Popping thread breaks & False Bobbin breaks

[Merlin1964]

Popping thread breaks are from to tight of top thread correct?
To correct, increase top thread feed right? Machine default is 100, I have increased to 112 and it stopped. but now I am getting False bobbin breaks.

any ideas?

Thanks

Jeff

[Rod or Sharon]

Well Jeff,

There is a lot of information left out here....

How old is the machine? XT or Amaya, etc.

What Version software are you running?

When was the last time the machine had a complete lubrication sequence done to it?

Have you checked the hook timing?

What kind of thread, poly, rayon, brand name?

Is this during a satin stitch run or a fill run?

How wide are the satin stitch columns? How dense are the fill and/or satin elements?

How dense is the overall design?

Is it one you digitized yourself?

Bobbin tension?

Speed? Presserfoot height?

Hooping too loose? Taut but not stretched...

Type of material you are sewing on....i.e, knit, soft, rough, etc.?

Is this happening during trimming?

Burrs on needles?

Needle orientation...turned slightly to the right?

Are you running in Auto or Standard actifeed?

When did it start doing this, all at once or gradually over a period of time?

Thats just a few for starters.

The false bobbin breaks are because the threadbreak sensor tube is losing contact with the thread because it is not pulling up tight enough against it anymore because too much thread is being fed too fast. Whew....!

Rod Springer
Amaya Tech & Trainer

[Merlin1964]

Ummmm, I am new here. But here goes.....

2004 AMAYA

AMAYA OS 5.07.056
Release 100505.0
RSA 2.82

CSA 1.64

I just did the lube for 30million stitches

Hook timing is what the books states.

Thread is Poly

Speed is 900 - 1200spm

Preasure is one notch above lowest setting.

Thread feed/run is or was at 100, but I had to go to 112 to stop the thread popping breaks.

Material thickness is set at 5, tried from 3 to 8. 5 doesnt pull bobbin thread to the surface

Reset bobbin tension to bounce method, I tried a little tighter and a little looser same results

Hooping is what I always have done, maybe I have to loosen it on this machine compaired to my old machine

Material = muslin with 2oz tear/wash away backing

Design is purchased from Embroidery Library.

Needles are off to the right not front.

replaced needles so all are new.

yes satin stitch and it is very narrow.

I will turn thread feed down 1 at a time. Sat when I get back to the shop

I will keep working with it. Like I have stated, I just purchased the machine 2 weeks ago and am just started working with it.

Jeff

[Rod or Sharon]

Jeff,

Ver 5.07.056 is way back there....AOS is now up to 10.00.xxx. Your Version did not have the Auto acti-feed feature so you are stuck with changing the material thickness manually. In those days the default was a material thickness of 3. This took care of a lot of things and your presets gave you some guidelines as to where to go from there.

I think your main problem is the narrow columns you are trying to stitch. The density of this column may be a big culprit also.

You also should be using a cut-a-way stabilizer and not a tear-a-way. The tear-a-way does not add any real stability to the fabric.

Think of it this way...if your needle size is a 75/11 for example, the diameter of the needle is approximately .075 inches. The column you are stitching will undoubtablly be much narrower than this diameter. With the needle going from one side of the column to the other and if the density is tight, the needle has a very distinct chance to not pick up any material between the needle penetrations to tie the bobbin and top thread to. If this happens, the bobbin and top thread will come up through the fabic and try to tie themselves together in nothing but air. A couple of stitches like this and POP and you have your popping thread break.

What really needs to happen is to try to add some pull compensation to the narrow colums to widen them out some and get some cut-a-way backing under the garment.

A tight hooping is ok

Try putting your presserfoot all the way down. You need to hold the material down as tightly as you can.

Reduce your machine speed to under 900 for this design, it may help.

What is your Column feed, in Settings, Threadfeed set to? It used to be a default of 50 back in those days, but is not a default of 40. The column feed has to do with the width of the bobbin column on the backside of the embroidery. By tighteng up this column and then adding a bit more to your material thickness is the way we used to try to control the bobbin thread from showing on top of the column. Using a colored bobbin works too, to hide the bobbin thread from showing.

The run/fill setting only applies to fill stitches. It will add thread to the individual stitch, but does not lenghten the stitch from one needle penetration to the other.

A good test to see if the machine is sewing like it should, would be to go into C drive, Program Files, Melco Embroidery Systems, Amaya, Test Designs and sew the AMPASS test design. Set this up on 2 layers of medium to heavy cut-a-way backing hooped as tight as you can get it. Presserfoot down. Try your machine speed at 1000 for starters and work up to 1200spm. Column feed at 40. Run/fill speed at 100. This is a well groomed design used to test the machine in just about every direction it will sew and will all kind of columns and fills and stitches. If it will sew this well...you may have a design issue with what your are dealing with.. .

Rod Springer
Amaya Tech & Trainer