Bernina 820 Service And Maintenance Manual
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Bernina 820 Service And Maintenance Manual

Bernina 820 Service And Maintenance Manual

Embroidery module
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Service- and Maintenance Manual
BERNINA Embroidery Module 830
BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland
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  • Page 1 Service- and Maintenance Manual BERNINA Embroidery Module 830 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 2: Table Of Contents

    7.2 Test pattern assessment ........................56 Chapter 8 – Lubrication plan ..................57 8.1 Y-Arm ..............................57 8.2 X-Carriage ............................. 60 Chapter 9 – Maintenance Guidelines ................62 Document Revision History ....................62 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 3: Chapter 1 - General Information

    It is important that only devices approved and distributed by BERNINA® are used on the embroidery module. When servicing or repairing, always use genuine parts and original accessories, either those delivered with the machine or purchased afterwards.

  • Page 4: Esd-Related Note: Electrostatic Discharge (Esd)

    4. Only use conductive ESD-capable plastic/foil pouches and ESD transport boxes for dispatching electronic components – even if the components might be faulty. Electrostatic_Discharge_ESD 5. To prevent consequential damage or harm, treat faulty PCBs in the same manner as new ones. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 5: Tools And Gauges

    Mounting all springs Pinning various 002 733.50.00 Angular pinning tool positions Pair of composite Disconnecting ribbon 031564.50.01 tweezers cables 032948.50.00 IC-Extraction tool Extracing the EEPROM Measuring Commercially Digital Multimeter resistance/voltage BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 6: Chapter 2 - Description Of Technical Details

    The Y-carriage and the X-Carriage can be affected by the accumulation of dust, lint, and thread remnants, as well as by belt residue. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 7: Block Diagram. (Revision 0.8)

    2.3 Block diagram. (Revision 0.8) The electronics of the BERNINA embroidery module primarily consists of the following circuit boards: (PCBA = Printed Circuit Board Assembled). hoop coding PCBA Frame Y-Init. interrupter Connector 7 pin Flexible cable 7 pole Connector 7 pin...

  • Page 8: Pcbs, Plugs And Cables

    When a rib on the Y-Arm cover passes through the sensor the position is from this point on known. 4 x Hoop coding sensors Colour Target brown PCBA-Y-Arm Y-Arm sensor PCBA-Y-Arm BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 9 A connection from/too the PCBA -Main-EMB Connections: As shown Function: • PCBA-X-Carriage transmits signals to and from the PCBA-Y-Arm and PCBA-EMB-Main. Colour Target PCBA-Main EMB white PCBA-PCBA-Main white PCBA-Y-Arm PCBA-Y-Arm BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 10 X-Carriage is from this point on now known PCBA-Main EMB Colour Target white PCBA-Y-Arm white PCBA-Main-EMB PCBA-Y-Arm PCBA-X-Carriage Front (rear view) For details see front view above. X-Initialising sensor BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 11 Factory use only white Stepping motor X-Carriage white X-Carriage sensor rear white X-Carriage sensor front black Encoder X-Carriage Machine / Module Connection EEPROM Factory use only Encoder-X-Carriage X-Carriage sensor (front) BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 12: Chapter 4 - Replacing Assemblies / Parts

    Place the Y-Carriage in the position shown. • Remove the 2 screws a + b (T10 M3x8). • Remove the 6 screws c (T20 M4x15). • Turn the module over and remove the cover. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 13 Unclip the 2 snap locks g Note: Screws f are accessed using an extra long Torx 20 screwdriver through the two holes of the base plate (see picture below). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 14: Replacing The Pcba-Emb-Main

    Mount the EEPROM in the exchange circuit board. • Refit the PCBA -Main-EMB in the module. • Reconnect the cables b through e. • Refit the cover along with the cable a. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 15: Replacing The Pcba-Frame

    Using a pair of composite tweezers (031564.50.00) disconnect the cable a from its socket. Note! The ribbon cable is just slotted in. View in direction of arrow from picture 1 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 16 Refit the belt in the slide block b, being careful that it is under the guide c. • Connect the ribbon cable a. • In service program Test 7m adjust the belt tension (item • Refit the upper Y-Carriage cover (item 4.1). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 17: Replacing The Pcba-Y-Arm

