Barudan BEKY Series Embroidery Machine: Common Problems & Fixes

1. Frequent Thread Breakage high likelihood

How to tell

The machine stops frequently, displaying a thread break error, or you notice loose threads and incomplete stitching on your design.

Fix

1. Check the thread path for any snags, twists, or obstructions from the cone to the needle. Ensure the thread is correctly seated in all guides and tension discs.
2. Inspect the needle for bends, burrs, or dullness. Replace the needle if it shows any signs of damage. Ensure the needle is inserted correctly and facing the right direction.
3. Verify the upper thread tension. It should be firm enough to pull the thread smoothly but not so tight that it snaps. Adjust tension knobs incrementally.
4. Check the bobbin tension. It should be consistent and not too tight or too loose. A simple drop test can help: hold the bobbin case by the thread and it should slowly unwind a few inches.
5. Clean the thread path, tension discs, and rotary hook area of any lint or debris.
6. Ensure you are using the correct thread type and weight for your needle size and fabric.
7. Inspect the rotary hook for any burrs or damage that could be snagging the thread. If damaged, replacement may be necessary.

A damaged rotary hook can cause thread breaks. Consider the Koban KHS20-RYP2 Rotary Hook Jumbo 2.0X with Trimmer for Barudan BEKY.

Parts involved: Needles & needle bars → Thread path & tension → Rotary hooks & bobbin cases → Lubrication & maintenance → Threads & supplies →

2. Skipped Stitches high likelihood

How to tell

Your embroidery design has gaps or missing stitches, appearing as uneven or incomplete lines.

Fix

1. Replace the needle. A bent, dull, or incorrect needle is a primary cause of skipped stitches. Ensure it's the correct type and size for your fabric and thread.
2. Check the needle insertion. The needle scarf must face the rotary hook for proper loop formation.
3. Verify the upper thread tension. Too loose tension can prevent proper loop formation for the hook to catch.
4. Inspect the bobbin case and bobbin for proper seating and tension.
5. Ensure the fabric is hooped correctly and taut, without wrinkles or slack. Use appropriate backing.
6. Clean the rotary hook area. Lint buildup can interfere with hook timing and thread pickup.
7. Check for any play in the needle bar or presser foot mechanism. Loose components can affect stitch formation.

Parts involved: Needles & needle bars → Thread path & tension → Rotary hooks & bobbin cases → Hoops & frames → Lubrication & maintenance → Head & mechanical parts →

3. Bird's Nesting (Thread Bunching Under Fabric) medium likelihood

How to tell

A tangled mess of thread forms on the underside of your fabric, often causing the machine to jam or stop.

Fix

1. The most common cause is incorrect upper thread tension, usually too loose. Increase the upper thread tension incrementally until the nesting stops.
2. Ensure the bobbin is wound correctly and inserted properly into the bobbin case. Check bobbin tension; it should be consistent.
3. Clean the bobbin case and rotary hook area thoroughly. Lint buildup can interfere with thread movement.
4. Verify the needle is inserted correctly and is not bent or damaged.
5. Ensure the presser foot is set at the correct height and is not too high or too low for the fabric thickness.
6. Check that the fabric is hooped securely and taut, with appropriate stabilizer.

Parts involved: Thread path & tension → Rotary hooks & bobbin cases → Needles & needle bars → Hoops & frames → Lubrication & maintenance → Presser feet & sewing parts →

4. Machine Not Reading Designs from Floppy Drive medium likelihood

How to tell

The machine displays an error message related to the floppy disk, cannot find the design file, or fails to load the design.

Fix

1. Ensure the floppy disk is inserted correctly and is not damaged or corrupted. Try a different, known-good floppy disk.
2. Verify the design file format is compatible with your Barudan BEKY machine (e.g., .U01).
3. Clean the floppy drive head using a floppy drive cleaning kit.
4. Consider upgrading your floppy drive to a USB floppy emulator. This eliminates reliance on fragile floppy disks and allows for easier design transfer via USB stick.
5. If using an emulator, ensure the USB stick is formatted correctly (FAT32) and the design files are placed in the root directory or correct virtual floppy folders.

Upgrade to a Gotek SFRM72-FU USB Floppy Emulator for Barudan BEKY or an EILASUNG FDD-UDD U144K USB Floppy Drive Emulator for Barudan to resolve floppy drive issues permanently.

Parts involved: Floppy, USB & memory → Circuit boards & electronics →

5. Poor or Uneven Stitch Quality medium likelihood

How to tell

Stitches appear loose, uneven, inconsistent, or the design looks distorted.

Fix

1. Adjust upper and bobbin thread tension. Imbalanced tension is a common cause. The bobbin thread should show about 1/3 on the top side of the fabric.
2. Replace the needle. A worn or incorrect needle can significantly impact stitch quality.
3. Ensure the fabric is hooped correctly and taut, with appropriate backing for the design density.
4. Clean the entire thread path, including tension discs, thread guides, and the rotary hook area, to remove lint and debris.
5. Check for any burrs or damage on the needle plate, presser foot, or rotary hook that could be snagging thread.
6. Verify the machine's speed settings. Running too fast for complex designs or certain materials can reduce stitch quality.
7. Lubricate the machine according to the manufacturer's recommendations. Lack of lubrication can cause mechanical drag and affect stitch formation.

Parts involved: Thread path & tension → Needles & needle bars → Hoops & frames → Rotary hooks & bobbin cases → Lubrication & maintenance → Presser feet & sewing parts →

6. Needle Breakage medium likelihood

How to tell

The needle snaps during operation, often with a loud 'pop' sound, and the machine stops.

Fix

1. Replace the needle. Ensure you are using the correct needle type and size for your fabric and thread. A needle that is too fine for heavy fabric or too large for fine fabric can break.
2. Check for a bent needle bar or presser foot. If these are out of alignment, the needle can strike them.
3. Verify the fabric is hooped securely and taut. Loose fabric can 'bounce' and cause the needle to hit the hoop or needle plate.
4. Inspect the needle plate hole for damage or burrs. A damaged hole can deflect the needle.
5. Ensure the presser foot is at the correct height, allowing the fabric to move freely but holding it down during stitching.
6. Check for any obstructions in the embroidery area, such as pins or clips.
7. If using a rotary hook, check its timing. Incorrect timing can cause the needle to strike the hook.

Parts involved: Needles & needle bars → Hoops & frames → Presser feet & sewing parts → Rotary hooks & bobbin cases → Head & mechanical parts →

7. Machine Stops or Won't Sew low likelihood

How to tell

The machine is powered on but will not start stitching, or it stops mid-design without a clear error message.

Fix

1. Check all safety sensors, such as the emergency stop button, hoop sensor, and thread break sensors. Ensure they are not tripped or obstructed.
2. Verify the machine's door or cover is fully closed, as some models have safety interlocks.
3. Ensure the design is loaded correctly and the start point is set.
4. Check for any error messages on the control panel and consult your machine's manual for their meaning.
5. Inspect for any visible mechanical jams, such as tangled thread in the rotary hook area or a jammed needle bar.
6. If the machine stops intermittently, check the power supply and connections for stability.
7. If the machine powers on but no functions respond, there might be an issue with the control panel or main circuit board. For motor-related stops, check motor drivers.

If motor issues are suspected, an IHSS57-36-10-RC/EC Nema23 Integrated Stepper Motor Driver could be a relevant replacement.

Parts involved: Sensors & switches → Control panels & displays → Circuit boards & electronics → Motors & drivers → Cables & wiring → Rotary hooks & bobbin cases →