Barudan N Series Manual Mecanico

N SERIESM e c h a n i c a l G u i d e

Copyright 4/01BARUDAN CO., LTD.

906 Josuiji, Ichinomiya-city, Aichi-pref., JapanPhone: 0586-76-1137Fax: 0586-77-1499

Table of Contents

Chapter 1 Machine Basics 1-1

Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . 1-3Danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

NS/NR Machines (220V 3 Phase) . . . . . . . . . . . . . . . . . . 1-5NY/NB Machines (120V Single Phase). . . . . . . . . . . . . . . . 1-6

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-6Sewing Head Components. . . . . . . . . . . . . . . . . . . . . . . . . 1-8Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-10Threading the Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-13Sewing Head Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Thread Break Detection . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Disengaging a Sewing Head . . . . . . . . . . . . . . . . . . . . . . . 1-20Replacing Bobbins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Stitch Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Needle Anatomy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Important Conditions For Forming Stitches . . . . . . . . . . . . . 1-23Tension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24Top Thread Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24Adjusting the Top Tension . . . . . . . . . . . . . . . . . . . . . . . . 1-25Adjusting the Bobbin Tension . . . . . . . . . . . . . . . . . . . . . . 1-27Take-Up Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . 1-28Sewing Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29Positioning the Design on the Garment . . . . . . . . . . . . . . . . . 1-29

Millimeter Conversion Chart . . . . . . . . . . . . . . . . . . . . 1-31Backing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

Backing Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . 1-31Softouch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32Tearaway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32Cutaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33Nylon Backing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33Backing Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Water Soluble Topping . . . . . . . . . . . . . . . . . . . . . . . 1-33Needle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

Needle Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34Needles/Backing Chart . . . . . . . . . . . . . . . . . . . . . . . 1-35

Chapter 2 Machine Care 2-1

Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Bobbin Case Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Hook Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2-1Machine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2ZN/ZQ Arm Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3YN/YS Arm Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5YN/YS Bridge Type Head. . . . . . . . . . . . . . . . . . . . . . . . . 2-7ZQ Bridge Type Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Chapter 3 Troubleshooting 3-1

Quick Fixes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Error Codes and Display Prompts . . . . . . . . . . . . . . . . . . . . 3-5Take-Up Spring Replacement . . . . . . . . . . . . . . . . . . . . . . 3-11Hook Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Position Finger Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3-15Field Limit Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Chapter 4 Machine Parameters 4-1

Machine Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Machine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Reducing Speed Based On Stitch Length . . . . . . . . . . . . . . 4-17Long Stitches Divided Into Jumpstitches . . . . . . . . . . . . . . 4-17

Thread Trimmer Programs . . . . . . . . . . . . . . . . . . . . . . . . 4-18Soft Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Sub Soft Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20MSU - Machine Setup Parameters . . . . . . . . . . . . . . . . . . . . 4-21

Chapter 5 Machine Options 5-1

Drop Table System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Spider Hoops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Distancing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Sock Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Spectacle Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6Roll To Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Roll To Roll Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9WS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

WS Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10WS Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12WS Type 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Group Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12Sewing Start Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13Pattern Origin is in the Center . . . . . . . . . . . . . . . . . . . . 5-14Pattern Origin is notin the Center . . . . . . . . . . . . . . . . . . 5-15

Chapter 1 Machine Basics

Machine Installation

Normally, your machine is installed by a technician. Instructions are provided if the machineever needs to be moved. Check that you have all accessories from the installation kit:

· Leveling BoltsArm type machine: four (4) leveling feet and four (4) leveling bolts for thefour and six head machines; and six (6) leveling bolts for the twelve andfifteen head machines.Bridge type machine: five (5) leveling pads.Note: For the NYHE-ZQ -B04 model, the four (4) leveling bolts arelocated next to each of the casters. Place a Mounting Base under eachLeveling Bolt and adjust the Bolts so the weight of the machine isslightly off of the Casters.

· Light FixtureAlready assembled above the sewing area. The 110Vmachines have a separate power cord for the Lamp Assembly. Therefore,they need to be plugged into a separate outlet.Do not plug into the outleton the front of the Driver Box..

· Felt Pads(one per needle per sewing head) If necessary, place a Felt Padon 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 regardingvoltage, have a qualified electrician check it.

· NY/NB- The voltage should be 100v to 120v. If in doubt regardingvoltage, 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 boxpower 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 amanual 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 theinstallation kit.

2. Install the adjusting bolts in the appropriate slots. Adjust so they support themachine without lifting it. See the illustration above.

CAUTION: If you tighten the bolts more than 30 degrees, you may causethe 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 outletimmediately 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 thisembroidery machine is used by, or near children.

· Use this embroidery machine only for its intended use as described in thismanual.

· Use only attachments recommended by the manufacturer, as contained inthis 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. Contactyour distributor for repairs or service by an authorized, qualifiedtechnician.

· Never operate the embroidery machine with any air openings blocked.Keep ventilation openings of the machine free from the accumulation oflint, 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 whereoxygen is being administered.

· To disconnect, turn all controls to the off position, then remove the plugfrom the outlet.

· Do not unplug by pulling on the cord. To unplug, grasp the plug, not thecord.

· Keep fingers away from all moving parts. Special care is required aroundthe sewing machine needles.

· Always use the proper needle plate. The wrong plate can cause the needleto 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 theneedle area, such as threading the needle, changing a needle, replacing thebobbin, changing the presser foot, or the like.

· Always unplug the machine from the electrical outlet when removingcovers, lubricating or when making any other user servicing adjustmentsmentioned in the instruction manual.

· Connect this embroidery machine to a properly grounded outlet only. SeeGrounding Instructions.

· Always unplug before relamping. Replace bulb with same type ratedWatts.

· Keep fingers away from moving parts, especially the area near trimmerblades.

Grounding Instructions

This product must be grounded. In the event of malfunction or breakdown, groundingprovides 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 agrounding plug. The plug must be plugged into an appropriate outlet that is properly installedand grounded in accordance with all local codes and ordinances.

DANGER! Improper connection of the equipment-grounding conductorcan result in a risk of electric shock. The conductor with insulation havingan outer surface that is green, with or without yellow stripes, is theequipment-grounding conductor.Do not connect the equipmnet-groundingconductor 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, orif in doubt as to whether the product is properly grounded. Do not modify the plug providedwith the product Ð if it will not fit the outlet, have a proper outlet installed by a qualifiedelectrician.

NS/NR Machines (220V 3 Phase)

This product is for use on a circuit having a nominal rating more than 120-V, and isfactory-equipped with a specific electric cord and plug. No adapter should be used with thisproduct. If the product must be reconnected for use on a different type of electric circuit, thereconnection should be made by qualified service personnel; and after the reconnection, theproduct should comply with all local codes and ordinances.

NY/NB Machines (120V Single Phase)

This product is for use on a nominal 120Vcircuit, and has a grounding plug that looks likethe plug illustrated. A temporary adapter, whichlooks like the adapter illustrated in sketches Band C, may be used to connect this plug to a2-pole receptacle as shown in sketch B if aproperly grounded outlet is not available. Thetemporary adapter should be used only until aproperly grounded outlet can be installed by aqualified electrician. The green colored rigidear, lug, and the like, extending from the adapter must be connected to a permanent groundsuch as a properly grounded outlet box cover. Whenever the adapter is used, it must be heldin 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 samefor 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. Whenproblem 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 bymachine 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 oroverstitching.

8.Thread Detection LED- LED shows top thread problem by blinking red, bobbinthread 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 beenmade. 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, placethe new cone on the thread stand. Blow the thread through the tube and tie the end to thethread that is threaded through the tension unit with a square knot and gently pull it throughthe sewing head. Repeat for each needle. To completely rethread a sewing head, follow thesesteps 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 isnumbered according to needle.

