Bernina B 590 Installation and user guide

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 1 von 172
DRAFT – VERSION
Service- and Maintenance Manual
Of the 5 Series (VIO type)
B 590
B 500
B 570
B540
B 535

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DRAFT – VERSION
Contents
Chapter 1 - General Information.......................................................................................6
1.1. Safety Regulations..............................................................................................................6
1.2 Warning: Dangerous voltage levels!.....................................................................................6
1.3 ESD-related note: Electrostatic Discharge (ESD).................................................................8
1.4 Tools and gauges.................................................................................................................9
1.5 Handling adjustments.........................................................................................................12
1.6 Abbreviations/Names Used................................................................................................12
1.7 Cleaning.............................................................................................................................13
1.8 Technical specifications of 5 Series....................................................................................14
Chapter 2 – Electronics and Wiring ...............................................................................16
2.1 BERNINA B 590 (B 570 QE, B 535, B 520 & B 500 Embroidery Only) Block Diagram .......16
2.2 PCBA-Power......................................................................................................................17
2.3 PCBA-CPU-Module (ARM9) General Information...............................................................18
2.3.1 PCBA-CPU-Module/ARM9................................................................................................................ 18
2.4 PCBA-Base General Information........................................................................................19
2.4.1 PCBA-Base with feed-dog drop detection......................................................................................... 19
2.5 PCBA-Position Hall ............................................................................................................20
2.6 PCBA-Threader..................................................................................................................20
2.7 PCBA-Cover including display and touch screen................................................................21
2.7.1 PCBA-Front cover (B 590, B 570 QE, B 540, B 535 & B 500 Embroidery Only).............................. 21
2.7.2 PCBA-Stitching head (PCBA-RET) (B 590, B 570 QE, B 540, B 535 & B 500 Embroidery Only).... 21
2.8 PCBA-Lower-Thread Observer (LTO) ................................................................................22
2.9 ABC sensor support (presser-foot recognition)...................................................................22
2.11 Handling of Electronic Components..................................................................................23
2.12.1 Returning Defective Electronic Components. ................................................................................. 23
2.11.2 Repairs of Electronic Components (PCBA's).................................................................................. 23
Chapter 3 - Troubleshooting...........................................................................................24
3.1 General troubleshooting flow chart.....................................................................................24
3.2 Operating Voltage Functional Test .....................................................................................25
3.2.1 Use and functions of LEDs..............................................................................................25
3.3 Upper-thread sensor............................................................................................................................. 27
3.4 Lower-thread sensor ..........................................................................................................28
3.5 Touch screen calibration ...................................................................................................................... 29
3.6 EEPROM missing or misprogrammed ................................................................................................. 29
3.8 Update failed......................................................................................................................30
3.9 Sewing-off guidelines .........................................................................................................32
3.10 Personal notes regarding troubleshooting ........................................................................36
Chapter 4 – Removal and Refitting of Components.....................................................37
4.1 Covers See ESD-related note.................................................................................37
4.1.1 Service Cover.................................................................................................................................... 37
4.1.2 Front cover ........................................................................................................................................ 38
4.1.3 Rear Cover ........................................................................................................................................ 41
4.1.4 Freearm cover ................................................................................................................................... 42
4.1.5 Base-plate cover................................................................................................................................ 43
4.2 Electronics, Sensors, Switches, Magnets...........................................................................44
4.2.1 PCBA-Power including PCB housing................................................................................................ 44
4.2.2 PCBA-CPU-Module (ARM9) General Information ............................................................................ 46
4.2.3 PCBA-CPU-Module (ARM9).............................................................................................................. 47
4.2.4 PCBA-Base with feed-dog drop detection........................................................................................ 48
4.2.4.1 EEPROM (Electrically Erasable Programmable Read-Only Memory)........................................... 48
4.2.5 PCBA-Position Hall............................................................................................................................ 49
4.2.6 PCBA-Threader................................................................................................................................. 50
4.2.7 PCBA-Front cover including display and touchscreen...................................................................... 51
4.2.8 PCBA-RET (B 590, B 570 QE, B 540, B 520 & B 500 Embroidery Only)......................................... 52
4.2.9 PCBA-Lower thread sensor cpl......................................................................................................... 53

