Barudan N Series Manual Mecanico

N SERI ES
Me c h a n i c a l Gu i d e
Copyright 4/01
BARUDAN CO., LTD.
906 Josuiji, Ichinomiya-city, Aichi-pref., Japan
Phone: 0586-76-1137
Fax: 0586-77-1499
Table of Contents
Chapter 1 Machine Basics 1-1
Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 1-3
Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
NS/NR Machines (220V 3 Phase) . . . . . . . . . . . . . . . . . . 1-5
NY/NB Machines (120V Single Phase). . . . . . . . . . . . . . . . 1-6
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-6
Sewing Head Components. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-10
Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-13
Sewing Head Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Thread Break Detection . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Disengaging a Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-20
Replacing Bobbins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Stitch Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Needle Anatomy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Important Conditions For Forming Stitches . . . . . . . . . . . . . 1-23
Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Top Thread Tensions. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Adjusting the Top Tension . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Adjusting the Bobbin Tension . . . . . . . . . . . . . . . . . . . . . . 1-27
Take-Up Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-28
Sewing Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Positioning the Design on the Garment . . . . . . . . . . . . . . . . . 1-29
Millimeter Conversion Chart . . . . . . . . . . . . . . . . . . . . 1-31
Backing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Backing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Softouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Tearaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Nylon Backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Backing Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Water Soluble Topping . . . . . . . . . . . . . . . . . . . . . . . 1-33
Needle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Needle Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Needles/Backing Chart . . . . . . . . . . . . . . . . . . . . . . . 1-35
Chapter 2 Machine Care 2-1
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bobbin Case Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Hook Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2-1
Machine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
ZN/ZQ Arm Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
YN/YS Arm Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
YN/YS Bridge Type Head. . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ZQ Bridge Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Maintenance Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Chapter 3 Troubleshooting 3-1
Quick Fixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Error Codes and Display Prompts . . . . . . . . . . . . . . . . . . . . 3-5
Take-Up Spring Replacement . . . . . . . . . . . . . . . . . . . . . . 3-11
Hook Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Position Finger Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3-15
Field Limit Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Chapter 4 Machine Parameters 4-1
Machine Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Machine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Reducing Speed Based On Stitch Length . . . . . . . . . . . . . . 4-17
Long Stitches Divided Into Jumpstitches . . . . . . . . . . . . . . 4-17
Thread Trimmer Programs . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Soft Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Sub Soft Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
MSU - Machine Setup Parameters . . . . . . . . . . . . . . . . . . . . 4-21
Chapter 5 Machine Options 5-1
Drop Table System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spider Hoops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Distancing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Sock Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Spectacle Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Roll To Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Roll To Roll Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
WS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
WS Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
WS Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
WS Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Group Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Sewing Start Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Pattern Origin is in the Center . . . . . . . . . . . . . . . . . . . . 5-14
Pattern Origin is not in the Center . . . . . . . . . . . . . . . . . . 5-15
Chapter 1 Machine Basics
Machine Installation
Normally, your machine is installed by a technician. Instructions are provided if the machine
ever needs to be moved. Check that you have all accessories from the installation kit:
Leveling Bolts
Arm type machine : four (4) leveling feet and four (4) leveling bolts for the
four and six head machines; and six (6) leveling bolts for the twelve and
fifteen head machines.
Bridge type machine : five (5) leveling pads.
Note: For the NYHE-ZQ -B04 model, the four (4) leveling bolts are
located next to each of the casters. Place a Mounting Base under each
Leveling Bolt and adjust the Bolts so the weight of the machine is
slightly off of the Casters.
Light FixtureAlready assembled above the sewing area. The 110V
machines have a separate power cord for the Lamp Assembly. Therefore,
they need to be plugged into a separate outlet. Do not plug into the outlet
on the front of the Driver Box..
Felt Pads(one per needle per sewing head) If necessary, place a Felt Pad
on each of the Spool Pins located on the Thread Stand before threading.
Verifying Machine Outlet Voltage
1.Check the installation site outlet voltage.
NS/NR- The voltage should be 200v to 250v. If in doubt regarding
voltage, have a qualified electrician check it.
NY/NB- The voltage should be 100v to 120v. If in doubt regarding
voltage, have a qualified electrician check it.
NOTE: The machine can be configured to operate from 200-250v.
Contact your Technician for instructions.
2. Check that the outlet is grounded.
3.Plug the machine power cord into a wall outlet and verify voltage on the drive box
power strip.
4.Check voltage at the outlet on the back of the automat. It should be 100 volts.
Voltage can range from 90v to 120v (-10% to +20% ).
Leveling an Arm Type Machine
1.Mount the four (4) leveling feet, one on each corner of the machine frame. Use a
manual or hydraulic jack capable of lifting the weight of the machine to raise it.
CAUTION! Be alert to the dangers of lifting the machine.
NOTE: The level and lifting device (jack) are not included in the
installation kit.
2. Install the adjusting bolts in the appropriate slots. Adjust so they support the
machine without lifting it. See the illustration above.
CAUTION: If you tighten the bolts more than 30 degrees, you may cause
the frame to bow.
Important Safety Instructions
When using an embroidery machine, basic safety precautions should always be followed.
This machine is intended for commercial use.
Read all instructions before using this machine.
Save these instructions.
Danger
To reduce the risk of electric shock:
An embroidery machine should never be left unattended when plugged in.
Always unplug this embroidery machine from the electric outlet
immediately after using and before cleaning.
Warning
To reduce the risk of burns, fire, electric shock, or injury to persons:
Do not allow to be used as a toy. Close attention is necessary when this
embroidery machine is used by, or near children.
Use this embroidery machine only for its intended use as described in this
manual.
Use only attachments recommended by the manufacturer, as contained in
this manual.
Never operate this embroidery machine if it has a damaged cord or plug,
if it is not working properly, if it has been damaged or is wet. Contact
your distributor for repairs or service by an authorized, qualified
technician.
Never operate the embroidery machine with any air openings blocked.
Keep ventilation openings of the machine free from the accumulation of
lint, dust, and loose cloth.
Never drop or insert any object into any opening.
Do not use outdoors.
Do not operate where aerosol (spray) products are being used or where
oxygen is being administered.
To disconnect, turn all controls to the off position, then remove the plug
from the outlet.
Do not unplug by pulling on the cord. To unplug, grasp the plug, not the
cord.
Keep fingers away from all moving parts. Special care is required around
the sewing machine needles.
Always use the proper needle plate. The wrong plate can cause the needle
to break.
Do not use bent needles.
Do not pull or push fabric while stitching. It may deflect the needle,
causing it to break.
Switch the sewing machine off when making any adjustments in the
needle area, such as threading the needle, changing a needle, replacing the
bobbin, changing the presser foot, or the like.
Always unplug the machine from the electrical outlet when removing
covers, lubricating or when making any other user servicing adjustments
mentioned in the instruction manual.
Connect this embroidery machine to a properly grounded outlet only. See
Grounding Instructions.
Always unplug before relamping. Replace bulb with same type rated
Watts.
Keep fingers away from moving parts, especially the area near trimmer
blades.
Grounding Instructions
This product must be grounded. In the event of malfunction or breakdown, grounding
provides a path of least resistance for electric current, to reduce the risk of electric shock.
This product is equipped with a cord having an equipment-grounding conductor and a
grounding plug. The plug must be plugged into an appropriate outlet that is properly installed
and grounded in accordance with all local codes and ordinances.
DANGER! Improper connection of the equipment-grounding conductor
can result in a risk of electric shock. The conductor with insulation having
an outer surface that is green, with or without yellow stripes, is the
equipment-grounding conductor.Do not connect the equipmnet-grounding
conductor to a live terminal if the cord needs to be repaired or replaced.
Check with a qualified electrician if grounding instructions are not completely understood, or
if in doubt as to whether the product is properly grounded. Do not modify the plug provided
with the product if it will not fit the outlet, have a proper outlet installed by a qualified
electrician.
NS/NR Machines (220V 3 Phase)
This product is for use on a circuit having a nominal rating more than 120-V, and is
factory-equipped with a specific electric cord and plug. No adapter should be used with this
product. If the product must be reconnected for use on a different type of electric circuit, the
reconnection should be made by qualified service personnel; and after the reconnection, the
product should comply with all local codes and ordinances.
NY/NB Machines (120V Single Phase)
This product is for use on a nominal 120V
circuit, and has a grounding plug that looks like
the plug illustrated. A temporary adapter, which
looks like the adapter illustrated in sketches B
and C, may be used to connect this plug to a
2-pole receptacle as shown in sketch B if a
properly grounded outlet is not available. The
temporary adapter should be used only until a
properly grounded outlet can be installed by a
qualified electrician. The green colored rigid
ear, lug, and the like, extending from the adapter must be connected to a permanent ground
such as a properly grounded outlet box cover. Whenever the adapter is used, it must be held
in place by the metal screw.
NOTE: If there is doubt as to whether an outlet box is properly grounded,
consult a qualified electrician.
Environmental Specifications
Temperature: 5 to 40 degrees centigrade (Operational)
-10 to 60 degrees centigrade (Storage)
Humidity: 45 to 85%RH without condensation
Sewing Head Components
There are several types of Barudan sewing heads. However, basic components are the same
for each.
1.Thread Guide with Felt Pad Cover - Holds thread in place to prevent tangling
2.Pretensioners- Adjust the top thread tension for each of the needles.
3.UTSM- Under Thread Sensor Mechanism. Bobbin thread detection. When
problem occurs with bobbin thread, the thread detection LED blinks green.
4.Top Thread Tensioners- Adjust the top thread tension for each of the needles.
5.Take-Up Spring/Thread Break Detectors - Helps form stitches. Used by
machine to detect thread breaks.
6.Thread Break Switch- Enables/disables thread break detection on each head.
7.Automend Button- Controls the reversing of the pantograph for repair work or
overstitching.
8.Thread Detection LED- LED shows top thread problem by blinking red, bobbin
thread problem by blinking green, and slider error problem by blinking fast red.
9.Take-Up Lever- Pulls the thread through the fabric after the stitch has been
made. Controls the flow of thread during stitch formation.
10.Presser Foot- Holds down the fabric during sewing.
Threading the Sewing Head
The machine is shipped with each needle pre-threaded. To quickly change the thread, place
the new cone on the thread stand. Blow the thread through the tube and tie the end to the
thread that is threaded through the tension unit with a square knot and gently pull it through
the sewing head. Repeat for each needle. To completely rethread a sewing head, follow these
steps which correspond to the diagram on the facing page.
Threading a ZQ Head with the UTSM
Refer to Diagram on the previous page.
Preparation for threading the sewing head:
Remove the felt pad covering the first thread guide.
Double up the end of the thread and twist.
Before placing cones of thread on thread stand, notice that each tube is
numbered according to needle.
Place a circular felt pad and cone of thread on each spindle of the thread
stand.
Insert the twisted end of thread in the end of the tube.
1.Using canned or compressed air, blow air into the tube and release the thread. The
thread will immediately blow through the tube and out the first guide.
2.Take the thread through the slotted post of first tensioner.
3.Take the thread from the left to right of UTSM tension wheel and wrap it one and
one-half times around the wheel and take the thread down to the left side of both
the top and bottom pegs.