· Place a circular felt pad and cone of thread on each spindle of the threadstand.

· 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. Thethread 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 andone-half times around the wheel and take the thread down to the left side of boththe top and bottom pegs.

4.Pull the thread to the right of the tensioner assembly and wrap it one and one-halftimes between the nylon wheels and over the take-up spring.

NOTE: To ensure proper threading, pull the thread down, and check thatthe 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 guidefrom 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 threadcan go through the hole, then pass the thread through the last eyelet.

12.Optionally, thread the small pigtail that circles the needle, immediately below theapron. Either pass the thread through from the top, or pass it through the smallopening on the right side of the pigtail.

13.Thread the eye of the needle from front to back and pass the thread through thelarge hole in the presser foot.

· After all needles have been threaded, replace the felt pad to avoid kinksand loops in the thread.

Threading the Sewing Head

The machine is shipped with each needle pre-threaded. To quickly change the thread, placethe new cone on the thread stand, tie the end to the thread that is threaded through the threadstand 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 onthe facing page.

Threading a YS/YN Head

1.Place the circular felt pad on the thread stand before placing the new thread coneon the thread stand.

2.Pull the thread from the cone through the eyelet on the thread stand that is directlyabove the cone.

3.Take the thread through the top eyelet of the first tensioner then to the right of thetensioner between the silver discs and through the bottom eyelet of the tensioner.

NOTE: Depending on thread type and fabric used, the tensioner may bethreaded differently, always starting at bottom.

4.Take the thread through the top eyelet of the second tensioner then to the right ofthe tensioner between the silver discs and through the bottom eyelet of thetensioner.

5.Pull the thread to the right of the tensioner assembly and wrap it one and one-halftimes between the nylon wheels and over the take-up spring.

NOTE: To ensure proper threading, pull the thread down, and check thatthe 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 guidefrom 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 thethread can go through the hole, then thread through the last eyelet.

· Optionally, thread the small pigtail that circles the needle, immediatelybelow the apron. Either pass the thread through from the top, or pass itthrough 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 forSteps 1-2 and 8-17.

1.Place the circular felt pad on the thread stand before placing the newthread cone on the thread stand (1).

2.Pull the thread from the cone through the eyelet on the thread standthat is directly above the cone (2).

3.Take the thread through the top eyelet of the first tensioner (3) then tothe right of the tensioner between the silver discs and through thebottom eyelet of the tensioner.

4.Take the thread from the left to right of the UTSM tension wheel andwrap 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 itone and one-half or two and one-half times between the nylon wheelsand 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 thethread can go through the hole, then thread through the last eyelet (13).

Optionally, thread the small pigtail that circles the needle, immediatelybelow the apron. Either pass the thread through from the top, or pass itthrough the small opening on the right side of the pigtail.

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 standthat is directly above the cone.



5.Take the thread down to the top peg and wrap it around the bottom of the peg fromleft 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.

8.Pull the thread to the right of the tensioner assembly and wrap it one and one-halftimes between the nylon wheels and over the take-up spring. To ensure properthreading, pull the thread down, and check that the take-up spring bounces up anddown with the thread movement.










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 standthat is directly above the cone.



5.Pull the thread to the right of the tensioner assembly) and wrap it one and one-halftimes between the nylon wheels and over the take-up spring.

NOTE: To ensure proper threading, pull the thread down, and check thatthe take-up spring bounces up and down with the thread movement.










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 andwhich heads will sew.

Thread Break Detection

Thread Break The Thread Break Switch enables both the top and bobbin threadSwitch 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 inthe down position. (For ZN/ZQ machines, this switch also cancelsthe sewing head.)

Top Thread The top thread detection is controlled with the brass post locatedDetection next to the take-up spring on the lower tension assembly.

It acts as a sensor, detecting top thread breaks. If the thread breaksor goes slack, a small current is conducted through the brass postduring the stitch cycle, causing the LED on the sewing head to flashred, indicating a thread break. The sewing head will stop and thepantograph will automatically move back a few stitches. If you needto back up farther in the pattern, see Repairing Missed Stitches.

UTSM - Bobbin The bobbin thread detection is controlled by the UTSM (UnderThread DetectionThread Sensor Mechanism).

UTSM Switch The UTSM switch must be on (UP position) to enable bobbin threaddetection. Note: The Thread Detection Switch and the UTSMswitch must both be on (up position).

ONHead Switch

Press buttonfor automend

Red LED lightsto indicate the headis sewing andblinks to indicateneedle 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 isstopped, turn off the thread break switch by placing it in the down position; to restart the headplace 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 machinesewing.

CAUTION! A sewing head must never be turned off whilethe machine is sewing.

2. Switch off the appropriatethread break switch. This willcancel the thread break detection on this head.

3.Engage thehead shut-off pinto prevent the needles frommoving up and down. Pull the pin forward.

NOTE: It is best to do a manual thread cut beforedisengaging a head so that when it is restarted, the needledoes 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 themachine 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 solenoidwill 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 wereactivated, the head that was just turned on will also have its thread keep solenoidclamp activated.

NOTE: To prevent the active needle of a head that has been turned backon from becoming unthreaded, you should hold on to the end of the threadwhile moving the Start/Stop bar to resume sewing.

Replacing Bobbins

The machine is shipped to you with bobbins in place, ready tosew. Follow these steps when you need to replace a bobbin.

The bobbins are enclosed in the bobbin cases, which must beremoved in order to replace the bobbin.

Removing the Bobbin Case

1.Pull the bobbin case latch toward you, and the casewill slide out of the hook assembly.

· On an E type cylinder bed machine, first open the hinged hook guard toexpose the bobbin case.

Inserting the Bobbin in the Case

1.Place the bobbin in the case, so that the bobbin rotates clockwise when you pullthe 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 frontof 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 thehook 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 distinctªclickº. 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 hookassembly. If resistance is felt, remove the bobbin case, realign the case withthe hook and reinsert it.

Stitch Theory

To fix problems that may occur as you are sewing, it is important to understand how stitchesare 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 formingstitches.

Eye Carries the top thread through thefabric and into the bobbinassembly.

Scarf Small notch, or cutout, on the backof the needle that provides theclearance needed for the hookpoint to pass without striking the needle during stitch formation.

Groove Small groove, or channel, on the front of the needle that providesthe thread a place to sit, protecting it as the needle penetrates thefabric.

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 threadbehind the needle.

3.As the needle rises, the hook point passes behind the scarf, picking up the loop ofthread from the back of the needle.

4.As the needle continues to rise, the point of the hook pulls the loop of threaddown. 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 tightenedby the upper and lower tensions. The needle reaches its highest point and beginsthe 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 beconsidered when making adjustments. The top thread, located in the thread stand, iscontrolled by the top tension; and the bobbin thread, located in the bobbin case, is controlledby the bobbin tension. These tensions determine the quality of the embroidery. Factors suchas 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 settingthe proper tensions.

The top tension and bobbin tension work together to form stitches, but they are adjustedseparately. Tension should be set to allow 30% bobbin thread to show on the reverse side ofthe embroidery. For example, if the bobbin thread is white and the top thread is blue, theunderside view of the stitch will be white in the center, representing one third of the totalstitching, 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 ªIº Test

1.Barudan supplies a sew test disk with every machine. Using the I Test on the sewtest disk, Sew one ªIº, change to the next needle, sew another ªIº, change to thenext needle, and so on.

2.Turn the sample over and look at the back of the stitching. Proper tension wouldshow two thirds top thread color and one third bobbin thread.

Well Balanced The top row of I's in the illustration above show properly adjustedTension 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 noProblem bobbin thread. All the letters have the same problem, so the bobbin

tension needs adjustment. Bobbin tension, since it is controlled byone tensioning mechanism, will be consistent from one needle to thenext. In this example, the tension should be looser.

