Bernina B 535 Manuals

Manuals and User Guides for Bernina B 535. We have 3 Bernina B 535 manuals available for free PDF download: Service And Maintenance Manual

Bernina B 535 Service And Maintenance Manual

Bernina B 535 Service And Maintenance Manual (187 pages)

Embroidery Module

Brand: Bernina | Category: Sewing Machine | Size: 9 MB

Table of Contents

Table of Contents
2
Chapter 1 - General Information
6
Safety Regulations
6
Warning: Dangerous Voltage Levels
7
ESD-Related Note: Electrostatic Discharge (ESD)
8
Tools and Gauges
9
Handling Adjustments
12
Abbreviations/Names Used
12
Cleaning
13
Technical Specifications of 4 & 5 Series
14
Chapter 2 - Electronics and Wiring
17
BERNINA B 590 (BERNINA Series 4 & 5) Block Diagram
17
PCBA-Power
18
PCBA-CPU-Module (ARM9) General Information
19
PCBA-CPU-Module/Arm9
19
PCBA-Base General Information
20
PCBA-Base with Feed-Dog Drop Detection
20
PCBA-Position Hall
21
PCBA-Threader
21
PCBA-Cover Including Display and Touch Screen
22
Pcba
22
PCBA-Stitching Head (PCBA-RET)
23
PCBA-Lower-Thread Observer (LTO)
24
ABC Sensor Support (Presser-Foot Recognition)
24
PCBA Embroidery Module Detection
25
Handling of Electronic Components
26
Returning Defective Electronic Components
26
Repairs of Electronic Components (Pcba's)
26
Chapter 3 - Troubleshooting
27
General Troubleshooting Flow Chart
27
Operating Voltage Functional Test
28
Use and Functions of Leds
28
Upper-Thread Sensor
30
Lower-Thread Sensor
31
Touch Screen Calibration
32
EEPROM Missing or Misprogrammed
32
Machine Doesn't Start after Repair
32
Update Failed
33
Sewing-Off Guidelines
35
Personal Notes Regarding Troubleshooting
39
Chapter 4 - Removal and Refitting of Components
40
Covers
40
Service Cover See ESD-Related Note
40
Front Cover
41
Rear Cover
44
Freearm Cover
45
Base-Plate Cover
46
Electronics, Sensors, Switches, Magnets
47
PCBA-Power Including PCB Housing
47
PCBA-CPU-Module (ARM9) General Information
49
PCBA-CPU-Module (ARM9)
50
PCBA-Base - with Feed-Dog Drop Detection
51
EEPROM (Electrically Erasable Programmable Read-Only Memory)
51
PCBA-Position Hall
52
PCBA-Threader
53
PCBA-Front Cover Including Display and Touchscreen
54
PCBA-Head
55
PCBA-Lower Thread Sensor
56
Sensor Support ABC (Presser Foot Recognition)
57
Head Frame and Frame Arm LED Sewing Light
58
PCBA-Embroidery Module Detection
60
Electromechancial/Mechanical Components
61
Hook and Hook Driver
61
Main Feed-Dog
64
Replacing the Hook Driver Belt
65
Stitch Plate Carrier with Integrated Thread-Cutting Unit
66
Replacing the Knife of Integrated Thread-Cutter Unit
68
Base Shaft
70
Crank Shaft and Stitch Length Stepping Motor
71
Replacing Base Shaft and Upper Shaft Connecting Belt
72
Feed-Dog Carrier and Advance Link
73
Upper Feed Crank
74
Upper Feed (Dual Feed)
74
Clutch Carriage
75
Upper-Thread Tension Unit with Thread Take-Up Cover
77
Toothed Rack, Machines with Stepper Motor Presser Foot Pressure
78
Toothed Rack, Machines with Manual Presser Foot Pressure
80
Presser Foot Bar
81
Assembly Unit BERNINA Dual Feed BDF
82
Needle-Bar Support
84
Needle Bar
85
Needle Clamp
86
Threading Mechanism
87
Thread Tension
89
Thread Take-Up Lever and Thread Regulator Spring
90
Thread Regulator Spring
91
Main Motor
91
Presser-Foot Pressure Stepping Motor
92
Stitch-Width Stepping Motor
93
Winder Unit
94
Chapter 5 - Adjustments
95
Belt Tensions
95
Vertical Shaft-/Base Shaft Belt Tension
95
Drive Motor Belt Tension
96
Hook Drive Belt Tension
97
Head-Frame Plate Position (Rough Setting)
98
Position of Head-Frame Plate/Stitch Plate in Y-Direction
98
Position of Head-Frame Plate/Stitch Plate in X-Direction
99
Presser-Foot Adjustment
100
Darning Foot Height
100
Presser-Foot Fixation
101
Needle Settings
102
Distance between Needle Bar and Presser-Foot Bar
102
Needle Distribution
103
Zigzag Stitch Width Limiter
104
Hook, Needle Drive and Feed-Dog Movement Timing
105
Feed-Dog Lift Movement (Base Shaft and Main Shaft Timing)
105
