Bernina 1230 User manual

BERNINA
Service
manual
1230
(Supplement to
service manual 1130/20)
*
FRITZ GEGAUF
LTD.
Manufacturers
of BERNINA Sewing-Machines
8266 Steckborn Switzerland
88/10
GB 006 807 50 02

Impressum
Authers:
P. Kenyon
T. Kalberer
Graphics:
F. Rapold
Typeset
and printed:
by
Bodan
AG,
Kreuzlingen
2
1230

Contents
Page
Technical
data
5
Description
of Print L-4200
6
Print A-1230
6
Print
S-1230
6
Block schematic
model 1230
7
Plug
connections
8
Print A-1230
9
Print
S-1230
10
Print
L-4200
11
Diagnosing
instructions
12
Test
adapter
L-4200
13
Power
supply
- 4200
14
Test
panel - 1230
15
Test programme
with service-panel
16
Warning against
dangerous voltages
17
Starting
the
service
programme
17
Ending
the service
programme
17
Diagnosis
18+19
Test
A
L-4200
20
B
Print
L-4200/R-4200
(Drive
signal)
21
C Connection
S-1 230/L-4200
22
D
Mains
cord (cord reel)
23
E
Connection
of
print S-1
230/foot
control
unit
24
F
Print P-4200
25
G
Complete
light holder
26
Hi Step
motors:
27
o PrintS-1230
o
Hall-sensors
H2
0 Position
Hall-sensorS.L.
28
o Position
Hall-sensor
S.B.
I
Step motors
pinning
position
29
K
Foot control
unit
30
L Foot
control
digital/analog
31
M
Print
A-1230
32
Print S-1230
Print
L-4200
N
Ret-button
33
0
Equalization
of the
forward/reverse
feed
34
P1,2
Buttonhole
35+36
Q
Sewing-off:
37
o Stitch
length
o Stitch
width
o Needle
position
L.C.R.
o Long
stitch
Function
test
38
+ 39
1230 3

Important:
A comparison
ot the models 1230 and 1130 is not made as from a
technical
point
of view. They are identical.
All
gauges, instruments,
adjustments
etc, which are
applicable
to
model 1130 are also valid here. BERNINA has only changed the test
programme
which
also simplifies
things
for you.
These
instructions are to
be used in
conjunction with
the service
manual
cl. 1130.
This
manual remains
the
property of
our company,
repro-
duction, publication or information
to
a third party
without
our
written approval
is forbidden.
FRITZ
GEGAUF LTD.,
Manufacturers
of
BERNINA Sewing-Machines
Steckborn
(TG) Switzerland
4 1230

Technical
data
BERNINA
model
1230
Stitch
lenght
max.
forward
5 mm
Automatic
long
stitch
10 mm/2:1
max.
reverse
5 mm
Basting
device
30mm/6:1
Increment
0-1
0,05mm
Working
space
105x195mm
1-3
0,1 mm
Overall
length 375mm
3-5 0,2 mm
Overallwidth
184mm
Max. stitch
width
5,5 mm
Overall
heigth
350 mm
Increment
0,1 mm
Motor
90 W
Needle system
130/705
H
No of
stitches per/min.
min.-max.
120-1050/min
Adjusting
needle 130/705
H/TCN
reduced
min.-max.
120-600/min
Hook
system BERNINA
CB
= Central
bobbin
Sewing
light:
bulb 2x6
V/4 W
Lowest
point of
needle bar =
0 degree Weight
10,5kg
Presser
foot
height = 7,5
mm
Darning
foot heigth
= 0,5 mm
Features
and functions
Needle position
5
Stitch
pattern
extended,
stitch
density
Light
beam
remains constant
Zig-zag
and
stitch
lenght
(freely
adjustable)
2 needle limiter
Automatic
basis
adjustments
Memory
Basic
marking
Blinker
7
practical
stitches
without
reverse
motion
LED
display
for
presser
foot
5
practical
stitches
with
reverse
motion
Upper
needle
stop (general)
12 decorative
stitches
with
reverse motion
Lower
needle stop
(general)
32 number
of stitch
patterns
Needle
positioning
upper/lower
with
foot
pedal
LED
control
for
programmed
pattern
Permanent reverse
sewing
Manual
stitch
sizeadjustment, memorized
Pattern
start
Main
switch
Fully
automatic
buttenhole Separate
light
switch
Buttonhole
3
step
Speed
control
using
the
foot
control
Keyhole
buttonhole
Letters
A
to
Z
Automatic long
stitch
Numbers
0
to
9
Basting
device
Characters
4
(- -
o
?)
Balance
for
forward
and
reverse
feed Memory
capacity
50
units (canbe
called
up
even
Clear
switch
after
mains
failure/interruption)
Single
pattern
Mirror
image
1230 5

