Advanced Interface Manual Rev 081718 Contents Copyright Notice 10 About This Manual 11 Melco OS V11 Version Changes 12 v11.09.XXX 12 v11.08.XXX 13 v11.07.XXX 14 v11.06.XXX 15 v11.05.XXX 15 v11.04.XXX 15 v.11.03.XXX 15 v11.02.XXX 16 v11.01.XXX 17 Hazards of Operation 18 Dangers de Service 19 Safety Warnings 20 Avertissements de sécurité 24 Safe Operating Principles 28 Specifications 29 Operator’s Kit Contents 31 Unpacking the Machine 32 Setting up the Machine 32 Install the Machine User Interface and X-Beam End Caps 34 Machine Overview 35 Cart Assembly 36 Software Activation & Deactivation 38 Lite 38 Product Activation 38 Product Deactivation 38 .Machine Connections 39 Do Not Share Networks 39 Connecting the Power Cables 39 Connecting the Network Cable (Single Machine) 40 Connecting the Network Cables (Multiple Machines) 41 Selecting The Connection 42 2 of 280 Powering Up the Machine 43 Initial Power Up Sequence 43 Upper Threading 44 Threading the Machine for the First Time 44 Quick Thread Change 46 Upper Thread Path 47 Bobbin Threading and Tensioning 51 Removing the Bobbin Case 51 Cleaning the Bobbin Case 51 Inserting a New Bobbin in the Bobbin Case & Checking the Tension 52 Bobbin Case Tension Gauge 52 Inserting the Bobbin Case 55 Initial Maintenance 56 Melco OS Screen Overview 57 Screen Overview 57 Loading a Design 61 Load Design 61 Load Design Wizard 62 Setting the Color Sequence 64 To enter a new color sequence: 64 To change a color in the existing color sequence: 65 To add a color to the existing color sequence: 65 To remove a color from the existing color sequence: 65 Additional Settings 65 Selecting a Hoop in the Software 66 Choosing the Appropriate Hoop Size 66 Customize Hoop List 66 Inches or Centimeters 67 Hoop Limits 67 Centering the Hoop 68 Setting the Sew Speed 69 How Fast Should I Sew? 69 Sew Speed Change from the Machine Keypad 69 Setting Sew Speed in Melco OS 70 Symptoms from Sewing too Fast 70 Acti-Feed 71 Material Thickness 71 Standard Acti-Feed 71 Auto Acti-Feed 72 3 of 280 Auto Acti-Feed Limits 73 Autofeed Lower Limit (Minimum) 73 Autofeed Lower Limit Suggestions 73 Autofeed Upper Limit (Maximum) 74 Appropriate Material Thickness Settings 75 Design Orientation or Rotation 76 When Should I Rotate My Design? 76 Choosing the Right Hoop 77 Choosing the Appropriate Hoop Shape 77 Choosing the Appropriate Hoop Size 77 Plastic or Wood? 77 Specialty Hoops 77 Hooping 78 Adjusting the Hoop Tension 78 Hooping the Garment or Fabric 79 Hooping Tips 81 Attaching or Moving the Hoop Support Arms 82 Attaching the Hoop Support Arms 82 Removing the Hoop Support Arms 84 Adjusting the Spring Clips 84 Loading a Hoop onto the Machine 85 Adjusting the Presser Foot 86 Keypad Operations 88 One Touch Controls 88 Key Combinations 89 LED Indicator 91 Sewing Your Design 92 After the Design is Sewn 92 Powering Down the Machine 93 Power Down Sequence 93 Needle Types and Replacements 94 Replacing a Needle 94 Choosing a Needle 95 Needle Points 96 Needle Coatings 96 4 of 280 Backings & Toppings 97 Backings 97 Backing Weights 99 Toppings 99 Thread Types 100 Thread Types 100 Thread Weight (Thickness) 101 Sewing Caps 102 Installing & Removing the Wide Angle Driver 103 Red Wide Angle Driver Installation 103 Red Wide Angle Driver Removal 106 Red Wide Angle Driver Cap Support Wings (Option) 107 Installation and Adjustment of the Cap Support Wing Assembly (Option) 107 Removal of the Cap Support Wing Assembly (Option) 109 Adjusting the Red Wide Angle Driver 111 Testing for Appropriate Adjustment 111 Adjustment Procedure 112 Selecting Hoops for the Wide Angle Driver 114 Hooping a Cap on the Conventional Cap Frame 115 Prepare the Cap 115 Hooping the Cap 115 Hooping a Cap on the Wide Angle Cap Frame 118 Prepare the Cap 118 Loading/Removing a Hoop with the Wide Angle Driver 125 Loading a Hoop 125 Removing a Hoop 126 Digitizing for Caps 127 Design Size for Caps 127 Sew Order for Cap Designs 128 Sew Settings for Caps 129 Adjusting the Presser Foot for Caps 130 Centering a Design on a Cap 131 Wide Angle Driver Maintenance 133 Wide Angle Driver Maintenance 133 5 of 280 Melco OS Menu Items 134 File Menu 134 View Menu 136 Commands Menu 139 Tools Menu 141 Tools Menu > Options 143 Preferences Tab 143 Measurement Units Tab 143 Barcode Options Tab 143 Notifications Tab 144 Ethernet Tab 144 Tools Menu > Settings 145 Machine Tab 145 Settings Tab 147 Move Tab 150 Color Sequence Tab 