Cutter Selector Index Error

[integrity]

On first of the day power up, every time I start to sew the first design the first time I get "cutter stepper index error." I go to the maintenance tabs set cutter to home, I can hear it move a bit, or if I run the cycle test, it seems OK and we are off to the races. No problems with the rest of the sewing, until I turn the machine off and back on. I have observed with the back cover off that the stepper motor moves a small rotation on start-up, and restores with the maintenance steps above. In addition, when I run the selector stepper cycle, it causes the cutter to move off zero, back and forth, like it is dragging the cutter along with it or catching a crossed electrical signal. I have removed the channel covers and let the rods run free, so there shouldn't be any catching each other under the needle plate - still does that.

Even tho the maintenance steps will resolve the issue, I am annoyed that I have to remember to do this every new day or machine start from "off." My other machine NEVER does this.

3-year old AMAYA XT with V9 or V7 OS, same error with both OS in the same way.

[Rod or Sharon]

I have removed the channel covers and let the rods run free************************????

Please explain what these are....

Rod Springer
Amaya tech & Trainer

[The Embroidery Authority - OLD]

I'm scratching my head on this one too, Rod.

I'm guessing he removed the push/pull cable housings???? Or possibly only the sewing arm covers????

David, You might have an issue with one of your trimmer assembly motors or possibly with the main board or power supply of the machine.

The Amaya OS software version could cause this too but you say you've experienced it with two different versions of software. My next question would have to do with the RSA files associated with both softwares. This gets a little involved but how did you test with two different software versions?? Were both versions installed on the same PC.... and at the same time?? Had you uninstalled one version when testing the other version?? Were you certain to have the "Forced Download" feature turned on?

Personally, I would start over by uninstalling all version of Amaya OS and then installing the last version of 2007 Amaya OS. If you don't have this CD, Melco should make it available for you. Make sure you have "Forced Download" turned on (click on TOOLS, OPTIONS, ETHERNET, then "Forced Download") and then see if the problem still exists. If so, then you could be having troubles with your machine.
At this point you might want to consider a tech visit.

Best of luck,
Ed

[integrity]

Rod, when Sharon takes your leash off, doesn't she let you run free!?

Yes, Ed, I took the cover off the cylinder arm and the needleplate, just make sure one wasn't rubbing the other. Even removed the knife, and the selector stepper would cause the cutter stepper to move about 30-45 degrees, far enough off home to create the error.

Called Melco, spoke with Gary, and we are going to remove all instances of the Amaya OS, v7 and 9 down to the registry editor and start from scratch install. The thing that perplexed us both is that I have an original v9 DVD and when I did the last online update I have another V 9 (with the space) folder. So he is sending me the latest DVD and hence the real clean install. But that doesn't explain why the other machine doesn't misbehave when it is getting the same RSA and CSA loads on startup.

Dave

[The Embroidery Authority - OLD]

Dave,
I think back to my very first electronic job (18 years old) where I used to ask my boss questions like:
Could this be the source of the problem?
Is that what caused the symptoms?
Would this have been the culprit?

To which his answer was always...
"It's not impossible".

What I took from that is problems aren't always going to make sense.

So when you ask why the other machine doesn't misbehave...
I simply would say it's not the same machine. Doesn't matter that they both came from Melco or they both say Amaya on the covers. They will never be the same machine and so we then begin to troubleshoot.

I once saw a motor on an embroidery machine that operated just fine at normal speeds but started to demonstrate problems at slightly higher speeds. The fact that the machine changes speeds while sewing was really throwing a monkey wrench into my troubleshooting as the problem was intermittent.
Ultimately, the motor was bad in the sense that it didn't meet factory specifications but it would perform fine if you just slowed the machine down.
My point is that things aren't always clear cut.
And yes, I did change out that motor.

Best of luck to you.
Ed

[integrity]

Well, as suspected, that total wipe of the Melco folder and apps, and a clean install of the v9 AOS (updated to 9.00.088 via online update), did not solve my/this problem.

I'll get back to Gary with the update. Do you really think one of the other major components would be culprit? Is there a sub-board that controls the steppers that could be replaced?

Dave

[Greenwing]

Have you tried to go into the tools, maintenance, steppers
and actually change the trimmer type to “0" and set.
Then try to cycle trimmer. Clean

When I was having trouble with the trimmer that came with the XT
the OS was not keeping the type in memory and I had to actually set it.
Even though it displayed the correct one.

Worth a try.

[Greenwing]

And yes there is a trimmer subboard..

it is right back there by the trimmer motors

Have you had the back cover of the machine off??

and seen both wires / rods are securly attached to the mounts on the discs of the motors??

[The Embroidery Authority - OLD]

The trimmer PCB (printed circuit board) that Jerome spoke of will only be on machines within a certain group of serial numbers. So you may or may not see a trimmer circuit board in the rear of the machine. I can't remember what that serial number range is but I would have to look it up and I'm not at home as of now.
If you are having troubles with the trimmer electronics and your machine doesn't have a seperate trimmer PCB, then your trimmer electronics will be on the mainboard.

[integrity]

Thanks for your input, Jerome, and Ed,

The issue is not that I can't clear the error, it is that it always happens on first power-on startup. Once I toggle the "home" key, all is fine for the next 8 hours. It just annoys me to have to make the extra effort to go into Tool and Maintenance and toggle the stepper back into "home" position. And only that one machine.

Yes, the trimmer type is setting properly to "0" with or without the "detect trimmer" request, and the status list shows trimmer "0" always, so I don't think it is forgetting its roots.

The machine serial # is 326743, if you find your list, Ed. Thank God the human body has many duplicated bilateral body parts so we can compare the left side to the right side and look for asymmetries. Hopefully, we can get both machines restored to full equality.

"Turning my production into problems"
Dave