Base Shaft-/Load Lock Screw Distance
106
Loop Lift
107
Needle- / Hook Distance
109
Needle Penetration in y Directions
109
Needle Height
110
Needle Height Without Basting Device
111
Feed Dog Settings
112
Main Feed-Dog Horizontal Position
112
Main Feed-Dog Height 0.9-1. 0 MM
112
Main Feed Mechanical Balance - Basic Setting
114
Upper Feed (Dual Feed)-/Main Feed Synchronization (Pinning Position)
115
Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting
116
Fine-Adjustment
116
Clutch Carriage/Thread Cutter
117
Clutch Carriage Solenoid Adjustment
117
Clutch Carriage Alignment
118
Clutch Carriage Timing
119
Thread Cutter
120
Thread Guide Plate
120
Hall Position Synchronization
121
Threader
122
Basting Device (B 590)
123
Needle Bar Guide
123
Time of Clutch Release
124
Thread Regulator
125
Thread Tension
126
Upper Thread Tension
126
Lower-Thread Tension (Basic Setting)
127
Winder
128
Lower-Thread Sensor Position
129
Chapter 6 - Service Program
130
Starting the Test Program
130
Section 1 - Service Information
132
Machine Basic Data
132
Machine Firmware Data and Technical Information
132
Machine Operating Hours Data
133
Stitch Counter Data
133
BSR (BERNINA Stitch Regulator) Data
133
Machine Servicing Data
134
Saving Customer Data
134
Customer Related Data (Customer Information)
135
Dealer Related Data (Dealer Information)
135
Log File
136
Section 2 - Screen, Symbols
136
Touch Screen Calibration
136
LCD (Screen Brightness)
137
Blank Dark LC Display (Screen)
137
Blank White LC Display (Screen)
137
RGB (Red, Green and Blue) Screen
138
Keyboard Lights
138
LED Sewing Light and Brightness
139
Section 3 - Location of Sensors in the Machine
139
Threader Sensor
139
Presser-Foot Micro Switch
140
Lower-Thread Sensor
140
Feed-Dog Drop
141
Bobbin Winder Micro-Switch
142
Frei Hand System FHS
142
Section 4 - Signalse
143
Stitch Width and Stitch Length Knobs
143
Functions of Keys and Buttons on Machine
144
Start-/Stop Slide (SSU)
144
Foot Control
145
Upper Thread Observer (UTO)
145
BERNINA Stitch Regulator (BSR)
146
PCBA-Position
146
Speaker
147
USB Ports
147
Basting Solenoid
148
Presser-Foot Recognition
148
BSR Foot Interface
149
Section 5 - Locations of Stepping Motors in the Machine
150
Stitch-Width Stepping Motor
150
Presser-Foot Pressure Stepping Motor
151
Upper-Thread Tension Stepping Motor
151
All Stepping Motors in Pinning Position
152
Winder Motor
153
Stitch-Length Stepping Motor
154
Section 6 - Adjustments
155
Sewing-Off (User Interface)
155
Electronic Balance Calibration
156
BERNINA Dual Feed Balance
158
Buttonhole Calibration
159
Thread Cutter Clamping Mechanism (Solenoid)
160
Thread Cutting
161
Resetting Upper-Thread Tension to Default
161
Resetting to Factory Settings (Reset All)
162
Automatic Upper-Thread Tension
163
Test Tie on
164
Start-/Stop Slide (SSU) Calibration
165
Normal SSU Stitching Speed
165
BSR Sewing Mode
166
Magnetic Position Encoder Calibration
167
Section 7 - Embroidery Module (EMB)
167
Section 11 - Check-Out Tests
168
Chapter 7 - Lubrication Diagram
169
Lubrication of Modified Hook Driver When Removed from Machine
174
Chapter 8 - Firmware Update
175
Update Procedure
175
Update Alternative Access
177
After Replacing the PCBA-CPU Module
177
Chapter 9 - Maintenance Guidelines
178
Purpose of the Maintenance Guidelines
178
Explanatory Notes on the Stitch- and Hour Counter
178
When Is a Cleaning Message Displayed
178
When Is a Maintenance Message Displayed
178
How Are the Stitches Counted
179
Implementation of the Maintenance Intervals
179
Maintenance Intervals
179
Cleaning- and Service-Stitch Reset
179
Wear-And-Tear-Parts Definition
180
Non-Hour-Related Parts
180
Operating-Time-Related Parts
181
Maintenance Checklist
182
Measures to be Taken before the Servicing
182
Measures to be Taken after the Service
182
Functional Check
183
Maintenance Checklist BERNINA Series 4 + 5 VIO
184
Embroidery Module
185
Chapter 10 - Document Revision History
186
Chapter 11 - Appendix - Document List
187