    Remove screw a (T20 M4x16) and washer. • Lift the X-Carriage upwards ca. 45° at points b. Rubber pads • Slide the X-Carriage out through the openings in the base cover c and remove. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 18 • Remove screw a (T10 M3x8). • Remove the cable duct cover b. Unplug cable c. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 19 Thread the two cables through the cable duct provided. Exchanging the PCBA-Y-Arm: • Remove 6 screws a (T10 M3x10). • Remove the lower Y-Arm cover, paying attention to the row of 10 clips. 10 x Clips BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 20 Place the X-Carriage into the base cover and secure, being careful that the rubber pads are correctly in place. • Reconnect the cable and upper Y-Arm cover (item 4.1). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 21: Replacing The Pcba-X-Carriage Front Resp. X-Carriage Rear

    Lift the X-Carriage upwards ca. 45° at points b. Picture 1 Rubber pads • Slide the X-Carriage out through the openings in the base cover c and remove (see picture 2). Picture 2 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 22 Remove the belt out of the guide track c. Picture 3 See picture 4 • Remove screw d (T10 M3x8). • Remove the cable duct cover e. Picture 4 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 23 • Remove screw i (T10 3x8) and remove the PCBA-X carriage front resp. rear. Note: The same procedure applies to either the front or rear circuit boards. Picture 6 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 24 Secure with screw a T20 M4x16 and washer. Note: The rubber pads must not come out of their locations see picture 1! • Mount the upper X-Carriage cover item 4.1 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 25: Replacing The Stepping Motor Y-Arm

    Unplug the 2 cables a and b. • Unhook the 2 springs at points c. • Turn the Y-Arm over. • Loosen both screws d and e (T6) and remove the flexible gearwheel f. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 26 Remount the lower Y-Arm cover (item 4.4 picture 3). • Remount the Y-Arm onto the X-Carriage (item 4.4). • Remount the upper Y-Arm cover (item 4.1). • Remount the upper X-Carriage cover BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 27: Replacing The Stepping Motor X-Carriage

    Unplug both cables a and b. • And remove from the ferrite kern c. • Unhook the 2 springs d and e. • Remove the 2 screws f (T10 M3x4). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 28 Reconnect both cables, being careful that they passed through the ferrite kern. • Remount the 2 springs, being careful of their positions. • Refit the X-Carriage as a complete part into the base housing. • Mount the upper X-Carriage cover. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 29: Replacing The Y-Arm Drive Belt

    At the opposite end, the screw and washer are in a fixed position (the belt tensioner is up against the Y- Arm frame e). This can be simply sliddened out after the opposite side has been removed! (See photo below). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 30 (032764.50.40). • Slide out the belt tensioner in the direction of the arrow. • Slide the belt upwards and out of the two racks of the slide block. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 31 Remove the 2 securing screws j (T20 M4x25), being careful not to loose the nuts from the gearbox, and remove. • Remove the upper half k of the gearbox. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 32 Using a small screwdriver push the belt drive roller pin n out of the block, and remove the roller. • The belt can now be taken out and exchanged. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 33 Refit the lower Y-Arm cover. • Refit the Y-Arm to the X-Carriage. • Using service program test 7m adjust the belt tension accordingly (item • Refit the upper Y-Arm cover (item 4.1). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 34: Replacing The X-Carriage Drive Belt(S)

    2) (Picture 2) The grooves in the pin are no longer situated in the bracket. 3) (Picture 3) Remove the pin and the belt drive pinion. 4) (Pictures 4 + 5) Remove the washer, being careful to note the positioning! BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 35 Fit the belt tension bracket. • Refit the whole X-Carriage into the lower X-Carriage cover. • Adjust the belt tension according to service program 7n. • Remount the upper X-Carriage cover. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 36: Replacing The Flexible Gearwheel / Bearing Of The X-Carriage Drive

    4.4). • Remove the tension adjustment screws a (M4x10 hexagon head 7mm) on both sides of the carriage. • Remove both X-drive belts out of the drive pinions b. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 37 The bearing sleeve on the right (as pictured) does not have this as the sleeve must be able to move axially to compensate any differences (+/- 0,5mm) in the frames guide brackets. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 38 Pin first of all the left side carriage e with a 4mm pin, using one of the three positioning holes f in which you have access to one of the securing screws g (T6) of the drive pinion (see photo below). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 39 (see photo below). • Secure the flexible gearwheel, making sure that it is fully in mesh with the drive pinion of the stepping motor j. • Replace the X-Carriage cover. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 40: Chapter 5 - Adjustments

