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Melco BRAVO User Manual

Operating system
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Rev 250116

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Summary of Contents for Melco BRAVO

  • Page 1 User Manual Rev 250116...

  • Page 2: Table Of Contents

    Contents Copyright Notice About This Manual BRAVO OS Version Changes v12.07.XXX v12.06.XXX v12.05.XXX v12.04.XXX v12.03.XXX v12.02.XXX v12.01.XXX Hazards of Operation Dangers de Service Safety Warnings Avertissements de sécurité Safe Operating Principles Specifications Operator’s Kit Contents Unpacking the Machine Setting up the Machine...
  • Page 3 Cleaning the Bobbin Case Inserting a New Bobbin in the Bobbin Case & Checking the Tension Bobbin Case Tension Gauge Inserting the Bobbin Case Initial Maintenance Bravo OS Screen Overview Screen Overview Loading a Design Load Design Load Design Wizard...
  • Page 4 Setting the Sew Speed How Fast Should I Sew? Sew Speed Change from the Machine Keypad Setting Sew Speed in Bravo OS Symptoms from Sewing too Fast Acti-Feed Material Thickness Standard Acti-Feed Auto Acti-Feed Auto Acti-Feed Limits Minimum (Autofeed Lower Limit)
  • Page 5 Powering Down the Machine Power Down Sequence Needle Types and Replacements Replacing a Needle Choosing a Needle Needle Points Needle Coatings Backings & Toppings Backings Backing Weights Toppings Thread Types Thread Types Thread Weight (Thickness) Sewing Caps Installing & Removing the Wide Angle Driver Red Wide Angle Driver Installation Red Wide Angle Driver Removal Red Wide Angle Driver Cap Support Wings (option)
  • Page 6 Centering a Design on a Cap Wide Angle Driver Maintenance Wide Angle Driver Maintenance Bravo OS Menu Items File Menu View Menu Commands Menu Tools Menu Tools Menu > Options Measurement Units Tab Notifications Tab Ethernet Tab Tools Menu > Settings...
  • Page 7 Setting the Color Sequence Using Active Colors Manually Assigning Needles Automatically Assigning Needles Setting the Color Sequence with Active Colors Sewing An Appliqué Anatomy Of An Appliqué Design Setting the Color Sequence for an Appliqué Design Sewing the Appliqué Laser Alignment (Design Registration) Thread Feeder Home Adjustment Procedure Machine Maintenance Cleaning...
  • Page 8 Troubleshooting Machine Caused Thread Breaks Cleaning Under the Needle Plate Center the Needle Plate Pinch Rollers Need Maintenance Rotary Hook Support Adjustment Adjusting the Rotary Hook Support Resetting the Machine Deleting the Jobs & Machines Folders Power Up the Machine With Force Download On Additional Troubleshooting Miss-Starts Skipped Stitches...

  • Page 9: Copyright Notice

    Copyright Notice © Copyright Melco, 2023 ALL RIGHTS RESERVED. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without prior written approval from the author. The author reserves the right to revise this publication and to make changes in it at any time without obligation of the author to notify any person or organiza- tion of such revisions or changes.

  • Page 10: About This Manual

    About This Manual This manual contains instructions on repairs and adjustments to the embroidery machine, in addition to other technical information. If you do not fully understand any information in this manual, you are advised to contact your local au- thorized technical support provider for assistance.

  • Page 11: Bravo Os Version Changes

    0. The values can now be -10 to +10. • Added buttons for bug reporting and importing machine properties from Melco engineering. • Canceling out of the hook maintenance timer will now also stop any trimmer movements.
  • Page 12 v12.05.XXX • Various firmware updates and improvements. • Various bug fixes and improvements. Note: The machine might sound different during operation after loading this software update. v12.04.XXX • Various firmware updates and improvements. • Various bug fixes and improvements. Note: The machine might sound different during operation after loading this software update. v12.03.XXX •...
  • Page 13 • Added support for BRAVO X and Needle Plate Trimmer (NPT). • Various firmware updates and improvements. • Various bug fixes and improvements. Note: The machine might sound different during operation after loading this software update. • Added Hoops •...
  • Page 14 • Simplified user view along with tradition BRAVO OS view. This is optimized for a touch screen Windows device. • Removed the monthly maintenance from the recommended initial maintenance steps. • Security Updates • Bobbin tension changes • 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 15 • Added hoops (Subject to Package Sew Field Restrictions): • Mighty Hoops: • 16.625” x 17.25” (41.3 x 43.8 cm) • 10” x 5” (25.4 x 12.7 cm) • 6” x 9” (15.25 x 22.86 cm) • 12” x 15” (30.5 x 38.1 cm) •...

  • Page 16: Hazards Of Operation

    Hazards of Operation There are risks in operating any mechanical equipment, the following is intended to elevate your aware- ness of both the areas of risk and the meaning of the warning signs located on the machine. Always refrain from interfering with mechanical or electromechanical parts while in operation unless otherwise specified in this manual.

  • Page 17: Dangers De Service

    Dangers de Service Le tableau suivant montre des zones de risques ou points de danger qu’on peut rencontrer lors du ser- vice. Portez toujours des lunettes protectrices lors du maniement de la machine pour éviter des blessures corporelles en cas d’une casse d’aiguille. Rayon laser Ne regardez pas directement au rayon laser.

  • Page 18: Safety Warnings

    Safety Warnings The list below specifies safety warnings that you should heed during normal operation and maintenance of your machine. • Do not attempt to lubricate the machine while it is in operation. • Failure to engage the emergency stop button on the machine keypad while removing or replac- ing needles can result in the machine starting through machine or operator error.
  • Page 19 The following table lists specific safety warnings that you should heed when you perform procedures (such as repairs and technical adjustments) that extend beyond normal operation and maintenance. Area Of Machine Warning Entire Machine Personal injury may result if proper precautions are not observed. Remove rings, watches, and any other metallic objects from hands and wrists before servicing the machine.
  • Page 20 Laser Assembly The laser assembly replacement procedure is intended to be performed only by specially trained Melco service technicians and personnel. Disassembly by un- trained individuals will void any warranty protection and can result in personal injury or damage to the machine.
  • Page 21 Area Of Machine Warning Needle Case During needle case removal, once you have completed the first two steps of the procedure. Do not proceed without engaging the emergency stop button or by turning the machine off. The machine may begin operating if you do not do so.

  • Page 22: Avertissements De Sécurité

    Avertissements de sécurité Le liste ci-après comprend avertissements de sécurité spécifiques que vous devriez rappeler lors du service normal et lors de l’entretien de la machine. • N’essayez pas de lubrifier la machine lorsqu’elle est en marche. • N’oubliez pas d’actionner le bouton d’arrêt d’urgence de la machine si vous voulez enlever ou remplacer des aiguilles sinon vous risquez que la machine commence à...
  • Page 23 Le tableau suivant comprend des avertissements de sécurités spécifiques que vous devriez respecter lors des travaux de réparation, des réglages techniques ou d’autres procédures qui sont hors le service normal ou d’entretien. Zone de la machine AVERTISSEMENT! Machine entière Des blessures corporelles peuvent être causées en cas de non-respect des précautions soigneuses.
  • Page 24 La procédure d’ajustage de la lumière Laser ne doit être faite que par des tech- niciens et du personnel Melco spécialement entraînés et autorisés. Le démon- tage par des personnes non entraînées annulera toute protection de garantie et peut causer des blessures corporelles et endommager la machine.
  • Page 25 Zone de la machine AVERTISSEMENT! Système Groupe DEL Les lampes DEL peut être trop chaudes pour les toucher quand elles sont illuminées. Il faut les débrancher pendant quelques minutes pour pouvoir les toucher et pour éviter de petites brûlures. Couteau mobile Eloignez-vous des composants mobiles qui sont exposés pendant l’ajustage du couteau mobile.