4.Pull the thread to the right of the tensioner assembly and wrap it one and one-half
times between the nylon wheels and over the take-up spring.
NOTE: To ensure proper threading, pull the thread down, and check that
the take-up spring bounces up and down with the thread movement.
5.Thread through the top thread guide.
6.Thread through the next guide.
7.Thread through the third guide.
8.Pass the thread to the right of the take up lever, then through the next thread guide
from back to front.
9.Thread the eyelet in the take-up lever from right to left.
10.Thread through the next thread guide.
11.Reach underneath the apron and push the thread keep pin forward, so the thread
can go through the hole, then pass the thread through the last eyelet.
12.Optionally, thread the small pigtail that circles the needle, immediately below the
apron. Either pass the thread through from the top, or pass it through the small
opening on the right side of the pigtail.
13.Thread the eye of the needle from front to back and pass the thread through the
large hole in the presser foot.
After all needles have been threaded, replace the felt pad to avoid kinks
and loops in the thread.
Threading the Sewing Head
The machine is shipped with each needle pre-threaded. To quickly change the thread, place
the new cone on the thread stand, tie the end to the thread that is threaded through the thread
stand with a square knot and gently pull it through the sewing head. Repeat for each needle.
To completely rethread a sewing head, follow these steps which correspond to the diagram on
the facing page.
Threading a YS/YN Head
1.Place the circular felt pad on the thread stand before placing the new thread cone
on the thread stand.
2.Pull the thread from the cone through the eyelet on the thread stand that is directly
above the cone.
3.Take the thread through the top eyelet of the first tensioner then to the right of the
tensioner between the silver discs and through the bottom eyelet of the tensioner.
NOTE: Depending on thread type and fabric used, the tensioner may be
threaded differently, always starting at bottom.
4.Take the thread through the top eyelet of the second tensioner then to the right of
the tensioner between the silver discs and through the bottom eyelet of the
tensioner.
the spring bounces up and down with thread movement.
9.Thread through the fourth guide.
10.Pass the thread to the right of the take-up lever, then through the next thread guide
from the back to the front.
12.Pass the thread through the second to last thread guide.
13.Reach underneath the apron and push the thread keep pin forward so the
thread can go through the hole, then thread through the last eyelet.
Optionally, thread the small pigtail that circles the needle, immediately
below the apron. Either pass the thread through from the top, or pass it
through the small opening on the right side of the pigtail.
14.Thread the eye of the needle from front to back.
15.Pass the thread through the hole in the presser foot.
Threading the YS/YN Head with the UTSM
Refer to the YS/YN Head threading illustration on the previous page for
Steps 1-2 and 8-17.
1.Place the circular felt pad on the thread stand before placing the new
thread cone on the thread stand (1).
2.Pull the thread from the cone through the eyelet on the thread stand
that is directly above the cone (2).
3.Take the thread through the top eyelet of the first tensioner (3) then to
the right of the tensioner between the silver discs and through the
bottom eyelet of the tensioner.
4.Take the thread from the left to right of the UTSM tension wheel and
wrap it one and one-half times around the wheel.
5.Take the thread down to the left side of both the top and bottom pegs.
6.Pull the thread to the right of the tensioner assembly (5) and wrap it
one and one-half or two and one-half times between the nylon wheels
and over the take-up spring.
7.Thread through the top thread guide (6).
8.Thread through the next guide (7).
9.Thread through the third guide (8).
10.Thread through the fourth guide (9).
11.Pass the thread to the right of the take-up lever, then through the next thread guide
(10) from the back to the front.
12.Thread the eyelet in the take-up lever (11) from right to left.
13.Pass the thread through the second to last thread guide (12).
14.Reach underneath the apron and push the thread keep pin forward so the
thread can go through the hole, then thread through the last eyelet (13).
15.Thread the eye of the needle from front to back (14).
16.Pass the thread through the hole in the presser foot (15).
1 times
Threading a ZN Head with the UTSM
Refer to the ZN Head threading illustration on the previous page for Steps 1-2 and 8-17.
2.Pull the thread from the cone through the back of the eyelet on the thread stand
that is directly above the cone.
tensioner.
5.Take the thread down to the top peg and wrap it around the bottom of the peg from
left to right.
6.Take the thread over the UTSM tension wheel from the left to right.
7.Take the thread down to the bottom peg and place it on the left side of peg.
times between the nylon wheels and over the take-up spring. To ensure proper
threading, pull the thread down, and check that the take-up spring bounces up and
down with the thread movement.
from back to front.
17.Pass the thread through the large hole in the presser foot.
Threading a ZN Head
2.Pull the thread from the cone through the back of the eyelet on the thread stand
that is directly above the cone.
tensioner.
5.Pull the thread to the right of the tensioner assembly) and wrap it one and one-half
the take-up spring bounces up and down with the thread movement.
from back to front.
14.Pass the thread through the large hole in the presser foot.
Sewing Head Controls
When using the machine, you may need control over whether thread breaks are detected and
which heads will sew.
Thread Break Detection
Thread Break The Thread Break Switch enables both the top and bobbin thread
Switch detection. It is located on the front of the sewing head. The thread
break switch is on when the switch is in the up position and off in
the down position. (For ZN/ZQ machines, this switch also cancels
the sewing head.)
Top Thread The top thread detection is controlled with the brass post located
Detection next to the take-up spring on the lower tension assembly.
It acts as a sensor, detecting top thread breaks. If the thread breaks
or goes slack, a small current is conducted through the brass post
during the stitch cycle, causing the LED on the sewing head to flash
red, indicating a thread break. The sewing head will stop and the
pantograph will automatically move back a few stitches. If you need
to back up farther in the pattern, see Repairing Missed Stitches.
UTSM - Bobbin The bobbin thread detection is controlled by the UTSM (Under
Thread DetectionThread Sensor Mechanism).
UTSM Switch The UTSM switch must be on (UP position) to enable bobbin thread
detection. Note: The Thread Detection Switch and the UTSM
switch must both be on (up position).
ON
Head Switch
Press button
for automend
Red LED lights
to indicate the head
is sewing and
blinks to indicate
needle thread break
OFF
Disengaging a Sewing Head
A head can be shut off when it is not needed. For ZN/ZQ machines, while the machine is
stopped, turn off the thread break switch by placing it in the down position; to restart the head
place the thread break switch in the up position.
For YS/YN machines see the instructions below.
Disengaging a Sewing Head
1.Move theStart/Stop barto the right to stop the machine
sewing.
CAUTION! A sewing head must never be turned off while
the machine is sewing.
2. Switch off the appropriatethread break switch . This will
cancel the thread break detection on this head.
3.Engage thehead shut-off pinto prevent the needles from
moving up and down. Pull the pin forward.
NOTE: It is best to do a manual thread cut before
disengaging a head so that when it is restarted, the needle
does not become unthreaded.
Restarting a Sewing Head
1.Move theStart/Stop barto the right to stop the machine from sewing.
CAUTION! A sewing head must never be turned back on while the
machine is sewing.
2.Move thethread break switchto the on position.
3.Disengage thehead shut-off pinto release the needle. Move the pin to the back.
The red LED on the front of the sewing head will be lighted during sewing.
When a head is turned back on, it will begin to sew and its thread keep solenoid
will be released when the Start/Stop bar is moved to the left to begin sewing again.
If the other heads were not sewing, and their thread keep solenoid clamps were
activated, the head that was just turned on will also have its thread keep solenoid
clamp activated.
NOTE: To prevent the active needle of a head that has been turned back
on from becoming unthreaded, you should hold on to the end of the thread
while moving the Start/Stop bar to resume sewing.
Replacing Bobbins
The machine is shipped to you with bobbins in place, ready to
sew. Follow these steps when you need to replace a bobbin.
The bobbins are enclosed in the bobbin cases, which must be
removed in order to replace the bobbin.
Removing the Bobbin Case
1.Pull the bobbin case latch toward you, and the case
will slide out of the hook assembly.
On an E type cylinder bed machine, first open the hinged hook guard to
expose the bobbin case.
Inserting the Bobbin in the Case
1.Place the bobbin in the case, so that the bobbin rotates clockwise when you pull
the end of the thread.
2.Guide the thread into the slot on the side of the bobbin case.
3.Pull the thread under the tension spring and wrap it through the pigtail on the front
of the bobbin case.
4.Leave several inches of thread hanging from the bobbin case.
Replacing the Bobbin Case
1.Hold the latch on the bobbin case open, positioning the case on the shaft of the
hook assembly, ensuring that the bobbin remains in place.
2.Make sure the thread you left hanging is on top.
3.Release the latch and press the bobbin case into position until you hear a distinct
click. If you do not hear the click, remove the bobbin case and try again.
CAUTION! Do not attempt to force the bobbin case into the hook
assembly. If resistance is felt, remove the bobbin case, realign the case with
the hook and reinsert it.
Stitch Theory
To fix problems that may occur as you are sewing, it is important to understand how stitches
are formed. Timing is the relationship between the rotary hook assembly and sewing needle.
The hook and the needle must be in perfect synchronization to have properly formed stitches.
Needle Anatomy
The anatomy of the needle is an important factor in forming
stitches.
Eye Carries the top thread through the
fabric and into the bobbin
assembly.
Scarf Small notch, or cutout, on the back
of the needle that provides the
clearance needed for the hook
point to pass without striking the needle during stitch formation.
Groove Small groove, or channel, on the front of the needle that provides
the thread a place to sit, protecting it as the needle penetrates the
fabric.
How Stitches Are Formed
1.The needle starts downward and penetrates the fabric.
2.The needle reaches its lowest point, then begins to rise, forming a loop of thread
behind the needle.
3.As the needle rises, the hook point passes behind the scarf, picking up the loop of
thread from the back of the needle.
4.As the needle continues to rise, the point of the hook pulls the loop of thread
down. This enlarges the loop.
5.The upper thread encircles the bobbin thread, forming a knot.
6.The knot is then drawn into the fabric by the take-up lever. The knot is tightened
by the upper and lower tensions. The needle reaches its highest point and begins
the downward motion, repeating the entire process.
Important Conditions For Forming Stitches
The hook must approach the thread loop at the correct moment.
The hook must pass within a given distance of the needle.
The needle must be at the correct height.
Tension Adjustments
Top Thread Tensions
Tension is the tautness of the thread as stitches are formed. There are two tensions to be
considered when making adjustments. The top thread, located in the thread stand, is
controlled by the top tension; and the bobbin thread, located in the bobbin case, is controlled
by the bobbin tension. These tensions determine the quality of the embroidery. Factors such
as the type of material you are using, the tightness of the fabric in the hoop, the backing used,
the size and style of lettering, and the type of thread being used will all play a part in setting
the proper tensions.
The top tension and bobbin tension work together to form stitches, but they are adjusted
separately. Tension should be set to allow 30% bobbin thread to show on the reverse side of
the embroidery. For example, if the bobbin thread is white and the top thread is blue, the
underside view of the stitch will be white in the center, representing one third of the total
stitching, and the outside edges will be blue, representing two thirds of the total stitching.