Top Tension The bottom row of I's in the illustration above show letters that lookProblem quite different from one another. Top tension will vary from needle

to needle, since each needle tension is controlled by three differenttensioning points. Letters #1, #2 and #7 show too much bobbinthread; letters #3, #4 and #9 have hardly any bobbin threadshowing; 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 topthread to the back. Letters #3, #4 and #9 need the top tension tightened because there is toomuch 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 thecone 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 onlyneed adjustment when you change from a light weight thread to a heavier weight, or viceversa.

Adjusting the Pretensioners

1.If the thread does not flow freely, loosen the pressure on the spring that holds thedisk down by turning the thumb nut counterclockwise.

2.If the thread flows too freely, increase the pressure on the spring that holds thedisk down by turning the thumb nut clockwise.

The top tensioners controls the top thread tension. If the top tension is too tight, the bobbinwill not be able to pull enough of the top thread to the back of the embroidery. Top tensionthat is too tight may cause thread breaks, needle breakage, or puckering of the fabric. If thetension is too loose, the bobbin will pull too much of the top thread to the back of theembroidery, causing the thread to loop on either the top side or the back side of themonogram, possibly both. The monogram will look rough, and will not lie smoothly on thefabric. 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 orthread. 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 anarrow between them. Turn the top tension diskclockwise, toward the+ sign, totightenthe top thread tension.

2.Turn the top tension diskcounterclockwise, toward the- sign, toloosenthe topthread 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 somuch 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. Totest the tension, insert a bobbin in the case and slowly pull the end of the thread. The threadshould 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 allnew 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 underthe thread tension spring on the bobbin case may hold the spring awayfrom the thread, diminishing the tension. BEFORE MAKING ANYADJUSTMENTS TO THE BOBBIN CASE, check this area for lint orthread. If the built up lint or thread is overlooked, the operator could beadjusting bobbin tension to no avail. Over tightening the bobbin tensionwill bend the top of the tension spring and the bobbin case will have to bereplaced.

Adjusting the Bobbin Tension

1.Turn the screw on the bobbin caseclockwisetotightenbobbintension.

2.Turn the screw on the bobbin casecounterclockwisetoloosenthebobbin tension.

Once the tensions have been adjusted forthe type of thread you plan to use, onlyminor changes will be needed as thefabric, letter size, and alphabet stylechanges.

Take-Up Spring Adjustment

Located behind each upper plastic tension disc is a hook spring called the tension take-upspring. The tension take-up spring picks up the excess slack on the thread while the machineis sewing. This is particularly important when the machine is sewing small letters. Thetake-up spring may require adjustment for two reasons.

Fabric You may find it necessary to adjust the tension take-up spring whenChange 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 thickerfabric, tighten the tension. Follow the steps listed below foradjusting the take-up spring tension.

False Thread There may be a time when you notice that the machine isBreak Detection experiencing constant thread break detection's. The machine keeps

stopping, but the thread is not broken. When this occurs, the tensiontake-up spring is too tight.

Adjusting the Take-up Spring

1.Toloosenthe tension, insert ascrewdriver into the post and turncounterclockwise, no more than 1/8 ofa turn. Sew off a sample to check thetension. Repeat the procedure ifnecessary.

2.Totightenthe tension, insert ascrewdriver into the post and turnclockwise, 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. Beforehooping, use Float, the H and V values or Perimeter Trace to determine the pattern size andchoose 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 theembroidery appears straight. It is best to use a framing board system which holds the hoopstationary 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 customerpreference, size and style of the garment, size and style of the design and the degree ofdifficulty in working with the garment. We have assembled some guidelines for placingdesigns on some popular garments. These measurements are approximate and refer to thecenter point of the entire design.

NOTE: Monograms and names should be placed on the left front unlessotherwise specified. For children's clothing, these measurements should bescaled down.

EMBROIDERY PLACEMENT GUIDELINES

Millimeter Conversion Chart

The chart below will help you convert fractional inches to millimeters.

FRACTIONALINCH

MILLIMETEREQUIVALENT

Backing Materials

The use of backing materials and/or toppings will enhance your embroidery. The type ofbacking needed is determined by the fabric being embroidered. In most cases, backing will beneeded to prevent stitches from pulling and distorting the garment. Backing materials givestrength to unstable fabrics (knits) and a better appearance on woven fabrics (less puckeringand pulling).

Fabrics fit into three general categories

Wovens Non-stretch materials such as satin jackets, towels, denim andcanvas.

Knits Stretch materials such as sweaters, sweatshirts, jerseys andt-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 andbacking, 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 tonon-adhesive. All serve different purposes. The most universal backings are medium-weighttearaway or cutaway types.

Too much backing is just as bad as not enough. Use one piece of medium-weight backing ortwo pieces of light-weight backing as a general rule. Heavier fabrics generally have a tighterweave and will need less backing.

Backing should be cut to completely fit in the hoop, not just as a strip to fit across the centerof 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. Softouchbacking is used with many knits and stretch fabrics. These materials cannot be pulled tightlyin a hoop by themselves because they will stretch out of shape. Softouch is used to addstability to the garment while it is being sewn. Without Softouch backing, knits will not holdthe 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 itunderneath the area of the garment that is going to be monogrammed. Hoop the garment asusual, using the backing material as though it were part of the garment. Make sure that thegarment is as smooth and snug as possible in the hoop. You may wish to use a dissipatingbonding adhesive spray to bond the backing to the garment for better stability.

Cut away the excess backing after embroidering, leaving a small margin around theembroidery. Do not cut the backing between letters and designs. Leaving it in place givesadded stability to the embroidery after laundering.

Softouch can also be used with thinner woven fabrics to give better clarity and detail tointricately embroidered designs.

Tearaway

Tearaway is a non-woven material that provides some of the stability of Softouch, but can betorn away like paper. It is used with non-stretch fabrics. It is hooped in the same manner asSoftouch, 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 helpreduce puckering and pulling on these fabrics.

Cutaway

Cutaway backings include a large assortment of fabrics: heavy nonwovens, woven cottonbuckram; and woven nylon polyester. A cutaway backing is a fuller product and providesmore support than tearaway backing. Cutaway backings are generally more expensive but aremore popular with experienced operators.

Nylon Backing

Nylon backing is used with many knits and stretch fabrics. Use nylon as a substitute forSoftouch if the design is not worn against the skin. Hooping procedures for nylon areidentical 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 allowsthe hooped garment to move smoothly while sewing, decreasing the chance of dragging. Thebacking paper is not put in the hoop with the material, but is placed under the hoop, betweenthe garment and the sewing surface. When the embroidery is finished the paper can be pulledaway.

CAUTION! Backing paper has a tendency to shred during sewing. Smallpieces of paper can get caught in the hook and jam the machine. Be sure toclean 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 knitfabrics, 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 toppingoutside 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 toppingparticles. 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 fewminutes.

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 fabricPoint 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-wovenPoint 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 theneedle.

3.Insert the new needle as far up as possible. Make sure the groove on the needle isfacing the front of the sewing head. An improperly inserted needle will not onlynot 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 Stitchesmagazine. Use it as a quick reference for thematerial covered in this chapter.

NEEDLES/BACKING CHART

FABRICNEEDLE

SIZE/TYPEBACKING TOPPING COMMENTS

NEEDLES/BACKING CHART

FABRICNEEDLE

SIZE/TYPEBACKING 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 ofbuilt-up lint and dust.

· You should have both soft-bristle and stiff-bristle brushes and a shop vacavailable 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 oilthat may splatter when the machine is oiled.