  • Page 26: Safe Operating Principles

    Safe Operating Principles The following list contains some safe operating principles you should follow when operating the machine. • No untrained persons should be permitted within the designated working area around the machine. • No untrained persons should operate the machine. •...

  • Page 27: Specifications

    Specifications For indoor use only Operating Software Bravo OS Lite Bravo OS Flex Type/# of Heads Upper Arm-Lower Arm/1 Upper Arm-Lower Arm/1 to 4 Modular Modular # Needles Maximum Tubular Frame Size 360mm x 300mm (14.2”x11.8”) 450mm x 430mm (17.7”x 16.9”)
  • Page 28 Operating Software Bravo OS Lite Bravo OS Flex Motor Capacity (kV) X and Z: 100 Watts Y: 250 Watts X and Z: 100 Watts Y: 250 Watts Machine Construction Material Aluminum Aluminum PhysicalSpecificationswithCart Width 724mm (28.5”) 724mm (28.5”) Height 1541mm (60.7”) 1541mm (60.7”)

  • Page 29: Operator's Kit Contents

    Operator’s Kit Contents The Operators Kit contains many of the tools required for the assembly of the cart and initial maintenance of the machine. The rest of the tools will be used in other adjustments and procedures of your machine. Item No.

  • Page 30: Unpacking The Machine

    Unpacking the Machine If your machine was delivered, this may have been completed by the delivery service. It is still recom- mended that you reconcile your shipment with your packing list. It is important to check the packing list instead of the invoice. The invoice will show all items that were ordered, but the packing list will indicate if any items are on back order.
  • Page 31 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. 7. With two people, lift the machine using the hand holds located on the bottom of the machine casting.

  • Page 32: Install The Machine User Interface And X-Beam End Caps

    Install the Machine User Interface and X-Beam End Caps 1. Locate the box containing the user interface 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 Route the network cable (shown in yellow) that came with the user interface assembly, from under the right side machine cover,...

  • Page 33: 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 33 of 248...

  • Page 34: Cart Assembly

    Cart Assembly Thecart consistsofthefollowing listed items. To assemble, use the 4mm hex wrenchincludedinyourMachine Operator’sKit. Item # Qty Description Left Cart Leg Assembly Right Cart Leg Assembly Cart Base Support Cart Rear Support M6 x 12mm Button Head Screw M6 Flat Washer Cart Shelf Machine Locator M6 Split Lock Washer...

  • Page 35: Stage 2 - Installing The Rear Support

    Stage 2 – Installing the Rear Support 1. Rotate the Cart to its upright position. 2. Assemble Item D (Rear Support) to the rear side of the Cart resting on item C (Base Support), with the obround opening facing towards the bottom of the Cart. 3.

  • Page 36: Stage 4 - Installing The Cart Shelf

    Stage 4 – Installing the Cart Shelf 1. Position item G (Cart Shelf) between the two Cart Legs, items A and B, with the (4) Machine Locators (item H) resting on the Cart Legs, items A and B. IMPORTANT: The side of item G (Cart Shelf) labeled with the “F”...

  • Page 37: Software Activation & Deactivation

    Software Activation & Deactivation BRAVO OS can use a virtual security key as opposed to a physical one. This means that if no physical se- curity key is present when you initially launch your software, you will be prompted to activate the product using the product serial number.

  • Page 38: Machine Connections

    Machine Connections This section will describe how to correctly connect the power and communications 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. The method for connecting the machine to the computer will vary depending on the number of machines.

  • Page 39: Connecting The Network Cable (Single Machine)

    Connecting the Network Cable (Single Machine) For a single machine to computer connection, a crossover cable is required. (You can also use 2 Ethernet cables and an Ethernet switch). 1. Connect one end of the crossover cable into the Ethernet jack on the machine. 2.

  • Page 40: Connecting The Network Cables (Multiple Machines)

    Connecting the Network Cables (Multiple Machines) For connecting multiple machines to the computer, an Ethernet switch device and cables are required. The switch is a small electronic device that allows multiple devices to be connected through a network. You can connect as many machines as your switch will allow. 1.

  • Page 41: 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. Select Tools>Options>Ethernet Tab from the menu bar at the top of the screen. This step is usually only required for the initial power up.

  • Page 42: 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 is launched and the Main Screen is being displayed. 3.

  • Page 43: 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. Understanding the upper threading will also help in troubleshooting.
  • Page 44 To use the clovers: 1. Push the clover over the thread tube. 2. Collapse the clover to the thread tube as the cone is loaded onto the machine. 3. Releasing the clover will cause it to expand inside the cone core and stabilize the thread cone. 44 of 248...

  • Page 45: Quick Thread Change

    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 46: Upper Thread Path

    8. When finished, line up the thread under the pinch roller and press the pinch roller back down. 9. 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. With your hands out of the way, press the adjustment and cen- ter keys on the keypad simultaneously to close the grabber and move the thread into the holder behind the needles.
  • Page 47 • If using compressed air, place the end of the thread in to the top of the thread supply tube. Feed enough that the thread will stay without holding it. Now blow the compressed air into the tube. The air will carry the thread and shoot out the front of the machine. 3.
  • Page 48 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. 10. Thread the needle from front to back. Cutting the end of the thread may allow it to more easily pass through the eye.
  • Page 49 Press the keys again to open the grabber. 14. Trim the end to about an inch in length 49 of 248...

  • Page 50: Bobbin Threading And Tensioning

    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. Removing the Bobbin Case •...

  • Page 51: Inserting A New Bobbin In The Bobbin Case & Checking The Tension

    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 fashion.

  • Page 52: Using The Gauge

    Using the Gauge 1. Clean and thread the bobbin 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 case into the tension gauge with the extended portion of the latch falling into the guide as shown in red.

  • Page 53: Adjusting Bobbin Tension

    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 test- ing.

  • Page 54: 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 55: Initial Maintenance

    Initial Maintenance The first time the machine is powered on, it is highly recommended that an initial maintenance be per- formed. To step through this maintenance, It is recommended that you go through the first three maintenance sets when you first set up your ma- chine.

  • Page 56: Bravo Os Screen Overview

    If you have not done so, launch the software and power up the machine. When Bravo OS is open and communicating with the machine, you will see a window similar to the one below. Some icons, windows, and tabs may not be visible depending on the level of software you are running.
  • Page 57 Machine List This list of the machines connected to and communicating with Bravo OS may or may not appear de- pending on the level of your software. This list is used to choose which machine or machines you wish to a design to or set settings for.

  • Page 58: View Window

    View Window This area displays the design that is currently loaded to the machine as well as the currently selected hoop. This area is helpful in determining proper hoop size as well as embroidery location. This area may be blank if this is the first time the machine has been connected to the computer or if the machine has been switched off for a long time.
  • Page 59 Machine Bar This bar, typically found at the bottom of the screen, displays the current status of a running machine. It will show a status log, sew speed, progress bar and percentage, as well as the current needle, color, and position.

  • Page 60: Loading A Design

    Loading a Design This section will walk you through loading a design to your machine. There are multiple ways to accom- plish this, but for now, we will stick to the main two commands. • Load Design • Load Design Wizard The Load Design command will simply load a design to the selected machine or machines.

  • Page 61: Load Design Wizard

    4. After a loading progress bar displays, the design will appear on screen and be loaded into your machine. 5. The design is loaded and you can progress to setting the color sequence. Load Design Wizard To load a design using the Load Design Wizard, you can use either the menu drop-down command or the icon on the toolbar.
  • Page 62 3. 1day.ofm is a good file to start with. It is most commonly located in the “Designs” folder on your local drive. 4. After a loading progress bar displays, the design will appear on screen and be loaded into your machine.