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4.2.10 Sensor support ABC (presser foot recognition) .............................................................................. 54
4.2.11 Head frame and frame arm LED sewing light ................................................................................. 55
4.2.12 PCBA-Embroidery module detection............................................................................................... 57
4.3 Electromechancial/Mechanical Components......................................................................58
4.3.1 Hook and hook driver ........................................................................................................................ 58
4.3.2 Main feed-dog and feed-dog carrier.................................................................................................. 61
4.3.3 Replacing the hook driver drive belt.................................................................................................. 62
4.3.4 Stitch plate carrier with integrated thread-cutting unit....................................................................... 63
4.3.4.1 Replacing the blade of built-in thread-cutter unit............................................................................ 65
4.3.5 Base shaft.......................................................................................................................67
4.3.6 Crank shaft and stitch length stepping motor...................................................................68
4.3.7 Replacing base shaft and vertical shaft connecting belt...................................................69
4.3.8 Feed-dog carrier and advance link ..................................................................................69
4.3.9 Upper feed crank.............................................................................................................70
4.3.10 Upper feed (Dual Feed).................................................................................................71
4.3.11 Clutch carriage ................................................................................................................................ 72
4.3.11.1 Adjusting the thread-cutter and stitching-start solenoid ............................................................... 73
4.3.12 Thread take-up cover with automatic upper-thread tensioning unit................................74
4.3.13 Needle-bar support........................................................................................................75
4.3.14 Needle bar....................................................................................................................................... 75
4.3.15 Needle clamp ................................................................................................................76
4.3.16 Threading mechanism...................................................................................................77
4.4.16.1 Threader head............................................................................................................78
4.3.17 Thread tension................................................................................................................................. 79
4.3.18 Thread take-up lever and thread regulator spring..........................................................80
4.3.18.1 Thread regulator spring................................................................................................................ 80
4.3.19 Main motor....................................................................................................................................... 81
4.3.20 Stitch length stepping motor............................................................................................................ 82
4.3.21 Presser-foot pressure stepping motor............................................................................................. 83
4.3.22 Stitch-width stepping motor............................................................................................................. 84
Chapter 5 – Adjustments ................................................................................................85
5.1 Belt Tensions .....................................................................................................................85
5.1.1 Vertical shaft-/base shaft belt tension ............................................................................................... 85
5.1.2 Drive motor belt tension..................................................................................................................... 86
5.1.3 Hook drive belt tension....................................................................................................87
5.2 Head-frame plate position ..................................................................................................88
5.2.1 Position of head-frame plate/stitch plate in Y-direction..................................................................... 88
5.2.1 Position of head-frame plate/stitch plate in Y-direction..................................................................... 88
5.2.2 Position of head-frame plate/stitch plate in X-direction..................................................................... 89
5.3 Presser-foot adjustment .....................................................................................................90
5.3.1 Darning foot height..........................................................................................................90
5.3.2 Presser-foot fixation........................................................................................................................... 91
5.4 Needle settings...................................................................................................................92
5.4.1 Distance between needle bar and presser-foot bar .......................................................................... 92
5.4.2 Needle distribution............................................................................................................................. 93
5.4.3 Zigzag stitch width limiter .................................................................................................................. 94
5.5 Hook, needle drive and feed-dog movement timing............................................................94
5.5.1 Feed-dog lift movement (base shaft and main shaft timing)............................................................. 94
5.5.2 Base shaft-/load lock screw distance ................................................................................................ 95
5.5.3 Loop lift.............................................................................................................................................. 96
5.5.4.1 Needle penetration in Y directions ................................................................................................. 98
5.5.5 Needle height .................................................................................................................................... 99
5.5.5.1 Needle height without basting device........................................................................................... 100
5.6 Presser-foot settings ........................................................................................................101
5.6.1 Main feed-dog horizontal position ................................................................................................... 101
5.6.2 Main feed-dog height 0.9-1.0mm .................................................................................................... 101
5.6.3 Main feed-dog Position within stitch plate in X-direction................................................................. 103
5.6.4 Main feed mechanical balance - basic setting................................................................................. 104
5.6.5 Upper feed (Dual Feed)-/main feed synchronization (pinning position).......................................... 105
5.6.6 Upper feed-dog (Dual Feed) mechanical balance – Basic setting.................................................. 106