· Periodically vacuum the vents of the driver box. Do not use compressedair 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 cleanedevery four hours. Brushlint and dust out of the bobbin case. Failure to keep the bobbin case clean can cause tensionproblems. If tension is adjusted without first removing dust and lint, the tension spring on thebobbin 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 onpage 1-27.

Hook Assembly Maintenance

The hook assembly should becleaned every four hourswhen the machine is used in anormal production setting. The hook assembly should beoiled 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. Ifyou can't remove all the lint/dust with a brush, use compressed air to blow thehook assembly clean.

It is best to oil at the end of the day, when the machine will be idle, so excess oil can drip offthe assembly.

Oiling the Hook Assembly

1.With all lint and dust removed from the hook assembly, place one drop ofclearsewing machine oilin the raceway. A hypodermic oiler works best because itoffers 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 lubricationfrequencies. The diagrams and charts on the following pages are a guide for the lubricationschedule necessary to keep the machine running properly. Refer to the appropriatediagram/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

THE MACHINE SHOULD ALWAYS BE TURNED OFF BEFORE IT IS OILED.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 manyhead components without removing the entire cover.

THE MACHINE SHOULD ALWAYS BE TURNED OFF BEFORE IT IS OILED.OILING PROCEDURES ARE BASED ON AN 8 HOUR WORKDAY.

B2F1

A1

B1D2

E1

E1

D3

D3

B3

E4

E3

D2

E2

F1

B2

B2

B2

A1

C1D1

B5

YN/YS BRIDGE TYPE HEAD OILING


ZQ Bridge Type Head

THE MACHINE SHOULD ALWAYS BE TURNED OFF BEFORE IT ISOILED. OILING PROCEDURES ARE BASED ON AN 8 HOURWORKDAY.

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. Theillustrations below show these locations.

CAUTION! For continued protection against risk of fire and electricshock, replace with same type and rating of fuse. Disconnect power beforeservicing.

USE RECOMMENDED REPLACEMENT FUSES OR UL EQUIVALENT

LOCATIONAMP

RATINGREPLACEMENT

TYPE

Maintenance Log

DATE INITIALS CLEANEDPART

LUBRICATEDTYPE OF

LUBRICANTPROBLEMS

Chapter 3 Troubleshooting

Quick Fixes

There are a number of problems that you may encounter while sewing that can be simplyremedied.

PROBLEM CAUSE SOLUTION




Error Codes and Display Prompts

The chart below explains the various prompts displayed during operation and tells you theappropriate action. The chart also includes the machine error codes and steps necessary tocorrect machine malfunctions.

ERROR CODES

Take-Up Spring Replacement

After repeated adjustments, the take-up spring may begin to showwear. You may notice that adjusting the take-up spring no longercorrects tension problems. In this case, you need to replace thetake-up spring.

Replacing the Take-Up Spring

1.Remove the outer tension knob, turning itcounterclockwiseuntil 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 feltdisc.

5.Remove the second white plastic disc (flat). You may need to push onit from behind with the blade of a flat screwdriver.

Notice the position of the take-up spring in reference to the assemblyport. 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. Makesure the new spring rests against the brass post.

8.Replace the white plastic disc with the flat side facing you. Make sure itisfirmly seated on top of the brass post(it will partially cover thepost) so the take-up spring cannot go around the post. The white plasticdisc 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 itclockwiseuntil 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 theMechanical Guide.

Hook Timing

Hook timing is probably the most misunderstood aspect of embroidery machine mechanics. Ithas nothing to do with the type of fabric, tension or synchronization of the heads on amultihead machine.

Hook timing is the proper position of the hook assembly in relation to theneedle in order to form a stitch. The hook is directly attached to the drive shaft, eliminatingthe need to routinely re-time it. Re-timing of the hook only becomes necessary due to externalfactors.

· 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 failsto 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 themain motor drive belt. Remove the cover to access it.

The main drive pulley on a bridge machine is located on the side of themachine opposite the automat under a metal cover.

Always rotate the main drive pulley in the direction that rotates the hookcounterclockwise.

4. Rotate the main drive pulley to where the indicator point to 24 degrees. The pointof the hook should be directly behind the scarf of the needle and above the needleeye.

5.Check the hook-to-needle clearance. There shouldbe approximately one half to one thread-widthclearance between the hook point and the back ofthe needle. Improper adjustment would cause thehook point to miss the small loop and create askipped stitch.

6.Replace the covers.

Adjusting the Hook Timing

1.Clean any thread debris or lint from the hook areawith compressed air.

2.Loosen the three screws at the rear of the hook. Thiswill 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 theindicator points to 24 degrees. The point ofthe hook should be directly behind the scarf ofthe needle and above the needle eye.

5.Check the hook-to-needle clearance. Thereshould be approximately one half to onethread-width clearance between the hookpoint and the back of the needle. Improperadjustment would cause the hook point to miss the small loop and create a skippedstitch.

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 anH O Xtest as follows:

· Using a block alphabet, programªH O Xºin capital letters, 20mm high,into the machine. These letters are used because they encompass all thevarious directions of the pantograph.

· Sew the letters.

· Check for any irregularities in the sewing. If the machine is not properlytimed, it will result in skipped stitches.

Position Finger Adjustment

The adjustable position finger is mounted in front of the hook assembly to secure the hookbasket in place and balance the bobbin thread down the center of the embroidery. Theposition finger is adjustable in two directions, left to right, and front to back. Adjustment ofthe position finger is required if the bobbin thread is running left or right of center, or if theposition finger was removed during the replacement of the hook assembly.

Sometimes the finger moves out of adjustment. When correct, the position finger nose, theprotruding 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 itsstroke.

NOTE: The handwheel is located between heads 1 and 2 under a plasticcover at the back of the sewing table. Remove the cover to access thehandwheel.The handwheel on a bridge machine is on the side of the machine oppositethe automat under a metal cover.

3. Loosen the screw slightly, taking care to use the correct size screwdriver since thescrew is very flat and easily stripped.

4.Carefully move the position finger, centering the nose to the needle. To make sureyou are looking at the needle straight on, use the lubrication hole, behind the throatplate, as a reference. Visually line up the needle with this hole, then adjust theposition finger.

5.Carefully retighten the screw.

Field Limit Settings

Field limit settings protect the machine by preventing the hoop or pantograph frame fromrunning into the needle. Setting field limits establishes the size of the sewing field. In thefactory, they are set a safe distance from the inside edge of the pantograph frame. Thisensures 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 thestart 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 thatstop themachineif the pantograph moves too near a limitinstead of shutting it offcompletely. Softlimits 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, limitsshould be set at least ten millimeters smaller than the inside diameter of the hoops that will beused.

If you correctly change soft limits to match the hoop, it is not necessary to change mechanicalfield limits. However, if you consistently sew in smaller size hoops and want additionalprotection, 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. Eachguide 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 andmove the pantograph so the sewing needle is inthe center of the hoop you will be using.

2.Use the jog keys to move the pantograph towardthe hoop until the presser foot of the needleclosest to the hoop is 10mm from the left insideedge of the hoop.

3.With a 2.5mm ball driver or a hex key, loosen the left limit switch screws on theV-guide rail.

4.Move the limit switch toward the magnet very slowly, just until the automat shutsoff. Without moving the limit switch, tighten the screws to secure it at its newsetting.

5.With the automat off, manually move the pantograph toward you until you canturn the automat on again.

6.Use the jog keys to move the pantograph until the presser foot of the needle on theopposite 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 shutsoff. Without moving the limit switch, tighten the screws to secure it at its newsetting.


10.Use the jog keys to move the pantograph until the presser foot is 10mm from thebottom 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 thefront of the machine. If possible, try adjusting them from behind themachine.

12. Move the limit switch very slowly toward the magnet, just until the automat shutsoff. Without moving the limit switch, tighten the screws to secure it at its newsetting.