  • Page 63: Setting The Color Sequence

    Setting the Color Sequence This section will walk you through setting the color sequence for the design. The color sequence can be accessed from a few places. • Status Tab: • Click on the Color Sequence button. • Through the Load Design Wizard •...

  • Page 64: To Change A Color In The Existing Color Sequence

    4. Click on the cone number (needle number) in the thread cone display in the order you wish to sew. If the light green was on needle 4 in the example above, you would click on the circled 4 first. This would place a “1-16” in the Color-Needle field on the left. This indicates that color 1 will sew on needle 4.

  • Page 65: Selecting A Hoop In The Software

    Choosing the Appropriate Hoop Size The Bravo OS view window will show how the current design will fit into the selected hoop. Ideally, the hoop used to embroider a design fits as closely as possible without the design exceeding the hoop limits.

  • Page 66: Inches Or Centimeters

    If the hoop you have selected is too small for your design, you will be able to see this in the Bravo OS window. If the design crosses the dotted line, the dotted line will become a thicker solid black line indi- cating that the design falls outside of the recommended sewing area.

  • Page 67: Centering The Hoop

    Centering the Hoop If the hoop is not centered on the machine, it may be centered using either: • The Center Hoop icon in Bravo OS • The Hoop and Center keys on the machine keypad. 67 of 248...

  • Page 68: Setting The Sew Speed

    Setting the Sew Speed This section will walk you through sew speed for your machine. This can either be done from: • Machine Keypad • Software Controls • If the software level prevents you from using the software controls, you will need to use the machine Keypad to change the sew speed.

  • Page 69: Setting Sew Speed In Bravo Os

    Setting Sew Speed in Bravo OS To adjust the sew speed setting in Bravo OS: 1. Click on either the up or down arrow just to the right of the speed setting. • Pressing up will increase speed by 50 s.p.m.

  • Page 70: Acti-Feed

    Acti-Feed Acti-feed is the feature that replaces the tensioning system on a conventional embroidery machine. It uses thread feed gears, rollers, and a thread sensor bar to feed the appropriate amount of thread for each stitch. Acti-Feed is the system that calculates and feeds the correct amount of thread per stitch during sewing. The amount of thread feed per stitch is dependent on material thickness.

  • Page 71: Auto Acti-Feed

    Auto Acti-Feed Auto Acti-feed is used to feed thread based on feedback from the thread sensor bar. This allows auto acti-feed to change the material thickness number as it is sewing to reflect changes in the material. This mode is ideal for any material or application that changes thick- ness.

  • Page 72: Auto Acti-Feed Limits

    It is helpful were the thread could pull tight, but a little more loft is desired. The autofeed lower limit can be accessed through the Status Tab of the main Bravo OS screen. The auto- feed lower limit is shown as the “Minimum”.

  • Page 73: Appropriate Material Thickness Settings

    Appropriate Material Thickness Settings Finding just the right settings or limits for your acti-feed is not always necessary, but it can make a marked improvement in sew quality and machine performance. Sew quality and thread breaks are indicators of appropriate or inappropriate thread feed. Those symp- toms are listed in sections below.

  • Page 74: Design Orientation Or Rotation

    Design Orientation or Rotation This section will walk you through changing the orientation of the loaded design. To change the orientation of the design: 1. Click on the Design Orientation F Every click on the orientation F will rotate the icon by 90°. When the clicking stops, the design will rotate and the F icon will reset.

  • Page 75: Choosing The Right Hoop

    Choosing the Right Hoop Hooping a garment properly and selecting the right hoop for the job is essential to quality embroidery pro- duction. The hoop provides the means to move the product at high speeds and accurately place the stitch. If the hoop is too loose, the wrong size, or if the product is hooped poorly, this can adversely affect the design.

  • Page 76: Hooping

    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. For example, changing from a T-shirt to a sweatshirt would require a change in hoop tension.

  • Page 77: Hooping The Garment Or Fabric

    10. Now, without loosening the screw, remove the hoop from the garment. 11. Tighten the adjustment screw a turn or two more. 12. The outer hoop is now adjusted. The appropriate tightness of a hoop can be tested by tapping rapidly with moderate pressure on the fabric inside the hoop.
  • Page 78 • It may be helpful to start by placing one hand just below and off of the outer hoop to stabilize and smooth the fabric. • 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.

  • Page 79: Hooping Tips

    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. They help grip slick or bulky goods because of the larger surface area and slight tooth the wood provides.

  • Page 80: Attaching Or Moving The Hoop Support Arms

    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 81 6. Tighten the thumb screws to finger tight. 7. Using a 6mm hex wrench, tighten the screws a quarter to half turn more. Do not overtighten as the screws are designed to snap before damage to the x-carriage can occur. If the hoop brackets shift forward and back, the spring clip may need to be adjusted.

  • Page 82: Removing The Hoop Support Arms

    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 83: Loading A Hoop Onto The Machine

    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 84: 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 machine must be on and communicating with it.
  • Page 85 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 86: 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 87: Key Combinations

    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. Hoop + Down Arrow: Moves the hoop so the needle will sew lower in the hoop Hoop + Left Arrow: Moves the hoop so the needle will farther left in the hoop.
  • Page 88 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 89: 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 RSA files Start software, check loaded yet...

  • Page 90: Sewing Your Design

    Sewing Your Design A general checklist for sewing a design would be ; Load a Design ; Set the Color Sequence ; Select a Hoop ; Set the Machine Speed ; Set the Acti-feed ; Check Design Orientation ; Hoop the Garment ;...

  • Page 91: Powering Down The Machine

    Powering Down the Machine This section will describe how to correctly power down the machine. Power Down Sequence 1. Close Bravo OS. 2. Power down the machine with the power switch. 91 of 248...

  • Page 92: Needle Types And Replacements

    Needle Types and Replacements Embroidery quality can be greatly effected 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, nee- dles will need to be changed.

  • Page 93: Choosing A Needle

    Choosing a Needle Your machine utilizes DBxK5 needles. Among other things, this means that they are industrial needles with larger eyes. Needle Sizes Needles come in a variety of sizes, and most are marked with two numbers. For example, you will find 75/11 needles.

  • Page 94: Needle Points

    Needle Points Needle points also come in a variety of options. The main two are sharp and ball point. Sharp point needless 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 95: Backings & Toppings

    Backings & Toppings Backings Appropriate backing is essential for embroidering most fabrics. Without backing, fabrics can slip even when they are hooped tightly. Using the proper backing is directly linked to the production of consistent- ly high quality embroidery. It is important to understand that many different embroiderers with identical criteria may choose completely different backing and topping formulas and still achieve successful em- broidery results.
  • Page 96 Specialty Backings Specialty backings such as poly mesh and nylon mesh are also options. While they may not be as stable as traditional cut-aways, they are much less visible through lighter weight garments. They also tend to be softer than other backings. Water soluble backing is also available for jobs that require that no backing be left after the completion of the embroidery.

  • Page 97: Backing Weights

    Embroidery on T-Shirt Cut-away backing provides needed stability to the thin knit of a T-shirt. The embroidery holds the shape of the design. Tear-away backing allows the T-shirt to pull and pucker as the design is sewn. Backing Weights Backing comes in different thicknesses. Many times, you can ask for sample packets from suppliers to find what will work best with your application.

  • Page 98: Thread Types

    Thread comes in a few compositions. These have different properties that can drastically affect sewing and quality. Polyester Polyester thread has become the standard thread for Melco embroidery machine users. • Stronger than other threads • Fewer thread breaks when sewing •...