Description
The electronics
of the model
1230
sewing
S-1230
control
print
machine
is essentially located
on three
large
The complete sewing
machine
control
is located
printed
circuit
boards;
the power
print
L-4200,
the
on the
S-1230
control
print. The
S-1 230
control
control print
S-1230
and
the display
print
A-1 230
print is located
on
the A-1
230 printfrom
the
rear.
(compare
to the
block schematic
diagram).
The
The most
important control
elements
are
the
tasks
of the
3 units
correspond to
the known microcomputer, and
the
power drive
for
the step
functions
of
L-4200,
S-4200
and A-4200 prints
motors.
A
new feature
over
model
1130 is that
the
from the
model
1130.
bobbin
winder
motor is
also controlled
by
the
microprocessor.
The bobbin winder motor speed
1-4200
powerprint
can
now be
controlled
from
the foot
control.
The
L-4200
power
print is
mounted
above
the
The S220
service
switch
on print
S-1 230
isa
motor
on the
rear side
of sewing
machine.
The
service
aid. This
switch
has two
positions:
normal
circuit
components
on
the L-4200
have the
follow-
sewing
operation,
and
service
position.
In the
ing functions:
service
position,
several
buttons
and
diodes
on
-the
display
panel are
assigned
other functions.
-Motor
control:
This
allows
the service
technician to
execute
The
main
motor control
operates
with the mains
necessary
adjustment
and
testing
functions
using
voltage.
The main
motor
is a
DC motor
with
the
display
panel (refer to
the special
section
pulse-width
modulated
speed
control.
The
service
programme).
The service switch
must
closed
loop control
circuit
on the
small
R-4200
always
be set into
the sewing
position
for
normal
print is
located
on the
power print.
sewing
operations.
All circuit
components
for the
motor control
The microcomputer
on print
S-1 230
receives
an
operate
at dangerous
voltage
levels,
analog
signal
from
the foot
control,
which it
then
The safety
regulations
must be
adhered to.
converts
into a
digital
signal and
transmits to
print
R-4200 as setpoint
for the motor
speed. The
- Power supply:
R-4200
print controls
the
motor
speed
to the
Generates
the
following
D.C.
voltages:
speed specified
by the S-print,
using
a setpoint
-
- 30V
for the
step motors actual
value
comparison.
When
the foot
control
is
-
5V for
the logic
circuitry
on the
S-1 230
and
released,
the
setpoint
goes
to zero,
the brake
is
A-1230
prints
actuated
from the
microcomputer
on the
S-print
- 6V
for the sewing
light via
the R-4200
print,
and
the motor
is rapidly
- 30V
for the
bobbin winder
motor
braked.
Components
are
protected from
overload,
in
Signal
transfer
between
the
S-1230
and R-4200
the case
of faults,
by
three fuses
F 150,
F 151
print is
realised
using a
4-pole cable.
Signal
and F
152. If a
fuse blows
only
original
replace-
transfer
is
realised
through
an opto-coupler
ment fuses,
with
the correct
rating
may be
used.
providing
electrical
isolation
and thus
eliminating
dangerous
voltage
levels
from
the foot
control
A-1230
display
print
and the
S-1230
control print.
The
display
section
is mounted
directly
behind
the
The
step motors
are
in random positions
when
operating
control
panel.
The display
and
ope-
sewing
machine
is switched
on.
Random
values
rating control
elements
are soldered
onto
the L-
can also
be in the
microcomputer control
shaped
printed
circuit.
memory.
In
order
to have a
defined
state,the
step
A time
multiplex control
allows
the numerous
motors
are rotated
into
their calibrated
position
LEDs
and control
elements
to
be connected
to
the
by a
microcomputer
command, and
the position
open loop
control
on the
S-1 230
control
print
value is
set to zero
in the
microcomputer
memory.
using
only
16 connection
lines.
This
starting
state
allows
the selection
and
sewing
of any stitch programme.
6 1230