14.Use the jog keys to move the pantograph until the presser foot is 10mm from thetop inside edge of the hoop.

15.Move the limit switch very slowly toward the magnet, just until the automat shutsoff. Without moving the limit switch, tighten the screws to secure it at its newsetting.


17.Test the new limit settings by pressing the jog keys in all directions to ensure thatthe machine shuts off before the hoop runs into a needle.

CAUTION! The origin sensor should never be moved from its factorysetting.

When finished sewing in a smaller hoop, reset the field limits to the factorymeasurements 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 howevery pattern is sewn, unlike Program parameters, which are pattern specific. The MachineConditions Table explains the function, normal setting and range of values for eachparameter.

Machine Conditions parameters are accessed differently on each automat. The followingsections give separate instructions for the NS/NY automat and the NR/NB automat. Refer tothe appropriate section for your machine.

MACHINE CONDITIONS TABLE

SETTING FUNCTION ACTION

SETTING ACTION

TRIMMERTYPE

MSU #10ATC TYPESETTING KNIFE POSITION

SETTINGPANTOGRAPHMOVEMENT

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 isselected. A box displays around the selectedparameter.

5.Change the value as desired. Refer to thetable on the preceding pages for a descriptionof each parameter and its range of values.

· Press A, below the minus icon, to decreasethe value.

· Press B, below the plus icon, to increasethe value.

6.When changes to the MC parameters arecomplete, press the Manual key to savechanges and close the list. Wait a fewseconds, until the basic screen appears,before executing other BENS commands.

To return changed parameters to systemdefaults, use the Initialize MC command.This command restores default values for allparameters 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 fiveseconds. The following screen displays, prompting you for confirmation to returnall MC parameters to default values.

5.PressC, below theYesicon, to restore original MC values. To cancel thecommand, pressD, 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), pressG,below theNexticon, to move to the nextmenu 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 parameteryou want to change is selected. A box outline displays around the selectedparameter.

4.Use the numeric keypad to change the value as desired. Refer to the table on thepreceding pages for a description of each parameter and its range of values.

NOTE: Parameters with ON/OFF values are also changed on the numerickeypad. 1 = ON and é = OFF.

5.Press [SET] on the keypad to confirm the new value. Changed parameters displayin red.

6. When changes are complete, pressC,below theMCicon, to save the changes andclose the list of parameters.

To return changed parameters to system defaults, use the Initialize MC command. Thiscommand restores default values for all parameters in the Machine Conditions list.

Initializing Machine Conditions - BENR/NB

1.At the Drive screen (blue icons), pressG,below theNexticon, to move to the nextmenu level.

2.PressC, below theMC icon, to open the list of Machine Conditions parameters.

3. PressB, below theInitializeicon. The BENR prompts you for confirmation toreturn parameters to default values.

4.PressB, below theYesicon, to restore original MC values. To cancel thecommand, pressC, below theNoicon. The BENR beeps when initialization iscomplete.

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 orgarments can be sewn at this speed. When the machine is sewing, it must wait for the needleto come out of the fabric, and the pantograph to move and stop again before the needle goesback into the fabric. The higher the sewing speed, the greater the acceleration needed and theless time the pantograph has to move. If the frame and garments are heavy and the sewingspeed 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 thatdo not require more time will be slowed down as well, reducing productivity. The machinehas two methods of minimizing stitch distortion: automatically slowing down the machine forlong 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, willslow down to a percentage of the speed control setting. The machine automatically adjusts thespeed 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 theminto shorter jumpstitches. The value set in Jump Divide, MC parameter 7, determines at whatlength a stitch will be split. In this case, inertia is reduced because the machine has tworevolutions in which to carry out the movement. Certain patterns may have mainly shortstitches, with a few solitary long stitches, i.e., a small flower connected by long stitches toother flowers. In this case, it would be most productive to break the long stitches into shorterones than to slow down the machine each time a long stitch is encountered. Jump Divideprovides 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 themachine 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, ifyour machine has Mark 4 trimmers or Mark 6 trimmers with the optional thread fingerdevice. The table below and on the next page shows the function of each program.

THREAD TRIMMER PROGRAMSMARK 4 and 6 TRIMMERS

SETTING FUNCTION ACTION

Soft Limits

Soft limits are field limits set within the software that protect the machine by preventing thehoop or pantograph frame from running into the needle. Movement too close to the framecould 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 tooclose to the field limit, the machine will shut off. If the frame moves too close to the softlimit, the machine stops and an error message is displayed. This gives you the opportunity toreposition the pantograph within the limits, without the problems caused by the machineshutting 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 isnot necessary to change the soft limits to sew within a smaller size hoop, making the sewingfield smaller can prevent running into the hoop. As a general rule, set soft limits at least tenmillimeters 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 previoussection to access the list of MC parameters.

2.Use the jog keys to move through the list tothe soft limit parameter you want to change(parameters 19 through 22).

3.When the desired parameter is selected, pressthe Origin key in the center of the jog keys.A small value box, showing the Absolute Vand H values, displays on the left side of thescreen below the parameter's icon. Thepantograph moves to mechanical origin.

4.Use the jog key corresponding to the selected parameter to move the pantograph tothe 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 theparameter's new value.

NOTE: Ignore the negative sign before the value, and round the numberone decimal place. For example, if the value box shows -2471 as the ABSpantograph position, enter 247 for the new value. If the value box shows386 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 boxand 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 inmemory as Frame Type 1, 2 and 3. These values are programmed in Program, underparameter #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 donot 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 SoftLimits 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, abovethe 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 positionsare 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, ifdesired.

11.When sewing designs, you can enter the Program menu and select whatever storedframe/hoop size you wish to use at the time.

12.Once programmed, Frame Types 1, 2, and 3 remain in memory unless or untilmemory 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. Thefollowing table explains each Machine Setup parameter.

Note: As of System Software version NR 3.30 R00, NS 3.30 R03 and NT2.10 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 ªONº

MSU Parame-ter

Value TypeMax.Speed

SlowDownStart

SlowDownSpeed

Chapter 5 Machine Options

Drop Table System

The two-position drop table system increases the flexibility of the machine in high productionsettings by allowing the table to be positioned at two lower levels. The tubular pantograph ofthe drop table makes it easy to hoop finished garments and assembled caps, as well as flatgoods.

Lowering the Table

1.Move the pantograph as far back as it willgo, making sure the H member is over thestationary part of the table.

CAUTION! Failure to position thepantograph so that the H member is overthe stationary part of the table will severelydamage the machine.

2. Make sure there is nothing beneath the tablethat will keep it from dropping smoothly andfreely.

3.Standing in the center of the drop section,gently press down on the table top until thecatch lever hooks onto thefirst bar. Thetable will be in thmeiddle position.

To lower it further, continue to gently pressdown on the table top until the catch lever hooks onto thelow-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. Makesure that the pantograph H member is as far back as it will go and thatnothing 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 overthe stationary part of the table.

CAUTION! Failure to position the pantograph so that the H member isover 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 tableautomatically, slowly rises to its next level. Repeat if the table needs to be raisedhigher.

Spider Hoops

Embroidering finished goods requires the use of hoops that are the right size for the designthat will be sewn. For those designs or garments that are too small to be hooped in a standardwooden hoop, use a set ofªspiderºhoops.

The inner hoop in a spider hoop is designed to securely hold the next size smaller hoop. Seeillustration on next page. This design allows you to select the graduated size that is best forthe garment and design.

Spider hoops are used on machines with both rectangular pantographs and tubularpantographs.

Installing the Spider Hoop on a Rectangular Pantograph

1.Remove all the thumbscrews that secure the porto-clip frame from the pantographframe.

2.Remove the four sections of the porto-clip frame.