  • Page 99: Thread Weight (Thickness)

    Rayon Rayon threads are made of natural fibers and can have slightly higher sheens than polyester. • Wide variety of colors • Beautiful Sheen • Less strength than polyester • Not chlorine resistant • Usually requires slower sew speeds Thread Weight (Thickness) Thread is commonly referred to by its weight.

  • Page 100: Sewing Caps

    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. ; Select the appropriate hoop in software ; Load the Wide Angle Driver (this may need adjustment the first time) ;...

  • Page 101: Installing & Removing The Wide Angle Driver

    Failure to remove the hoop arms will result in the wide angle driver colliding with the arms during sewing. 5. Remove the hook guard: For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) Loosen the thumb screw securing the hook Using a 2mm hex wrench, loosen the two guard and slid it away from the machine.
  • Page 102 It should slide smoothly into the t-channel. The t-nut must go all the way back to the hard stop or the shaft will be set too far forward on the machine. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 8.
  • Page 103 “Center” keys on the keypad of the machine. Then, slide the red driver assembly onto the lower arm and support shaft. Notice the orientation of the ring in the picture. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 103 of 248...
  • Page 104 12. Using two of the thumb screws from the hoop arms, attach the red driver to the x-carriage of the machine. The driver will attach to the two innermost holes. Tighten them to finger-tight, and then use a 6mm Allen wrench to tighten an eighth to quarter turn more. Do not over-tighten the screws as they are designed to break before damage to the machine can occur.

  • Page 105: Red Wide Angle Driver Removal

    To close the bar, simultaneously press the “Adjustment” and “Center” keys on the keypad of the machine. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 3. Remove the hook guard.
  • Page 106 4. Loosen the knobs of the lower shaft support. Then, slide the lower support shaft out of the t-channel and off the machine. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 5. Reattach the hook guard by sliding it back into place and tightening the screw(s).

  • Page 107: Red Wide Angle Driver Cap Support Wings (Option)

    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. They may also need to be removed for any design that pushes the physical limit of any specific cap style or a smaller cap.
  • Page 108 • Do not over-tighten the screws as they are designed to break before damage to the machine can occur. 8. Move the driver and carriage back until the cap support wing assembly fully covers the needle plate. 9. Place a business card between the cap support wings and the needle plate. 10.

  • Page 109: Removal Of The Cap Support Wing Assembly (Option)

    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 110 5. Place the 4 nuts back on the threaded standoffs of the cap support wing assembly to prevent their loss. 110 of 248...

  • Page 111: Adjusting The Red Wide Angle Driver

    A single business card should be able to slide between them with little resistance. A gap of two business cards is acceptable. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 4. If the gap is too small or too large, the driver will need to be adjusted using the steps below.

  • Page 112: Adjustment Procedure

    3. Position the driver so that the bushing is aligned to the front of the support shaft and the driver ring is centered with the hole in the needle plate. Reference the ring’s frame location tab. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm)
  • Page 113 4. Place a business card of medium to heavy stock (or equivalent) between the needle plate and the driver ring. This will act as a spacer. The ring should just rest on the card. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 5.

  • Page 114: Selecting Hoops For The Wide Angle Driver

    Selecting Hoops for the Wide Angle Driver When selecting a hoop for use with the wide angle driver, select a hoop that is labeled with the driver color first. Hoop Red Driver Graphite Driver Red WACF Graphite WACF Red CCF Graphite CCF Red Micro (2.6 x 3.7in) Graphite Micro (2.6 x 3.7in)

  • Page 115: Hooping A Cap On The Conventional Cap Frame

    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. To prepare the cap, 1.
  • Page 116 Don’t pinch them between the back of the frame and the gauge. 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.
  • Page 117 The sweatband may not touch the vertical ridge of the frame. That’s okay. Different caps have varying sweatband widths and not all will appear the same when hooped. 5. The cap and backing should ride over the two posts with teeth on the sides of the frame. 6.

  • Page 118: Hooping A Cap On The Wide Angle Cap Frame

    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. To prepare the cap, 1.
  • Page 119 Don’t pinch them between the back of the frame and the gauge. 2. Swing the metal strap open. 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.
  • Page 120 relatively centered on the frame. The centering mark on the bill-stop can be used for reference. The sweatband may not touch the vertical ridge of the frame. That’s okay. Different caps have vary- ing sweatband widths and not all will appear the same when hooped. 5.
  • Page 121 sweatband of to the cap. 9. Continue bringing the strap around the front of the cap. On the front of the cap, the teeth of the strap must fall into the seam for the bill. 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.
  • Page 122 • To adjust the cap frame strap, loosen the two wing nuts on the left side of the frame. • 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. •...
  • Page 123 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 backward and over the clip posts on the both sides. Indent the cap material along the clip posts. 16.
  • Page 124 • 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. 18. The cap is now ready to be placed on the wide angle driver on the machine. 124 of 248...

  • Page 125: Loading/Removing A Hoop With The Wide Angle Driver

    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 under the needle case. 2.

  • Page 126: Removing A Hoop

    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. 1. Press the three locking clamps on the driver while gently pulling back on the frame. 2.

  • Page 127: Digitizing For Caps

    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 128: Sew Order For Cap Designs

    Sew Order for Cap Designs Now that you have the size of the design figured out, the design needs to be digitized for a cap. One of the challenges with embroidering caps is that the fabric moves and flags. The trick to sewing caps successfully is to use the design sew order to move the material where it can to little harm.

  • Page 129: Sew Settings For Caps

    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 rotated 180° in the software. For assistance on this, review the Design Orientation &...

  • Page 130: Adjusting The Presser Foot For Caps

    Adjusting the Presser Foot for Caps The presser foot will need to be adjusted any time you significantly change the thickness of the material you’re sewing on. With caps, adjusting the presser foot is a little different than with flat goods. Because they cap flags (bounces) and has a seam, it is often best to set the presser foot to a standard setting and adjust from there.

  • Page 131: Centering A Design On A Cap

    Centering a Design on a Cap Unless you hooped absolutely perfectly, and that is exceeding difficult to do, you will most likely need to adjust the hoop position on the machine to better center the design on your cap. The best way to accomplish this is to have the hoop loaded on the machine first. Screen Versus Cap Pressing the move to Center button in the software or commanding it from the keypad of the machine is convenient, but it doesn’t work well for caps.

  • Page 132: Trace The Design

    Centering Horizontally With the cap frame loaded on the machine, use the Hoop Key and the left or right arrow on the machine keypad to center the cap horizontally. If the cap has six panels, you will have a seam running down the middle of the front.

  • Page 133: Wide Angle Driver Maintenance

    Wide Angle Driver 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 134: Bravo Os Menu Items

    Bravo OS Menu Items This section will describe the options and commands listed under the menu items in Bravo OS. File Menu Load Design Selecting File>Load Design opens a dialog box for selecting a design to load to your machine. You can find this function in two locations.

  • Page 135: View Menu

    View Menu Toolbars  Selecting View>Toolbars will open a fly-out in which a list of available toolbars is shown. Selecting on of these toolbars will show or hide the toolbar. Visible toolbars are display with a check beside them. Hidden toolbars have no check. The toolbars follow.
  • Page 136 Appliqué Selecting Commands>Appliqué will move the hoop arms as far forward as possible with the needle still with- in the hoop limits. In order to use this command, the machine must be stopped and at head up position. Once the frame has been moved out, a prompt will appear to move it back to the original position. This command can be useful in accessing the hoop to place appliqué...

