thread breaks

[danielk]

hello all

One of my xt's is suffering from allot of thread breaks. I had a melco tech come down and check the machine out for me. When he got there the machine behaved itself, after he left the threads started to break again. I've tried everything first it was the bobbin that was breaking now its the thread. I broke 16 needles of thread in a row. I checked the foot, and the bobbin tension it was fine. i tried a different design all the same thing. Today i found a new problem though, when the machine trims the thread doesn't stay in the needle. Ive tried everything and i really think the tech doesn't know what it is either.

some advice would be greatly appreciated

thanks

Dan

[Theresa S.]

have you changed your needles recently? Make sure the straight groove is in the front; and the little scooped out part close to the eye is in the back; otherwise it won't sew.

[danielk]

ive changed the needles 100 times thinking thats what it was. i even replaced the bobbin case and ordered new bobbins just in case they were defective. a little extreme i know, but ive literally tried everything.

[sschroed2]

I have experienced the same problem. I ended up having my entire thread feed roller assy replaced and it got much better. But I still have the same problems periodically. Especially the thread pulling out of the needle after a trim. And it doesn't do it on the same needle or at the same trim point every time on a design. I can run a design 20 times and it may do it on anywhere fron 2 to 10 of the sewouts. I'm beginning to think it's more related to the thread. My tech explained how many times the thread moves back & forth through the needle during the sew process and what I seem to see is a slight rub on the thread which then begins to fray. I have the problems more when the thread is split after a trim. So will tell you it's related to the way the design was digitized, I don't believe that when it's not consistent. I use only Melco poly thread & I love the colors and sheen, but I think the thread has room for improvement.

Sorry I can't help, but sometimes it helps just to know you are not alone. However as a after thought. DEFINITELY check your needle alignment, & check for burrs on the needle (drag your finger nail down the edges of the needle, if there's a burr you will feel it. My tech talked me into a Tecra Tool magnifying light which I use to align my needles. Don't try to align the needle eye, instead align the grove that is on the needle at the top where it slides into the needle bar. It's much easier to see & get centered. Also, I've had brand new needles that I had trouble with & just throw them away and grab a new one.

[danielk]

thank you, i appreciated the advice this xt however has only 2 mil stitches on it. I just wish it would go away. i will check the needles but the tech did that yesterday and he said they were all fine. im so disappointed im really considering another kind of machine if this is going to be a constant problem. the other ones are fine. so i dont know.

[Theresa S.]

another thing I just thought of...when you're re-threading, be sure and pull enough thread off the spool so you are getting a nice smooth section of thread to go forward with. Are you making sure it's getting enough thread...that is, your tension is not too tight? When I first started, I had a thick project that made me nuts; I had to adjust the fabric thickness quite a bit...play around on some scrap fabric.

[sschroed2]

Another thought (I know this will sound crazy) but think about removing your software and re-loading it. Make sure you do it to Melco instructions, if you don't have them, call and ask for them. You would be suprised at how many things got corrected by reinstalling my software for OS & DS. When really strange things start happening, I do this when all else fails. Don't know if it's a problem related to Microsoft or the Melco software, but the software does develop some issues over time and it doesn't have to be a long time.

[Dorothy Compton]

Thread breaks can be caused by SO many things here's a partial list to check:

1. Make sure the presser foot is adjusted correctly (too high will cause thread breaks, too low can "bruise" the fabric)

2. Make sure thread feed if on auto has the bottom limit appropriately set (Under Setting, Thread--too low will cause thread breaks, too high will cause false bobbin breaks)--you can always try turning the auto feed off and set the standard feed appropriately.

3. Make sure thread is coming off the spool without hindrance (if using a small spool sometimes the thread can get caught under the base)

4. Oil the rotary hook.

5. Dried out thread (put in ziplock bag in the freezer over night).

6. Bulletproof design, short stitches (edit)

These are my top check points.

As for the thread coming out of the needle, is this after a trim and it starts stitching again...if so, change the thread inch count to a higher number(I think it's under Settings, I'm not sure which tab; mine is set on 9).

My philosophy is that if the machine runs fine on the Ampass design, the machine is good and the operator needs to find what else is going on...usually something the operator can control. Good Luck.

Dorothy Compton, Owner
Bee Embroidered
www.BeeEmbroidered.com
(916) 635-7467

[Steve I]

So if the tech came, did he do anything? If he did and the problem persists, I would think you could call him back out to recheck (at no charge).

[TinaK]

I would get a few breaks within the design and I knew it wasn't the design so I up'd my number on the auto tension under settings I believe to a 3 so the auto tension can not go lower then a 3 and I now have very few if any thread breaks. What a difference that made...

Just my 2 cents for what it is worth....

[danielk]

thank you everyone so much. The tech is coming back tomorrow, i dont think he knows what the problem is though. he was there for 3 hours the other day. He said its something stupid he's missing he checked the presser foot the feed everything and he still cant find the problem. maybe im doing something wrong but its only one machine the rest of them work fine.