Model
1230
block
schematic
L4200
F150
A 1230
A1230
RECTIFIER
J
FOOT
CONTROL
£
BUTTON HOLE
SENSOR
S REVERSE
SWITCH
D -MAGNET
BASTING
DEVICE
0(
POSITION
INDICATOR
S4 WIDH
OBBINWINDER
ROTARY ENCODE
STITCH WIGTHT
ROTAR ENCOE
ZUSERVICE
PROGRAMME
ROITAY
LENCOD
STITCH
WIDTH
STITCH LENGTH
STEP MOTORS
1230
7

0
I
Brake
P250
P 200
C
2
+!
5V
S
2
-2
S
E1"C4
3
Drive
green
2
2OX
4
Nominal
Vau
4re -L
2~ig~
S
gr
me1
Sewing
light
44
2o
CL
S.L.
5'
5
--
5
4
up
2
Step
motor
8 1 7__C_ 4 S.B,
P 251
P2
+ 5V
Mains
0
V
Hall-Sensor
1
3
S.L.
Housing
22
+5V
2
3
L
H ll-Sensor
V,
M ain m o r
4
4
n
osition
-S.B.
M
M
5 o + r
Magnet
7
6
-
asting
device
78
.8 t +'=
A- O1230
A13
S-1230t"o303K+1s 0
2
-0 CL
200
L-L20
5
SB
a13
St123
13
K-1130
1C4
3
red
+3
Bobwiwinder
0 30
R
4
ED
Rt
110
K-13
5 R-Button
• • • •

Print A-1230
Utility stitch
display
Needle
positions
Bar graph
stitch
width
and
switches
Presser foot
display
Buttonhole
display
Bar
graph stitch
length
1230 9

S-1230 Print
Data lines to print A-1230
Potentiometer
for
adjusting
buttonhole
sensor A
Potentiometer for adjusting
buttonhole
sensor
B
Foot control
2-pole black
Control
signals from/to
L-print
4-pole green
Buttonhole sensors
Reverse switch 6-pole black
L- Stitch length sensor, 3-pole red
Stitch
width sensor,
3-pole black
Position indicator
5-pole black
Power
supply from
L-print
5-pole red
Magnet basting device, 2-pole green
Service switch Pos. Service
I Pos. Normal
Bobbin winder motor
4-pole blue
Stitch length step motor
4-pole red
Stitch width step motor
4-pole black
Warning!
If print S-1230
has to be replaced,
then buttonhole
adjustment
and
forward/reverse feed equalization must be carried out.
10 1230

Print L-4200
Important!
Never fit
heat sink and securing screws without
insulating foil or insulating washer, because a
short circuit
will occur. The heat sink with its
Galvanically
insulating foil must sit fully on the fixing angle,
in
separated
order to achieve best results in transfering heat
low voltage from the heat sink to the sewing
machine housing.
4- Not used
P157 P160
4 [
1 45V
41 I
Power supply
for
P159
1-
print
S
and A-4200
1Control
signals
to
print S-4200
Sewing light
Equalization of speed
Connector
for
print R-4200
Main motor
Circuits
in this area
operate at dangerous
voltages. Observe the
F Main notice
on page 17.
Mains
123011