  • Page 137: Tools Menu

    Selecting Tools>System Information generates a .TXT document on the local drive of your computer list- ing all the information about your computer and Bravo OS settings that a technician may need to diag- nose an issues with your machine or software. This is usually only used when prompted by a technician.
  • Page 138 2. The hoop can then be jogged or moved for alignment purposes. 3. Start sewing the design. 4. If for any reason the machine or the computer must be restarted, e.g., loss of power, restart Bravo OS and the machine(s).

  • Page 139: Tools Menu > Options

    Tools Menu > Options Selecting Tools > Options will open a window with several tabs. A description of these tabs follows. Measurement Units Tab Use this type to specify the measurement units you would prefer to use for the design size, cursor position, ruler, stitch length, connec- tors length, the grid and grid ruler, as well as the hoops.
  • Page 140 Force Download (S/N 340361141 and earlier) When this box is checked, the RSA and CSA files on the connected PC are downloaded to the machine when the machine is turned on (the PC must also be turned on for the forced download to occur). Power fail will not work is Force Download is enabled.

  • Page 141: Tools Menu > Settings

    Enable All Thread Detection When this parameter is turned on, Bravo OS will detect thread breaks. If bobbin detection is enabled, Bravo OS will also detect when the machine is out of bobbin thread or if there is a bobbin thread break.
  • Page 142 Inching Stitch Count The quantity of “slow stitches” the machine will make at the beginning of sewing before it goes to full speed. Tail Length This parameter (choices are short, medium, and long) refers to the length of thread tail left after a trim. The default is medium tail.
  • Page 143 Feeder Home Adjust In the small percentage of machines that exhibit clicking when color changing, this feature can be used to alleviate that issue. Read the Thread Feeder Home Adjust section for the full procedure. Backup On Thread Break When a break is detected, the machine will back up the specified number of stitches. As bobbin breaks typically take a few more stitches to detect, that number is usually larger.

  • Page 144: Settings Tab

    When this setting is enabled, the machine will always return to design origin after designs are sewn. Use Colors from Design When this parameter is turned on, Bravo OS will display loaded designs with the colors stored in the design. This parameter does not affect the color se- quence.
  • Page 145 Column Width Adjustment Settings This setting allows you to adjust the width of all columns when they are being sewn. If you have Auto-Compensate selected, the column width values are selected automati- cally depending on if you are sewing on a cap hoop or a flat hoop.

  • Page 146: Move Tab

    Move Tab The move tab is used to move the machine to a different hoop po- sition or to a different part of a design. You can move to a specific stitch number, the beginning of a color, or to an X/Y location. X Distance and Y Distance These parameters allow you to move the machine to certain X and Y coordinates.

  • Page 147: Color Sequence Tab

    Color Sequence Tab You can access the color sequence through the menu bar by clicking on Tools > Settings, and then clicking on the Color Sequence tab. This tab is also available by clicking on the Color Sequence button in the Status or Adv Status tab of the Machine Views toolbar.
  • Page 148 If a file format does not contain design color information when loaded into Bravo OS, it will be given a color for each color block in the file. These colors do not represent the colors in which the design was intended to sew.

  • Page 149: Clear All

    Other Color Sequence Commands Appliqué This button inserts an appliqué pause into the color sequence. When the machine encounters an ap- pliqué pause, it pauses and moves the rack out (towards the operator). Press the Start button on the machine to move the rack back in and resume sewing. See Sewing an Appliqué...

  • Page 150: Timers Tab

    Timers Tab Selecting Tools>Settings>Timers Tab provides access to the software and machines maintenance timers. These timers are based on the stitch count of the machine and will count down. As the timers expire, a maintenance timer prompt will appear to remind you to perform the routine maintenance on your machine.

  • Page 151: Tools Menu > Maintenance

    Tools Menu > Maintenance Information Tab The information tab displays information on the machine(s) that the software is connected to. 151 of 248...

  • Page 152: Head Timing Tab

    Head Timing Tab The Head Timing Tab allows you or a technician to inter- act with the machine for troubleshooting and mainte- nance purposes. It is mainly used to move the z-position (in essence, the needle shaft position) of the machine. Head Up Head Up position is the position that is sometimes referred to as the z-home position.

  • Page 153: Head Timing Keypad Functions

    Head Timing Keypad Functions When the Head Timing tab is open in the software, several special keypad functions are available. These keypad functions are only available when the Head Timing tab is open. The following table describes these functions. Go To Head Up Position Adjustment Key + Up Arrow Go To Bottom Center Position Adjustment Key + Down Arrow...
  • Page 154 Head Up > Bottom Center (Used for Color Calibration) Frame Back Key Always starts at needle one. When this key is pressed once, machine goes to Head Up position twice, then goes to Bottom Center. When the Frame Back key is pressed again, the machine color changes to the next needle, then goes to Bottom Center on that needle.

  • Page 155: Steppers Tab

    Steppers Tab The Steppers Tab is used mostly by technicians. The availability of functions will depend on the machine that is connected to the software. Certain functions only affect legacy equipment or legacy hardware. If functions are unavailable for the machine or trimmer type, they will grey out. Color Change Button Function...
  • Page 156 Cutter (XT and ACAT Trimmers) The cutter functions change depending on machine and trimmer type. Not all functions are available on all machines. If the function is unavailable, it is not applicable to the connected machine hardware. Button Function Moves the Cutter to the Home position Moves the Cutter to the full out position Home Moves the Cutter to the Home position...
  • Page 157 Thread Feed Button Function Bkwd 200 Moves the drive thread feed drive motor backward 200 steps Fwd 200 Moves the drive thread feed drive motor forward 200 steps (used commonly for the thread feed 200 test) Home Moves the thread feed motor to the home position Step >...

  • Page 158: Calibration Tab

    Calibration Tab The calibration tab is used for calibrating the color change table. Essentially this is the information that keeps all of the machine nee- dles in the center of the hole in the needle plate. If this calibration is off, it can cause thread breaks and needle breaks.

  • Page 159: Sensors Tab

    Sensors Tab The Sensors Tab contains information on the state of the sensors in the machine. X-Axis Count The X-Axis Count Sensor provides information on the current rotational position of the X servo motor. This motor is responsible for the left/right (X Axis) motion of the machine carriage.
  • Page 160 Blocked = 0 - 180 degrees of current Z position Open = 181 - 359 degress of current Z postiion Z-Axis Safe The Z-Axis Safe Sensor provides information to the machine related to color change operations. Blocked = Not at HEADUP Open = Normal idle state at HEADUP Color Change Index (Some models only) Blocked = Not on needle center...

  • Page 161: Keypad Tab

    Keypad Tab If you are experiencing problems with your keypad, you may want to perform a keypad test. A keypad test will tell you if the keypad is communicating with your machine. Use the Keypad Tab in the Maintenance window to perform a key- pad test.

  • Page 162: Design Filter

    Design Filter Selecting Tools>Design Filter accesses the design filter settings. These settings will filter a design upon design load. To utilize these filters, check to box to the left of the desired filter. Accumulate Jump Stitches When you digitize a jump stitch between two points, the computer makes the move in increments of the stitch length you are using.
  • Page 163 Short Stitch Length This function allows you to enter a length, from 0 to 10 points, that defines what a short stitch is. For example, if you enter a length of 3 points; then any stitch that has a length of 3 points or less will be considered a short stitch, and will be acted upon by the other short stitch functions.

  • Page 164: Hoop Manager (Hoop Setup)

    Hoop Manager (Hoop Setup) Selecting Tools>Hoop Setup will access the hoop list so that it may be customized. Customize Hoop List 1. Click on the Tools menu. 2. Select Hoop Setup. 3. Place check marks by any hoops you own or wish to be in the list, and uncheck any hoops that you do not. 4.