3.Line up the clamping arms on the spider frame with the threaded pantograph holesthat 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. Thedistancing board attaches to the tubular pantograph arms in much the same way as a standardtubular hoop.

Installing the Spider Hoop/Distancing Board

1.Insert the spider hoop in the distancing board.

2.Remove the standard hoop from the tubular pantographarms by grasping both sides of the hoop and pulling itforward.

3.Align the side extensions on the distancing board with thetubular pantograph arms.

4.Push back until the board snaps into place.

5.Insert the pantograph thumbscrew through the support atthe back center of the board and tighten it.

Sock Frame

A special framing device and pantograph attachment are used forembroidering socks. The directions given are for the sock frameused 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 thepantograph 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 surfaceusing 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 pushdown, applying equal pressure to both sides of the frame.

4.Pull the bottom of the sock over the framing board and remove thesock 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. Theframe will be held in place magnetically.

2.Align the sock frame in the sewing field so that the design will becentered in the frame. Use the jog keys to position the pantographaccordingly.

NOTE: It is recommended that you sew on practice cloth beforeembroidering 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. Choosebetween 3 settings: 1=Normal, 2=second repetition mirrored and 3=second

repetition rotated 180°. See thOeperation Guidefor information on changingprogram options.

5.Press the Memory key, to exit the list of program options.

6.Use thejog keysto position the pantograph at theorigin of the second sockto besewn,P1in the illustration on the next page.

7.PressDrive key. The green light on the Drive key is steady, indicating themachine is in Drive mode.

8.Use thejog keysto position the pantograph at the origin of the first sock to besewn,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 errormessage displays. Repeat Steps 7 and 8 to mark the origin of the first sockand begin sewing.

The machine sews Design 1. When Design 1 is complete, the pantograph moves tothe P1 position and sews Design 2.

The machine repeats this process infinitely, moving back to P2 when Design 2 iscomplete, and continues to sew.

NOTE: You may want to insert a stop code at the end of the pattern to stopthe 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. Theillustrations below show examples of spectacle boards on arm-type and bridge machinemodels.

To prepare the pattern for use on a spectacle board, add together the patterns to be used, withthe 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 theOperation Guide formore information.

You can also use the Socks program option, to sew repetitions of a single pattern, with twoorigin points. See theOperation Guidefor information on Program options.

Roll To Roll

Your machine may have an optional roll to roll device. With this option, when the machinesees an SE (Sub End) function code it automatically activates the device, advancing the boltof fabric. If you have a roll to roll system, an additional manual option is available tomanually operate the device. MSU parameter 23, and MC parameter 23 must both be on forthe roll to roll option to be displayed. See instructions on changing MC parameters. If yourmachine is equipped for Roll to Roll, your technician will set MSU#23 correctly duringinstallation.

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, pressD, 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 backwith the needle still in the same place in the fabric, then continue sewing the design. This letsyou create a long panel of embroidery.

· KeepMSU #23(Roll to Roll TypeO)FF. Normally, with a roll to rolldevice 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 rolloption. Turning #23 on lets the SE function code be displayed when usingTeach, F List or F Mod.

The design should have a different start and end point. An SE code is programmed at the laststitch in the design. The start and end point should be at the same horizontal position so thatwhen 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 anddisplays the D32 message on screen.The needle will remain down in thefabric.

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'sorigin 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 lineup 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 WSis activated, two heads work together, so you can have 18 colors in the design. If youpurchased a WS equipped machine, you can sew manually, using every head, or activate oneof the WS setups.

Two MSU parameters set up the machine for this system:

· #21, WS Head Spacesets 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 changeMSU 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, 15pieces per run

· Group 1: even numbered headsGroup 2: odd numbered heads

· MC parameter#24, WS Systemmust be turnedONto activate thesystem. See instructions on accessing MC parameters.

· The machineautomaticallymoves from even to odd heads and vice versawhen 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. Theheads 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 canceledmanuallywith the head shut-off switch.

· The machine does not make the group change automatically. Only onegroup of heads is on at a time. When the machine sees a group code, itstops sewing. At this time, you must turn off the heads in the currentgroup, turn on the heads in the new group, and use the jog keys to movethe 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 isa 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 thecode for the desired needle twice.

· If the design was not punched for the WS system you will need to insertnew function codes for group changes.

Function codes for group changes are:19(Group 1) and20(Group 2). To make a manualgroup change, press[N] + code = [SET]. For example: [N] 20 [SET] changes to Group 2heads.

Sewing Start Point

When you have the WS system set up for 18 colors, you must correctly position thepantograph for the design start point.

Example:

· 30 head machine, head space 200mm - gives a field size of 400mm oneach 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 lightabove 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 PerimeterTrace, to make sure the pattern will sew within the field limit.

NOTE: On a BENS/NY automat, you must press the Drive key, putting themachine 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 anotherPerimeter 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 ispositioned at the correct place for the active group. If Group 1 is active, itshould be at the mark to the left of machine origin.

Pattern Origin is notin the Center pattern origin is not in the center

If the of the pattern, you must calculate where the 200mmoverlap is measured:

· Example: Pattern measures 367mm x 200mm with theorigin at top rightof 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 theexact location of the pattern origin.

3.Follow all steps on the previous page to set up the pattern for sewing, making sureto use the measurements for your pattern in step 2, not simply 100mm.

HINT: Positioning the pantograph correctly for the start point of a WSdesign is much easier if the pattern origin is in the center of the pattern.

IndexAAdjusting tensions . . . . . . . . . . . 1-24Adjusting the bobbin tension . . 1-27 - 1-28Adjusting the hook timing . . . . . . . 3-14Adjusting the Position Finger . . . . . 3-15Adjusting the Take-Up Spring . 1-28 - 1-29Adjusting the top tension. . . . . 1-25,1-27Arm Type Head Lubrication . . . . . . 2-5Automend button . . . . . . . . . . . . 1-8

BBacking . . . . . . . . . . . . . . . . 1-31Backing Chart . . . . . . . . . . . . . 1-35Backing guidelines. . . . . . . . . . . 1-31Backing Paper . . . . . . . . . . . . . 1-33Backings

Backing Paper . . . . . . . . . . . 1-33Cutaway . . . . . . . . . . . . . . 1-33Nylon Backing . . . . . . . . . . 1-33Softouch . . . . . . . . . . . . . . 1-32Tearaway . . . . . . . . . . . . . 1-32Water Soluble Topping . . . . . . 1-33

Bath towels . . . . . . . . . . . . . . 1-30Birdnests . . . . . . . . . . . . . . . . 3-3Bobbin case maintenance . . . . . . . . 2-1Bobbin tension problem . . . . . . . . 1-25Broken needle . . . . . . . . . . . . . . 3-2Burr . . . . . . . . . . . . . . . . . . . 3-3

CChanging Soft Limits . . . . . . . . . 4-19Checking tensions . . . . . . . . . . . 1-24Checking the hook timing . . . . . . . 3-13Checking top tension . . . . . . . . . 1-27Cleaning the bobbin case . . . . . . . . 2-1Cleaning the hook assembly . . . . . . 2-1Cleaning the machine . . . . . . . . . . 2-1

DDanger. . . . . . . . . . . . . . . . . . 1-3

Conversion Chart . . . . . . . . . . . 1-31

Disengaging a Sewing Head . . . . . . 1-20Display Prompts. . . . . . . . . . . . . 3-5Distancing Board . . . . . . . . . . . . 5-3Drop Table System . . . . . . . . . . . 5-1

EEmbroidery Placement Guidelines . . 1-30Environmental Specifications . . . . . . 1-6Error Codes . . . . . . . . . . . . . . . 3-5