Diagnostic
instructions
- As
opposed
to model
1130,
model 1230
is equipped
with
a service
programme.
The service
programme
is essen-
tially designed
for
test and
adjustment
tasks.
-
The diagnostic
instructions
should
be adhered
to for
repair
work.
Reference
should
be made
to the
service
programme
for
adjustment and
equalization
tasks.
Warning
of dangerous
voltage
levels
Mains
voltage
(refer
to
print L-4200)
Circuit
components
on
the L-4200
power
print, the
main
motor
and
the cable
drum,
carry dangerous
voltage
levels.
For your
own safety,
print L-4200
should
only
be touched
after
about
30 seconds
after
the mains
voltage
has been
switched
off, which
is the
time required
by
the capacitors
to
discharge after the mains plug has been removed.
Warning:
The sewing
machine
may
only be connected
to the
mains
supply
when the chassis
cover
or
the auxiliary
cover
is
mounted.
Work
may only
be carried
out
on the
L-4200
print, main
motor
and cable
drum
when the
mains
plug has
been
withdrawn
from
the mains
supply.
Electrically
isolated
low voltages
(refer to
print L-4200)
Several
circuit
components
on the
L-4200 print
operate
with
electrically
isolated
low voltages
(40
V or less).
With
the
exception
of the power
print
L-4200,
the main
motor
and
the cable
drum, the
other
modules
also operate
with
elec-
trically
isolated low
voltages!
There
is no
danger
involved
in touching
these
components
during
operation.
Warning!
The
following
should
be additionally
observed
when carrying
out
repair
and adjustment
work:
-
Changing
from
the service
programme
to normal
operation,
and
vice
versa
is only
possible
after changing
the
position
of the
service
switch
on the
S-1230
print, and
briefly
switching
off the
mains
voltage.
-
The following
adjustments
should
be made
each time
a S-1230
print
is replaced:
Forward/reverse
feed:
test programme
0
Buttonholer:
test programme
P
- Switch
off the
mains voltage
before
touching
and
replacing
the
R-print.
12 1230

Test
adaptor
L-4200
The
power
supply
for
electrical
parts
which
are con-
nected
to
print
L-4200
and
the main
motor
control
are
checked
with
the
aid of
the test
adaptor.
" When
all LEDs
Ato
E ligth
up,
then
the power
supply
for:
-
the
step
motors
- the
logic
circuit
- the
sewing
light
is
correct.
Bobbin
winder
motor,
LED
E,
cannot
be
tested.
" If only
LED
B doesn't
light up,
then
the voltage
for the
logic
is too
high (more
than 5,5
V).
*
If only
LED
C doesn't
light
up, then
voltage
for the
logic
is too
low
(less than
4,5
V).
*
When the
motor
switch
is in
the
((on))
position,
the
electric
brake
is released,
the motor
receives
the
desired
value
and
will
run at
the
set
speed.
LED
F
for
the drive
signal
must
be lit.
Speed
regulation
is made
by turning
the potentiometer.
* When the
motor
switch
is
placed
in
the ((off)
position
the
signal
returns
to zero,
and
the
electric
brake
should
engage.
The
motor
slows
down
to a stop.
LED
F must go out.
TEST
-ADAPTER
L 4200
r
30V
SCHRITTMOTOR
STEP MOTOR
r-Bl
C,5v
0
5V
LOGIC
Ri>4,5V
0
F
6V
O
NAEHLICHT
~1
SEWING
LIGHT
E30V 0
SPULERMOTOR
BOBBIN
WINDER
BERNINA
=
LAUFSIGNAL
DRIVE
SIGNAL
TOFF@0ON
Q
MOTOR
1230
13

Power
supply
4200
The
power
supply
4200 delivers
current
for
the logic
of
print A-1
230
and print
S-1 230,
the step
motors,
the
sewing
light.
So that
the whole
machine
can
work with
a
safe low voltage,
the main
motor
receives
30 V
for
safety
reasons.
The
power
supply
is useful
when a
mechanical
adjust-
ment
is to be
made,
for which
the rigidity
plate
with print
L-4200
has to
be removed.
Supply apparatus
iI~1i4200
II~IIMotor
LW
IN
OFF
When the
mains switch
is ((on)) the
light indicates
that the
appliance
isworking.
With the
switch in
the ((off)) posi-
tion, the appliance is
turned off.
Motor
switch (ion)), the
main
motor will rotate
slowly.
Adaptor
print
with cord
ist pluggable.
There is a
400 mA fuse
at the rear.
Important cl.
1230:
The connection
for
the bobbin winder
motor
is not used.
14
1230