  • Page 165: Set Machine Name & S/N

    Set Machine Name & S/N Selecting Tools>Set Machine Name and S/N will bring up the Machine Identification Configuration screen. This screen can also be accessed from the Configure Button at the top of the Machine List. This screen will allow you to rename and change the order of the machines you currently have connect- ed to the software.
  • Page 166 From the Machine Display Order Configuration window you can: • Change the order of machines by clicking on the machine you wish to add to your list and then click add. • When a machine is selected in the Machine Display Order Configuration window you can click on Move Up or Move Down to move the machine up or down in the list order.

  • Page 167: Tools Menu > Security

    Tools Menu > Security Selecting Tools > Security will bring up the security tools. General Tab The General Tab will contain information on the security keys attached to the computer and the serial numbers of those keys. Misc Tab The Miscellaneous Tab contains information on the vendor, the map rev, and the driver. 167 of 248...

  • Page 168: Toolbars

    Toolbars The toolbars in your software provide quick access to many of the software tools and features. They can be hidden or shown by navigating to View > Toolbars and ensuring that any toolbar you wish to see has a check beside it. Standard Toolbar The standard toolbar contains many tools dealing with the files as well as the help documentation.

  • Page 169: Machine Bar

    Machine Bar The machine bar appears at the bottom of the screen. It shows information about the machines that are connected to the software. The first area of the machine bar identifies and displays information about the active machine (the ma- chine with focus).

  • Page 170: Machine List

    Machine List The machine list appears by default on the left side of the screen. It displays all machines that are currently connected to the software. The machine list displays the machines current status, for example Idle indicates the machines is currently not in use. Machines serial numbers that are in bold are currently selected.

  • Page 171: Machine Views

    Machine Views The machine views appear by default on the right side of the screen. These views are meant to give you quick access to the majority of settings needed to run a job as well as the most needed machine informa- tion.

  • Page 172: Setting The Color Sequence Using Active Colors

    Setting the Color Sequence Using Active Colors If a color sequence is programmed in the Color - Needle box, needles will assign to active colors based on that information. It may be best and far less confusing to click [Clear All] before beginning to assign needles.

  • Page 173: Sewing An Appliqué

    Sewing An Appliqué Appliqué and tackle twill designs are designs that are specifically digitized for using fabric instead of stitches to fill in an area of a design. There are entire magazine and book articles devoted to different ways of doing appliqué with different types of fabric.
  • Page 174 3. Tack-down Stitch - After the material has been placed, the edges are tacked down with a tack- down stitch. This stitch is usually an inset walk or run stitch, a zig-zag or tackle stitch, or an e-stitch or blanket stitch. The purpose of this stitch is to attach the material to the product as quickly as possible without shifting the material and losing the registration.

  • Page 175: Setting The Color Sequence For An Appliqué Design

    Setting the Color Sequence for an Appliqué Design Appliqué elements can occur anywhere in the sequence of an em- broidery design. It may help to look at the sew order in a run sheet or design software to make sure of where in the design the appliqué pieces are to be applied.

  • Page 176: Laser Alignment (Design Registration)

    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 reference point (for example, the top of the stripe on the left side).
  • Page 177 Desired Alignment Keypad Commands Design to Right of the Line: 1. Laser + Right: 2. Laser + Left: 3. Laser + Center: 177 of 248...

  • Page 178: Thread Feeder Home Adjustment Procedure

    If you change control boards, you will have to readjust the feeder home or you can write down the adjustment value from the old board and enter it into the new board using Melco This feature is available in RSA versions 4.02 and later. If you switch to an older version of RSA file, the machine will revert back to the old way of homing the thread feeder, but the settings will NOT be erased.

  • Page 179: Machine Maintenance

    Machine Maintenance This section describes the procedures involved in maintaining your machine. This section is very import- ant, because maintenance is essential to the performance of your machine. Cleaning It is very important that you clean your machine regularly. Dust and lint accumulation can damage both electrical and mechanical systems.
  • Page 180 Rotary Hook and Trimmer Assembly area Lint and dust can build up in the trimmer assembly and the rotary hook. Clean this at least once per day. 1. Turn off the machine. 2. Remove the needle plate by removing the two screws on the underside of the extrusion. 3.

  • Page 181: Lubrication & Maintenance Schedule

    Lubrication & Maintenance Schedule Any tools or supplies needed for these procedures are provided in your operator’s kit. Using the correct lubricants properly and when specified by scheduled maintenance is critical to the op- eration of the machine. Failure to use the proper lubricants as specified can shorten the usable life span of internal components and can void the warranty.

  • Page 182: 200,000 Stitch Maintenance

    Melco cannot be held responsible for any machine damage due to lack of or wrong type of lubrication. Melco cannot be held re- sponsible for any machine damage due to not following the listed maintenance steps.
  • Page 183 Image Instructions “Apply Oil Using a small oiler bottle, apply one (1) drop of sewing machine oil to the hook oiling area. This area is highlighted in green in the image. Press the next button to continue.” “Insert Bobbin Case Insert the bobbin and case into the machine with the pigtail facing up.

  • Page 184: 2,000,000 Stitch Maintenance

    Melco cannot be held responsible for any machine damage due to lack of or wrong type of lubrication. Melco cannot be held re- sponsible for any machine damage due to not following the listed maintenance steps.
  • Page 185 Image Instructions "Right Upper V-Rail Using a piece of lint-free cloth, wipe clean both the front and back surfaces of the upper v-rail on the RIGHT side of the needlecase. After cleaning the v-rail, use a small oiler bottle to apply a drop of oil each to the front and the back surfaces of the v-rail.
  • Page 186 Image Instructions “Remove Link Cover Remove the link cover by pulling up. It is held in place with two magnets and should release fairly easily. Press the next button to continue.” “Clean Link Area Clean the link area using compressed air. Press the next button to continue.”...
  • Page 187 Image Instructions “Move Knife Using the 2.5mm Allen wrench as a pin, move the movable knife back and forth ten (10) times to spread the oil. With compressed air, blow out the needle plate. Using a lint free cloth, wipe the needle plate. Press the next button to continue.”...

  • Page 188: 10,000,000 Stitch Maintenance

    Melco cannot be held responsible for any machine damage due to lack of or wrong type of lubrication. Melco cannot be held re- sponsible for any machine damage due to not following the listed maintenance steps.
  • Page 189 Image Instructions "WARNING! If you currently have a hoop or clamping system on the machine, please remove it. Failure to fully remove a clamping system can result in damage to the machine. When you press on the next button, the machine will move to the appropriate position.
  • Page 190 Image Instructions "Remove End Cap Cover (Left) Remove the end cap cover on the left side of the x-beam as shown in the image. Press the next button to continue." "Clean Rails (Left) Wipe any lint, dust, and old grease from the front and back steel rails inside the x-beam as shown in the image.
  • Page 191 Image Instructions "Oil the Bearing Block (Left) Using a small oiler bottle, place twenty five (25) drops of sewing machine oil into the oiling port as shown in the image. Note: You may need to add a few drops and wait before adding more to prevent the oiling port from overflowing.
  • Page 192 Image Instructions "Position Gauge Position the x-cable tension gauge (P/N 33909) on the x-cable as shown in the image. Press the next button to continue." "Test Tension If the x-cable is positioned within the large cut-out on the right side of the x-cable tension gauge as shown in the image, the ten- sion is within specification.
  • Page 193 If you proceed without removing the x-cable tension gauge, dam- age to your machine will occur and a service call will be necessary. Note: Melco will not be responsible for any damage to the ma- chine or related service costs caused by not removing the tension gauge.
  • Page 194 If you proceed without removing the x-cable tension gauge, dam- age to your machine will occur and a service call will be necessary. Note: Melco will not be responsible for any damage to the ma- chine or related service costs caused by not removing the tension gauge.
  • Page 195 Image Instructions "Move Lever With a small flat blade screwdriver, carefully move and hold the grabber connecting lever over to the left as shown in the image. Press the next button to continue." "Grease Eccentric Surface Using the grease applicator, apply a small amount of HP grease onto the grabber eccentric surface between the grabber connect- ing lever and the grabber home flag as shown in the image.

