Bernina B485 Manuals

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Bernina B485 Service And Maintenance Manual

Bernina B485 Service And Maintenance Manual (218 pages)

Brand: Bernina | Category: Sewing Machine | Size: 10 MB

Table of Contents

Table of Contents
2
Chapter 1 - General Information
7
Safety Regulations
7
Warning: Dangerous Voltage Levels
8
ESD-Related Note: Electrostatic Discharge (ESD)
9
Tools and Gauges
10
Handling Adjustments
13
Abbreviations/Names Used
13
Cleaning
14
Technical Specifications of 4 & 5 Series
15
Chapter 2 - Electronics and Wiring
18
Block Diagram BERNINA B 590 (BERNINA 4 and 5 Series Equipement and Function Depend on Model Type)
18
PCBA-Power
19
PCBA-CPU-Module (ARM9) General Information
20
PCBA-CPU-Module/Arm9
20
PCBA-Base General Information
21
PCBA-Base with Feed-Dog Drop Detection
21
PCBA-Position Hall
22
PCBA-Threader
22
PCBA-Cover Including Display and Touch Screen
23
Pcba
23
PCBA-Stitching Head (PCBA-RET)
24
PCBA-Lower-Thread Observer (LTO)
25
ABC Sensor Support (Presser-Foot Recognition)
25
PCBA Embroidery Module Detection
26
Handling of Electronic Components
27
Returning Defective Electronic Components
27
Repairs of Electronic Components (Pcba's)
27
Chapter 3 - Troubleshooting
28
Symptoms Overview
28
General Information
28
How Does the Position Sensor Work
28
Information about the Three Main Pcbas
29
PCBA Base
29
Indication Lights
29
Circuit Board Labelling
30
PCBA CPU Module
30
Indication Lights
31
Circuit Board Labelling
32
PCBA Power Supply
33
Circuit Board Labelling
33
Errors
34
Gears Error in Sewing Mode
34
Possible Causes
34
Stepper Error: Short to Ground Phase A/B
35
Possible Causes and Solutions
35
Error Loading Application ECC or CRC
35
Troubleshooting
36
Symptoms and Repair Approach
36
Gears Error Is Displayed
36
Stepper Error Is Displayed
36
Machine Not Booting/ "No Power"/ "Dead
36
Nothing Is Displayed, Stepper Motors Are Initializing
36
Display Shows Lines or Wrong Colours
37
No/Irregular Presser Foot Detection
37
Machine Is Stuck in a Boot Loop/ Only Starts up to BERNINA Logo
37
Flow Charts
38
How to Read Flow Charts
38
The Basic Elements of a Flow Chart
38
Overview
39
Not Booting to Black Start Screen
40
Application Not Starting
41
Errors and Warnings
42
Touch Not Working
43
SS Slider
44
Buttons
45
Stepper Motors
46
Main Drive Not Working
47
Applications (Service Program)
48
Applications 2 (Service Program)
49
Applications 3 (Service Program)
50
Peripherals (Service Program)
51
Thread Cutter: Possible Faults
52
If the Machine Is Mechanically Blocked after the Thread Cut
52
Only One Thread Is Cut During a Thread Cut
52
Sewing Fault after Thread Cut
52
Excessive Sources of Noise
53
Upper-Thread Sensor
54
Lower-Thread Sensor
55
Touch Screen Calibration
56
EEPROM Is Missing or Is Incorrectly Programmed
56
Machine Doesn't Start after Repair
57
Pop-Up Messages Upon Starting the Machine in Customer Mode
58
The Machine Needs to be Cleaned/Lubricated
58
Cleaning the Thread Cutter
58
Machine Requires Maintenance
59
Error Message Even Though Embroidery Module Is Connected
59
Update Failed
60
Error Messages During Firmware Update
60
Other Reasons for Faulty FW Update
60
Case 2: the EEPROM Needs to be Replaced
61
Case 3: Machine Repeatedly Requests a FW Update
61
Case 4: the EEPROM Is Replaced and the Wrong Machine Identification Has Been Loaded
62
Case 5: Wrong FW on PCBA CPU Module
62
Sewing-Off Guidelines
63
Straight Stitch (Default Settings)
63