A02 . . . . . . . . . . . . . . . . . 3-5A04 . . . . . . . . . . . . . . . . . 3-5A05 . . . . . . . . . . . . . . . . . 3-5A08 . . . . . . . . . . . . . . . . . 3-5A11 . . . . . . . . . . . . . . . . . 3-5A20 . . . . . . . . . . . . . . . . . 3-6A21 . . . . . . . . . . . . . . . . . 3-6A22 . . . . . . . . . . . . . . . . . 3-6A23 . . . . . . . . . . . . . . . . . 3-6A24 . . . . . . . . . . . . . . . . . 3-6A26 . . . . . . . . . . . . . . . . . 3-6A27 . . . . . . . . . . . . . . . . . 3-6A28 . . . . . . . . . . . . . . . . . 3-6A29 . . . . . . . . . . . . . . . . . 3-7A30 . . . . . . . . . . . . . . . . . 3-7A31 . . . . . . . . . . . . . . . . . 3-7A32 . . . . . . . . . . . . . . . . . 3-7A33 . . . . . . . . . . . . . . . . . 3-7A35 . . . . . . . . . . . . . . . . . 3-7A36 . . . . . . . . . . . . . . . . . 3-7D01 . . . . . . . . . . . . . . . . . 3-7D02 . . . . . . . . . . . . . . . . . 3-7D03 . . . . . . . . . . . . . . . . . 3-8D04 . . . . . . . . . . . . . . . . . 3-8D05 . . . . . . . . . . . . . . . . . 3-8D06 . . . . . . . . . . . . . . . . . 3-8D07 . . . . . . . . . . . . . . . . . 3-8D08 . . . . . . . . . . . . . . . . . 3-8D09 . . . . . . . . . . . . . . . . . 3-8

D12 . . . . . . . . . . . . . . . . . 3-8D13 . . . . . . . . . . . . . . . . . 3-8D14 . . . . . . . . . . . . . . . . . 3-9D15 . . . . . . . . . . . . . . . . . 3-9D16 . . . . . . . . . . . . . . . . . 3-9D17 . . . . . . . . . . . . . . . . . 3-9D19 . . . . . . . . . . . . . . . . . 3-9D20 . . . . . . . . . . . . . . . . . 3-9D21 . . . . . . . . . . . . . . . . . 3-9D22 . . . . . . . . . . . . . . . . . 3-9D23 . . . . . . . . . . . . . . . . . 3-9D25 . . . . . . . . . . . . . . . . 3-10D26 . . . . . . . . . . . . . . . . 3-10D27 . . . . . . . . . . . . . . . . 3-10D28 . . . . . . . . . . . . . . . . 3-10D29 . . . . . . . . . . . . . . . . 3-10D30 . . . . . . . . . . . . . . . . 3-10D31 . . . . . . . . . . . . . . . . 3-10D32 . . . . . . . . . . . . . . . . 3-11D33 . . . . . . . . . . . . . . . . 3-11D34 . . . . . . . . . . . . . . . . 3-11

Error Messages . . . . . . . . . . . . . 3-5Eye of the needle. . . . . . . . . . . . 1-22

FFabric puckering . . . . . . . . . . . . 3-1False Thread Breaks . . . . . . . . . . 1-28Field Limit Settings. . . . . . . 3-16 - 3-17Fur Coats. . . . . . . . . . . . . . . . 1-30Fuse Replacement . . . . . . . . . . . 2-11

GGolf Sweaters . . . . . . . . . . . . . 1-30Groove of the needle. . . . . . . . . . 1-22Grounding Instructions . . . . . . . . . 1-5

HHand towels . . . . . . . . . . . . . . 1-30Hook Timing. . . . . . . . . . . . . . 3-13Hooping problems. . . . . . . . . . . . 3-2Hooping Socks . . . . . . . . . . . . . 5-5How stitches are formed . . . . . . . . 1-23

Humidity . . . . . . . . . . . . . . . . 1-6

IImproper backing . . . . . . . . . . . . 3-1Improper threading . . . . . . . . . . . 3-2Initializing Machine Conditions - NR/NB. . . . . . . . . . . . . . . . . . . . . 4-16Initializing Machine Conditions on theNS/NY . . . . . . . . . . . . . . . . . 4-14Inserting the bobbin . . . . . . . . . . 1-21

JJackets . . . . . . . . . . . . . . . . . 1-30

LLeveling an arm type machine . . . . . 1-2Looping . . . . . . . . . . . . . . . . . 3-4Lubrication . . . . . . . . . . . . . . . 2-2

Arm Type Head. . . . . . . . . . . 2-5Bridge Type Head . . . . . . . . . 2-7ZN/ZQ Type Head . . . . . . . . . 2-3

MMachine Basics . . . . . . . . . . . . . 1-1Machine Care . . . . . . . . . . . . . . 2-1Machine Conditions. . . . . . . . . . . 4-1

Appliqu . . . . . . . . . . . . . . 4-11Auto Start . . . . . . . . . . . . . . 4-9Back Limit. . . . . . . . . . . . . 4-11Borer . . . . . . . . . . . . . . . . 4-1Clamp Frame . . . . . . . . . . . 4-13Draw Mode . . . . . . . . . . . . 4-13Frame Start . . . . . . . . . . . . 4-12Front Limit . . . . . . . . . . . . 4-11J-Con . . . . . . . . . . . . . . . . 4-2Jump Divide . . . . . . . . . . . . 4-7LCD Bright . . . . . . . . . . . . 4-12LCD Mode . . . . . . . . . . . . 4-12Left Limit . . . . . . . . . . . . . 4-11Low Speed . . . . . . . . . . . . . 4-6Needle Down . . . . . . . . . . . 4-12O Admit. . . . . . . . . . . . . . . 4-9

Overlap . . . . . . . . . . . . . . . 4-8Right Limit . . . . . . . . . . . . 4-11Roll to Roll . . . . . . . . . . . . 4-11SF Spectacle Frame . . . . . . . . 4-13Stitch Back . . . . . . . . . . . . . 4-8Stitch Clamp . . . . . . . . . . . . 4-1Swing . . . . . . . . . . . . . . . . 4-9T-Break . . . . . . . . . . . . . . . 4-7T-Break Off. . . . . . . . . . . . . 4-8Trim Dir . . . . . . . . . . . . . . 4-10Trim Jumps . . . . . . . . . . . . . 4-1Trim On/Off . . . . . . . . . . . . 4-3Trim Vector . . . . . . . . . . . . 4-10V. Motor. . . . . . . . . . . . . . 4-25WS System . . . . . . . . . . . . 4-11

Machine Conditions - NR/NB . . . . . 4-15Machine Conditions - NS/NY . . . . . 4-13Machine Installation . . . . . . . . . . 1-1Machine lubrication . . . . . . . . . . . 2-2Machine Options . . . . . . . . . . . . 5-1

Distancing Board . . . . . . . . . . 5-3Drop Table System . . . . . . . . . 5-1Roll to Roll . . . . . . . . . . . . . 5-7Sock Frame . . . . . . . . . . . . . 5-3Spider Hoops . . . . . . . . . . . . 5-2WS System . . . . . . . . . . . . 5-10

Machine Parameters. . . . . . . . . . . 4-1Machine Setup Parameters. . . . . . . 4-21Maintenance Log . . . . . . . . . . . 2-13Mark 4 & 6 Trimmer Programs . . . . 4-18MC Parameters . . . . . . . . . . . . . 4-1Millimeter Conversion Chart . . . . . 1-31MSU . . . . . . . . . . . . . . . . . . 4-21MSU Parameters

ATC Option . . . . . . . . . . . . 4-25ATC Type . . . . . . . . . . . . . 4-24Brake Type . . . . . . . . . . . . 4-26C. Change Type . . . . . . . . . . 4-27Clamp Off Angle . . . . . . . . . 4-24Detect Des. . . . . . . . . . . . . 4-21F. (Frame) Motor Type . . . . . . 4-27Frame Param . . . . . . . . . . . 4-22

