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Saurer Melco EMC 10 Technical Manual

Embroidery peripheral
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Technical Manual for
the EMC 10
embroidery peripheral
European Compliance Version
Part Number 110304-01, Revision A
•
Ten Needle
•
Automatic Color Change
•
Under Thread Control
A Saurer Group Company

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Summary of Contents for Saurer Melco EMC 10

  • Page 1 Technical Manual for the EMC 10 embroidery peripheral • Ten Needle • Automatic Color Change • Under Thread Control European Compliance Version A Saurer Group Company Part Number 110304-01, Revision A...
  • Page 2 1575 West 124th Avenue Denver, Colorado 80234 United States of America Internet Address: publications@melco.com Copyright © Melco Embroidery Systems, 1996. 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 of Melco Embroidery Systems.

  • Page 3: Table Of Contents

    Table Of Contents Table of Contents 1. Introduction 1 - 1 Scope Of Manual 1 - 1 Warranty Registration 1 - 1 Standard Conventions Used In Manual 1 - 1 Explanation Of Symbols 1 - 2 Glossary Of Terms 1 - 2 Functional Arrangement 1 - 3 Maintenance Philosophy...
  • Page 4 Table Of Contents Trimmer Set Up And Adjustments 2 - 22 Z Timeout Errors 2 - 22 Trimmers Not Trimming Properly 2 - 24 Spring Knife 2 - 25 Under Thread Presser 2 - 28 Movable Knife 2 - 29 Checking Select Position 2 - 32 Select Position Adjustment...
  • Page 5 Table Of Contents Replacing The Thread Break Wiper Brush 3 - 32 Replacing A Needle Bar 3 - 32 Needle Case Removal 3 - 35 Installing Needle Case 3 - 37 Replacing Needle Case Cross Roller Bearing 3 - 38 Replacing Reciprocator / Needle Bar Guide Shaft 3 - 39 Jump Stitch Solenoid Replacement...
  • Page 6 Table Of Contents This page intentionally left blank EMC 10 Melco Embroidery Systems...

  • Page 7: Introduction

    The EMC 10 Embroidery Peripheral Technical Manual is designed to provide the user with information necessary to perform repairs beyond routine operator maintenance. The Melco EMC 10 Embroidery Peripheral is one of several embroidery peripherals in Melco’s EDS II and EDS III family of products. The EMC 10 is a single head embroidery machine, which is assembled with the Melco ten-needle, cylinder arm embroidery head.

  • Page 8: Glossary Of Terms

    1 - 2 Glossary Of Terms • Typing with the computer keyboard is referred to in BOLD letters, for example: Type: run and press Enter to start. • To indicate that two keys must be pressed simultaneously the following conventions are used: with the computer keyboard, the first key to be pressed and held down is simply referred to, then the second key which needs to be pressed while the first key is held down is referred to after a comma, for example: Press Shift,8 to type an asterisk (*).

  • Page 9: Functional Arrangement

    Static Electricity And Grounding Strap Use 1 - 3 Functional Arrangement The EMC 10 is functionally arranged into four sections (five sections with Trimmer Option): the Controller, the Keyboard, the Embroidery Head (with optional trimmer), and the Carriage section. Figure 1-1 shows these and other functional parts of the embroidery peripheral.

  • Page 10: Warranty Considerations

    1 - 4 Configuring the EMC 10 Failure to use a grounding strap, or failure to practice other good maintenance or repair techniques may cause damage to the machine and possible harm to personnel. Warranty Considerations Some areas of maintenance require factory trained personnel to assure proper service.

  • Page 11: Configuration Procedure

    Configuration Procedure 1 - 5 CAUTION! If the EMC 10 is not configured with the correct Peripheral Program, it will not run properly, and may become damaged. The second configuration item is the network address (or Unit Number). The Unit Number must be set and be different for each peripheral attached to an EDS II or EDS III computer or network.
  • Page 12 1 - 6 Configuring the EMC 10 4. While holding these three keys down, turn ON the EMC 10 by pressing the rocker switch to the ON position. Hold these keys depressed until the unit ‘‘beeps’’ and the Display shows a message depicting the Peripheral Program currently selected.

  • Page 13: Service Adjustments

    Display Screen Intensity 2 - 1 2. Service Adjustments General This section of the manual provides detailed information for performing machine adjustments required during maintenance or parts replacement. The procedures are guidelines for performing service maintenance, and must be used by personnel practicing good maintenance technique.

