Bernina 5 Series - User Manual

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BERNINA International AG Seestrasse 161 CH-8266 Steckborn Switzerland Seite 1 von 187

Service- and Maintenance Manual

of the 4 and 5 Series (VIO)

Main Page

Table of Contents2
Chapter 1 - General Information6
Safety Regulations6
Warning: Dangerous Voltage Levels7
ESD-Related Note: Electrostatic Discharge (ESD)8
Tools and Gauges9
Handling Adjustments12
Abbreviations/Names Used12
Cleaning13
Technical Specifications of 4 & 5 Series14
Chapter 2 - Electronics and Wiring17
BERNINA B 590 (BERNINA Series 4 & 5) Block Diagram17
PCBA-Power18
PCBA-CPU-Module (ARM9) General Information19
PCBA-CPU-Module/Arm919
PCBA-Base General Information20
PCBA-Base with Feed-Dog Drop Detection20
PCBA-Position Hall21
PCBA-Threader21
PCBA-Cover Including Display and Touch Screen22
Pcba22
PCBA-Stitching Head (PCBA-RET)23
PCBA-Lower-Thread Observer (LTO)24
ABC Sensor Support (Presser-Foot Recognition)24
PCBA Embroidery Module Detection25
Handling of Electronic Components26
Returning Defective Electronic Components26
Repairs of Electronic Components (Pcba's)26
Chapter 3 - Troubleshooting27
General Troubleshooting Flow Chart27
Operating Voltage Functional Test28
Use and Functions of Leds28
Upper-Thread Sensor30
Lower-Thread Sensor31
Touch Screen Calibration32
EEPROM Missing or Misprogrammed32
Machine Doesn't Start after Repair32
Update Failed33
Sewing-Off Guidelines35
Personal Notes Regarding Troubleshooting39
Chapter 4 - Removal and Refitting of Components40
Covers40
Service Cover See ESD-Related Note40
Front Cover41
Rear Cover44
Freearm Cover45
Base-Plate Cover46
Electronics, Sensors, Switches, Magnets47
PCBA-Power Including PCB Housing47
PCBA-CPU-Module (ARM9) General Information49
PCBA-CPU-Module (ARM9)50
PCBA-Base - with Feed-Dog Drop Detection51
EEPROM (Electrically Erasable Programmable Read-Only Memory)51
PCBA-Position Hall52
PCBA-Threader53
PCBA-Front Cover Including Display and Touchscreen54
PCBA-Head55
PCBA-Lower Thread Sensor56
Sensor Support ABC (Presser Foot Recognition)57
Head Frame and Frame Arm LED Sewing Light58
PCBA-Embroidery Module Detection60
Electromechancial/Mechanical Components61
Hook and Hook Driver61
Main Feed-Dog64
Replacing the Hook Driver Belt65
Stitch Plate Carrier with Integrated Thread-Cutting Unit66
Replacing the Knife of Integrated Thread-Cutter Unit68
Base Shaft70
Crank Shaft and Stitch Length Stepping Motor71
Replacing Base Shaft and Upper Shaft Connecting Belt72
Feed-Dog Carrier and Advance Link73
Upper Feed Crank74
Upper Feed (Dual Feed)74
Clutch Carriage75
Upper-Thread Tension Unit with Thread Take-Up Cover77
Toothed Rack, Machines with Stepper Motor Presser Foot Pressure78
Toothed Rack, Machines with Manual Presser Foot Pressure80
Presser Foot Bar81
Assembly Unit BERNINA Dual Feed BDF82
Needle-Bar Support84
Needle Bar85
Needle Clamp86
Threading Mechanism87
Thread Tension89
Thread Take-Up Lever and Thread Regulator Spring90
Thread Regulator Spring91
Main Motor91
Presser-Foot Pressure Stepping Motor92
Stitch-Width Stepping Motor93
Winder Unit94
Chapter 5 - Adjustments95
Belt Tensions95
Vertical Shaft-/Base Shaft Belt Tension95
Drive Motor Belt Tension96
Hook Drive Belt Tension97
Head-Frame Plate Position (Rough Setting)98
Position of Head-Frame Plate/Stitch Plate in Y-Direction98
Position of Head-Frame Plate/Stitch Plate in X-Direction99
Presser-Foot Adjustment100
Darning Foot Height100
Presser-Foot Fixation101
Needle Settings102
Distance between Needle Bar and Presser-Foot Bar102
Needle Distribution103
Zigzag Stitch Width Limiter104
Hook, Needle Drive and Feed-Dog Movement Timing105
Feed-Dog Lift Movement (Base Shaft and Main Shaft Timing)105
Base Shaft-/Load Lock Screw Distance106
Loop Lift107
Needle- / Hook Distance109
Needle Penetration in y Directions109
Needle Height110
Needle Height Without Basting Device111