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5.7 Clutch carriage/thread cutter ............................................................................................107
5.7.1 Clutch carriage solenoid adjustment............................................................................................... 107
5.7.2 Clutch carriage alignment................................................................................................................ 108
5.7.3 Clutch carriage timing...................................................................................................................... 109
5.7.4 Thread cutter ................................................................................................................................... 110
5.8 Hall position synchronization............................................................................................111
5.9 Threader...........................................................................................................................112
5.10 Basting Device ...............................................................................................................112
5.10.1 Needle bar guide........................................................................................................................... 112
5.10.2 Time of clutch release ................................................................................................................... 113
5.11 Thread regulator.............................................................................................................114
5.12 Thread tension ...............................................................................................................115
5.12.1 Upper thread tension..................................................................................................................... 115
5.12.2 Lower-thread tension (basic setting) ............................................................................................ 116
5.13 Winder............................................................................................................................117
5.14 Lower-thread sensor position .........................................................................................118
Chapter 6 - Service Program ........................................................................................119
Starting the Test Program ......................................................................................................119
6.1 Section 1 – Service Information........................................................................................121
1a Machine basic data.............................................................................................................................. 121
1b Machine firmware data and technical information............................................................................... 121
1c Machine operating hours data............................................................................................................. 122
1d Stitch counter data............................................................................................................................... 122
1e BSR (BERNINA Stitch Regulator) data............................................................................................... 122
1f Machine servicing data......................................................................................................................... 123
1g Saving customer data.......................................................................................................................... 123
1h Customer related data (Customer Information)................................................................................... 124
1i Dealer related data (Dealer Information)............................................................................................. 124
1j Log file .................................................................................................................................................. 125
6.2 Section 2 – Screen, symbols............................................................................................125
2a Touch screen calibration ..................................................................................................................... 125
2b LCD (screen brightness)...................................................................................................................... 126
2c Blank dark LC display (screen)............................................................................................................ 126
2d Blank white LC display (screen).......................................................................................................... 126
2e RGB (Red, Green and Blue) screen.................................................................................................... 127
2f Keyboard lights..................................................................................................................................... 127
2h LED sewing light and brightness......................................................................................................... 128
6.3 Section 3 – Location of sensors in the machine................................................................128
3a Threader sensor .................................................................................................................................. 128
3b Presser-foot micro switch.................................................................................................................... 129
3c Lower-thread sensor............................................................................................................................ 129
3d Feed-dog drop..................................................................................................................................... 130
3g Bobbin winder micros witch................................................................................................................. 131
3h Frei Hand System FHS........................................................................................................................ 131
6.4 Section 4 – Signals...........................................................................................................132
4a Stitch width and stitch length knob(s).................................................................................................. 132
4b Functions of keys and buttons on machine......................................................................................... 133
4c Start-/Stop Slide (SSU)........................................................................................................................ 133
4d Foot control.......................................................................................................................................... 134
4f Upper Thread Observer (UTO)............................................................................................................. 134
4g BERNINA Stitch Regulator (BSR)....................................................................................................... 135
4h PCBA-Position..................................................................................................................................... 135
4i Speaker................................................................................................................................................. 136
4j USB ports.............................................................................................................................................. 136
4k Basting solenoid .................................................................................................................................. 137
4l Presser-foot recognition........................................................................................................................ 137
4m BSR foot interface .............................................................................................................................. 138
6.5 Section 5 – Locations of stepping motors in the machine.................................................139
5a Stitch-width stepping motor................................................................................................................. 139
5b Presser-foot pressure stepping motor................................................................................................. 140
5c Upper-thread tension stepping motor.................................................................................................. 140

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5e All stepping motors in pinning position................................................................................................ 141
5f Bobbin winder motor............................................................................................................................. 141
5g Stitch-length stepping motor................................................................................................................ 142
6.6 Section 6 – Adjustments...................................................................................................143
6a Sewing-off (user interface) .................................................................................................................. 143
6b Electronic balance calibration.............................................................................................................. 144
BERNINA Dual Feed balance .................................................................................................................. 146
6c Buttonhole calibration.......................................................................................................................... 147
6d Thread cutter clamping mechanism (solenoid) ................................................................................... 148
6e Thread cutting...................................................................................................................................... 149
6f Resetting upper-thread tension to default............................................................................................ 149
6g Resetting to factory settings (Reset all)............................................................................................... 150
6j Automatic upper-thread tension ........................................................................................................... 151
6k Test Tie On.......................................................................................................................................... 151
6l Start-/Stop slide (SSU) calibration........................................................................................................ 152
6m Normal SSU stitching speed............................................................................................................... 152
6n BSR sewing mode............................................................................................................................... 153
6o Magnetic position encoder calibration................................................................................................. 154
6.7 Section 7 – Embroidery module (EMB).............................................................................154
6.11 Section 11 – Check-out tests..........................................................................................155
Important!.................................................................................................................................................. 155
Check-out tests:........................................................................................................................................ 155
Chapter 7 – Lubrication Diagram .................................................................................156
7.1. Lubrication of modified hook driver when removed from machine.................................................... 161
Chapter 8 – Firmware Update ......................................................................................162
8.1 Update Procedure............................................................................................................162
8.2 Update alternative access.................................................................................................................. 164
8.3 After replacing the PCBA-CPU module.............................................................................................. 164
Chapter 9 - Maintenance Guidelines............................................................................165
9.1 Purpose of the Maintenance Guidelines...........................................................................165
9.2 Explanatory notes on the stitch- and hour counter............................................................165
9.2.1 When is a cleaning message displayed?........................................................................................ 165
9.2.2 When is a maintenance message displayed?................................................................................. 165
9.2.3 How are the stitches counted?........................................................................................................ 165
Calculation table....................................................................................................................................... 166
9.2.4 Implementation of the maintenance intervals.................................................................................. 166
9.3 Maintenance intervals.......................................................................................................166
9.3.1 Cleaning- and service-stitch reset................................................................................................... 166
9.4 Wear-and-tear-parts definition..........................................................................................167
9.4.1 Non-hour-related parts .................................................................................................................... 167
9.5 Maintenance checklist......................................................................................................168
9.5.1 Measures to be taken before the servicing ..................................................................................... 168
9.5.2 Measures to be taken after the service ........................................................................................... 168
9.5.3 Functional check.............................................................................................................................. 169
9.5.4 Maintenance checklist BERNINA 590, 570 QE, 540, 520, 500....................................................... 170
9.5.5 Embroidery module ......................................................................................................................... 171
Chapter 10 – Document Revision History...............................................................................172