  • Page 14: Power Supply (5 Volt Setting)

    2 - 2 Keyboard Section 1. Refer to specific instructions for removing covers in Section 3, then remove the keyboard cover. Use care not to allow the keyboard/display to come in contact with any portion of the machine that will short circuit any voltages. Also, do not touch the components on the printed circuit board.

  • Page 15: Carriage Assembly

    X Drive Belt Tension 2 - 3 3. Inside the electronics section, locate the 4 axis driver board directly in front of the CPU PCB. This board has a row of test points near the top left area of the board.

  • Page 16: Y Drive Belt Tension

    2 - 4 Carriage Assembly 2. Attach the Melco one pound fixture (p/n 995357-01) to the belt, midway between the X carriage assembly and the idler pulley assembly on the right end of the beam. socket head beam channel cap screw ruler for measuring 1 inch...
  • Page 17 Y Drive Belt Tension 2 - 5 3. Properly attach a Gates 5M Tensiometer to the belt, midway between the beam and the idler pulley tensioning assembly and check the tension. Y carriage and beam Gates 5M Tensiometer midway between idler pulley the beam and the idler pulley...

  • Page 18: Motor Belt Tension

    2 - 6 Carriage Assembly X Motor Belt Tension Note: This procedure requires the use of a special service tool: a 20 pound pull gauge. 1. Loosen the four X motor screws enough to move the motor on the motor bracket.

  • Page 19: Carriage Assembly Movement

    X Carriage Assembly Movement 2 - 7 X Carriage Assembly Movement 1. Move the X carriage assembly to the middle of the beam. 2. Hold the beam secure, then grasp at one end, then the other, and push backward and forward seeking any movement of the X carriage inside the beam channel.
  • Page 20 2 - 8 Carriage Assembly 6. Hook a 0 to 10 pound pull gauge onto the X carriage hoop holder actuator lever (see Figure 2-7). 0 to 10 pound pull gauge X carriage assembly Figure 2 - 7 7. Pull the pull gauge to the right slowly until the X carriage begins to move. 8.

  • Page 21: Embroidery Head

    Z Encoder System Introduction 2 - 9 Embroidery Head Z Encoder System Introduction The ability to place stitches precisely at high speed is dependent on the accurate operation of the electronics and electromechanical assemblies. The "key" to this is the Z encoder. The information provided to the CPU and 4 axis driver by the Z encoder is the basis for all the embroidery head activity.

  • Page 22: Z Encoder Inspection

    2 - 10 Embroidery Head Z Encoder Inspection "FACTORY SERVICE ADVISED" This procedure is a guide for determining the condition of the three channel optical encoder. If unauthorized personnel attempt to service this area, the FACTORY WARRANTY MAY BE VOIDED if the work is improperly performed and damage occurs.

  • Page 23: Z Shaft Encoder Calibration

    Z Shaft Encoder Calibration 2 - 11 Shaft Pulley socket head cap screws Z Encoder Shaft Coupler Z Encoder Cable to 4 Axis Driver Board Z Motor Figure 2 - 9 If the previous "test" fails or is in question, contact your local Melco service representative for advise.
  • Page 24 2 - 12 Embroidery Head 4. Locate the green LED on the top left of the CPU. Most likely this LED will not be glowing. It is only supposed to glow for a 1 degree duration each revolution of the Z shaft encoder. 5.

  • Page 25: Thread Tensioner Check Spring Adjustment

    Thread Tensioner Check Spring Adjustment 2 - 13 Thread Tensioner Check Spring Adjustment After replacing a thread check spring, install the thread tensioner into the thread tensioner mounting bracket. You must then adjust the tension of the check spring against the thread break contact. To set this tension: 1.

  • Page 26: Cross Roller Bearing Centering

    2 - 14 Embroidery Head If you rotate less than 2 spokes you will begin to lose the force needed to make a tight stitch. You may have enough stroke but not enough force to cinch up the stitch tightly. You may also begin to have failure of thread break detection. You must have enough rotation to cause the check spring to make a good contact with the thread break contact post.

  • Page 27: Retainer Plate Bearing Adjustment

    Retainer Plate Bearing Adjustment 2 - 15 4. Position the left edge of the cross roller bearing in line with the left edge of the retainer plate and the center of the needle bar guide shaft felt pad. (The second roller of the cross roller bearing should just be engaging between the embroidery head v-rail and the needle case v-rail.) 5.