An excellent way to test the tensions is by using the I test.
Running an I Test
1.Barudan supplies a sew test disk with every machine. Using the I Test on the sew
test disk, Sew one I, change to the next needle, sew another I, change to the
next needle, and so on.
2.Turn the sample over and look at the back of the stitching. Proper tension would
show two thirds top thread color and one third bobbin thread.
Well Balanced The top row of I's in the illustration above show properly adjusted
Tension tension. Slight variations will occur, depending on the fabric,
backing, thread type and letter size.
Bobbin Tension The middle row of I's in the illustration above show almost no
Problem bobbin thread. All the letters have the same problem, so the bobbin
tension needs adjustment. Bobbin tension, since it is controlled by
one tensioning mechanism, will be consistent from one needle to the
next. In this example, the tension should be looser.
Top Tension The bottom row of I's in the illustration above show letters that look
Problem quite different from one another. Top tension will vary from needle
to needle, since each needle tension is controlled by three different
tensioning points. Letters #1, #2 and #7 show too much bobbin
thread; letters #3, #4 and #9 have hardly any bobbin thread
showing; letters #5, #6 and #8 show properly adjusted tension.
When different problems show up on different letters, the problem is in the top tensions.
Letters #1, #2 and #7 need the top tension loosened so the bobbin can pull more of the top
thread to the back. Letters #3, #4 and #9 need the top tension tightened because there is too
much of the top thread being pulled to the back.
Adjusting the Top Tension
There is a pretensioner for each needle. The pretensioners control the flow of thread from the
cone to the top tensioners. The pretensioners are set, according to the type of thread you are
using, to allow a smooth flow of thread to the top tensioners. The pretensioners should only
need adjustment when you change from a light weight thread to a heavier weight, or vice
versa.
Adjusting the Pretensioners
1.If the thread does not flow freely, loosen the pressure on the spring that holds the
disk down by turning the thumb nut counterclockwise.
2.If the thread flows too freely, increase the pressure on the spring that holds the
disk down by turning the thumb nut clockwise.
The top tensioners controls the top thread tension. If the top tension is too tight, the bobbin
will not be able to pull enough of the top thread to the back of the embroidery. Top tension
that is too tight may cause thread breaks, needle breakage, or puckering of the fabric. If the
tension is too loose, the bobbin will pull too much of the top thread to the back of the
embroidery, causing the thread to loop on either the top side or the back side of the
monogram, possibly both. The monogram will look rough, and will not lie smoothly on the
fabric. The bobbin tension on the back side of the monogram will look very narrow.
You may find it necessary to adjust the top tension to compensate for variances in material or
thread. Generally when you are using a thicker material (e.g., heavy jackets) or thicker thread,
the upper tension should be set more loosely.
Adjusting the Top Tension
1.The plastic knob on the top tension assembly is marked with a + and -, with an
arrow between them. Turn the top tension disk clockwise , toward the+ sign, to
tightenthe top thread tension.
2.Turn the top tension diskcounterclockwise , toward the- sign, toloosenthe top
thread tension.
Checking the Top Tension
1.Rotate the handwheel so that the take-up lever is at its highest position.
2.Pull thread slowly, from front to back. You should feel some resistance, but not so
much that the thread feels as if it will break.
Adjusting the Bobbin Tension
The bobbin tension is set by adjusting the larger screw on the bottom of the bobbin case. To
test the tension, insert a bobbin in the case and slowly pull the end of the thread. The thread
should unwind slowly and smoothly out of the bobbin case, yielding a slight resistance.
Experience will help you determine the correct degree of tension. The tension is preset on all
new bobbin cases, so readjusting bobbin tension is not often necessary. A poly-core,
cotton-wrapped thread is recommended for the bobbin; however, other types will also work.
CAUTION! After continued use, an accumulation of lint or thread under
the thread tension spring on the bobbin case may hold the spring away
from the thread, diminishing the tension. BEFORE MAKING ANY
ADJUSTMENTS TO THE BOBBIN CASE, check this area for lint or
thread. If the built up lint or thread is overlooked, the operator could be
adjusting bobbin tension to no avail. Over tightening the bobbin tension
will bend the top of the tension spring and the bobbin case will have to be
replaced.
Adjusting the Bobbin Tension
1.Turn the screw on the bobbin case
clockwisetotightenbobbin
tension.
2.Turn the screw on the bobbin case
counterclockwise toloosenthe
bobbin tension.
Once the tensions have been adjusted for
the type of thread you plan to use, only
minor changes will be needed as the
fabric, letter size, and alphabet style
changes.
Take-Up Spring Adjustment
Located behind each upper plastic tension disc is a hook spring called the tension take-up
spring. The tension take-up spring picks up the excess slack on the thread while the machine
is sewing. This is particularly important when the machine is sewing small letters. The
take-up spring may require adjustment for two reasons.
Fabric You may find it necessary to adjust the tension take-up spring when
Change you switch to very thin or very thick fabric. To sew on thinner
fabric, lighten the tension on the take-up spring. To sew on thicker
fabric, tighten the tension. Follow the steps listed below for
adjusting the take-up spring tension.
False Thread There may be a time when you notice that the machine is
Break Detection experiencing constant thread break detection's. The machine keeps
stopping, but the thread is not broken. When this occurs, the tension
take-up spring is too tight.
Adjusting the Take-up Spring
1.Toloosenthe tension, insert a
screwdriver into the post and turn
counterclockwise , no more than 1/8 of
a turn. Sew off a sample to check the
tension. Repeat the procedure if
necessary.
2.Totightenthe tension, insert a
screwdriver into the post and turn
clockwise , no more than 1/8 of a turn.
Sew off a sample to check the tension.
Repeat the procedure if necessary.
Sewing Preparation
Using the proper size hoop when embroidering finished goods ensures the best results. Before
hooping, use Float, the H and V values or Perimeter Trace to determine the pattern size and
choose a hoop slightly larger than the pattern. It is recommended to leave at least a 1/2"
clearance around the pattern. The garment must be hooped straight and tight so the
embroidery appears straight. It is best to use a framing board system which holds the hoop
stationary so you can use both hands when straightening and smoothing the fabric.
Positioning the Design on the Garment
The placement of a design on a garment is subject to many variables, such as customer
preference, size and style of the garment, size and style of the design and the degree of
difficulty in working with the garment. We have assembled some guidelines for placing
designs on some popular garments. These measurements are approximate and refer to the
center point of the entire design.
NOTE: Monograms and names should be placed on the left front unless
otherwise specified. For children's clothing, these measurements should be
scaled down.
EMBROIDERY PLACEMENT GUIDELINES
Millimeter Conversion Chart
The chart below will help you convert fractional inches to millimeters.
FRACTIONAL
INCH
MILLIMETER
EQUIVALENT
Backing Materials
The use of backing materials and/or toppings will enhance your embroidery. The type of
backing needed is determined by the fabric being embroidered. In most cases, backing will be
needed to prevent stitches from pulling and distorting the garment. Backing materials give
strength to unstable fabrics (knits) and a better appearance on woven fabrics (less puckering
and pulling).
Fabrics fit into three general categories
Wovens Non-stretch materials such as satin jackets, towels, denim and
canvas.
Knits Stretch materials such as sweaters, sweatshirts, jerseys and
t-shirts.
Special Non-woven, non-knit materials such as felt, leather or suede.
Backings are used with all knits and stretch fabrics, as well as with most thin or sheer fabrics.
Backing Guidelines
A loose knit fabric can be embroidered, but without selecting proper stitch density and
backing, the garment can be stretched and possibly cut. The operator's concern is to keep
fabrics from stretching, puckering, or popping through the stitches during sewing. In general ,
thinner garments, need more stable backing.
Backings range from very light-weight tearaway to heavy-weight cutaway, from iron-on to
non-adhesive. All serve different purposes. The most universal backings are medium-weight
tearaway or cutaway types.
Too much backing is just as bad as not enough. Use one piece of medium-weight backing or
two pieces of light-weight backing as a general rule. Heavier fabrics generally have a tighter
weave and will need less backing.
Backing should be cut to completely fit in the hoop, not just as a strip to fit across the center
of the hoop. When dealing with an open weave fabric that you don't want to move or gather,
using spray adhesive on the backing will help keep the two together, adding stability.
Softouch
Softouch is a woven backing material made of 100% non-shrinkable polyester. Softouch
backing is used with many knits and stretch fabrics. These materials cannot be pulled tightly
in a hoop by themselves because they will stretch out of shape. Softouch is used to add
stability to the garment while it is being sewn. Without Softouch backing, knits will not hold
the stitching and can even be forced down into the hole in the throat plate.
To use Softouch backing, cut a piece slightly larger than the hoop you are using and place it
underneath the area of the garment that is going to be monogrammed. Hoop the garment as
usual, using the backing material as though it were part of the garment. Make sure that the
garment is as smooth and snug as possible in the hoop. You may wish to use a dissipating
bonding adhesive spray to bond the backing to the garment for better stability.
Cut away the excess backing after embroidering, leaving a small margin around the
embroidery. Do not cut the backing between letters and designs. Leaving it in place gives
added stability to the embroidery after laundering.
Softouch can also be used with thinner woven fabrics to give better clarity and detail to
intricately embroidered designs.
Tearaway
Tearaway is a non-woven material that provides some of the stability of Softouch, but can be
torn away like paper. It is used with non-stretch fabrics. It is hooped in the same manner as
Softouch, but it is not strong enough for heavier knits or stretchy materials. Tearaway gives
body to thin materials and is well suited for nylon jackets, blouses, sheets, etc. It will help
reduce puckering and pulling on these fabrics.
Cutaway
Cutaway backings include a large assortment of fabrics: heavy nonwovens, woven cotton
buckram; and woven nylon polyester. A cutaway backing is a fuller product and provides
more support than tearaway backing. Cutaway backings are generally more expensive but are
more popular with experienced operators.
Nylon Backing
Nylon backing is used with many knits and stretch fabrics. Use nylon as a substitute for
Softouch if the design is not worn against the skin. Hooping procedures for nylon are
identical to those for Softouch backing.
Backing Paper
Backing paper is used beneath fabrics with a looped or rough texture, e.g., towels or canvas,
and with garments that have a rubber lining, e.g., rain slickers or waterproof bags. This allows
the hooped garment to move smoothly while sewing, decreasing the chance of dragging. The
backing paper is not put in the hoop with the material, but is placed under the hoop, between
the garment and the sewing surface. When the embroidery is finished the paper can be pulled
away.
CAUTION! Backing paper has a tendency to shred during sewing. Small
pieces of paper can get caught in the hook and jam the machine. Be sure to
clean away all excess pieces of paper that may be left after embroidering.
Water Soluble Topping
Water soluble plastic foil is used as a topping to prevent stitching from getting lost in knit
fabrics, keep terry cloth loops down, and to allow greater clarification of intricate details.
Using Water Soluble Topping
1.Place water soluble topping on top of the fabric and hoop both.
2.After the embroidery process is complete, tear away the water soluble topping
outside the design.
3.Spritz very lightly with warm water to dissolve water soluble topping.