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Chapter 1 - General Information
1.1. Safety Regulations
IMPORTANT!
All electrical and electronic components operate at dangerous voltages. Remove the mains plug before
making any adjustments to the machine. Wait about 30 seconds after removing the plug (capacitor
discharge).
However, servicing-related work can be carried out in Service Program when the machine is powered.
This service manual is intended to help with minor repairs and adjustments.
The instructions do not claim to be complete or comprehensive. The manual does not provide guidance
for complete assembly or disassembly.
Important:
To enable the work described to be performed correctly, the sewing and embroidery computer
must be in good mechanical and electrical condition (running smoothly, properly oiled and all
leads connected)!
When adjustments are carried out in the correct order, the machine will function flawlessly.
It is important that only devices approved and distributed by BERNINA® are connected to the
sewing/embroidery computer ports.
When servicing or repairing, always use genuine parts and original accessories, either those delivered
with the machine or purchased afterwards.
Which are:
•Power cable
•Foot control
•Buttonhole foot
•Presser foot 1
•Bobbin
•Other accessories
•BERNINA stitch length regulator (BSR) foot.
The Service Manual and Instructions are protected by copyright laws. It must only be used by authorized
dealers. It is prohibited to disclose the service manual to unauthorised third parties.
This Manual is subject to revisions without notice. The recipient is responsible for updating the information
provided by BERNINA International AG, Steckborn, Switzerland.
This service manual is only available in electronic format. It can be downloaded from BERNINA Infogate at
http://infogate.bernina.com under ‘Service Manual’ in the ‘Tech. Service’ register.
If you don't have access to Infogate, contact your local BERNINA importer. They'll be glad to be of
assistance.
Disclaimer
Masthead
Author: Dieter Uhmeier
1.2 Warning: Dangerous voltage levels!
IMPORTANT!

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The power connection, the main switch, the PCBA Power, and the power cable all carry dangerous
voltages.
Therefore always disconnect the machine from the power supply before starting any work on the
machine. This applies unless otherwise instructed where required.
Note:
The capacitors require 30 seconds to discharge after the power supply has been switched off. We
recommend to wait for the complete discharging of the capacitors before starting any servicing
work on the PCBs.

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1.3 ESD-related note: Electrostatic Discharge (ESD)
Protection of electrical and electronic components against electrostatic discharges
Be sure to follow these important guidelines:
1. Always work at a stationary, ESD-compliant workstation equipped with the appropriate ESD protective
devices including conductive table and/or floor mat, earth connection box and earthing wristband when
doing service work.
The cable of the earthing wristband and the earth connection box must have a built-in resistance of 1 M
ohm to ensure protection.
2. Always put on an earthing wristband before starting to work. Always remove any synthetic parts like
plastic bags, covers etc. from your workstation.
3. Only open ESD protective packaging at your ESD-proof workstation while wearing an earthing wristband.
Electronic components must be placed on conductive table mats only. Packing is carried out under the
same conditions.
4. Only use conductive ESD-capable plastic/foil pouches and ESD transport boxes for dispatching electronic
components even if the components might be faulty.
Electrostatic Discharge (ESD)
5. Treat faulty PCBs in the same manner as new ones to prevent consequential damage or harm.
Note:
For more information see 2.12
.
Electrostatic charges are caused by:
a person's walking (influence)

friction between and separation of two insulating materials
(triboelectricity)
If this static electricity discharges through electronic components, these may
be partially or irreparably damaged. Electrostatically
charged persons
represent the greatest danger for components. This can be dissipated by