  • Page 28: Lower Rail Retainer Adjustment

    2 - 16 Embroidery Head socket head cap screws retainer plate needle case bearing (left V-rail side) retainer plate retainer plate bearing (right side) assembly (cross roller installed and v-rail centered) adjustment install v-rail embroidery fixture adjustment head V-rail fixture here Figure 2 - 13 6.

  • Page 29: Jump Stitch Solenoid

    Jump Stitch Solenoid 2 - 17 gap between zero front of head preload and .002" roller bearing lower rail needle case retainer lower rail (needle case removed to NOTE: if trimmer option show detail) installed, grabber parts screw (under must be removed to lower rail retainer) access screw.

  • Page 30: Bracket Positioning

    2 - 18 Embroidery Head A typical dimension for the gap between the relaxed solenoid plunger and needle bar driver reciprocator is approximately 0.015 to 0.045 inches (0.4 to 1.1 mm). Refer to Figure 2-15 for an illustration of the gap location. Gap 0.015"- 0.045"...

  • Page 31: Color Change Motor Belt Tension

    Color Change Motor Belt Tension 2 - 19 2. Attach it to the head with the 2 screws removed earlier, then check the alignment to be within the above 3 positions. Be sure that the plunger contacts the reciprocator mechanism, that the mechanism works properly, and that the jump stitch assembly does not contact the embroidery head connecting rod during its mechanical motion.

  • Page 32: Thread Break Brush Adjustment

    2 - 20 Embroidery Head Thread Break Brush Adjustment The thread break brush must be adjusted to make proper contact with the thread break contact posts coming off the rear of the thread tensioner assembly PCB. 1. Put the needle case in any selected needle position. 2.

  • Page 33: Trimmer Option

    Sequence of Trim Events 2 - 21 Trimmer Option The trimmer option for the EMC 10 Embroidery Peripheral is assembled and thoroughly tested before the machine is shipped. Although the set up of the trimmers should not change during normal use, there are a few things to be aware of to prevent problems.

  • Page 34: Trimmer Set Up And Adjustments

    2 - 22 Trimmer Option 8. When the trim is complete the peripheral begins embroidering again automatically. Trimmer Set Up And Adjustments The following procedures provide a guide for adjusting various portions of the trimmer system. "FACTORY SERVICE ADVISED" Note: This procedure requires the use of several service tools: a medium screw driver, a small screw driver, a 3/32"...
  • Page 35 Trimmer Set Up And Adjustments 2 - 23 2. Remove the rear bed cover of the head to expose the trimmer camming area as seen in Figure 2-18. solenoid pin end Drill hole in rear of shown engaged cam. (must be facing in cam groove nearly straight upward at embroidery head...

  • Page 36: Trimmers Not Trimming Properly

    2 - 24 Trimmer Option You should not feel any restrictions during the rotation. If you do, you may have a damaged trimmer cam or trimmer solenoid. NOTE: You may remove the trimmer solenoid for inspection or replacement. However, when the trimmer solenoid mount is moved, the movable knife home position may become mis-adjusted.

  • Page 37: Spring Knife

    Trimmer Set Up And Adjustments 2 - 25 Physical Condition Of Trimmer Parts Figure 2-19, identifies those components that comprise the trimmer system: the Component Identification spring knife, movable knife, and the under thread presser. These components are covered by the front bed plate and the needle plate (see inset in Figure 2-19). Remove the screws holding these covers to gain access to the trimmer area.
  • Page 38 2 - 26 Trimmer Option 2. Pull the movable knife forward with a small hex wrench hooked behind it. 3. With a black marking pen mark the areas of the movable knife as shown in the left illustration of Figure 2-20. ink wipeoff in Apply Ink in these ink wipeoff in...
  • Page 39 Trimmer Set Up And Adjustments 2 - 27 3. Obtain a piece of upper thread from the tensioner assembly and drape it over the movable knife (see Figure 2-21). 2. Push Movable Knife back with your thumb or forefinger, to cut the thread.

  • Page 40: Under Thread Presser

    2 - 28 Trimmer Option Under Thread Presser The under thread presser, shown in Figure 2-22, holds the bobbin thread after a trim. This permits a loop of bobbin thread for the next stitch. While the under thread presser holds the bobbin thread there should only be enough pressure applied to hold the thread in place under the movable knife.