4.A soft bristle brush may be used to help remove remaining water soluble topping
particles. Pass the brush lightly over the top of embroidery to raise up the topping.
NOTE: Embroidery should not be left damp or wet longer than a few
minutes.
Needle Types
The type of needle you use is determined by the type of fabric you are embroidering.
Normal Normal point needles pierce, or split, the threads of the fabric
Point without cutting them. Using normal point needles results in the
cleanest possible stitch.
Ball Ball point needles deflect and slip between the threads of the fabric.
Point Ball point needles are best suited to fine knits and wovens, which
have a tendency to snag or run.
Sharp Sharp point needles have a cutting edge to penetrate non-woven
Point materials. Sharp point needles are used only for leather and similar
materials.
Needle Insertion
When you receive the machine, all needles should already be in place. However, you will,
from time to time, need to change a needle.
Replacing a Needle
1.Turn off the main power to the machine.
2.Loosen the needle set screw located on the back of the needle bar and remove the
needle.
3.Insert the new needle as far up as possible. Make sure the groove on the needle is
facing the front of the sewing head. An improperly inserted needle will not only
not sew, but can damage the hook assembly.
4.Tighten the needle set screw to secure the needle.
Needles/Backing Chart
The following chart was taken from Stitches magazine. Use it as a quick reference for the
material covered in this chapter.
NEEDLES/BACKING CHART
FABRIC
NEEDLE
SIZE/TYPE
BACKING TOPPING COMMENTS
NEEDLES/BACKING CHART
FABRIC
NEEDLE
SIZE/TYPE
BACKING TOPPING COMMENTS
Chapter 2 Machine Care
Cleaning the Machine
It is important to clean the machine before oiling. Keep all areas of the machine clean of
built-up lint and dust.
You should have both soft-bristle and stiff-bristle brushes and a shop vac
available for routine cleaning.
An air compressor is useful for cleaning hard to reach areas.
A mild spray cleaner can be used on the table top to clean up excess oil
that may splatter when the machine is oiled.
Periodically vacuum the vents of the driver box. Do not use compressed
air to blow the vents clean, as this will force debris into the driver box.
A maintenance log, attached to the machine, is recommended. Keep a chart of the daily,
weekly and biweekly maintenance performed on the machine.
Bobbin Case Maintenance
In a normal production setting, the bobbin case should be cleaned every four hours . Brush
lint and dust out of the bobbin case. Failure to keep the bobbin case clean can cause tension
problems. If tension is adjusted without first removing dust and lint, the tension spring on the
bobbin case can be bent too far and the case will need to be replaced.
Cleaning the Bobbin Case
1.When the case is removed for cleaning, check the shaft for wear.
2.Brush lint and dust out of the case with a small soft-bristle brush.
3.Replace the bobbin in the case and test the tension, as detailed on
page 1-27.
Hook Assembly Maintenance
The hook assembly should be cleaned every four hours when the machine is used in a
normal production setting. The hook assembly should be oiled every4 to 6 hours.
Cleaning the Hook Assembly
1.Remove the bobbin case from the hook assembly.
2.Brush any lint or dust from the hook assembly with a small stiff-bristle brush. If
you can't remove all the lint/dust with a brush, use compressed air to blow the
hook assembly clean.
It is best to oil at the end of the day, when the machine will be idle, so excess oil can drip off
the assembly.
Oiling the Hook Assembly
1.With all lint and dust removed from the hook assembly, place one drop of clear
sewing machine oil in the raceway. A hypodermic oiler works best because it
offers greater control over how much oil is dispensed.
2.Sew off the machine on practice cloth to prevent oil stains on production goods.
Machine Lubrication
Different parts of the machine require different types of lubricants and different lubrication
frequencies. The diagrams and charts on the following pages are a guide for the lubrication
schedule necessary to keep the machine running properly. Refer to the appropriate
diagram/chart for the type of sewing head on your machine.
The machine should always be turned off before it is oiled.
Oiling procedures are based on an 8-hour workday.
ZN/ZQ Arm Type Head
THE MACHINE SHOULD ALWAYS BE TURNED OFF BEFORE IT IS OILED.
OILING PROCEDURES ARE BASED ON AN 8-HOUR WORKDAY.
ZQ/ZN ARM TYPE HEAD OILING
PART IDENTIFICATION LUBRICANT FREQUENCY
ZQ/ZN ARM TYPE HEAD OILING
YN/YS Arm Type Head
OILING PROCEDURES ARE BASED ON AN 8 HOUR WORKDAY.
YS/YN ARM TYPE HEAD OILING
YN/YS Bridge Type Head
The head cover on a YN bridge machine has a small removable door that lets you oil many
head components without removing the entire cover.
OILING PROCEDURES ARE BASED ON AN 8 HOUR WORKDAY.
B2 F1
A1
B1
D2
E1
E1
D3
D3
B3
E4
E3
D2
E2
F1
B2
B2
B2
A1
C1
D1
B5
YN/YS BRIDGE TYPE HEAD OILING
ZQ Bridge Type Head
THE MACHINE SHOULD ALWAYS BE TURNED OFF BEFORE IT IS
OILED. OILING PROCEDURES ARE BASED ON AN 8 HOUR
WORKDAY.
F1
B2
B2
B2
A1 B5
C1
D1
E3
ZQ BRIDGE TYPE HEAD
Fuse Replacement
Fuses are located on the front of the driver box and one on the back of the automat. The
illustrations below show these locations.
CAUTION! For continued protection against risk of fire and electric
shock, replace with same type and rating of fuse. Disconnect power before
servicing.
USE RECOMMENDED REPLACEMENT FUSES OR UL EQUIVALENT
LOCATION
AMP
RATING
REPLACEMENT
TYPE
Maintenance Log
DATE INITIALS CLEANED
PART
LUBRICATED
TYPE OF
LUBRICANT
PROBLEMS
Chapter 3 Troubleshooting
Quick Fixes
There are a number of problems that you may encounter while sewing that can be simply
remedied.
PROBLEM CAUSE SOLUTION
Error Codes and Display Prompts
The chart below explains the various prompts displayed during operation and tells you the
appropriate action. The chart also includes the machine error codes and steps necessary to
correct machine malfunctions.
ERROR CODES
Take-Up Spring Replacement
After repeated adjustments, the take-up spring may begin to show
wear. You may notice that adjusting the take-up spring no longer
corrects tension problems. In this case, you need to replace the
take-up spring.
Replacing the Take-Up Spring
1.Remove the outer tension knob, turning it counterclockwise
until it comes off the tension assembly.
2.Remove the thread sensor disc from the tension assembly post.
3.Remove the inner tension knob, including the spring that rests inside it.
4.Remove the first white plastic disc (spool shaped), then the green felt
disc.
5.Remove the second white plastic disc (flat). You may need to push on
it from behind with the blade of a flat screwdriver.
Notice the position of the take-up spring in reference to the assembly
port. There is a groove in back where the spring locks in place.
6.Remove the worn take-up spring.
7.Insert the new spring, placing it in the same position as the old one. Make
sure the new spring rests against the brass post.
8.Replace the white plastic disc with the flat side facing you. Make sure it
isfirmly seated on top of the brass post (it will partially cover the
post) so the take-up spring cannot go around the post. The white plastic
disc traps the spring in place.
9.Replace the green felt disc.
10.Replace the top white plastic disc with the flat side facing you.
11.Replace the inner tension knob with the spring resting inside it.
12.Replace the outer tension knob, turning it clockwiseuntil it is secure,
but not too tight, on the tension assembly.
13.Adjust the new take-up spring as instructed on page 1-29 in the
Mechanical Guide .
Hook Timing
Hook timing is probably the most misunderstood aspect of embroidery machine mechanics. It
has nothing to do with the type of fabric, tension or synchronization of the heads on a
multihead machine.
Hook timing is the proper position of the hook assembly in relation to the
needle in order to form a stitch. The hook is directly attached to the drive shaft, eliminating
the need to routinely re-time it. Re-timing of the hook only becomes necessary due to external
factors.
Something gets caught in the hook assembly.
The size of the needle is changed by more than one size.
An accumulation of thread behind the hook pushes the hook out of line.
The most common indication that the hook timing needs adjustment is when the machine fails
to form and complete a stitch.
Checking the Hook Timing
1.Leave the needle and bobbin threaded and remove the throat plate.
2.For easier access to timing, set the machine to the last needle.
3.Locate the main drive pulley with degree indicator.
NOTE: The main drive pulley on an arm type machine is driven by the
main motor drive belt. Remove the cover to access it.
The main drive pulley on a bridge machine is located on the side of the
machine opposite the automat under a metal cover.
Always rotate the main drive pulley in the direction that rotates the hook
counterclockwise.
4. Rotate the main drive pulley to where the indicator point to 24 degrees. The point
of the hook should be directly behind the scarf of the needle and above the needle
eye.
5.Check the hook-to-needle clearance. There should
be approximately one half to one thread-width
clearance between the hook point and the back of
the needle. Improper adjustment would cause the
hook point to miss the small loop and create a
skipped stitch.
6.Replace the covers.
Adjusting the Hook Timing
1.Clean any thread debris or lint from the hook area
with compressed air.
2.Loosen the three screws at the rear of the hook. This
will allow you to advance or retard the hook.
3.Locate the main drive pulley with degree indicator.
4.Rotate the main drive pulley to where the
indicator points to 24 degrees. The point of
the hook should be directly behind the scarf of
the needle and above the needle eye.
5.Check the hook-to-needle clearance. There
should be approximately one half to one
thread-width clearance between the hook
point and the back of the needle. Improper
adjustment would cause the hook point to miss the small loop and create a skipped
stitch.
6.When the correct position has been attained, tighten the three screws on the hook.
7.Replace the throat plate.
8.Use a monogram keyboard, such as the JM-IV, to do an H O Xtest as follows:
Using a block alphabet, program H O Xin capital letters, 20mm high,
into the machine. These letters are used because they encompass all the
various directions of the pantograph.
Sew the letters.
Check for any irregularities in the sewing. If the machine is not properly
timed, it will result in skipped stitches.
Position Finger Adjustment
The adjustable position finger is mounted in front of the hook assembly to secure the hook
basket in place and balance the bobbin thread down the center of the embroidery. The
position finger is adjustable in two directions, left to right, and front to back. Adjustment of
the position finger is required if the bobbin thread is running left or right of center, or if the
position finger was removed during the replacement of the hook assembly.
Sometimes the finger moves out of adjustment. When correct, the position finger nose, the
protruding part, lines up centered with the hook assembly shaft.
Adjusting the Position Finger
1.Remove the throat plate.
2.Rotate the handwheel until the needle reaches the lowest point, the bottom of its
stroke.
NOTE: The handwheel is located between heads 1 and 2 under a plastic
cover at the back of the sewing table. Remove the cover to access the
handwheel.
The handwheel on a bridge machine is on the side of the machine opposite
the automat under a metal cover.
3. Loosen the screw slightly, taking care to use the correct size screwdriver since the
screw is very flat and easily stripped.
4.Carefully move the position finger, centering the nose to the needle. To make sure
you are looking at the needle straight on, use the lubrication hole, behind the throat
plate, as a reference. Visually line up the needle with this hole, then adjust the
position finger.