Test-Panel 1230
37
(5123456 =00 0o00M
SL SB
HKALL~I
- BLANCE '3
..
SENSOR
-
POSITION
AUTO
84z
8+4+2+1
8 A
RET 5 Z
cn
0000.o0
000
~ HALL-
SENSOR
SL SB
STOP SL SB
00j0
0*0-
1230 15

Test-Programmes
with Service-Panel
Manual
What is to be tested
1230 See also service manual
1130
page
1 Hall sensor
position
28 Page
64 a (see also BERNINA
= for stitch length
Information No.
78)
E
E2 Hall
sensor position
28
cD for stitch width
0
3 Sewing-off
(straight stitch, zigzag,
37
it long stitch and
basting stitch)
Cl)
0
o Pinning position for step motors
29 Section 49, resp. 53
E SL and
SB
pages 37 + 41
E
0 Forward-reverse feed 34 Section 41, pages 32 + 33
a
equalization
a- Step
motor/Hall
27
Page 64
sensors
7
Position indicator/
25 Page
62
P-print
8 Digital/analog foot
control 31
9
Drive signal
21 Page 58
10 Ret button 33
11
Buttonholer potentiometer
35 Pages 69
+ 70
equalization
16 1230

LDanger
high
level
voltage!
Mains
voltage
(see
print
L-4200)
Circuits
on
the
power
print
L-4200,
the
main
motor and
the
cord
drum
operate
at dangerous
voltages.
As some
capacitors
discharge
approx.
30 seconds
after
pulling
out the
mains
plug,
you
should
wait
this long
before
touching
print
L-4200.
Test-programm
model
1230
(service
operation)
1.
Test-programme
start
-
Remove
belt
cover
(service
instructions model
1130,
section
6).
-
Set
service
switch
on the
S-print into
service
position (refer
to Fig.
S-1
230,
page
10).
- Switch-on sewing
machine/D.C.
mains
adaptor
unit.
The
sewing
machine
is now
in service
programme
no.
6 (step
motors), move
to
and from
with
an
acustical
noise.
- Push clear button (min. 2 sec.).
- Mount
service
panel.
The
sewing
machine
is
now
in the
initial
state
of
the
service
operation.
The
individual
test
programmes
1 to
6 can
be selected
from
this state.
The
initial
state
can always
be
selected
by
depressing
the
clear
button.
The
following
sensor
signals
can
now
be checked:
-
Position
indicator/P-print
(test 5
model
1130).
-
Foot
control
digital
and analog
(new).
-
Drive signal
(partially
covered
in test
1,
test
adaptor
model
1130).
-
Ret button (new).
- Adjust buttonholer
potentiometer
(partially
section
42 model 1130).
Termination
of
the test-programme
-
Switch
off
the sewing
machine/D.C.
mains
Attention:
adapter.
When changeing
from normal
operation - Service
-
Bring
the service
switch
on the
S-print
into
the
operation
- normal
operation.
normal
position.
- Switch
off the
machine/mains
adapter.
The sewing machine
can
now be
operated
-
Bring the
serviceswitch
into
the desired
position.
normally.
- Switch
on the
machine/mains
adapter.
1230
17