151 Color Groups 155 Settings By Color Tab 156 Thread Feed Tab 158 Timers Tab 159 Tools Menu > Maintenance 160 Information Tab 160 Head Timing Tab 161 Head Timing Keypad Functions 162 Steppers Tab 164 Calibration Tab 167 Sensors Tab 168 Keypad Tab 170 Design Filter 171 Hoop Manager (Hoop Setup) 173 Predefined Hoops 173 User-Defined Hoops 175 Additional Settings 177 Custom Hoop Shape 178 Custom Sew Field Shape 180 Set Machine Name & S/N 181 Tools Menu > Accelerator Editor 183 To setup a shortcut: 183 To remove a shortcut: 183 To restore system defaults: 183 Tools Menu > Security 184 6 of 280 Toolbars 185 Standard Toolbar 185 Machines Operations Toolbar 186 View Toolbar 187 Machine Bar 188 Machine List 189 Machine Views 190 Status Tab 190 Advanced Status Tab 191 Design Queue 192 Master Queue (Flex+ ONLY) 194 Setting the Color Sequence Using Active Colors 196 Manually Assigning Needles 196 Automatically Assigning Needles 196 Setting the Color Sequence with Active Colors 196 Additional Information on Color Sequence 197 Color Properties 197 Sewing An Appliqué 199 Anatomy Of An Appliqué Design 199 Setting the Color Sequence for an Appliqué Design 201 Sewing the Appliqué 201 Using a Boring Tool 202 Laser Alignment (Design Registration) 203 Scaling Designs with Laser Registration 205 Setting Up the Design in DesignShop 205 Using Barcodes with Melco OS 209 Enable Barcodes in the Software 209 Creating the Barcode 209 The Barcode Reader 209 Large Table Top Attachment (Option) 210 Installing the Large Table Top Attachment 210 Removing the Large Table Top Attachment 211 Thread Feeder Home Adjustment Procedure 212 Machine Maintenance 213 Cleaning 213 7 of 280 Lubrication & Maintenance Schedule 215 Maintenance Schedule 215 200,000 Stitch Maintenance 216 2,000,000 Stitch Maintenance 218 10,000,000 Stitch Maintenance 220 30,000,000 Stitch Maintenance 228 Thread Feed Roller Maintenance 234 Thread Break Troubleshooting 239 Diagnosing a Thread Break 239 Thread Break Diagnostic Table 240 Thread Breaks From Machine Issues 243 Troubleshooting the Upper Thread Path 243 Troubleshooting the Bobbin Thread 245 Troubleshooting Designs 247 Troubleshooting Tie Stitches 249 Troubleshooting Corners 252 Stitches Too Small 254 Troubleshooting Density 260 Troubleshooting the Needle 262 Troubleshooting the Presser Foot 263 Troubleshooting Scaled Designs 264 Troubleshooting Application Thread Breaks 265 Embroidering Abrasive or Coated Materials 265 Is the Needle Size Appropriate for the Design? 265 Is the Backing Appropriate for the Material? 265 Is the Design Appropriate for the Material? 266 Are You Using Adhesives? 266 Is the Garment Hooped Properly? 266 Are You Using Specialty Threads? 266 Troubleshooting Machine Caused Thread Breaks 267 Cleaning Under the Needle Plate 267 Center the Needle Plate 268 Pinch Rollers Need Maintenance 269 Rotary Hook Support Adjustment 271 Adjusting the Rotary Hook Support 273 Resetting the Machine 274 Deleting the Jobs & Machines Folders 274 Power Up the Machine With Force Download On 274 8 of 280 Additional Troubleshooting 275 Miss-Starts 275 Skipped Stitches 275 Loose/Looping Stitches 276 Needle Breaks 276 Registration Issues 276 Test Design Analysis 277 Software Messages 279 9 of 280 Copyright Notice © Copyright Melco, 2018 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. All precautions have been taken to avoid errors or misrepresentations of facts, equipment, or products. However, the manufacturer does not assume any liability to any party for loss or damage caused by errors or omissions. The machine technology is protected by - but not limited to - the following patents: • Pat. US 6,445,970 B1 • Pat. US 6,823,807 • Pat. CH 693569 A5 • Pat. US 6,736,077 B2 • Pat. US 6,732,668 B2 • Pat. US 6,871,605 • Pat. US 6,983,192 B2 • Pat. US 7,308,333 B2 • Pat. US 7,513,202 • Pat. US 8,851,001 B2 • Pat. US 9,702,070 • Other patents pending 10 of 280 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. 11 of 280 Melco OS V11 Version Changes v11.09.XXX • “Optimized Locks” has been moved from design filters and is now located under Tools>Settings>Machine Tab. It is now called “Enable Tie In / Tie Off”. • Improvements for machines with serial numbers of 403291 (or newly replaced boards) and above include: • Tie stitches added through “Enable Tie In / Tie Off” now occur in the firmware. This will not show in OS, but will be present in the sew-out.