  • Page 196: 30,000,000 Stitch Maintenance

    Melco cannot be held responsible for any machine damage due to lack of or wrong type of lubrication. Melco cannot be held re- sponsible for any machine damage due to not following the listed maintenance steps.
  • Page 197 Image Instructions "Remove Right Upper Arm Front Cover After removing the mounting screws, move the right upper arm front cover slightly away from the machine. Then, rotate it counter clockwise as shown in the image and remove it completely from the machine.
  • Page 198 Note: Melco will not be responsible for any damage to the ma- chine or related service costs caused by not performing this step. When you click the next button, the needlecase will move to the next maintenance position.
  • Page 199 Image Instructions "Clean and Grease Guide With a clean piece of cloth, wipe clean the needle bar guide chan- nel indicated in the image. The image uses cloth wrapped around the grease applicator for better control of the cloth. With a clean piece of cloth, apply a thin film of HP grease to the inside of the channel as shown in the image.
  • Page 200 Note: Melco will not be responsible for any damage to the ma- chine or related service costs caused by not performing this step. When you click the next button, the needlecase will move to the next maintenance position.
  • Page 201 Image Instructions "Clean and Grease Guide With a clean piece of cloth, wipe clean the needle bar guide chan- nel indicated in the image. The image uses cloth wrapped around the grease applicator for better control of the cloth. With a clean piece of cloth, apply a thin film of HP grease to the inside of the channel as shown in the image.

  • Page 202: Thread Feed Roller Maintenance

    Melco cannot be held responsible for any machine damage due to lack of or wrong type of lubrication. Melco cannot be held re- sponsible for any machine damage due to not following the listed maintenance steps.
  • Page 203 Image Instructions "Clean Assembly Using a clean cloth, remove any lint and old grease from the cradle that holds the rollers. In the image, this is done with the cloth wrapped around the grease applicator for better control of the cloth.
  • Page 204 Image Instructions "Reinstall Covers Reinstall the front covers by holding them at the bottom and tilting them up. Insert the top of the cover into the slot at the top of thread feeder assembly. You will probably feel a slight click as it locks into place.
  • Page 205 Image Instructions "Grease Lever Hub Using EMB Polymer grease, apply a small amount of grease to the lever hub as shown in the image. Press the next button to continue." "Grease Pinch Rollers Using EMB Polymer grease, apply a tiny amount of grease to the outer surface of one (1) of the three (3) small pegs inside the pinch roller as shown in the image.
  • Page 206 Image Instructions "Finished! This completes the quarterly maintenance procedure. Press the finish button to exit the maintenance procedure." 206 of 248...

  • Page 207: Thread Break Troubleshooting

    Thread Break Troubleshooting Thread breaks are an irritating part of embroidery, but they do not have to be merely tolerated. By follow- ing a few steps when rethreading the needle, you can begin to diagnose the nature of the thread break and hopefully avoid a subsequent one.

  • Page 208: Thread Break Diagnostic Table

    Thread Break Diagnostic Table Sections containing information about each of the possible solutions follow the table. Symptom Possible Solutions • Check for application specific issues like specialty thread or needle Thread breaks on type. this material/garment • If the application information does not help, contact Technical only.
  • Page 209 Real Bobbin Break • Use continuous filament polyester bobbin thread. • Check for an over-wound bobbin. • If the above items did not work, contact Melco Technical Support. • Change the needle. • Check the needle orientation. • Change the cone of thread. Some cones can become dam- Thread breaks on one aged and prevent smooth sewing.
  • Page 210 • Check the acti-feed settings. Missed Start • Check the bobbin tension and tail length. • If the above items did not work, contact Melco Technical Support. • Make sure the thread is lined up under the pinch roller. • Clean and grease the pinch rollers.

  • Page 211: Thread Breaks From Machine Issues

    Thread Breaks From Machine Issues Troubleshooting the Upper Thread Path The upper thread path should run smoothly the entire way from the cone of thread through the eye of the needle. If there is a rough spot or the thread does not follow the proper path, thread breaks are more likely.
  • Page 212 Thread Wrapped Around Thread Tube If the thread wraps around the thread tube at the top of the cone, the thread will most likely break. This is usually caused from the thread tube being extended too far above the cone. Adjust the thread tube to extend just above the cone.

  • Page 213: Troubleshooting The Bobbin Thread

    Troubleshooting the Bobbin Thread Thread breaks can occur from issues with the bobbin. To ensure that the bobbin is not the problem, look for the following issues when troubleshooting thread breaks. • Wrong Type of Bobbin • Bobbin Thread is Low or Out •...
  • Page 214 Remove the bobbin case and insure that the rotary hook is clean. Clean the area with a brush or canned air. Then, with the pigtail in the twelve o’clock position and the bobbin facing the machine, insert the bobbin case into the rotary hook. If the lever on the case is not used, you can hear the bobbin case click into place.

  • Page 215: Troubleshooting Designs

    Troubleshooting Designs How a design has been digitized can greatly affect how it sews. Testing against a standard test design is a good way to tell if the design you’ve been trying to sew is actually the cause of your thread breaks. Sew the test design on a swatch of broadcloth and a couple pieces of cut-away backing.
  • Page 216 Thread Breaks All Over the Design If thread is breaking everywhere in the design, and the test design sews well, it could be that the design is too dense, there are too many needle penetrations in concentrated areas, or perhaps the design was scaled down too far.

  • Page 217: Troubleshooting Tie Stitches

    Troubleshooting Tie Stitches Tie stitches are small grouping of stitches a the beginning and end of embroidery elements. Their pur- pose is to lock the thread in place and prevent it from pulling out when the machine starts sewing or trims.
  • Page 218 Tie In/Tie Off Property The properties window of DesignShop allows you to automatically add tie stitches to a wireframe design. To ensure that a wireframe design has tie stitches: Select the design in the project view and open the Object Properties window. With “All Elements”...
  • Page 219 For Melco OS, go to “Tools”, then select “Options”. In the “Machine” tab, check “Enable Tie In / Tie Off”. Click OK and load the design again for the filter to work. Once checked, the feature will stay on until unchecked.

  • Page 220: Troubleshooting Corners

    Troubleshooting Corners The problem of thread breaks in corners arises as stitches navigate around corners. It can be common for them to bunch up and cause puckering, thread breaks, and even holes in the garment. Notice the dark area of stitches in the example.
  • Page 221 Mitering Corners Mitering corners is another way to keep the stitches in a consistent direction and maintain an even stitch spacing. Mitering works well for less extreme angles and wider satin stitches. To miter a corner, Use a satin stitch element to sew to the inside edge of a corner. Continue the element but taper the end from the inside of the corner to the point.