Zigzag Stitch (Default Settings)
64
Chapter 4 - Removal and Refitting of Components
67
Covers
67
Service Cover
67
Front Cover
68
Rear Cover
71
Freearm Cover
72
Base-Plate Cover
73
Electronics, Sensors, Switches, Magnets
74
PCBA-Power Including PCB Housing
74
PCBA-CPU-Module (ARM9) General Information
76
PCBA-CPU-Module (ARM9)
77
PCBA-Base - with Feed-Dog Drop Detection
78
EEPROM (Electrically Erasable Programmable Read-Only Memory)
78
PCBA-Position Hall
79
PCBA-Threader
80
PCBA-Front Cover Including Display and Touchscreen
81
PCBA-Head
82
PCBA-Lower Thread Sensor (LTO)
83
Sensor Support ABC (Presser Foot Recognition)
84
Head Frame and Frame Arm LED Sewing Light
85
Head Frame LED Sewing Light
85
Head Arm Sewing Light
86
PCBA-Embroidery Module Detection
87
Electromechancial/Mechanical Components
88
Hook and Hook Driver
88
Assembly of Hook Guideway with Guiding Pins (with Front and Rear and Only Rear Calottes) → until 61/07
90
Assembly Hook Driver
92
Main Feed-Dog
93
Replacing the Hook Driver Belt
94
Stitch Plate Carrier with Integrated Thread-Cutting Unit
95
Replacing the Knife of Integrated Thread-Cutter Unit
97
Base Shaft
99
Crank Shaft and Stitch Length Stepping Motor
100
Replacing Base Shaft and Upper Shaft Connecting Belt
101
Feed-Dog Carrier and Advance Link
102
Upper Feed Crank
103
Upper Feed (Dual Feed)
103
Clutch Carriage
104
Upper-Thread Tension Unit with Thread Take-Up Cover
106
Toothed Rack, Machines with Stepper Motor Presser Foot Pressure
107
Toothed Rack, Machines with Manual Presser Foot Pressure
109
Presser Foot Bar
110
Assembly Unit BERNINA Dual Feed BDF
111
Needle-Bar Support
113
Needle Bar
114
Needle Clamp
115
Threading Mechanism
116
Threader Head
117
Thread Tension
118
Thread Take-Up Lever and Thread Regulator Spring
119
Thread Regulator Spring
120
Main Motor
120
Presser Foot Pressure Stepping Motor
121
Stitch-Width Stepping Motor
122
Winder Unit
123
Chapter 5 - Adjustments
124
Belt Tensions
124
Vertical Shaft-/Base Shaft Belt Tension
124
Drive Motor Belt Tension
125
Hook Drive Belt Tension
126
Head-Frame Plate Position (Rough Setting)
127
Position of Head-Frame Plate/Stitch Plate in Y-Direction
127
Position of Head-Frame Plate/Stitch Plate in X-Direction
128
Presser Foot Adjustment
129
Embroidery Foot Height (Exception Embroidery Only Machines)
129
Embroidery Foot Height (Embroidery Only Machines)
130
Presser Foot Fixation
131
Needle Settings
132
Distance between Needle Bar and Presser Foot Bar
132
Needle Distribution
133
Zigzag Stitch Width Limiter
134
Hook, Needle Drive and Feed-Dog Movement Timing
135
Feed-Dog Lift Movement (Base Shaft and Main Shaft Timing)
135
Base Shaft-/Load Lock Screw Distance
136
Loop Lift
137
Needle-/Hook Distance
139
Needle Penetration in y Directions
139
Needle Height
140
Needle Height Without Basting Device
141
Feed Dog Settings
142
Main Feed-Dog Horizontal Position
142
Main Feed-Dog Height 0.9 - 1. 0 MM
142
Main Feed Mechanical Balance - Basic Setting
144
Upper Feed (Dual Feed)-/Main Feed Synchronization (Pinning Position)
145
Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting
146
Clutch Carriage/Thread Cutter
147
Clutch Carriage Solenoid Adjustment
147
Distance between Spring and Clutch Lever
147
Clutch Carriage Alignment
148
Clutch Carriage Timing
149
Thread Cutter
150
Thread Guide Plate
150
Hall Position Synchronization
151
Threader
152
Basting Device (Only Machines with Basting Device)
153
Needle Bar Guide
153
Time of Clutch Release
154
Thread Regulator
155
Thread Tension