Fault
Possible
fault
on
Repair instructions
Display
panel
and
sewing
light
-
L-4200
print
- Test
A, resp.
M
not illuminated
- Mains
cable
- Test
D
Main
motor
not running
Machine
(dead))
Main
motor
does not
rotate other
- L-4200
print
- Test
A,
resp.
M
functions
OK
-
R-4200
print
- Replace
R-4200
print
after
switching
off mains
voltage
-
S-1230
print
- Replace
S-1230
print
- Foot
control
- Check
control,
replace
bobbin winder
motor
foot
control,
if nec.
test
K,L
- Connection
between S-1
230 and
- Test C
L-4200
prints
- Connection
between
S-1
230
print
-
Test
E
and
foot
control
- Main
motor
- Check
motor
cable
and
plug
aReplace
motor
0
Bobbin
winder
motor
does not
function,
-
S-1230
print
-
Replace
print
S-1230
other
functions
OK
- Bobbin
winder
- Replace
complete
bobbin winder
Sewing
light
does not
function
- Lamps
-
Replace
lamps
-
Lamp
holder
-
Test
G
-
Print L-4200
-
Test
A
Step
motors
do
not
position
-
Step
motor
print
S-1230
-
Test
Hi,
H2
- Connection
between
S-1230
and
L-4200 prints
-
Test
C
Front
panel
LED
does
not
illuminate,
Print
A-1
230
-
Replace
print
A-1230
however
selected
function
is
executed
when
button depressed

Fault
Possible
fault
on
Repair instructions
Selected
functions
not executed
when
-
Print
A-1230
-
Replace
print
A-i230,
if
malfunction
button
depressed
still
occurs,
replace
print
S-1230.
Test
with
new
S-1
230,
print
and
old
A-1
230
print.
Automatic buttonholing
does not
-
Buttonhole
foot
-
TestPlP2
function
-
PrintS-1230
-
Print
Ret-1230
Basting
device
does not
function
-
PrintS-1230
-
Replace
print
S-1230
-
Basting
device
magnet
-
Replace
magnet and
adjust
Reverse
button does
not
function
-
Print
S-1230
-
Start
service
test
programme,
depress
-
Print
Ret-1230
reverse
button,
LED
RET
must
illuminate,
if not:
replace
print
S-1230
to Z
or if nec.
Ret print.
Irregular
stitch
width
or
length
-
Step
motor
-
Test
Hi
H2
-
Check
mechnicol
and
optical
parts
of
Bar
graphs
do
not
react
to
stitch
-
Operating
chassis
the
rotary
encoder
adjustments
-
PrintA-1230
-
Replace
print
A-1
230
Main
motor
stops
after
5
seconds
-
Print
P-4200
-
Test
F
-
Print
S-1230
-
Replace
print
S-1230
No
needle
stop
-
Print
P-4200
-
Test
F
-
Print
S-1230
-
Replace
print
S-1230
-
Print
L-4200
-
Test
A
Stitch
pattern
no.
32
is to
short
- Feed
equalization
-
Test
0
=
orto
long
'0_ _ _ _ _ _ __ _ _ _ _ _ _ _ __ _ _ _ __O_ __ _ _ _ _ _ _ _

What
is
to be
tested
What
to adjust
Normal
condition
Print L-4200
Switch
off mains
supply
See also directive
in Test M
-
Fit safety
cover
- Connect
test
adaptor L-4200
instead
of the sewing light (2-pole, green),
connect connecting
cable
to print
S-4200
(4-pole
green,
control signals)
and connecting
cable to
print
S-4200
(5-pole
red, supply).
-
Set
the switch
on the
(off
position.
Switch
on mains
supply
- LEDsAto
D
illuminate
-
Motor rotates.
LED
F illuminated.
Speed can
be controlled
by
the
-
Motor
switch
to oon)
position
potentiometer.
(see also
test
B)
Motor brakes.
LED
F no longer
- Motor
switch to
aoffo position
illuminated
Important:
-
When
no lights
A-D
illuminate
carry ont
test
D mains
cord.
-
Replace
print
L-4200
if
one or
several
of
the LEDs
A
to D do
not
illuminate.
Before
going
further,
test
the
new
L-print
using
test 9 to determine
whether
the
L-print
failure
was
subsequent
to failure
of
the S-1
230
or A-1
230
prints.
If this
is the
case,
then these
faults
should
first
be
eliminated.
- Replace
print
R-4200
if
the voltages
A-D
are
available
but
the
motor
still
does not
run.
Subsequently
replace
print L-4200
if the
motor still
does not
run.