5.Carefully retighten the screw.
Field Limit Settings
Field limit settings protect the machine by preventing the hoop or pantograph frame from
running into the needle. Setting field limits establishes the size of the sewing field. In the
factory, they are set a safe distance from the inside edge of the pantograph frame. This
ensures that if the frame moves too near the needle the machine will shut off.
The machine shuts off immediately if the pantograph moves out of the set sewing field.
Movement too near the frames can be caused by careless positioning of the pantograph at the
start of a pattern, misjudging pattern size, or the machine going off pattern due to a torn tape.
In addition to the mechanical limits, the machine has soft limit settings that stop the
machineif the pantograph moves too near a limit instead of shutting it off completely. Soft
limits provide security without the problem of the machine powering off.
The sewing field should be made smaller to prevent running into the hoop. As a rule, limits
should be set at least ten millimeters smaller than the inside diameter of the hoops that will be
used.
If you correctly change soft limits to match the hoop, it is not necessary to change mechanical
field limits. However, if you consistently sew in smaller size hoops and want additional
protection, follow the instructions below to change mechanical field limit settings.
The field limit setting switches are underneath the table on the H and V guide rail bases. Each
guide rail has two limit switches, one to the left of the origin sensor, one to the right.
Changing the Field Limits
1.Power on the machine. Press the jog keys and
move the pantograph so the sewing needle is in
the center of the hoop you will be using.
2.Use the jog keys to move the pantograph toward
the hoop until the presser foot of the needle
closest to the hoop is 10mm from the left inside
edge of the hoop.
3.With a 2.5mm ball driver or a hex key, loosen the left limit switch screws on the
V-guide rail.
4.Move the limit switch toward the magnet very slowly, just until the automat shuts
off. Without moving the limit switch, tighten the screws to secure it at its new
setting.
5.With the automat off, manually move the pantograph toward you until you can
turn the automat on again.
6.Use the jog keys to move the pantograph until the presser foot of the needle on the
opposite side is 10mm from the right inside edge of the hoop.
7.Loosen the right limit switch screws on the V-guide rail.
8.Move the limit switch very slowly toward the magnet, just until the automat shuts
setting.
10.Use the jog keys to move the pantograph until the presser foot is 10mm from the
bottom inside edge of the hoop.
11.Loosen the left limit switch screws on the H guide rail.
NOTE: It may be difficult to see the H guide rail limit switches from the
front of the machine. If possible, try adjusting them from behind the
machine.
12. Move the limit switch very slowly toward the magnet, just until the automat shuts
setting.
14.Use the jog keys to move the pantograph until the presser foot is 10mm from the
top inside edge of the hoop.
15.Move the limit switch very slowly toward the magnet, just until the automat shuts
setting.
17.Test the new limit settings by pressing the jog keys in all directions to ensure that
the machine shuts off before the hoop runs into a needle.
CAUTION! The origin sensor should never be moved from its factory
setting.
When finished sewing in a smaller hoop, reset the field limits to the factory
measurements in order to utilize the full sewing field.
Chapter 4 Machine Parameters
Machine Conditions
Machine Conditions are parameters that can be set to ensure the highest possible productivity,
according to the characteristics of each pattern. Machine Conditions parameters affect how
every pattern is sewn, unlike Program parameters, which are pattern specific. The Machine
Conditions Table explains the function, normal setting and range of values for each
parameter.
Machine Conditions parameters are accessed differently on each automat. The following
sections give separate instructions for the NS/NY automat and the NR/NB automat. Refer to
the appropriate section for your machine.
MACHINE CONDITIONS TABLE
SETTING FUNCTION ACTION
SETTING ACTION
TRIMMER
TYPE
MSU #10
ATC TYPE
SETTING KNIFE POSITION
SETTING
PANTOGRAPH
MOVEMENT
Changing Machine Conditions - BENS/NY
1.Press theManual key. The Manual menu displays.
2.PressD, below theNexticon, to move to the next menu level.
3.PressA, below theMCicon. The list of Machine Conditions parameters displays.
4.Use the jog keys to move through the list,
until the parameter you want to change is
selected. A box displays around the selected
parameter.
5.Change the value as desired. Refer to the
table on the preceding pages for a description
of each parameter and its range of values.
Press A, below the minus icon, to decrease
the value.
Press B, below the plus icon, to increase
the value.
6.When changes to the MC parameters are
complete, press the Manual key to save
changes and close the list. Wait a few
seconds, until the basic screen appears,
before executing other BENS commands.
To return changed parameters to system
defaults, use the Initialize MC command.
This command restores default values for all
parameters in the MC list.
Initializing Machine Conditions - BENS/NY
1.Press theManual key. The manual menu displays.
2.PressD, below theNexticon, to move to the next menu level.
3.PressA, below theMCicon, to open the list of Machine Conditions parameters.
4.PressD, below theInitializeicon, and hold it down for approximately five
seconds. The following screen displays, prompting you for confirmation to return
all MC parameters to default values.
5.PressC, below theYesicon, to restore original MC values. To cancel the
command, press D, below theNoicon.
Wait a few seconds, until the confirmation screen is replaced by the basic screen,
before executing other BENS commands.
Changing Machine Conditions - BENR/NB
1.At the Drive screen (blue icons), press G,below theNexticon, to move to the next
menu level.
2. PressC,below theMCicon. The list of Machine Conditions parameters displays.
3.Use the jog keys or [+] and [-] keys to move through the list until the parameter
you want to change is selected. A box outline displays around the selected
parameter.
4.Use the numeric keypad to change the value as desired. Refer to the table on the
preceding pages for a description of each parameter and its range of values.
NOTE: Parameters with ON/OFF values are also changed on the numeric
keypad. 1 = ON and = OFF.
5.Press [SET] on the keypad to confirm the new value. Changed parameters display
in red.
6. When changes are complete, press C,below theMCicon, to save the changes and
close the list of parameters.
To return changed parameters to system defaults, use the Initialize MC command. This
command restores default values for all parameters in the Machine Conditions list.
Initializing Machine Conditions - BENR/NB
1.At the Drive screen (blue icons), press G,below theNexticon, to move to the next
menu level.
2.PressC, below theMC icon, to open the list of Machine Conditions parameters.
3. PressB, below theInitializeicon. The BENR prompts you for confirmation to
return parameters to default values.
4.PressB, below theYesicon, to restore original MC values. To cancel the
command, press C, below theNoicon. The BENR beeps when initialization is
complete.
5.PressC,below theMCicon, to save changes and close the list of parameters.
Machine Speed
The maximum speed of the machine is 750 stitches per minute, but not all stitches or
garments can be sewn at this speed. When the machine is sewing, it must wait for the needle
to come out of the fabric, and the pantograph to move and stop again before the needle goes
back into the fabric. The higher the sewing speed, the greater the acceleration needed and the
less time the pantograph has to move. If the frame and garments are heavy and the sewing
speed is high, the needle will not stitch in the right place, giving poor quality stitching.
The obvious prevention for this is to slow the machine down. However, shorter stitches that
do not require more time will be slowed down as well, reducing productivity. The machine
has two methods of minimizing stitch distortion: automatically slowing down the machine for
long stitches and breaking long stitches into smaller, shorter stitches.
Reducing Speed Based On Stitch Length
The machine looks ahead at upcoming stitches and, if it sees stitches of certain lengths, will
slow down to a percentage of the speed control setting. The machine automatically adjusts the
speed to the stitch length, based on certain MSU parameters.
Long Stitches Divided Into Jumpstitches
The other method the machine has of avoiding long stitches at high speeds is to divide them
into shorter jumpstitches. The value set in Jump Divide, MC parameter 7, determines at what
length a stitch will be split. In this case, inertia is reduced because the machine has two
revolutions in which to carry out the movement. Certain patterns may have mainly short
stitches, with a few solitary long stitches, i.e., a small flower connected by long stitches to
other flowers. In this case, it would be most productive to break the long stitches into shorter
ones than to slow down the machine each time a long stitch is encountered. Jump Divide
provides a programmable threshold which will break longer stitches into jumpstitches.
When sewing the flowers used as an example, the machine would always sew at full speed,
but the occasional long stitch between flowers would be converted into two jumpstitches,
which would not affect the final sewn results.
Jump Divide is programmable from 3.0mm to 12.7mm. Since 12.7mm is the longest stitch the
machine can sew, setting Jump Divide at 127, the default setting, turns off this function.
Thread Trimmer Programs
There are three trimming programs available which can be set in parameter 5, Trim On/Off, if
your machine has Mark 4 trimmers or Mark 6 trimmers with the optional thread finger
device. The table below and on the next page shows the function of each program.
THREAD TRIMMER PROGRAMS
MARK 4 and 6 TRIMMERS
SETTING FUNCTION ACTION
Soft Limits
Soft limits are field limits set within the software that protect the machine by preventing the
hoop or pantograph frame from running into the needle. Movement too close to the frame
could be caused by careless positioning of the pantograph at the start of the pattern,
misjudging the pattern size, or the machine going off pattern.
Soft limits can be set in addition to the normal mechanical field limits. If the frame moves too
close to the field limit, the machine will shut off. If the frame moves too close to the soft
limit, the machine stops and an error message is displayed. This gives you the opportunity to
reposition the pantograph within the limits, without the problems caused by the machine
shutting off. See instructions on changing mechanical field limits.
Soft limits provide a quick and easy way to change the size of the sewing field. Although it is
not necessary to change the soft limits to sew within a smaller size hoop, making the sewing
field smaller can prevent running into the hoop. As a general rule, set soft limits at least ten
millimeters smaller than the inside diameter of the hoops that will be used.
MC parameters 19, 20, 21 and 22 set the soft limits.
Changing the Soft Limits
1.Follow the instructions in the previous
section to access the list of MC parameters.
2.Use the jog keys to move through the list to
the soft limit parameter you want to change
(parameters 19 through 22).
3.When the desired parameter is selected, press
the Origin key in the center of the jog keys.
A small value box, showing the Absolute V
and H values, displays on the left side of the
screen below the parameter 's icon. The
pantograph moves to mechanical origin.
4.Use the jog key corresponding to the selected parameter to move the pantograph to
the position you want to set as the soft limit.
#19 Right Limit - use the right jog key
#20 Left Limit - use the left jog key
#21 Back Limit - use the top jog key
#22 Front Limit - use the bottom jog key
As you move the pantograph, the appropriate value in the box changes.
5.When the pantograph is in the desired position, refer to the value box for the
parameter 's new value.
NOTE: Ignore the negative sign before the value, and round the number
one decimal place. For example, if the value box shows -2471 as the ABS
pantograph position, enter 247 for the new value. If the value box shows
386 as the ABS pantograph position, enter 38 for the new value.
On a BENS/NY automat, use the menu keys to change the value.
Press A, below the minus icon, to decrease the value.
Press B, below the plus icon, to increase the value.
On a BENR/NB automat, use the numeric keypad to change the value.
6.When finished setting this parameter, press the Origin key to close the value box
and return the pantograph to mechanical origin.