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1.4 Tools and gauges
(commercially available, not available from Bernina):
Calliper, multimeter, TORX screwdrivers sizes 6, 8, 10, 10 with 200mm shaft length, 15, 20, 25, 25 with
200mm shaft length, angled Torx sizes 6 and 10, combination spanners in sizes 10mm and 8mm, open-
ended spanner in size 6mm
Special Tool set for 5 Series Art.-No.: 034384.74.07
Spezialwerkzeug Set 5er Serie
Trousse à outils spéciale pour la Série 5
Art.-No.
Name
Bezeichnung
Nom
Application
Verwendung
Application
Picture
Bild
Image
734541.71.00 Adjusting gauge hook driver B9 Einstelllehre Greifertreiber B9
Gabarit d’entraînement de crochet B9
Alignment of hook driver bearing /
hook race
Zentrierung Greifertreiber Lager /
Greiferbahn
Alignement du palier
d’entraînement de crochet / rail de
crochet
734956.50.00
Distance gauge for the new hook driver
(white bullet point)
Distanzlehre für den neuen Greifertreiber
(weisser Punkt)
Gabarit de distance pour le nouvel
entraînement de crochet (point blanc)
Adjusting distance between hook
and hook driver
Distanz-Einstellung zwischen
Greifer und Greifertreiber
Réglage de la distance entre le
crochet et l’entraînement de
crochet
734571.70.01 Loop lift gauge BERNINA 7-Series Schlingenhublehre BERNINA 7er-Reihe
Gabarit d’ascension de BERNINA Série 7
Adjusting the loop lift distance of
2.6mm
Einstellen des Schlingehubmasses
2.6mm
Ajuster l’ascension de 2.6mm
033924.70.00
Adjusting gauge for the bobbin thread
tension
Einstelllehre für die Unterfadenspannung
Gabarit de réglage de la tension du fil de
la boîte à canette
Adjusting the tension on the
bobbin case
Einstellen der
Unterfadenspannung
Pour ajuster la tension de la boîte
à canette
27.0 g
&
3.0 g
030475.51.01 Torx screwdriver
Torx Schraubenzieher T8
Tournevis torx
Adjusting tool for feed-dog height
at back and cutting device
Einstellung Transporteurhöhe
hinten und Fadenschnitteinheit
Réglage de la hauteur de la griffe
d‘entraînement à l’arrière et coupe
fil
030883.50.02 Distance gauge
Distanzlehre L =19.25mm
Gabarit de distance
Adjusting the needle height
Einstellen der Nadelhöhe
Réglage de la hauteur de l’aiguille
034370.50.00 Bobbin winder adjusting gauge Spulerlehre
Gabarit pour le dévidoir
Adjusting the thread quantity on
the bobbin
Einstellen der Füllmenge auf der
Spule
Ajuster la quantité de fil sur la
canette
734562.50.00
Auxiliary tool for mounting circlip
Hilfswerkzeug für die 1.5
Benzingsicherungmontage
Outillage auxilaire pour ressort circlip
Reassembling aid
Einbauhilfsmittel
Aide au montage
734258.52.00
Timing gauge for the clutch carriage
Einstelllehre für den Kupplungsschlitten
Jauge pour la barrette d’embrayage
pour couper le fil
Setting the timing of the thread
cutting system
Einstellen des
Fadenschnittsystems
Ajuster le système de coupe
Art-No: 034574.54.07

