is often a good idea to avoid sewing toward an anchor point. If the material is anchored to the backing or another element of the garment, like the bill of a cap, it will not move. Sewing toward one of these anchors can push a ripple of material.
  • Page 122 Sew Settings for Caps The settings in the software will need to be adjusted for better quality on a cap. Be sure to address the following. Design Orientation To be oriented appropriately for a cap, the design usually needs to be rotat- ed 180°...
  • Page 123 If the needle is not at the presser foot adjustment point, the presser foot will not appear to move. Even if the needle is at the adjustment point, it may be difficult to see a change in the presser foot. The material of the cap is pressing up against it and you may not see it lift off the material.
  • Page 124 is similar to measuring the design height that the cap can accommodate. Once measured, divide the measurement in half. Measure up from the bill that half distance to find a good vertically centered placement for the design. Divide this height in half.
  • Page 125 Trace the Design Tracing the design using the hoop and trace keys simultaneously on the keypad of the machine will also give you a good idea of where the design will be sewn. Watch the Hoop Limits Depending on the structure of the cap, you will be able to sew within varying distances from the hoop limits.

  • Page 126: Maintenance

    Maintenance Maintenance will need to be performed on your machine to keep it running at an optimal level. Machine maintenance procedures can be found under the Settings Screen. The Maintenance Screen will display procedures for the hook, weekly, monthly, and quarterly maintenance. Each procedure will move the machine to the appropriate location and walk through all the proper lubrications.
  • Page 127 4. Apply a thin film of hp grease to the grooves of the slider bearing. 5. Move the driver all the way to the opposite side and repeat the previous two steps. 6. Move the driver back and forth a few times to spread the grease. 7.

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