[The Embroidery Authority - OLD]

Daniel,
(Tech Speaking)
Remember that thread breaks are not the source of your problem, only the symptom. There are over 30 things that can cause thread breaks or thread frays and each area is equally important. It's also possible for you to have multiple problems at the same time so when you correct one, the other is still present and the symptom stays the same. Yes, very frustrating I know.
I am curious as to what your tech found, If anything. It's possible that if the problems went away when he/she was there, then the problem stems from the operator.
When a tech is dispatched for a service call, we are not paid to give the customer hours of training in addition to fixing the machine. Although, very often, I find myself giving the customer free information that I cannot bill Melco for, simply to demonstrate that more training is necessary on their part. Melco does allow us to answer some questions and we are supposed to explain to the customer all that was done to the machine. But remember that initial training can easily last 3-5 days and that is only considered basic training.
There is so much more information that is necessary from you for a tech to attempt to solve your thread break issue over the phone/Internet and even then it may be deemed not possible for what ever the reason. (ex. if your machine was out of time)
Your tech should be willing to return to your location to verify the machine is running as it should but also know that if the machine runs okay for the tech, it's only fair that the customer pay for that tech's travel expense for the return trip.
You should be able to run the Ampass design on one layer of broad cloth and two layers of cut a way backing using Organ brand needles size 75-11 ball point at around 1000 to 1200 spm set on Auto Thread feed. It's not expected to have zero thread breaks but if you have a reoccuring problem, or if problem patterns show themselves, it should be addressed.
You should be able to set needle position, bobbin tension, presser foot height, hoop arm position, garment hooping, and machine lubrication (etc..) correctly.
If you ever begin to experience thread breaks that seem to get out of control, be prepared to revert back to this recipe to see what's out of spec.
I've always found that troubleshooting tricky thread break problems would make a great "advanced training class".
Enough of my yapping, if you are still awake tonight, I happen be available to discuss your thread break troubles before heading off to bed. Feel free to call.
504-258-6260
Best of Luck to you,
Ed Orantes
Melco Tech & Trainer

[GF]

Ever try to schedule a training class? I've been requesting a repeat in my training for a year now and although every Melco person is very pleasant and seems eager to send me the schedule, I'm still waiting. I also want to take a digitizing class, and no information is available. I've called Colorado, I've emailed my sales rep, I've even spoke with the trainer at a recent show. Each has assured me they would get me the information when available, and nothing. I understand the frustration of some of these end-users and I do think Melco could improve their classroom scheduling and information regarding same. I love Melco and I love my Amayas. My tech is awesome and knowledgeable and has responded quickly and always fixed the problem. I would really like some more support in the education areas so I can become better informed on the use of the machines and the software. Has anyone else had difficulty finding classroom availability and scheduling for Melco?

[signman]

Yesterday and day before must have been a planted virus bug in all Amayas....WE had the same problem of none stop thread breaks!
Took me a day and a half to do 24 hats for one design, yesterday from 9 am to 5 pm for SIX hats with a different design that we've used several times a year. February our Amaya (original red) was given it's yearly physical and passed all tests-was running fine until this week. I changed half the needles 3 times, tried 80/12 needles thinking the hat was too hard for 75/11 size. Found all the 80/12 had the ends flattened. Double checked needle plate alignment, perfect dead center. Redid design 6 times (yup, every single hat!) and took out excess underlayment, decreased density .5 on everything (went from 4.5 to 5 on lettering, etc.) slightly moved some areas that ended up dead on the center seam...
very frustrating.
I saw the post from Tina about checking auto settings-cannot find it in our 'settings' box anywhere. We have Amaya OX 7.00-is it in there somewhere?
Also noticed the 'bobbin sensing' box was unchecked...checked it, went back, unchecked again...had to do it a couple times before it 'stayed'. I've also noticed the last week or so any changes I make in Designshop for new or old designs is gone the next morning...even had one design I radically changed, sewed it out...next morning went to review-and ALL changes were gone. Opened up Amaya OS, and that window came up WITH the final design from the night before WITh all the changes! Any idea what is going on? This computer is NOT hooked to anything else, no printer, no ethernet link, no internet...NOTHING.
So there are no bugs or viruses.

[Mr. Sew & Sew]

A few things on this "thread"

GF - I've called John D directly when I wanted to schedule training and while he travels a lot and sometimes takes a few days to return the call, it seems that works the best. He does the training so he knows the schedules best. Living 30 minutes from there allows me to run up there if I have a quick question about something. Sometimes I can bring a design or a sewout to John and have him quickly explain what my problem is. He's great with things like that.

DanielK - I went through the same issues when I started out with my XTs having never done embroidery before. I was ready to throw them out the window, but luckily they were too heavy to deadlift. Numerous phone calls to Melco, 2 tech visits, etc. and it was always something I was doing wrong, not the machine. Like - presser foot height, bad hooping (most of the time), needles turned on wrong angle, etc.

It's kind of like when I took golf lessons a few years back. I told the pro that I thought I needed new clubs. He took my 7 iron and smacked a perfect shot 160 yards down the center of the fairway and then handed it back to me and said "it's not the clubs". Stick with it and keep trying things.

And Roland - sometimes the machine knows you are busy and just doesn't want to cooperate. Hang in there pal!