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Common Tool Set for 5 Series Art.-No.: 034383.70.00
Allgemeines Werkzeug Set 5er Serie
Trousse à outils généralement pour la Série 5
Art.-No.
Name
Bezeichnung
Nom
Application
Verwendung
Application
Picture
Bild
Image
338109.03.3+
Adjusting needles
Einstellnadeln 130/705 H TCN
80
Needle and hook adjustment
Nadel- und Greifereinstellung
Réglage de l’aiguille et du crochet
Com.available
Handelsüblich
En commerce 130/705 H 100 Needle penetration in Y-direction
Nadeleinstich in Y-Richtung
Pénétration de l’aiguille en Y-direction
030475.51.00
Torx screwdriver
Torx Schraubenzieher T10
Tournevis torx
Disassembling & reassembling aid
Einbau- und Ausbauhilfsmittel
Aide au montage et au démontage
734101.50.00
Distance gauge
Distanzlehre
Gabarit de distance
Threader head height
Einfädlerkopf-Höhe
Hauteur de l’enfileur
730475.51.00
Distance plate
Distanzplatte
Plaque-étalon de distance
Adjusting the needle height
Einstellen der Nadelhöhe
Réglage de la hauteur de l’aiguille
032798.50.00 Synchroplate
Synchroplatte
Plaque de synchronisation
Basic position of the BERNINA dual
feed
Grundposition Obertransportfuss
Position de base pour BERNINA dual
feed
398024.03.1+
Feed-dog height gauge
Transporteur Höhenlehre
Gabarit de hauteur de la griffe
d‘entraînement
Checking of the feed-dog height
Kontrolle der Transporteur Höhe
Vérification de la hauteur de la griffe
d‘entraînement
398026.13.1+
Darning foot height gauge
Stopffuss Höhenlehre
Gabarit de hauteur pour le pied de
reprisage
Checking the darning foot level
Kontrolle der Stopffuss Höhe
Vérification du niveau du pied de
reprisage
002733.50.00
Pinning tool long
Absteckwerkzeug, lang 2X
Goupille de réglage, long
Pinning positions
Absteckpositionen
Positions de goupillage
007937.50.00
Pinning tool 3.0mm
Absteckwerkzeug 3.0mm 2X
Goupille de réglage 3.0mm
Pinning positions
Absteckpositionen
Positions de goupillage
001356.50.00
Pinning tool, short
Absteckwerkzeug kurz
Goupille de réglage, court
Pinning positions
Absteckpositionen
Positions de goupillage
031563.50.00 Excentric key 2.0mm
Exzenterwinkel 2.0mm
Clé excentrique 2.0mm
Alignment of head plate to the stitch
plate
Ausrichtung der Kopfplatte zur
Stichplatte
Alignement de la plaque frontale et de
la plaque à aiguille
007993.50.00 Angular Torx
Winkeltorx T8
Clé mâle coudée TORX
Adjusting tool for feed-dog height at
back
Werkzeug, Einstellung hintere
Transporteurhöhe
Outil de réglage de la hauteur de la
griffe d'entraînement à l'arrière
733019.70.00
Adjusting spanner compl.
Einstellschüssel kompl.
Tendeur pour le réglage de la tension
des courroies compl.
Adjusting the belt tension, setting the
distance of the needle bar clamp
Einstellung der Riemenspannung,
Distanzeinstellung Klemmstück /
Nadelstange
Réglage de la tension de courroie,
réglage de la distance du levier de
serrage de la barre à aiguille
008709.72.00
Upper thread adjusting gauge (5-
pieces-set)
Oberfaden Einstelllehren-Set (5-teilig)
Gabarit de réglage du fil supérieur (jeu
de 5 pièces)
Weight for setting the upper thread
tension
Einstellung der Oberfadenspannung
Réglage de la tension du fil supérieur

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Art.-No.
Name
Bezeichnung
Nom
Application
Verwendung
Application
Picture
Bild
Image
398112.03.0+
Spring mounting tool
Federhaken
Outil pour ressort
Spring hooking & unhooking aid
Ein- und aushängen von Federn
Crocher et décrocher les ressorts
001361.70.00
Excentric key
Exzenterschlüssel
Clé excentrique
Various adjustments
Verschiedene Einstellungen
Divers réglages
652010.20.++
Gauging thread DMC 50 BLANC
(white)
Eichfaden DMC 50 weiss
Fil de réglage DMC 50 BLANC
Upper- & lower thread-tension
Ober- und Unterfadenspannung
La tension des fils supérieur & de la
canette
033958.50.00
(Size 1.5)
033958.50.01
(Size 2.3)
033958.50.02
(Size 3.2)
C-Clip Holding Set
Benzinghalter Set
Kit outils circlip
(3-parted/3-teilig/en 3 parties
Ø1.5, 2.3, 3.2)
Assembly C-clips
Einbau Benzingsicherungen
Montage de circlips
Helpful Tools for BERNINA Sewing and Embroidery Systems
Hilfreiche Werkzeuge für BERNINA Näh- und Sticksysteme
Trousse à outils secourable pour les maschine à coudre informatisée de BERNINA
006038.50.00 Spring balance gauge Federwaage
Pèse-ressort
Tension of thread regulator spring
Anzugwert der Fadenregulatorfeder
Tension ressort du régulateur du fil
031935.50.00 Plug mounting tool Steckerstössel
Poussoir de la fiche
Mounting aid for plugs and cables
Hilfsmittel für Stecker und Kabel
Montage
Aide pour le montage de fiches et de
câbles
032948.50.00 IC extraction tool Ausziehwerkzeug
Tire-IC
Removal of EEPROM
Ausbau des EEPROM
Extraction de l'EEPROM
Com,available
Handelsüblich
En commerce
Multimeter (digital)
Multimeter (digital)
Multimètre numérique
•Continuity test
•Ohm measurement
•Voltage tests
•Durchgangsprüfungen
•Ohm Messungen
•Spannungs-Prüfungen
•Mesure de la résistance
•Mesure de la tension
•Mesure de la continuité
398022030
Feeler gauge 0.3mm
Tasterlehre 0,3mm
Jauge d’épaisseur 0,3 mm
Distance measurements
Distanzmessungen
Mesures de distance
398111030
Feeler gauge 0.15mm
Tasterlehre 0,15mm
Jauge d’épaisseur 0,15 mm
Com.available
Handelsüblich
En commerce
Feeler gauge 0.6mm
Tasterlehre 0,6mm
Jauge d’épaisseur 0,6 mm
031564.50.01 Tweezers Pinzette
Brucelles
Plugging and unplugging cables
Aus- und Einstecken von Kabel
Branchement et débranchement de
câbles plat
Com.available
Handelsüblich
En commerce
Watchmaker's magnifier 2.5x
(magnification approx. 4x)
Uhrmacherlupe 2.5x (Vergrösserung
ca. 4fach)
Loupe d'horloger (micros) 2.5x
(grossissement env. 4x)
Allows for more precise adjustments in
the hook-/needle area
Ermöglichung von präziseren
Einstellungen im Bereich Greifer –
Nadel
Permet des réglages plus précis dans
la zone du crochet et de l'aiguille