Feed Dog Settings112
Main Feed-Dog Horizontal Position112
Main Feed-Dog Height 0.9-1. 0 MM112
Main Feed Mechanical Balance - Basic Setting114
Upper Feed (Dual Feed)-/Main Feed Synchronization (Pinning Position)115
Upper Feed-Dog (Dual Feed) Mechanical Balance - Basic Setting116
Fine-Adjustment116
Clutch Carriage/Thread Cutter117
Clutch Carriage Solenoid Adjustment117
Clutch Carriage Alignment118
Clutch Carriage Timing119
Thread Cutter120
Thread Guide Plate120
Hall Position Synchronization121
Threader122
Basting Device (B 590)123
Needle Bar Guide123
Time of Clutch Release124
Thread Regulator125
Thread Tension126
Upper Thread Tension126
Lower-Thread Tension (Basic Setting)127
Winder128
Lower-Thread Sensor Position129
Chapter 6 - Service Program130
Starting the Test Program130
Section 1 - Service Information132
Machine Basic Data132
Machine Firmware Data and Technical Information132
Machine Operating Hours Data133
Stitch Counter Data133
BSR (BERNINA Stitch Regulator) Data133
Machine Servicing Data134
Saving Customer Data134
Customer Related Data (Customer Information)135
Dealer Related Data (Dealer Information)135
Log File136
Section 2 - Screen, Symbols136
Touch Screen Calibration136
LCD (Screen Brightness)137
Blank Dark LC Display (Screen)137
Blank White LC Display (Screen)137
RGB (Red, Green and Blue) Screen138
Keyboard Lights138
LED Sewing Light and Brightness139
Section 3 - Location of Sensors in the Machine139
Threader Sensor139
Presser-Foot Micro Switch140
Lower-Thread Sensor140
Feed-Dog Drop141
Bobbin Winder Micro-Switch142
Frei Hand System FHS142
Section 4 - Signalse143
Stitch Width and Stitch Length Knobs143
Functions of Keys and Buttons on Machine144
Start-/Stop Slide (SSU)144
Foot Control145
Upper Thread Observer (UTO)145
BERNINA Stitch Regulator (BSR)146
PCBA-Position146
Speaker147
USB Ports147
Basting Solenoid148
Presser-Foot Recognition148
BSR Foot Interface149
Section 5 - Locations of Stepping Motors in the Machine150
Stitch-Width Stepping Motor150
Presser-Foot Pressure Stepping Motor151
Upper-Thread Tension Stepping Motor151
All Stepping Motors in Pinning Position152
Winder Motor153
Stitch-Length Stepping Motor154
Section 6 - Adjustments155
Sewing-Off (User Interface)155
Electronic Balance Calibration156
BERNINA Dual Feed Balance158
Buttonhole Calibration159
Thread Cutter Clamping Mechanism (Solenoid)160
Thread Cutting161
Resetting Upper-Thread Tension to Default161
Resetting to Factory Settings (Reset All)162
Automatic Upper-Thread Tension163
Test Tie on164
Start-/Stop Slide (SSU) Calibration165
Normal SSU Stitching Speed165
BSR Sewing Mode166
Magnetic Position Encoder Calibration167
Section 7 - Embroidery Module (EMB)167
Section 11 - Check-Out Tests168
Chapter 7 - Lubrication Diagram169
Lubrication of Modified Hook Driver When Removed from Machine174
Chapter 8 - Firmware Update175
Update Procedure175
Update Alternative Access177
After Replacing the PCBA-CPU Module177
Chapter 9 - Maintenance Guidelines178
Purpose of the Maintenance Guidelines178
Explanatory Notes on the Stitch- and Hour Counter178
When Is a Cleaning Message Displayed178
When Is a Maintenance Message Displayed178
How Are the Stitches Counted179
Implementation of the Maintenance Intervals179
Maintenance Intervals179
Cleaning- and Service-Stitch Reset179
Wear-And-Tear-Parts Definition180
Non-Hour-Related Parts180
Operating-Time-Related Parts181
Maintenance Checklist182
Measures to be Taken before the Servicing182
Measures to be Taken after the Service182
Functional Check183
Maintenance Checklist BERNINA Series 4 + 5 VIO184
Embroidery Module185
Chapter 10 - Document Revision History186
Chapter 11 - Appendix - Document List187

Brand	Bernina
Model	5 Series
Category	Sewing Machine
Language	English

Bernina 5 Series - User Manual

Table of Contents

Bernina 5 Series Specifications

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