  • Page 41: Movable Knife

    Trimmer Set Up And Adjustments 2 - 29 The second part of checking under thread presser is to check if the bobbin thread is in fact being held in place. 1. While the machine is still turned off, remove the font bed cover and disconnect the connecting link from the movable knife drive arm by lifting it from the front pin (see Figure 2-19).
  • Page 42 2 - 30 Trimmer Option 4. Go to the TRIM MENU and perform a TRIM IMMEDIATE command. 5. The movable knife should be located under the spring knife, positioned as shown in Figure 2-23. If the sloped rear tip of the movable knife is not showing in front of the leading edge of the spring knife, the "home"...
  • Page 43 Trimmer Set Up And Adjustments 2 - 31 solenoid pin end shown engaged in cam groove Engage solenoid pin into cam groove by Indicator Tab pushing here with flat bladed screw driver trimmer solenoid Photo Sensor Movable Knife Connecting Link screws for "home"...

  • Page 44: Checking Select Position

    2 - 32 Trimmer Option Checking Select Position After adjusting the movable knife home position, you must check for the movable knife "select" position. If adjustment is required it is recommended that Melco factory-trained personnel be consulted. 1. Replace the standard needle plate on the embroidery head arm (See Figure 2-19).

  • Page 45: Select Position Adjustment

    Trimmer Set Up And Adjustments 2 - 33 Select Position Fixture (p/n 995372-01) this pin fits into the top of the needle plate hole. Movable Knife "select" position Needle Plate (with the rear of (Do not install the blade against the raised the fixture pin needle plate)

  • Page 46: Picker Finger Centering

    2 - 34 Trimmer Option 5. Remove the select position fixture. 6. Press the key to rotate Top Bobbin the head to the head up Drive Pulley locking position. collar screw belt 7. Perform the select position checking procedure again, locking to check that the movable collar...

  • Page 47: Picker Home Position

    Trimmer Set Up And Adjustments 2 - 35 Left Side View Front View The Picker should be centered on Picker Height the Bobbin Adjustment Shaft. Screws Dovetail clamp Dovetail clamp Adjust Picker Home Position here (locking set screw inside swivel pin body) Picker/dovetail bracket attachment screws (side to side picker assembly positioning is made by loosening these 2 screws.) Figure 2 - 27...

  • Page 48: Grabber Adjustments

    2 - 36 Trimmer Option Picker Height Picker Picker Home Depth Front End Bobbin End Picker Fixture Picker Depth Position Picker Home Position Picker Height Position locking socket head cap screw hex nut Figure 2 - 28 4. Retighten the 2 screws. 5.
  • Page 49 Trimmer Set Up And Adjustments 2 - 37 3. Manually rock the motor limit stop assembly to move the grabber blade all the way forward and all the way back one time (see Figures 2-29 and 2-30). This checks if the blade is binding somewhere in its travel. If so, find the mechanical bind and correct it.
  • Page 50 2 - 38 Trimmer Option To Adjust For A: 1. Position the grabber blade as far back as it will go into the grabber blade guide by manually rocking the motor limit stop assembly as shown in Figure 2-29. 2. Locate the socket head cap screw in the end of the grabber blade guide (see Figure 2-31).

  • Page 51: Under Thread Control (Utc) Adjustments

    Under Thread Control (UTC) Adjustments 2 - 39 Under Thread Control (UTC) Adjustments It is very important that you follow these instructions any time the rotary hook retaining finger or UTC is loosened or moved. Please follow the instructions in the order they occur.
  • Page 52 2 - 40 Trimmer Option 7. Additionally, align the center of the retaining finger tab to the center of the needle as indicated in Figure 2-32. 8. Tighten the UTC assembly mounting screws. 9. Place the UTC Combination Gauge on top of the needle plate support bracket as shown in Figure 2-33 and check that the UTC detection arm does not touch the bottom surface of the gauge which represents the bottom of the needle plate when it is installed.

  • Page 53: Sew Test

    Sew Test 2 - 41 13. If the knife touches the arm, reshape the arm slightly until it clears then repeat steps 9 through 12. 14. Re-attach the connecting link to the pin on the movable knife assembly. Caution! When installing the covers, be sure not to pinch the UTC Assembly wires! 15.
  • Page 54 2 - 42 Trimmer Option 3. Repeat steps 1 and 2 until the bobbin runs out at least once in both directions of diagonal stitching in the test design. 4. If the sensor does not detect when the bobbin runs out of thread, slightly loosen the UTC sensor body at the screws shown in Figure 2-35, and at the slotted screw hole (left side) move the sensor a very small amount away from the needle.

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