Barudan BENS 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 observe the thread snapping during embroidery.

Fix

1. Re-thread the machine completely, ensuring the thread is correctly seated in all guides and tension discs.
2. Check thread quality and age; old or poor-quality thread can break easily.
3. Inspect the needle for burrs, bends, or dullness. Replace if necessary.
4. Verify thread tension settings. Too tight tension is a common cause.
5. Clean the thread path, including tension discs and thread guides, to remove lint or debris.
6. Check the bobbin and bobbin case for proper winding and tension.
7. Ensure the thread support clamp is clean and not snagging the thread. Replace if damaged.
8. Inspect the rotary hook for burrs or damage that could fray thread.

Consider replacing worn HT270022 Thread Support Clamp or HT270021 Thread Support Clamp 10pcs if they are causing issues.

Parts involved: Thread path & tension → Needles & needle bars → Rotary hooks & bobbin cases → Screws, springs & small parts →

2. Skipped Stitches high likelihood

How to tell

The embroidery design has gaps where stitches should be, or the machine makes a 'clunking' sound as it tries to form a stitch but fails.

Fix

1. Replace the needle with a new, correct size and type for your fabric and thread.
2. Ensure the needle is inserted correctly, fully seated, and facing the right direction.
3. Check thread tension; both top and bobbin tension can contribute to skipped stitches.
4. Verify the rotary hook timing. Incorrect timing prevents the hook from catching the needle thread loop.
5. Clean the bobbin area and rotary hook to remove lint or debris.
6. Ensure the presser foot is set correctly and applying adequate pressure to the fabric.

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

3. Machine Freezing or Slowing Down medium likelihood

How to tell

The machine's display becomes unresponsive, the machine stops mid-design without an error, or operations become unusually slow.

Fix

1. Turn the machine off, wait a few minutes, and restart it. This can clear temporary glitches.
2. Ensure the machine's internal memory is not overloaded. Delete old designs if possible.
3. Check for any physical obstructions or binding in moving parts that might cause the motor to struggle.
4. If using a floppy disk, ensure it's not corrupted or damaged. Try a different disk.
5. Consider upgrading to a USB floppy emulator for more reliable data transfer and storage.

A common upgrade is a USB Floppy Emulator. Options include: Unbranded SFR1M44-DU26 USB Floppy Emulator 1.44MB, SFRM72-DU26 720KB USB Floppy Emulator Thin Half Size, SFRM72-DU26 720KB USB Floppy Emulator, Richpeace SFDR-III U-B1.44 BENSH-YN USB Floppy Emulator, Gotek SFRM72-FU SFRM72-FU-EG Floppy Drive Emulator, or Barudan SFRM72-DU26 Gotek USB Floppy Drive Emulator.

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

4. Uneven Stitch Quality / Puckering / Distorted Designs medium likelihood

How to tell

Stitches appear loose, tight, inconsistent, or the fabric gathers and distorts around the embroidery.

Fix

1. Adjust top and bobbin thread tension. Test on scrap fabric.
2. Ensure proper hooping. The fabric should be taut but not stretched in the hoop.
3. Use appropriate stabilizer for the fabric and design density.
4. Check needle size and type; a dull or incorrect needle can cause fabric damage.
5. Clean the thread path and bobbin area to ensure smooth thread flow.
6. Verify the presser foot height and pressure are suitable for the fabric thickness.

Parts involved: Thread path & tension → Hoops & frames → Needles & needle bars → Presser feet & sewing parts → Threads & supplies →

5. Machine Stops or Won't Sew medium likelihood

How to tell

The machine fails to start a design, stops abruptly without an error, or doesn't respond to the start command.

Fix

1. Check for error messages on the display and consult your machine manual.
2. Ensure all safety covers and doors are closed properly.
3. Verify the emergency stop button is not engaged.
4. Check thread sensors and bobbin sensors for lint or obstructions.
5. Confirm the embroidery unit is correctly attached and recognized.
6. Inspect cables and connections for looseness or damage.
7. If the control panel is unresponsive, it might indicate an issue with the panel or its driver board.

If the display is blank or erratic, an E831 Display Driver Board might be needed. If the control panel itself is faulty, a Barudan BENYHE-ZQ-B04 NYHE-ZQ-B04 Automat Control Panel Box could be the solution.

Parts involved: Sensors & switches → Cables & wiring → Control panels & displays → Circuit boards & electronics →

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

How to tell

A mass of tangled thread forms on the underside of the fabric, often causing the machine to jam.

Fix

1. This is almost always caused by incorrect top thread tension. Re-thread the machine and adjust top tension.
2. Ensure the bobbin is inserted correctly and its tension is appropriate.
3. Check for any obstructions in the thread path that might be preventing the top thread from feeding smoothly.
4. Inspect the needle for damage; a bent or dull needle can contribute to nesting.
5. Clean the bobbin case and rotary hook area thoroughly.

Parts involved: Thread path & tension → Rotary hooks & bobbin cases → Needles & needle bars →

7. Needle Breaking low likelihood

How to tell

Needles snap frequently during operation.

Fix

1. Ensure the correct needle size and type are used for the fabric and design.
2. Check for proper needle insertion – fully seated and correctly oriented.
3. Verify the needle bar is not bent or loose.
4. Inspect the rotary hook for damage or incorrect timing, which can cause the needle to strike it.
5. Ensure the presser foot is not hitting the needle.
6. Check for hoop movement or fabric shifting during embroidery.

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

8. Embroidery Unit Not Recognized / Floppy Drive Errors low likelihood

How to tell

The machine displays an error related to the embroidery unit, or the floppy drive fails to read/write disks, or shows 'disk error'.

Fix

1. Ensure the floppy disk is correctly inserted and not damaged.
2. Clean the floppy drive head with a specialized cleaning disk.
3. Check the cable connecting the floppy drive to the main board.
4. If using an external embroidery unit, ensure it's securely connected and powered on.
5. Consider replacing the old floppy drive with a modern USB Floppy Emulator for improved reliability and ease of use.

Upgrading to a USB Floppy Emulator is highly recommended. Compatible models include: Unbranded SFR1M44-DU26 USB Floppy Emulator 1.44MB, SFRM72-DU26 720KB USB Floppy Emulator Thin Half Size, SFRM72-DU26 720KB USB Floppy Emulator, Richpeace SFDR-III U-B1.44 BENSH-YN USB Floppy Emulator, Gotek SFRM72-FU SFRM72-FU-EG Floppy Drive Emulator, or Barudan SFRM72-DU26 Gotek USB Floppy Drive Emulator.

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