7.Repeat Steps 2-6 to change the other soft limit parameters as desired.
8.When changes are complete, exit the list of MC parameters.
Sub Soft Limits
This feature allows you to store three of your most commonly used frame/hoop sizes in
memory as Frame Type 1, 2 and 3. These values are programmed in Program, under
parameter #13, Frame Type.
Soft Limits can be set as you normally would in Machine Condition parameters #19-22.
Within soft limits, you can now save three sub soft limits, Frame Type 1, 2 and 3. If you do
not set any values in Frame Types 1-3, the default value is the same as the Soft Limits value.
Setting Sub Soft Limits
1.Enter the Program menu and select parameter #13, Frame Type.
2.Select Frame Type 1.
3.Press the Origin key. The Sub Soft Limit Setup Menu will display. The Sub Soft
Limits are set by two measurements:
P1, lower most left side of hoop
P2, upper most right side of hoop.
4.Use the jog keys to move the pantograph to P1.
5.Press D, below the Execute icon to save P1 position. Notice the P1/P2 icon, above
the A key is highlighted indicating it is now ready for you to program P2.
6.Use the jogs keys to move the pantograph to P2.
7.Press D, below the Execute icon to save P2 position.
8.Press B, below the Perimeter Trace icon, to check that the newly saved positions
are accurate.
9.Pressing the A key, P1/P2 icon, toggles between P1 to P2.
10.Continue to create Frame Type 2 and Frame Type 3 for other hoop/frame sizes, if
desired.
11.When sewing designs, you can enter the Program menu and select whatever stored
frame/hoop size you wish to use at the time.
12.Once programmed, Frame Types 1, 2, and 3 remain in memory unless or until
memory is reset or initialized.
13.To exit, press the Menu key.
MSU - Machine Setup Parameters
Machine Setup parameters pertain to the mechanical and electrical setup of the machine. The
following table explains each Machine Setup parameter.
Note: As of System Software version NR 3.30 R00, NS 3.30 R03 and NT
2.10 R01, changing the MSU parameters requires a System Disk.
MACHINE SETUP TABLE
Special Parameter for NT Only
Frame Motor Type for AC Servo
MSU Parameter Value Type
Frame Motor Type for Pulse Motor with Cap Frame Program ON
MSU Parame-
ter
Value Type
Max.
Speed
Slow
Down
Start
Slow
Down
Speed
Chapter 5 Machine Options
Drop Table System
The two-position drop table system increases the flexibility of the machine in high production
settings by allowing the table to be positioned at two lower levels. The tubular pantograph of
the drop table makes it easy to hoop finished garments and assembled caps, as well as flat
goods.
Lowering the Table
1.Move the pantograph as far back as it will
go, making sure the H member is over the
stationary part of the table.
CAUTION! Failure to position the
pantograph so that the H member is over
the stationary part of the table will severely
damage the machine.
2. Make sure there is nothing beneath the table
that will keep it from dropping smoothly and
freely.
3.Standing in the center of the drop section,
gently press down on the table top until the
catch lever hooks onto the first bar. The
table will be in thmeiddle position.
To lower it further, continue to gently press
down on the table top until the catch lever hooks onto the low-position bar .
NOTE: When using a cap frame, the table MUST be in the low position.
For tubular garments, the middle-position will offer more support.
NOTE: The drop table on the 15 head machine is divided into two sections.
All other machines have drop tables that run the length of the machine.
CAUTION! If there is any resistance, do not force the table down. Make
sure that the pantograph H member is as far back as it will go and that
nothing obstructs the downward movement of the table.
Raising the Table
1.Move the pantograph as far back as it will go, making sure the H member is over
the stationary part of the table.
CAUTION! Failure to position the pantograph so that the H member is
over the stationary part of the table will severely damage the machine.
2.Push the catch lever to the left to release it from the position bar. The table
automatically, slowly rises to its next level. Repeat if the table needs to be raised
higher.
Spider Hoops
Embroidering finished goods requires the use of hoops that are the right size for the design
that will be sewn. For those designs or garments that are too small to be hooped in a standard
wooden hoop, use a set of spiderhoops.
The inner hoop in a spider hoop is designed to securely hold the next size smaller hoop. See
illustration on next page. This design allows you to select the graduated size that is best for
the garment and design.
Spider hoops are used on machines with both rectangular pantographs and tubular
pantographs.
Installing the Spider Hoop on a Rectangular Pantograph
1.Remove all the thumbscrews that secure the porto-clip frame from the pantograph
frame.
2.Remove the four sections of the porto-clip frame.
3.Line up the clamping arms on the spider frame with the threaded pantograph holes
that correspond to the head you will use.
4.Secure the spider frame to the pantograph with the thumbscrews.
Distancing Board
On a tubular pantograph machine, the spider hoop is placed in a distancing board. The
distancing board attaches to the tubular pantograph arms in much the same way as a standard
tubular hoop.
Installing the Spider Hoop/Distancing Board
1.Insert the spider hoop in the distancing board.
2.Remove the standard hoop from the tubular pantograph
arms by grasping both sides of the hoop and pulling it
forward.
3.Align the side extensions on the distancing board with the
tubular pantograph arms.
4.Push back until the board snaps into place.
5.Insert the pantograph thumbscrew through the support at
the back center of the board and tighten it.
Sock Frame
A special framing device and pantograph attachment are used for
embroidering socks. The directions given are for the sock frame
used with a rectangular pantograph.
Attaching the Sock Frame Sash
1.Turn the machine power off.
2.Remove the top section of the porto-clip from the pantograph.
3.Match the thumbscrew holes in the sock frame sash with the holes in the
pantograph and secure with the thumbscrews.
Hooping Preparation
1.Attach the c-clamp securely to a table top or work bench.
2.Secure the framing board to the clamp using two (2) M6x20 bolts.
The framing board can also be permanently fastened to a surface
using the two bolt holes if you do not want to use the c-clamp.
3.Put the sock frame insert into the framing board, flat side down.
Hooping Socks
1.Align the backing material with the + in the framing board.
2.Slip a sock over the framing board, centering it.
3.Place the sock frame over the sock and the frame insert and push
down, applying equal pressure to both sides of the frame.
4.Pull the bottom of the sock over the framing board and remove the
sock frame and insert from the framing board.
Attaching the Sock Frame to the Sash
1.Insert the sock frame into the master on the sock frame sash. The
frame will be held in place magnetically.
2.Align the sock frame in the sewing field so that the design will be
centered in the frame. Use the jog keys to position the pantograph
accordingly.
NOTE: It is recommended that you sew on practice cloth before
embroidering socks to make sure that the alignment is correct.
Sewing Socks
1.PressMemory key.
2.Use the jog keys to select the pattern to be sewn on socks.
3.PressC, below theProgram icon, to access the list of program options.
4.Use the jog keys to move to#7, Socks , then change to the value you want. Choose
between 3 settings: 1=Normal, 2=second repetition mirrored and 3=second
repetition rotated 180 . See thOeperation Guidefor information on changing
program options.
5.Press the Memory key, to exit the list of program options.
6.Use thejog keysto position the pantograph at the origin of the second sock to be
sewn,P1in the illustration on the next page.
7.PressDrive key. The green light on the Drive key is steady, indicating the
machine is in Drive mode.
8.Use thejog keysto position the pantograph at the origin of the first sock to be
sewn,P2in the illustration below.
9.Move theStart/Stop barto theleftto begin sewing.
NOTE: If you did not move the pantograph in Step 7, the A26 error
message displays. Repeat Steps 7 and 8 to mark the origin of the first sock
and begin sewing.
The machine sews Design 1. When Design 1 is complete, the pantograph moves to
the P1 position and sews Design 2.
The machine repeats this process infinitely, moving back to P2 when Design 2 is
complete, and continues to sew.
NOTE: You may want to insert a stop code at the end of the pattern to stop
the machine, allowing you to change frames between repetitions.
Spectacle Boards
Spectacle boards let you hoop two small items in the space of a single, large hoop. The
illustrations below show examples of spectacle boards on arm-type and bridge machine
models.
To prepare the pattern for use on a spectacle board, add together the patterns to be used, with
the appropriate jog movement between. Make sure to use jump jog movement, not stitch jog.
You can also add jog movement after the second pattern, returning to the first pattern origin.
For details on reading in movement while adding two patterns, see the Operation Guide for
more information.
You can also use the Socks program option, to sew repetitions of a single pattern, with two
origin points. See the Operation Guidefor information on Program options.
Roll To Roll
Your machine may have an optional roll to roll device. With this option, when the machine
sees an SE (Sub End) function code it automatically activates the device, advancing the bolt
of fabric. If you have a roll to roll system, an additional manual option is available to
manually operate the device. MSU parameter 23, and MC parameter 23 must both be on for
the roll to roll option to be displayed. See instructions on changing MC parameters. If your
machine is equipped for Roll to Roll, your technician will set MSU#23 correctly during
installation.
Using Roll to Roll - BENS/NY
1.Press theManual key. The Manual menu displays.
2.PressD, below theNext icon. The next menu level displays.
3. PressC, below theRoll to Roll icon.
4. Use the menu keys to select the desired roll to roll option.
Using Roll to Roll - BENR/NB
1.At the drive screen, press D, below theManual icon.
2. PressB, below theRoll to Roll icon.
3. Select the desired roll to roll option.
Roll To Roll Simulation
You can also simulate a roll to roll device. With this feature, you can use a bolt of fabric,
insert an SE (sub end) function code at the end of the design to move the pantograph back
with the needle still in the same place in the fabric, then continue sewing the design. This lets
you create a long panel of embroidery.
KeepMSU #23(Roll to Roll TypeO)FF. Normally, with a roll to roll
device this option is set according to the thickness of the roll fabric.
SetMC#23(Roll to Roll) t1o(ON). This allows the manual roll to roll
option. Turning #23 on lets the SE function code be displayed when using
Teach, F List or F Mod.
The design should have a different start and end point. An SE code is programmed at the last
stitch in the design. The start and end point should be at the same horizontal position so that
when you continue embroidering the stitches line up correctly.
Using Manual Roll to Roll
1.When the machine reaches the stitch with an SE function code, it stops and
displays the D32 message on screen. The needle will remain down in the
fabric.
2.Release the fabric clamps, but otherwise do not move any part of the fabric.
3.Move the start/stop bar to the left. The pantograph moves back to the design 's
origin point. The needle is still down in the fabric.
4.Replace the fabric clamps, being careful not to move the fabric.
5.Move the start/stop bar to the left to continue sewing. The embroidery should line
up exactly with the previous stitches.
WS System
The WS option lets you increase the number of colors that can be used in a design. When WS
is activated, two heads work together, so you can have 18 colors in the design. If you
purchased a WS equipped machine, you can sew manually, using every head, or activate one
of the WS setups.
Two MSU parameters set up the machine for this system:
#21, WS Head Space sets up the space between heads
#22, WS Typesets up the type of WS system that will be used.
If your machine is equipped with a WS system, your technician will tell you how to change
MSU parameter 22 when the machine is installed.
WS Type 1
When MSU parameter 22 is changed to 1, it sets up the WS system to use 18 colors.