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 12 von 172
DRAFT – VERSION
1.5 Handling adjustments
•Will be explained within the respective items.
1.6 Abbreviations/Names Used
Throughout the whole manual the following abbreviations have been used. We have reserved the right not to
explain individual abbreviations within the text.
Abbreviation:
Stands for:
BDF
BERNINA Dual Feed (upper feed)
BSR
BERNINA Stitch Regulator
DC
Direct Current
EEPROM
Electronically Erasable Programable Read Only Memory
(elektrisch löschbarer, programmierbarer nur Lesespeicher)
EMB
Embroidery module
EMC
Electro Magnetic Compatibility
FHS
Free Hand System (knee-operated lever)
IR
Infra Red
LCD
Liquid Crystal Display
LED display
Light Emitting Diode
LMS
Length Measuring System
LTO
Lower Thread Observer
PCBA
Printed Circuit Board Assembled
RET
RETurn (PCBA-RET)
SP
Service Program
TFT
Thin Film Transistor
TTA
Thread Tension
UTO
Upper Thread Observer

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 13 von 172
DRAFT – VERSION
1.7 Cleaning
Remove and clean the covers.
Electrostatic charging may occur during cleaning. To prevent this, use antistatic office-equipment cleaning
agents.
We use and recommend BASF’s SURFACE CLEAN surface cleaner.
It forms a protective film against static electricity, and is suitable for both plastic and metallic surfaces.
IMPORTANT!
Never use alcohol, benzine, spirits or any other corrosive fluids, or abrasive pastes or
detergents!
Inside parts:
•Dust, lint, thread and fabric remnants can accumulate inside the machine behind the covers. and
may lead to malfunctions.
Head frame area:
•Thread take-up lever (joints), needle bar, needle bar support, and needle bar coupling.
•Main shaft (behind needle drive balance piece), synchronizer.
•Between the upper-thread tension discs, all along the thread path, incl. thread redirections
Freearm and base area:
•Bobbin carrier (under tension spring)
•Feed dog
•Hook/hook sensors
•Lower thread indicator
•Base shaft (lift-/advance cams)
•In the thread-cutting mechanism
Drive area:
•Drive motor/carbon dust
•Toothed-belt discs, and motor pulley
•Hook drive
Electronics area
•All sensors, light barriers, switches, electronic components