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Bernina B 535 Service And Maintenance Manual

Bernina B 535 Service And Maintenance Manual (172 pages)

Brand: Bernina | Category: Sewing Machine | Size: 12 MB

Table of Contents

Table of Contents
2
Chapter 1 - General Information

6
Chapter 2 - Electronics and Wiring

16
Chapter 3 - Troubleshooting

24
- General Troubleshooting Flow Chart
  24
- Operating Voltage Functional Test
  25
- Use and Functions of Leds
  25
- Upper-Thread Sensor
  27
- Lower-Thread Sensor
  28
- Touch Screen Calibration
  29
- EEPROM Missing or Misprogrammed
  29
- Update Failed
  30
- Sewing-Off Guidelines
  32
- Personal Notes Regarding Troubleshooting
  36
Chapter 4 - Removal and Refitting of Components

37
Chapter 5 - Adjustments

85
- Belt Tensions
  85
- Vertical Shaft-/Base Shaft Belt Tension
  85
- Drive Motor Belt Tension
  86
- Hook Drive Belt Tension
  87
- Head-Frame Plate Position
  88
- Position of Head-Frame Plate/Stitch Plate in Y-Direction
  88
- Position of Head-Frame Plate/Stitch Plate in X-Direction
  89
- Presser-Foot Adjustment
  90
- Darning Foot Height
  90
- Presser-Foot Fixation
  91
- Needle Settings
  92
- Distance between Needle Bar and Presser-Foot Bar
  92
- Needle Distribution
  93
- Zigzag Stitch Width Limiter
  94
- Hook, Needle Drive and Feed-Dog Movement Timing
  94
- Feed-Dog Lift Movement (Base Shaft and Main Shaft Timing)
  94
- Base Shaft-/Load Lock Screw Distance
  95
- Loop Lift
  96
- Needle Penetration in y Directions
  98
- Needle Height
  99
- Needle Height Without Basting Device
  100
- Presser-Foot Settings
  101
- Main Feed-Dog Horizontal Position
  101
- Main Feed-Dog Height 0.9-1.0Mm
  101
- Main Feed-Dog Position Within Stitch Plate in X-Direction
  103
- Main Feed Mechanical Balance - Basic Setting
  104
- Upper Feed (Dual Feed)-/Main Feed Synchronization (Pinning Position)
  105
- Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting
  106
- Clutch Carriage/Thread Cutter
  107
- Clutch Carriage Solenoid Adjustment
  107
- Clutch Carriage Alignment
  108
- Clutch Carriage Timing
  109
- Thread Cutter
  110
- Hall Position Synchronization
  111
- Threader
  112
- Basting Device
  112
- Needle Bar Guide
  112
- Time of Clutch Release
  113
- Thread Regulator
  114
- Thread Tension
  115
- Upper Thread Tension
  115
- Lower-Thread Tension (Basic Setting)
  116
- Winder
  117
- Lower-Thread Sensor Position
  118
Chapter 6 - Service Program