Sews with 18 colors, doubled field size, uses all heads, in groups, 15
pieces per run
Group 1: even numbered heads
Group 2: odd numbered heads
MC parameter#24, WS Systemmust be turnedONto activate the
system. See instructions on accessing MC parameters.
The machineautomaticallymoves from even to odd heads and vice versa
when G1 and G2 function codes are found in the pattern.
WS Type 2
When MSU parameter 22 is set to 2, the WS system lets you have a larger sewing field. The
heads used with WS Type 2 are shown in the illustration below.
Sews with 9 colors, tripled field size, ten pieces per run
Unused heads must be canceled manually with the head shut-off switch.
Uses heads 1, 4, 7, 10, 13, 16, 19, 22, 25 and 28
MC parameter#24, WS Systemmust be turnedOFF
WS Type 3
When MSU parameter 22 is changed to 3, it sets up the system to use 27 colors.
Sews with 27 colors, normal field size, ten pieces per run
Heads are in three groups; however, unused heads must be canceled
manuallywith the head shut-off switch.
The machine does not make the group change automatically. Only one
group of heads is on at a time. When the machine sees a group code, it
stops sewing. At this time, you must turn off the heads in the current
group, turn on the heads in the new group, and use the jog keys to move
the pantograph the required distance.
MC parameter#24, WY Systemmust be turnedOFF.
Group Codes
A design punched to be sewn on a WS system should have two codes inserted where there is
a group and color change.
At the first code, teach the group change.
At the second code, teach the needle within the group.
If there are two codes, and the change is within the same group, use the
code for the desired needle twice.
If the design was not punched for the WS system you will need to insert
new function codes for group changes.
Function codes for group changes are: 19(Group 1) and20(Group 2). To make a manual
group change, press [N] + code = [SET] . For example: [N] 20 [SET] changes to Group 2
heads.
Sewing Start Point
When you have the WS system set up for 18 colors, you must correctly position the
pantograph for the design start point.
Example:
30 head machine, head space 200mm - gives a field size of 400mm on
each pair of heads, with a 200mm overlap
Pattern measures 370 x 200
Pattern Origin is in the Center pattern origin is in the center
If the of the pattern:
1. With Group 1 heads active, move to the machine origin. (Watch for the red light
above the origin sensor to go on).
2.Measure 100mm to the left and 100mm to the right, and mark these two points.
The left mark is the origin for Group 1 heads (even # 's)
The right mark is the origin for Group 2 heads (odd # 's)
3.With Group 1 heads active, move to the mark on the left and execute a Perimeter
Trace, to make sure the pattern will sew within the field limit.
NOTE: On a BENS/NY automat, you must press the Drive key, putting the
machine in drive mode, before the Perimeter Trace icon is available.
4.Change to Group 2 heads, move to the mark on the right and execute another
Perimeter Trace.
5.PressF, below theDrive icon, to place the machine in Drive mode.
When you put the machine in Drive mode, make sure the pantograph is
positioned at the correct place for the active group. If Group 1 is active, it
should be at the mark to the left of machine origin.
Pattern Origin is not in the Center pattern origin is not in the center
If the of the pattern, you must calculate where the 200mm
overlap is measured:
Example: Pattern measures 367mm x 200mm with the origin at top right
of the pattern:
1.Take the width of the pattern and divide by two. 367mm divided by 2 = 183.5
2.Calculate the 200mm overlap.
83.5mm left of machine origin is the origin for Group 1 heads
283.5mm right of machine origin is the origin for Group 2 heads
Whether you need to measure left or right of machine origin will depend on the
exact location of the pattern origin.
3.Follow all steps on the previous page to set up the pattern for sewing, making sure
to use the measurements for your pattern in step 2, not simply 100mm.
HINT: Positioning the pantograph correctly for the start point of a WS
design is much easier if the pattern origin is in the center of the pattern.
Index
A
Adjusting tensions . . . . . . . . . . . 1-24
Adjusting the bobbin tension . . 1-27 - 1-28
Adjusting the hook timing . . . . . . . 3-14
Adjusting the Position Finger . . . . . 3-15
Adjusting the Take-Up Spring . 1-28 - 1-29
Adjusting the top tension. . . . . 1-25,1-27
Arm Type Head Lubrication . . . . . . 2-5
Automend button . . . . . . . . . . . . 1-8
B
Backing . . . . . . . . . . . . . . . . 1-31
Backing Chart . . . . . . . . . . . . . 1-35
Backing guidelines. . . . . . . . . . . 1-31
Backing Paper . . . . . . . . . . . . . 1-33
Backings
Backing Paper . . . . . . . . . . . 1-33
Cutaway . . . . . . . . . . . . . . 1-33
Nylon Backing . . . . . . . . . . 1-33
Softouch . . . . . . . . . . . . . . 1-32
Tearaway . . . . . . . . . . . . . 1-32
Water Soluble Topping . . . . . . 1-33
Bath towels . . . . . . . . . . . . . . 1-30
Birdnests . . . . . . . . . . . . . . . . 3-3
Bobbin case maintenance . . . . . . . . 2-1
Bobbin tension problem . . . . . . . . 1-25
Broken needle . . . . . . . . . . . . . . 3-2
Burr . . . . . . . . . . . . . . . . . . . 3-3
C
Changing Soft Limits . . . . . . . . . 4-19
Checking tensions . . . . . . . . . . . 1-24
Checking the hook timing . . . . . . . 3-13
Checking top tension . . . . . . . . . 1-27
Cleaning the bobbin case . . . . . . . . 2-1
Cleaning the hook assembly . . . . . . 2-1
Cleaning the machine . . . . . . . . . . 2-1
D
Danger. . . . . . . . . . . . . . . . . . 1-3
Conversion Chart . . . . . . . . . . . 1-31
Disengaging a Sewing Head. . . . . . 1-20
Display Prompts. . . . . . . . . . . . . 3-5
Distancing Board . . . . . . . . . . . . 5-3
Drop Table System . . . . . . . . . . . 5-1
E
Embroidery Placement Guidelines . . 1-30
Environmental Specifications. . . . . . 1-6
Error Codes . . . . . . . . . . . . . . . 3-5
A02 . . . . . . . . . . . . . . . . . 3-5
A04 . . . . . . . . . . . . . . . . . 3-5
A05 . . . . . . . . . . . . . . . . . 3-5
A08 . . . . . . . . . . . . . . . . . 3-5
A11 . . . . . . . . . . . . . . . . . 3-5
A20 . . . . . . . . . . . . . . . . . 3-6
A21 . . . . . . . . . . . . . . . . . 3-6
A22 . . . . . . . . . . . . . . . . . 3-6
A23 . . . . . . . . . . . . . . . . . 3-6
A24 . . . . . . . . . . . . . . . . . 3-6
A26 . . . . . . . . . . . . . . . . . 3-6
A27 . . . . . . . . . . . . . . . . . 3-6
A28 . . . . . . . . . . . . . . . . . 3-6
A29 . . . . . . . . . . . . . . . . . 3-7
A30 . . . . . . . . . . . . . . . . . 3-7
A31 . . . . . . . . . . . . . . . . . 3-7
A32 . . . . . . . . . . . . . . . . . 3-7
A33 . . . . . . . . . . . . . . . . . 3-7
A35 . . . . . . . . . . . . . . . . . 3-7
A36 . . . . . . . . . . . . . . . . . 3-7
D01 . . . . . . . . . . . . . . . . . 3-7
D02 . . . . . . . . . . . . . . . . . 3-7
D03 . . . . . . . . . . . . . . . . . 3-8
D04 . . . . . . . . . . . . . . . . . 3-8
D05 . . . . . . . . . . . . . . . . . 3-8
D06 . . . . . . . . . . . . . . . . . 3-8
D07 . . . . . . . . . . . . . . . . . 3-8
D08 . . . . . . . . . . . . . . . . . 3-8
D09 . . . . . . . . . . . . . . . . . 3-8
D12 . . . . . . . . . . . . . . . . . 3-8
D13 . . . . . . . . . . . . . . . . . 3-8
D14 . . . . . . . . . . . . . . . . . 3-9
D15 . . . . . . . . . . . . . . . . . 3-9
D16 . . . . . . . . . . . . . . . . . 3-9
D17 . . . . . . . . . . . . . . . . . 3-9
D19 . . . . . . . . . . . . . . . . . 3-9
D20 . . . . . . . . . . . . . . . . . 3-9
D21 . . . . . . . . . . . . . . . . . 3-9
D22 . . . . . . . . . . . . . . . . . 3-9
D23 . . . . . . . . . . . . . . . . . 3-9
D25 . . . . . . . . . . . . . . . . 3-10
D26 . . . . . . . . . . . . . . . . 3-10
D27 . . . . . . . . . . . . . . . . 3-10
D28 . . . . . . . . . . . . . . . . 3-10
D29 . . . . . . . . . . . . . . . . 3-10
D30 . . . . . . . . . . . . . . . . 3-10
D31 . . . . . . . . . . . . . . . . 3-10
D32 . . . . . . . . . . . . . . . . 3-11
D33 . . . . . . . . . . . . . . . . 3-11
D34 . . . . . . . . . . . . . . . . 3-11
Error Messages . . . . . . . . . . . . . 3-5
Eye of the needle. . . . . . . . . . . . 1-22
F
Fabric puckering . . . . . . . . . . . . 3-1
False Thread Breaks . . . . . . . . . . 1-28
Field Limit Settings. . . . . . . 3-16 - 3-17
Fur Coats. . . . . . . . . . . . . . . . 1-30
Fuse Replacement . . . . . . . . . . . 2-11
G
Golf Sweaters . . . . . . . . . . . . . 1-30
Groove of the needle. . . . . . . . . . 1-22
Grounding Instructions . . . . . . . . . 1-5
H
Hand towels . . . . . . . . . . . . . . 1-30
Hook Timing. . . . . . . . . . . . . . 3-13
Hooping problems. . . . . . . . . . . . 3-2
Hooping Socks . . . . . . . . . . . . . 5-5
How stitches are formed . . . . . . . . 1-23
Humidity . . . . . . . . . . . . . . . . 1-6
I
Improper backing . . . . . . . . . . . . 3-1
Improper threading . . . . . . . . . . . 3-2