156
Upper Thread Tension
156
Lower Thread Tension (Basic Setting, New Tension Gauge)
157
Lower Thread Tension (Basic Setting, Old Tension Gauge)
158
Winder
159
Lower Thread Sensor Position
160
Chapter 6 - Service Program
161
Starting the Test Program
161
Section 1 - Service Information
163
Machine Basic Data
163
Machine Firmware Data and Technical Information
163
Machine Operating Hours Data
164
Stitch Counter Data
164
BSR (BERNINA Stitch Regulator) Data
164
Machine Servicing Data
165
Saving Customer Data
165
Customer Related Data (Customer Information)
166
Dealer Related Data (Dealer Information)
166
Log File
167
Reset Thread Cutter Counter
167
Section 2 - Screen, Symbols
168
Touch Screen Calibration
168
LCD (Screen Brightness)
169
Blank Dark LC Display (Screen)
169
Blank White LC Display (Screen)
169
RGB (Red, Green and Blue) Screen
170
Keyboard Lights
170
LED Sewing Light and Brightness
171
Section 3 - Location of Sensors in the Machine
171
Threader Sensor
171
Presser-Foot Lifter
172
Lower-Thread Sensor
172
Feed-Dog Drop
173
Bobbin Winder Micro-Switch
174
Frei Hand System FHS
174
Section 4 - Signals
175
Stitch Width and Stitch Length Knobs
175
Functions of Keys and Buttons on Machine
176
Start-/Stop Slide (SSU)
176
Foot Control
177
Upper Thread Observer (UTO)
177
BERNINA Stitch Regulator (BSR)
178
PCBA-Position
178
Speaker
179
USB Ports
179
Basting Solenoid
180
Presser-Foot Recognition
180
BSR Foot Interface
181
Section 5 - Locations of Stepping Motors in the Machine
182
Stitch-Width Stepping Motor
182
Presser-Foot Pressure Stepping Motor
183
Upper-Thread Tension Stepping Motor
183
All Stepping Motors in Pinning Position
184
Winder Motor
185
Stitch-Length Stepping Motor
186
Section 6 - Adjustments
187
Sewing-Off (User Interface)
187
Electronic Balance Calibration
188
BERNINA Dual Feed Balance
190
Buttonhole Calibration
191
Thread Cutter Clamping Mechanism (Solenoid)
192
Thread Cutting
193
Resetting Upper-Thread Tension to Default
193
Resetting to Factory Settings (Reset All)
194
Automatic Upper-Thread Tension
195
Test Tie on
196
Start-/Stop Slide (SSU) Calibration
197
Normal SSU Stitching Speed
197
BSR Sewing Mode
198
Magnetic Position Encoder Calibration
199
Section 7 - Embroidery Module (EMB)
199
Section 11 - Check-Out Tests
200
Chapter 7 - Lubrication Diagram
201
Lubrication of Modified Hook Driver When Removed from Machine
205
Chapter 8 - Firmware Update
206
Update Procedure
206
Update Alternative Access
207
After Replacing the PCBA-CPU Module
207
Chapter 9 - Maintenance Guidelines
208
Purpose of the Maintenance Guidelines
208
Explanatory Notes on the Stitch- and Hour Counter
208
When Is a Cleaning Message Displayed
208
When Is a Maintenance Message Displayed
208
How Are the Stitches Counted
209
Implementation of the Maintenance Intervals
209
Maintenance Intervals
209
Cleaning- and Service - Stitch Reset
210
Wear and Tear Parts Definition
210
Non Hour Related Parts
210
Operating Time Related Parts
211
Maintenance Checklist
212
Measures to be Taken before the Servicing
212
Measures to be Taken after the Service
212
Functional Check
213
Maintenance Checklist BERNINA Series 4 + 5 VIO
214
Embroidery Module
215
Chapter 10 - Document Revision History
216
Chapter 11 - Appendix - Document List
218

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Bernina B485 Service And Maintenance Manual

Bernina B485 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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