119
- Starting the Test Program
  119
- Section 1 - Service Information
  121
- Machine Basic Data
  121
- Machine Firmware Data and Technical Information
  121
- Machine Operating Hours Data
  122
- Stitch Counter Data
  122
- BSR (BERNINA Stitch Regulator) Data
  122
- Machine Servicing Data
  123
- Saving Customer Data
  123
- Customer Related Data (Customer Information)
  124
- Dealer Related Data (Dealer Information)
  124
- Log File
  125
- Section 2 - Screen, Symbols
  125
- Touch Screen Calibration
  125
- LCD (Screen Brightness)
  126
- Blank Dark LC Display (Screen)
  126
- Blank White LC Display (Screen)
  126
- RGB (Red, Green and Blue) Screen
  127
- Keyboard Lights
  127
- LED Sewing Light and Brightness
  128
- Section 3 - Location of Sensors in the Machine
  128
- Threader Sensor
  128
- Presser-Foot Micro Switch
  129
- Lower-Thread Sensor
  129
- Feed-Dog Drop
  130
- Bobbin Winder Micros Witch
  131
- Frei Hand System FHS
  131
- Section 4 - Signals
  132
- Stitch Width and Stitch Length Knob(S)
  132
- Functions of Keys and Buttons on Machine
  133
- Start-/Stop Slide (SSU)
  133
- Foot Control
  134
- Upper Thread Observer (UTO)
  134
- BERNINA Stitch Regulator (BSR)
  135
- PCBA-Position
  135
- Speaker
  136
- USB Ports
  136
- Basting Solenoid
  137
- Presser-Foot Recognition
  137
- BSR Foot Interface
  138
- Section 5 - Locations of Stepping Motors in the Machine
  139
- Stitch-Width Stepping Motor
  139
- Presser-Foot Pressure Stepping Motor
  140
- Upper-Thread Tension Stepping Motor
  140
- All Stepping Motors in Pinning Position
  141
- Bobbin Winder Motor
  141
- Stitch-Length Stepping Motor
  142
- Section 6 - Adjustments
  143
- Sewing-Off (User Interface)
  143
- Electronic Balance Calibration
  144
- BERNINA Dual Feed Balance
  146
- Buttonhole Calibration
  147
- Thread Cutter Clamping Mechanism (Solenoid)
  148
- Thread Cutting
  149
- Resetting Upper-Thread Tension to Default
  149
- Resetting to Factory Settings (Reset All)
  150
- Automatic Upper-Thread Tension
  151
- Test Tie on
  151
- Start-/Stop Slide (SSU) Calibration
  152
- Normal SSU Stitching Speed
  152
- BSR Sewing Mode
  153
- Magnetic Position Encoder Calibration
  154
- Section 7 - Embroidery Module (EMB)
  154
- Section 11 - Check-Out Tests
  155
- Important
  155
- Check-Out Tests
  155
Chapter 7 - Lubrication Diagram

156
- Lubrication of Modified Hook Driver When Removed from Machine
  161
Chapter 8 - Firmware Update

162
- Update Procedure
  162
- Update Alternative Access
  164
- After Replacing the PCBA-CPU Module
  164
Chapter 9 - Maintenance Guidelines

165
Chapter 10 - Document Revision History

172

Bernina B 535 Service And Maintenance Manual

Bernina B 535 Service And Maintenance Manual (35 pages)

Embroidery Module

Brand: Bernina | Category: Sewing Machine | Size: 3 MB

Table of Contents

Table of Contents
2
Chapter 1 - General Information
3
Safety Regulations
3
ESD-Related Note: Electrostatic Discharge (ESD)
4
Tools and Gauges
5
Chapter 2 - Technical Specifications
6
BERNINA 5 Series Embroidery Module (VIO Type) Technical Specifications
6
Cleaning
6
Chapter 3 - Troubleshooting
7
Personal Notes Regarding Troubleshooting
7
Chapter 4 - Removal and Refitting of Components and Parts
8
Removing Covers
8
Top Cover
8
Y-Arm Cover
9
Y-Arm Bottom Cover
11
Electronics, Sensors
12
Y-Arm Flat Ribbon Cable
12
Y-Arm Stepping Motor
14
X-Slide Stepping Motor
14
Pcba Emb X
15
PCBA EMB Y-Arm
16
Mechanical Components
17
Y-Arm
17
Guide Angle and Rail
18
Chapter 5 - Adjustments
19
Y-Arm Belt Tension
19
X-Slide Belt Tension
19
Hoop Reference Point
19
Chapter 6 - Service Program
20
Starting the Test Program
20
Section 7 - Embroidery Module (EMB)
20
Embroidery Interface
21
Embroidery Hours
21
Operating Hours
21
Check Embroidery X-Axis
22
Check Embroidery Y-Axis
22
Test Embroidery Motors
23
Test Embroidery Motor X
23
Test Embroidery Motor y
24
Calibrate Embroidery Reference Point (Hoop Reference Point)
24
Testing the Test Patterns
25
Embroidery Mode
26
Hoop Recognition
27
Duration Run Embroidery Motors
27
Chapter 7 - Checking the Embroidery Module Using the Service Test Pattern
28
Description of Potential Problems
28
Assessing the Test Pattern Stitching
29
Chapter 8 - Lubrication Diagram
30
Chapter 9 - Maintenance Guidelines
34
Purpose of the Maintenance Guidelines
34
Embroidery Module
34
Chapter 10 - Document Revision History
35

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