Initializing Machine Conditions - NR/NB
. . . . . . . . . . . . . . . . . . . . . 4-16
Initializing Machine Conditions on the
NS/NY . . . . . . . . . . . . . . . . . 4-14
Inserting the bobbin . . . . . . . . . . 1-21
J
Jackets . . . . . . . . . . . . . . . . . 1-30
L
Leveling an arm type machine . . . . . 1-2
Looping . . . . . . . . . . . . . . . . . 3-4
Lubrication . . . . . . . . . . . . . . . 2-2
Arm Type Head. . . . . . . . . . . 2-5
Bridge Type Head . . . . . . . . . 2-7
ZN/ZQ Type Head . . . . . . . . . 2-3
M
Machine Basics . . . . . . . . . . . . . 1-1
Machine Care . . . . . . . . . . . . . . 2-1
Machine Conditions. . . . . . . . . . . 4-1
Appliqu . . . . . . . . . . . . . . 4-11
Auto Start . . . . . . . . . . . . . . 4-9
Back Limit. . . . . . . . . . . . . 4-11
Borer . . . . . . . . . . . . . . . . 4-1
Clamp Frame . . . . . . . . . . . 4-13
Draw Mode . . . . . . . . . . . . 4-13
Frame Start . . . . . . . . . . . . 4-12
Front Limit . . . . . . . . . . . . 4-11
J-Con . . . . . . . . . . . . . . . . 4-2
Jump Divide . . . . . . . . . . . . 4-7
LCD Bright . . . . . . . . . . . . 4-12
LCD Mode . . . . . . . . . . . . 4-12
Left Limit . . . . . . . . . . . . . 4-11
Low Speed . . . . . . . . . . . . . 4-6
Needle Down . . . . . . . . . . . 4-12
O Admit. . . . . . . . . . . . . . . 4-9
Overlap . . . . . . . . . . . . . . . 4-8
Right Limit . . . . . . . . . . . . 4-11
Roll to Roll . . . . . . . . . . . . 4-11
SF Spectacle Frame . . . . . . . . 4-13
Stitch Back . . . . . . . . . . . . . 4-8
Stitch Clamp . . . . . . . . . . . . 4-1
Swing . . . . . . . . . . . . . . . . 4-9
T-Break . . . . . . . . . . . . . . . 4-7
T-Break Off. . . . . . . . . . . . . 4-8
Trim Dir . . . . . . . . . . . . . . 4-10
Trim Jumps . . . . . . . . . . . . . 4-1
Trim On/Off . . . . . . . . . . . . 4-3
Trim Vector . . . . . . . . . . . . 4-10
V. Motor. . . . . . . . . . . . . . 4-25
WS System . . . . . . . . . . . . 4-11
Machine Conditions - NR/NB . . . . . 4-15
Machine Conditions - NS/NY . . . . . 4-13
Machine Installation . . . . . . . . . . 1-1
Machine lubrication. . . . . . . . . . . 2-2
Machine Options . . . . . . . . . . . . 5-1
Distancing Board . . . . . . . . . . 5-3
Drop Table System . . . . . . . . . 5-1
Roll to Roll . . . . . . . . . . . . . 5-7
Sock Frame . . . . . . . . . . . . . 5-3
Spider Hoops . . . . . . . . . . . . 5-2
WS System . . . . . . . . . . . . 5-10
Machine Parameters. . . . . . . . . . . 4-1
Machine Setup Parameters. . . . . . . 4-21
Maintenance Log . . . . . . . . . . . 2-13
Mark 4 & 6 Trimmer Programs . . . . 4-18
MC Parameters . . . . . . . . . . . . . 4-1
Millimeter Conversion Chart . . . . . 1-31
MSU . . . . . . . . . . . . . . . . . . 4-21
MSU Parameters
ATC Option . . . . . . . . . . . . 4-25
ATC Type . . . . . . . . . . . . . 4-24
Brake Type . . . . . . . . . . . . 4-26
C. Change Type . . . . . . . . . . 4-27
Clamp Off Angle . . . . . . . . . 4-24
Detect Des. . . . . . . . . . . . . 4-21
F. (Frame) Motor Type . . . . . . 4-27
Frame Param . . . . . . . . . . . 4-22
H. Motor. . . . . . . . . . . . . . 4-25
H. Sensor . . . . . . . . . . . . . 4-26
Jump on Time . . . . . . . . . . . 4-23
Light Curtain . . . . . . . . . . . 4-28
M. Option . . . . . . . . . . . . . 4-28
Max Speed. . . . . . . . . . . . . 4-21
Motor Ratio . . . . . . . . . . . . 4-23
Needles . . . . . . . . . . . . . . 4-21
Origin Sensor . . . . . . . . . . . 4-26
P. Coder . . . . . . . . . . . . . . 4-25
Roll to Roll Type . . . . . . . . . 4-27
Slow Down Speed. . . . . . . . . 4-23
Slow Down Start . . . . . . . . . 4-22
Stop Angle. . . . . . . . . . . . . 4-23
V. Sensor . . . . . . . . . . . . . 4-26
WS Head Space . . . . . . . . . . 4-27
WS Type . . . . . . . . . . . . . 4-27
N
Needle Anatomy . . . . . . . . . . . . 1-22
Needle breaks . . . . . . . . . . . . . . 3-2
Needle Eye . . . . . . . . . . . . . . . 3-4
Needle Insertion . . . . . . . . . . . . 1-34
Needle problems . . . . . . . . . . . . 3-2
Needle Replacement . . . . . . . . . . 1-34
Needle Types . . . . . . . . . . . . . 1-34
Needles/Backings Chart . . . . . . . . 1-35
Nylon Backing. . . . . . . . . . . . . 1-33
O
Oil ports . . . . . . . . . . . . . . . . . 2-6
Oiling
ZQ Bridge Head . . . . . . . . . . 2-9
Oiling Bridge Type Head . . . . . . . . 2-7
Oiling the Arm Type Head . . . . 2-5 - 2-6
Oiling the hook assembly . . . . . . . . 2-2
Oiling the ZQ/ZN Head. . . . . . . . . 2-4
P
PCB Board, faulty. . . . . . . . . . . . 3-1
Pillow cases . . . . . . . . . . . . . . 1-30
Position Finger Adjustment . . . . . . 3-15
Positioning the design on the garment . 1-29
Presser Foot . . . . . . . . . . . . . . . 1-8
Pretensioners . . . . . . . . . . . . . . 1-8
R
Replacing a needle. . . . . . . . . . . 1-34
Replacing Bobbins. . . . . . . . . . . 1-21
Replacing the bobbin case . . . 1-21 - 1-22
Replacing the Take-Up Spring . . . . 3-11
Restarting a Sewing head . . . . . . . 1-20
Roll to Roll Simulation . . . . . . . . . 5-9
Running an I Test . . . . . . . . . . . 1-24
S
Safety Instructions . . . . . . . . . . . 1-3
Scarf of the needle . . . . . . . . . . . 1-22
Setting Soft Limits. . . . . . . . . . . 4-19
Setting Sub Soft Limits . . . . . . . . 4-20
Setting the Field Limits . . . . . . . . 3-17
Sewing Head Components . . . . . . . 1-8
Sewing Head Controls . . . . . . . . . 1-19
Sewing Preparation . . . . . . . . . . 1-29
Sewing Socks . . . . . . . . . . . . . . 5-5
Sewing speed vs. application . . . . . . 3-3
Sheets . . . . . . . . . . . . . . . . . 1-30
Shirt Cuffs . . . . . . . . . . . . . . . 1-30
Shirt Pockets . . . . . . . . . . . . . . 1-30
Shirts . . . . . . . . . . . . . . . . . . 1-30
Sock Frame . . . . . . . . . . . . . . . 5-3
Soft LImits . . . . . . . . . . . . . . . 4-18
Specifications, Environmental . . . . . 1-6
Spectacle Boards . . . . . . . . . . . . 5-6
Speed, sewing . . . . . . . . . . . . . 4-17
Spider Hoops . . . . . . . . . . . . . . 5-2
Installing the Spider Hoop on a
Rectangular Pantograph . . . . . . 5-2
Stitch formation . . . . . . . . . . . . 1-23
Stitch Theory. . . . . . . . . . . . . . 1-22
Sub Soft Limits . . . . . . . . . . . . 4-20
T
Take-Up Lever . . . . . . . . . . . . . 1-8
Take-Up Spring . . . . . . . . . . . . . 1-8
Take-up spring adjustment . . . . . . . 3-4
Take-Up Spring Adjustment . . . . . . 1-28
Take-Up Spring Replacement . . . . . 3-11
Take-up spring, faulty. . . . . . . . . . 3-3
Temperature. . . . . . . . . . . . . . . 1-6
Tension adjustments . . . . . . . . . . 1-24
Tension problems . . . . . . . . . . . . 3-3
Thread Break Detection . . . . . . . . 1-19
Thread Break Detectors . . . . . . . . . 1-8
Thread Break Switch . . . . . . . 1-8,1-19
Thread Breaks. . . . . . . . . . . . . . 3-3
Thread Detection LED . . . . . . . . . 1-8
Thread frays . . . . . . . . . . . . . . . 3-4
Thread Guide . . . . . . . . . . . . . . 1-8
Thread Trimmer Programs. . . . . . . 4-18
Threading a YS/YN Head . . . . . . . 1-13
Threading a ZN Head . . . . . . . . . 1-18
Threading a ZN Head with the UTSM 1-17
Threading a ZQ Head with the UTSM 1-10
Threading the Sewing Head . . . 1-10,1-13
Threading the YS/YN Head . . . . . . 1-15
Ties. . . . . . . . . . . . . . . . . . . 1-30
Timing the Hook. . . . . . . . . . . . 3-13
Top tension problem. . . . . . . . . . 1-25
Top Thread Detection . . . . . . . . . 1-19
Top Thread Tensioners . . . . . . . . . 1-8
Top thread tensions . . . . . . . . . . 1-24
Trimmer Programs. . . . . . . . . . . 4-18
Troubleshooting. . . . . . . . . . . 3-1,3-5
Backing . . . . . . . . . . . . . . . 3-1
Bobbin problems . . . . . . . . . . 3-2
Broken hook point . . . . . . . . . 3-2
Digitizing in design problem . . . . 3-3
Fabric puckering . . . . . . . . . . 3-1
Hooping problem. . . . . . . . . . 3-1
Lack of lubrication . . . . . . . . . 3-3
Looping. . . . . . . . . . . . . . . 3-4
Needle Breaks . . . . . . . . . . . 3-2
Needle problem. . . . . . . . . . . 3-3
Needle problems . . . . . . . . . . 3-2
Needle, bent . . . . . . . . . . . . 3-2
Oiling problem . . . . . . . . . . . 3-3
On/off switch, faulty . . . . . . . . 3-1
PCB Board, faulty . . . . . . . . . 3-1
Sewing head off . . . . . . . . . . 3-1
Take-up spring, faulty . . . . . . . 3-1
Tension problems. . . . . . . . . . 3-1
Thread Breaks . . . . . . . . . . . 3-3
Threading problem . . . . . . 3-1 - 3-2
Timing problem. . . . . . . . . . . 3-2
Turning off a sewing head . . . . . . . 1-20
U
UTSM. . . . . . . . . . . . . . . . . . 1-8
UTSM Bobbin Detection . . . . . . . 1-19
UTSM Switch . . . . . . . . . . . . . 1-19
V
Voltage . . . . . . . . . . . . . . . . . 1-1
W
Warning . . . . . . . . . . . . . . . . . 1-4
Wash cloths . . . . . . . . . . . . . . 1-30
Water Soluble Topping . . . . . . . . 1-33
WS System. . . . . . . . . . . . . . . 5-10
Group Codes . . . . . . . . . . . 5-12
Z
ZN/ZQ Arm Type Head. . . . . . . . . 2-3
ZQ Bridge Type Head. . . . . . . . . . 2-9

Barudan N Series Manual Mecanico

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