  • Page 222: Stitches Too Small

    Stitches Too Small Some designs may contain elements with stitches that are too small to sew reliably well. DesignShop will begin filtering out every other stitch that falls below five points in length. This will help alleviate the issue, but it may not solve it completely. Look for the following if your design is having thread breaks on thin outlines or small elements or lettering.
  • Page 223 Thread Breaks On Small Satin Stitches If thread breaks are occurring on small satin stitches or on small lettering, it could be that your stitches are smaller than the needle that you’re using. This can cause some thread breaks. To find this problem areas, use the ruler tool in DesignShop to measure the stitches in the thinnest satin stitch areas.
  • Page 224 Use Pull Offset to Lengthen Stitch Lines To modify larger areas of designs, it might be more helpful to use pull offset. Pull offset is found in object properties under the “Pull Comp” sub-menu. Pull offset extends the stitch lines of an element by adding the specified amount to each side. If the ele- ment was 5 points wide at the thinnest point, a “3”...
  • Page 225 Use Minimum Column Width to Prevent Thread Breaks Another way to prevent tiny satin stitches from giving you thread breaks is to use the “Minimum Column Width”. This feature will prevent any multi-stitch line element (columns or fills) from creating a stitch less than the specified amount.
  • Page 226 “Short Stitches” “Short Stitches” is a feature that alternates the length of stitches on the inside of curves and sharper angles. It is meant to prevent thread breaks, thread build up, and damage to garments in those tighter areas. Newer versions of DesignShop have this feature on by default. While this feature is beneficial most of the time, it can cause stitches that are too small in smaller letter- ing or narrow satin stitches.
  • Page 227 Thread Breaks on Walk Stitches If walk stitches are the problem area of a design, it could be that the stitch length is just set too short. Try to avoid a stitch length of less than 15 points. Use Fewer Input Points Probably the most common cause of thread breaks on walk stitch elements from digitizing is using too many input points in a small area.

  • Page 228: Troubleshooting Density

    Troubleshooting Density The density of the stitches in a design can also lead to thread breaks. This usually occurs from one of the following. • Density Setting is Too Tight • What is an Ideal Density Setting? • Too Many Layers of Stitches •...
  • Page 229 For fill stitches: One density setting should work well throughout a fill. Fill stitches are usually comprised of a series of identical stitch lengths. A standard density setting of 3.8 points should work fairly well as a starting point for most fills. This setting may need to be adjusted for different stitch lengths, fill patterns, and applications.

  • Page 230: Troubleshooting The Needle

    Troubleshooting the Needle Proper needle orientation is essential to producing a proper stitch. If the needle orientation is incorrect, the loop of thread that is created while making a stitch may not be in the appropriate location to be caught by the rotary hook to complete the stitch. A damaged needle can also cause thread breaks.

  • Page 231: Troubleshooting The Presser Foot

    Troubleshooting the Presser Foot Proper presser foot height can contribute greatly to the sew quality of the machine. Look for the follow- ing issues when troubleshooting a thread break. Presser Foot Set Too High If the presser foot is set too high, you may see more material movement and a loss of design registration. This is often accompanied by thread breaks.

  • Page 232: Troubleshooting Scaled Designs

    Troubleshooting Scaled Designs Whether wireframe or expanded, scaling a design too far can lead to thread breaks. Shrinking Designs Scaling a design down can produce thread breaks by creating stitches smaller than the diameter of the needle. When wireframe designs are scaled down, all the input points are moved closer together. Since each input point results in a needle penetration, this can create stitches that are too small.

  • Page 233: Troubleshooting Application Thread Breaks

    Troubleshooting Application Thread Breaks Different sewing applications may cause thread breaks and other sew quality issues. Look for the follow- ing when diagnosing an application problem. • Embroidering Abrasive or Coated Materials • Is the Needle Size Appropriate for the Design? •...

  • Page 234: Is The Design Appropriate For The Material

    Is the Design Appropriate for the Material? While the majority of standard garment material will support the majority of embroidery designs, the design / material relationship is one that must be considered. Consider the difference in embroidering a 10 inch, 50,000 stitch design on a jacket back and then on a t-shirt.

  • Page 235: Troubleshooting Machine Caused Thread Breaks

    Cleaning Under the Needle Plate 1. Remove the bobbin case. 2. Remove the rotary hook guard: For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) Loosen the thumb screw securing the hook Loosen the two button head screws securing guard and slid it away from the machine.

  • Page 236: Center The Needle Plate

    3. With the needle lowered, loosen the screws securing the needle plate, and center the hole in the needle plate around the needle. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 4. Tighten the screws securing the needle plate.

  • Page 237: Pinch Rollers Need Maintenance

    Pinch Rollers Need Maintenance The most common sign that pinch rollers need maintenance is that the thread will walk to the side of the roller and create a “bird’s nest”. This is typically flagged by the software as a thread break, but when you look at the top thread, it doesn’t appear to be broken.
  • Page 238 5. Apply EMB Polymer grease to the top surface of the hub and on the outer surface of each of the three tabs inside the pinch roller. 6. With the roller tilted, pull the arm slightly to the left and reinsert the roller straight into place. 7.

  • Page 239: Rotary Hook Support Adjustment

    Inspect the Rotary Hook Support Gap 1. Remove the bobbin case. 2. Remove the rotary hook guard. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) Loosen the thumb screw securing the hook Loosen the two button head screws securing guard and slid it away from the machine.
  • Page 240 If not, it may be necessary to form the hook support to the correct alignment. If this is not possible, you may need to replace the hook support. For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) 7.

  • Page 241: Adjusting The Rotary Hook Support

    Adjusting the Rotary Hook Support For BRAVO X (Red Lower Arm) For BRAVO (Black Lower Arm) Use a hex wrench to loosen the two screws Use a hex wrench to loosen the two screws toward the front of the machine holding the holding the hook support.

  • Page 242: Resetting The Machine

    2. Using Windows Explorer, navigate to • for 32 bit systems, C:\Program Files\Melco\Bravo OS vXX • for 64 bit systems, C:\Program Files (x86)\Melco\Bravo OS vXX 3. Delete the “Jobs” and “Machines” folders. Power Up the Machine With Force Download On By powering up the machine and utilizing “Force Download”, a fresh new set of files will be sent to the...

  • Page 243: Additional Troubleshooting

    Additional Troubleshooting Miss-Starts Typically, a miss-start occurs when the machine starts the sewing process without grabbing the bobbin thread. Use the following table if you are experiencing miss-starts. Possible Causes Solutions Tail length (length of thread tail left after a trim) In the software, select Tools>Settings menu, then may be set too short click the Settings tab.

  • Page 244: Loose/Looping Stitches

    Problem Area Possible Causes Solutions Thread Bad thread Use the appropriate thread Loose/Looping Stitches Use the following troubleshooting table if you are encountering loose stitches in your embroidery. Possible Causes Solutions Thread feed is set too high. Lower the thread feed setting. Design density too tight.

  • Page 245: Test Design Analysis

    In software, click on Load Design or Load Design Wizard and locate AMPASSXXX or BRAVOPASXXX (where XXX is the latest released version), under C:\Program Files\Melco\Bravo OS\Test Designs\ AMPASSXXX.exp (or BRAVOPASSXXX.exp). Set the material thickness to 3 points and the maximum sew- ing speed to 1000-1200 s.p.m.
  • Page 246 If thread breaks occur when sewing: Check the following items: Circles (after startup) Burrs on needle plate hole Needle orientation Hoop may be hitting needle plate Inspect thread feeder rollers & pinch rollers for wear and/or damage Diamond Needle orientation Hook gap Inspect thread feeder rollers &...

  • Page 247: Software Messages

    Software Messages The software reports any messages, whether they are change messages or error messages, in the Machine Bar. Error Messages The following is an alphabetized list of software error messages and what to do when you encounter these messages. If the software ever displays an error message that is not listed here, or if you do not know how to respond to a message that is listed here or in the Technical Manual, contact Technical Support for assistance.
  • Page 248 Error Message Recovery Method HOOP Limit If the X beam or Y beam motion is not within the sewing field limits when the machine is running, the machine will stop and the software will give this error. Select a larger hoop in the software. Missed headup while sewing The Z axis controller missed a Head Up signal.

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