H. Motor. . . . . . . . . . . . . . 4-25H. Sensor . . . . . . . . . . . . . 4-26Jump on Time . . . . . . . . . . . 4-23Light Curtain . . . . . . . . . . . 4-28M. Option . . . . . . . . . . . . . 4-28Max Speed. . . . . . . . . . . . . 4-21Motor Ratio . . . . . . . . . . . . 4-23Needles . . . . . . . . . . . . . . 4-21Origin Sensor . . . . . . . . . . . 4-26P. Coder . . . . . . . . . . . . . . 4-25Roll to Roll Type . . . . . . . . . 4-27Slow Down Speed. . . . . . . . . 4-23Slow Down Start . . . . . . . . . 4-22Stop Angle. . . . . . . . . . . . . 4-23V. Sensor . . . . . . . . . . . . . 4-26WS Head Space . . . . . . . . . . 4-27WS Type . . . . . . . . . . . . . 4-27

NNeedle Anatomy . . . . . . . . . . . . 1-22Needle breaks . . . . . . . . . . . . . . 3-2Needle Eye . . . . . . . . . . . . . . . 3-4Needle Insertion . . . . . . . . . . . . 1-34Needle problems . . . . . . . . . . . . 3-2Needle Replacement . . . . . . . . . . 1-34Needle Types . . . . . . . . . . . . . 1-34Needles/Backings Chart . . . . . . . . 1-35Nylon Backing . . . . . . . . . . . . . 1-33

OOil ports . . . . . . . . . . . . . . . . . 2-6Oiling

ZQ Bridge Head . . . . . . . . . . 2-9Oiling Bridge Type Head . . . . . . . . 2-7Oiling the Arm Type Head . . . . 2-5 - 2-6Oiling the hook assembly . . . . . . . . 2-2Oiling the ZQ/ZN Head . . . . . . . . . 2-4

PPCB Board, faulty. . . . . . . . . . . . 3-1Pillow cases . . . . . . . . . . . . . . 1-30Position Finger Adjustment . . . . . . 3-15

Positioning the design on the garment . 1-29Presser Foot . . . . . . . . . . . . . . . 1-8Pretensioners . . . . . . . . . . . . . . 1-8

RReplacing a needle . . . . . . . . . . . 1-34Replacing Bobbins. . . . . . . . . . . 1-21Replacing the bobbin case . . . 1-21 - 1-22Replacing the Take-Up Spring . . . . 3-11Restarting a Sewing head . . . . . . . 1-20Roll to Roll Simulation . . . . . . . . . 5-9Running an I Test . . . . . . . . . . . 1-24

SSafety Instructions . . . . . . . . . . . 1-3Scarf of the needle . . . . . . . . . . . 1-22Setting Soft Limits . . . . . . . . . . . 4-19Setting Sub Soft Limits . . . . . . . . 4-20Setting the Field Limits . . . . . . . . 3-17Sewing Head Components . . . . . . . 1-8Sewing Head Controls . . . . . . . . . 1-19Sewing Preparation . . . . . . . . . . 1-29Sewing Socks . . . . . . . . . . . . . . 5-5Sewing speed vs. application . . . . . . 3-3Sheets . . . . . . . . . . . . . . . . . 1-30Shirt Cuffs . . . . . . . . . . . . . . . 1-30Shirt Pockets . . . . . . . . . . . . . . 1-30Shirts . . . . . . . . . . . . . . . . . . 1-30Sock Frame . . . . . . . . . . . . . . . 5-3Soft LImits . . . . . . . . . . . . . . . 4-18Specifications, Environmental . . . . . 1-6Spectacle Boards . . . . . . . . . . . . 5-6Speed, sewing . . . . . . . . . . . . . 4-17Spider Hoops . . . . . . . . . . . . . . 5-2

Installing the Spider Hoop on aRectangular Pantograph . . . . . . 5-2

Stitch formation . . . . . . . . . . . . 1-23Stitch Theory. . . . . . . . . . . . . . 1-22Sub Soft Limits . . . . . . . . . . . . 4-20

TTake-Up Lever . . . . . . . . . . . . . 1-8

Take-Up Spring . . . . . . . . . . . . . 1-8Take-up spring adjustment . . . . . . . 3-4Take-Up Spring Adjustment . . . . . . 1-28Take-Up Spring Replacement . . . . . 3-11Take-up spring, faulty. . . . . . . . . . 3-3Temperature . . . . . . . . . . . . . . . 1-6Tension adjustments . . . . . . . . . . 1-24Tension problems . . . . . . . . . . . . 3-3Thread Break Detection . . . . . . . . 1-19Thread Break Detectors . . . . . . . . . 1-8Thread Break Switch . . . . . . . 1-8,1-19Thread Breaks . . . . . . . . . . . . . . 3-3Thread Detection LED . . . . . . . . . 1-8Thread frays . . . . . . . . . . . . . . . 3-4Thread Guide . . . . . . . . . . . . . . 1-8Thread Trimmer Programs. . . . . . . 4-18Threading a YS/YN Head . . . . . . . 1-13Threading a ZN Head . . . . . . . . . 1-18Threading a ZN Head with the UTSM 1-17Threading a ZQ Head with the UTSM 1-10Threading the Sewing Head . . . 1-10,1-13Threading the YS/YN Head . . . . . . 1-15Ties. . . . . . . . . . . . . . . . . . . 1-30Timing the Hook. . . . . . . . . . . . 3-13Top tension problem . . . . . . . . . . 1-25Top Thread Detection . . . . . . . . . 1-19Top Thread Tensioners . . . . . . . . . 1-8Top thread tensions . . . . . . . . . . 1-24Trimmer Programs. . . . . . . . . . . 4-18Troubleshooting. . . . . . . . . . . 3-1,3-5

Backing . . . . . . . . . . . . . . . 3-1Bobbin problems . . . . . . . . . . 3-2Broken hook point . . . . . . . . . 3-2Digitizing in design problem . . . . 3-3Fabric puckering . . . . . . . . . . 3-1Hooping problem . . . . . . . . . . 3-1Lack of lubrication . . . . . . . . . 3-3Looping . . . . . . . . . . . . . . . 3-4Needle Breaks . . . . . . . . . . . 3-2Needle problem. . . . . . . . . . . 3-3Needle problems . . . . . . . . . . 3-2Needle, bent . . . . . . . . . . . . 3-2

Oiling problem . . . . . . . . . . . 3-3On/off switch, faulty . . . . . . . . 3-1PCB Board, faulty . . . . . . . . . 3-1Sewing head off . . . . . . . . . . 3-1Take-up spring, faulty . . . . . . . 3-1Tension problems. . . . . . . . . . 3-1Thread Breaks . . . . . . . . . . . 3-3Threading problem . . . . . . 3-1 - 3-2Timing problem. . . . . . . . . . . 3-2

Turning off a sewing head . . . . . . . 1-20

UUTSM . . . . . . . . . . . . . . . . . . 1-8UTSM Bobbin Detection . . . . . . . 1-19UTSM Switch . . . . . . . . . . . . . 1-19

VVoltage . . . . . . . . . . . . . . . . . 1-1

WWarning . . . . . . . . . . . . . . . . . 1-4Wash cloths . . . . . . . . . . . . . . 1-30Water Soluble Topping . . . . . . . . 1-33WS System. . . . . . . . . . . . . . . 5-10

Group Codes . . . . . . . . . . . 5-12

ZZN/ZQ Arm Type Head. . . . . . . . . 2-3ZQ Bridge Type Head. . . . . . . . . . 2-9

Date post:	08-Nov-2014
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Barudan N Series Manual Mecanico

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