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 14 von 172
DRAFT – VERSION
1.8 Technical specifications of 5 Series
Features
BERNINA 590
BERNINA 570
QE
BERNINA 540
BERNINA 535
BERNINA 500
Embroidery
only
Technical
Supply voltage
100 - 240 Volt
50-60 Hz
100 - 240 Volt
50-60 Hz
100 - 240 Volt
50-60 Hz
100 - 240 Volt
50-60 Hz
100 - 240 Volt
50-60 Hz
maximum power input in Watt
180
180
180
180
180
maximum power output in Watt
145
145
145
145
145
Eco mode (30% reduction)
Yes
Yes
Yes
Yes
Yes
Total memory space in MB
128
128
128
Overall size in mm, L-W-H
525 x 205 x
415
525 x 205 x
415
525 x 205 x
415
525 x 205 x
415
525 x 205 x
415
Weight in kg without
accessories
11.0
11.0
11.0
11.0
11.0
Weight of embroidery module in
kg
4.0
4.0
4.0
4.0
4.0
Weight in kg incl. packaging
18.3
18.3
18.3
18.3
18.3
Hook system
BERNINA
Hook
BERNINA
Hook
BERNINA
Hook
BERNINA
Hook
BERNINA
Hook
Motor
DC / 36 Volt
DC / 36 Volt
DC / 36 Volt
DC / 36 Volt
DC / 36 Volt
Stitching speed, min./max.
100 - 1000
SPM
100 - 1000
SPM
100 – 1000
SPM
100 – 1000
SPM
100 – 1000
SPM
Sideways Motion
--
--
--
--
--
BERNINA Dual Feed (upper
feed)
Yes
Yes
--
--
--
BERNINA Stitch Regulator
(BSR) port
Yes
Yes
Yes
Yes
--
Embroidery module connection
Yes
Yes
Yes
Yes
Yes
Automatic thread cutter
Yes
Yes
Yes
Yes
Yes
Embroidery speed, max.
1000 SPM
1000 SPM
1000 SPM
1000 SPM
1000 SPM
Embroidery file formats
EXP
EXP
EXP
EXP
EXP
Langstich und Heftmatik
Yes
Yes
--
--
--
Knee-operated lever/Free Hand
System (FHS)
Yes
Yes
Yes
Yes
Yes
Freearm space, diagonal
measure in mm
130 / (285)
130 / (285)
130 / (285)
130 / (285)
130 / (285)
Built-in upper thread threader
Yes
Yes
Yes
Yes
Yes
Automatic upper thread tension
Yes
Yes
Yes
Yes
Yes
Automatic presser-foot lifter
Yes
Yes
--
--
--
Presser-foot height in mm,
normal
7,5
7.5
7,5
7,5
7,5
Presser-foot height in mm, max.
extra lift
15
15
15
15
15
Presser-foot height with FHS in
mm
10,5
10,5
10,5
10,5
10,5
Lower- and upper thread
sensors
Yes
Yes
No/Yes
Yes
Yes
Max. stitch length forward in
mm
6.0
6.0
6.0
6.0
6.0
Max. stitch length reverse in
mm
6.0
6.0
6.0
6.0
6.0
Adjustable increments in mm
0,055
0,055
0,055
0,055
0,055
Max. stitch width in mm
9.0
9.0
9.0
5.5
0.0
Adjustable increments in mm
0,1
0.1
0,1
Sewing light (sewing area)
LED
LED
LED
LED
LED
Freearm area lighting
LED
LED
LED
LED
LED
Color TFT LCD (Thin Film
Transistor) with capacitive
touchscreen
Yes
Yes
Yes
Yes
Yes
Display size in mm (inch)
10,9 (4,3)
10,9 (4,3)
10,9 (4,3)
10,9 (4,3)
10,9 (4,3)
Resolution in pixel
480 x 272
480 x 272
480 x 272
480 x 272
480 x 272
Number of colors
262‘144
262‘144
262‘144
262‘144
262‘144
Display backlight in white
LED
LED
LED
LED
LED

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 15 von 172
DRAFT – VERSION
Features
BERNINA 590
BERNINA 570
QE
BERNINA 540
BERNINA 535
BERNINA 500
Embroidery
only
User interface
Touch screen
Touch screen
Touch screen
Touch screen
Touch screen
USB data stick/PC interface
1 / 1
1 / 1
1 / 1
1 / 1
1 / 1
Stitch packages
Number of sewing stitch
patterns (incl. alphabets)
1306
837
680
?
--
Alphabets / characters
8 / 798
6 / 545
5 / 439
5 / 439
--
Number of buttonhole types
(incl. eyelets)
16
14
12
12
--
Button sewing-on program
1
1
1
1
--
Number of utility stitch patterns
32
30
29
--
Number of decorative stitch
patterns
460
250
200
--
Embroidery design packages
Alphabets
8
7
4
4
8
Number of embroidery motifs
included
275
250
50
50
275

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 16 von 172
DRAFT – VERSION
Chapter 2 – Electronics and Wiring
Plug diagram and brief descriptions of electronic components
2.1 BERNINA B 590 (B 570 QE, B 535, B 520 & B 500 Embroidery Only) Block Diagram

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 17 von 172
DRAFT – VERSION
2.2 PCBA-Power

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 18 von 172
DRAFT – VERSION
2.3 PCBA-CPU-Module (ARM9) General Information
The PCBA--CPU-module contains:
•Processor (CPU)
•Memory
•Data
2.3.1 PCBA-CPU-Module/ARM9
Note:
If a PCBA-CPU-module requires early replacement, please refer to chapter 8.3.
PCBA-CPU-Module sits on base PCBA. When
replacing base PCBA remove PCBA-CPU-module
from the 'old' PCBA and add to new base PCBA.

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 19 von 172
DRAFT – VERSION
2.4 PCBA-Base General Information
The PCBA-Base contains:
•EEPROM (storing of machine-specific data, e.g. stitch counter and operating hours counter)
•5-volt and 36-volt voltage control LEDs
•PCBA-CPU-module interface
•FHS light barrier
•Speaker
•Stepping motors drivers
Internal connections:
•According to table
External connections:
•USB connections for PC and USB stick
•Foot control connection
Important!
When replacing the PCBA-Base, remove the EEPROM from the old PCBA and directly
fit it on the new PCBA.
Do not remove or plug in any connections when the sewing computer is switched on
or connected to the power supply.
2.4.1 PCBA-Base with feed-dog drop detection

BERNINA International AG Seestrasse 161 CH-8266 Steckborn Schweiz Seite 20 von 172
DRAFT – VERSION
2.5 PCBA-Position Hall
2.6 PCBA-Threader