    Rough adjustment (in case a belt has slipped a tooth): • Remove the tension adjustment screw b (M4x10 hexagon head 7mm). • Move the belt over the drive pinion gear c accordingly. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 41 Tighten the screw e (T6) of the drive pinion. • Remove the pins. • Tighten the second screw of the drive pinion. • Check again the position of both carriages according to above “Check”. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 42 As a secondary source and as a further guide, the arrows on both drive pinions should be facing in the same direction at any given time g. • Replace the upper X-Carriage cover. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 43: Adjustment Of Belt Tension Y-Arm

    Belt tensioner block is against the Y-Arm frame (fixed position b) • Start the machine in service mode. • Select service program Test 7n. • Adjust adjustment screw b (hexagon head 7mm)according to instructions in the service program. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 44: Adjustment Of X-Carriage Belt Tension

    Start the machine in service mode. Note: The Y-Arm cover must be mounted (initialising). • Mount the oval hoop. • Place the template in the hoop (Var. 00). • Select service test 7h. • Follow the instructions in the service program. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 45: Chapter 6 - Service Program

    If the message “Failed” appears, check the following on both the machine and module: • All Connections. • Damage to any of the cables (wear and tear). • Exchange the PCBA-Base. • Exchange the PCBA-Main-EMB BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 46 • Time Power: On = Total hours under power. • Time Standby: = Total hours under power but without activity. • Time Embroidery: = Stitching time in embroidery mode. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 47 A message “Test Successful” or “Test Failed” will appear and the bar graph changes to green. Repair notes: • Check the Y-Sensor position. • Check cables for damage/connections • Exchange the PCBA-Y-Arm (see chapter 4.4). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 48 Leave the test by selecting ( ). Repair notes: • Check Connections. • Damage to cables (wear and tear). • Exchange the X-stepping motor (see chapter 4.7). • Exchange the PCBA -Main-EMB_Print (see chapter 4.2) BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 49 • Check tests 7c to 7g. • Check X and Y belt tension (7m and 7n). • Check the gearing of both X and Y-Carriages for dirt, threads etc. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 50 The normal embroidery mode is displayed. • Attach embroidery module and hoop (oval). • Using cotton fabric with stabiliser. • Any given pattern can be tested using this mode. Repair notes: chapter 7.1 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 51 Activate the sensors (push down) as per table below. • Check position of hoop fixation. • Check Connections. • Damage to cables (wear and tear). • Exchange the hoop. • Exchange the PCBA-Frame. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 52 This test will determine whether or not commands are being sent and received correctly. • Check belt tension of the X-Carriage. • Check gearing of the X-Carriage. • Prove stepper motor or replace BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 53 • Tighten the screw (A) a further 180° degrees. • The belt tension is now correctly set. • Remount the upper Y-Arm cover. Repair notes: • Exchange the belt. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 54 The belt tension are now correctly set. • Remount the upper X-Carriage cover. Note: The adjustment must now be done to the second belt. Repair notes: • 4.9) Exchange the belt(s) (item BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 55: Chapter 7 - Testing The Module Using The Service Test Pattern

    If the pattern is embroidered faultlessly, then the fault has to be within the areas (1) the user, or (2) the pattern. BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 56: Test Pattern Assessment

    Must match fill (point D). Y- or X-Axis sluggish movement (carriage or drive gears). Corner point must match. Y- or X-Axis sluggish movement (carriage or drive gears). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 57: Chapter 8 - Lubrication Plan

    8.1 Y-Arm = Type of lubrication used: Klübersynth UH1 14 – 1600 (order number 002 779.72.02) = Surfaces mustn’t be lubricated. They must be free of oil, dirt or lubricants! BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 58 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 59 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 60: X-Carriage

    8.2 X-Carriage BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...
  • Page 61 BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

  • Page 62: Chapter 9 - Maintenance Guidelines

    First Release P.Kenyon Nov. 2008 Changes in following items: HP Horn, S Süess Chapter 2: new PCBA pictures Chapter 6: Repair notes added: • Hoop center reference point (test 7h). BERNINA International AG · Seestrasse 161 · CH-8266 Steckborn · Switzerland...

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