Final functional tests should always be conducted on the AMAYA Embroidery Peripheral whenever any major repairs or adjustments are made. The purpose of these functional tests is to ensure that the correct repairs and adjustments have been made and that no further machine functional issues remain.
Visual Inspection:
Always inspect the AMAYA after making any repairs and make sure that:
you have removed all tools and loose hardware;
all harnesses are correctly connected, routed, and tied;
all hardware is correctly installed and torqued according to Melco Torque Specifications;
all covers installed prior to any function test, except for specific troubleshooting specified in these instructions.
Configuration:
If you remove a machine from a configured cluster, you must reconfigure the machine cluster to remove the machine from that cluster or you will receive error messages when you attempt to operate any machine in the cluster.
If you add a machine to a configured cluster, you must also reconfigure the machine cluster to add the machine or you will receive similar error messages when you attempt to operate the machine.
This is a significant feature of the AMAYA. In multi-head cluster, you no longer have to shut the entire "4-, 6- or more head machine" down simply because one head failed. You simply remove the inoperative head from the cluster for repairs, reconfigure the cluster to remove the head, and the rest of the cluster is fully functional.
For configuration procedures refer to start the "Configuration Wizard" in the AMAYA OS ( AMAYA OS). This wizard has self-explanatory dialogs. If you should experience difficulty with the wizard, refer to the AMAYA OS help file (click on the "Help" button) or contact Melco Technical Support for assistance.
Functional Tests:
Immediately after any major repairs, it is recommended to run the machine through a set of functional tests. This is best accomplished by running the machine through a full run of the test design AMPASS01A. Visually observe the machine performance through all sixteen needles while the machine is sewing.
You should be observant to the following issues when running the AMAYA Functional Tests:
X/Y registration issues
bobbin tension
thread breaks, pull outs
unusual noises or behavior
Burn-in:
Immediately after replacing a motor, the Main PCB or the power supply assembly, the machine should be burned in using the test design "AMPASS01A". The machine has to be in the unthreaded mode for this test. The machine should be periodically observed by the customer or machine operator for correct operation during the machine burn-in. The burn-in should last a total of nine consecutive hours.
When a burn-in test is to be conducted at a customer site, it should be done after the test sews are all complete. The burn test should be initiated by the customer or service technician and the customer terminate the burn test after it is completed. It is not necessary that a service technician remain at the customer site while the burn test is run and a return service call after a burn test is not necessary unless problems arise from the burn test. The customer may opt not to do a burn test, but it is strongly recommended that this test be run after replacing any of the motors, the main PCB, or the power supply assembly.
The recommended minimum burn-in after replacing a major component is 3 hours. If the customer is satisfied with the machine operation after three hours in the burn-in test, then the customer may end the burn test and it is considered a successful test. The burn-in of machines after major repairs ensures quality performance of the machine and helps to identify quality and functional issues. In the long run, using the burn-in test after major repairs will save the customer a significant amount of money in terms of service calls and additional diagnostic work.
To burn in the machine, refer to the following procedures.
Test Sew Outs:
Test sew outs should be conducted after all major repairs, when a machine is reconfigured, and when major adjustments are made to a machine. This includes, but is not limited to:
replacements of motors, sensors, harnesses or the main PCB;
reconfiguration of any of the heads (in the multi-cluster mode);
replacement or retensioning any of the belts;
all service calls made by Melco service technicians.
Several small test designs have been created to test for specific functions. This reduces the amount of labor that a customer will be charged for. The main test design (AMPASS01A) has been broken down into smaller designs that are focused on specific machine functions. AMPASS01A test design should be run on a machine when a repair has affected all or most of the machine functions. However, if you do something simple, such as adjust or replace the grabber blade or the trimmer stepper motor, it is only necessary to run AMTRIM01A design (tests for trimmer problems). It is strongly recommended that the appropriate test sew outs be run to validate any repair or major adjustments to the AMAYA embroidery machine when it affects the functionality of the machine.
For instructions on test sews refer to Test Designs.
