F4-25C control box

maintenance guide
Global Customer Service
Delivery Department
25.1

2024 OVERSEAS DISTRIBUTOR CONFERENCE

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 One Product introduction

Two Panel and parameters introduction

Three
F4-25C Motherboard Awareness
Catalog
Four
Repair of F4-25C motherboard

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一. Product introduction
1、Electrical control appearance

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二、Panel and operation introduction
1、Operation panel appearance

NO icon instruction mark

Used to quickly set the maximum speed and adjust the
1 speed up
parameters
Used to initialize parameters, enter the setting interface,
2 Speed down
quickly adjust the maximum speed, etc.

Note: When the machine is running, the keys cannot be operated, and the
machine cannot be operated within 1s after operating the keys.

2、Standby interface
On the standby interface, the first digital tube displays "P", the second digital tube displays the currently set needle
stop position, and the upper and lower needle stops are as shown in the figure.

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3、Quick setting speed
In the standby interface, short press the 1 key or 2 key to set the speed, short press the 3 key to increase the
speed by 100RPM (value increment by 1), short press the 4 key to decrease the speed by 100RPM (value decrease
by 1), long press the 5 key ( 6 key) to achieve Fast increase (decrease), set parameters are automatically saved.

4、Set the needle stop position

In the standby interface, long press the 11 key to set the needle stop position, and the parameters are
automatically saved.

5、Setting parameters
In the standby interface, long press the 11 and 12 combination keys (about 3s) to enter the parameter setting
interface, the first digital tube displays "F" and the second digital tube does not display (hereinafter referred to as the
F interface, which is one of the setting interfaces) as right As shown in the figure.

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 After entering the parameter setting interface, short press 11 to change the serial number, press 12 to display the
corresponding parameter value, and then press 13 to change the parameter value; if the parameter value is modified,
short press 14 to save and display "OK" (Figure 3 ) And return to the current serial number display interface. If the
parameter value is not modified, it will directly return to the current serial number display interface. The motor
running in the setting interface will exit to the standby interface. The serial number of the F interface is cycled
according to the following table:

Factory
NO Parameter range mark
default
L Sewing speed 05 - 50 40 Decrease by 500rpm
M Needle stop switch 0-1 1 0: OFF 1: ON
d Needle filling function 0-2 1 0: Close1: Make half stitch2: Make one stitch
G Safety switch 0-1 1 0: OFF 1: ON
H Sleep time 0-6 3 Unit: 10min Set 0 to close the sleep function
C Speed up parameters 0-9 5 The larger the value, the faster the speed
n Pointing parameters 0-9 3 The larger the value, the larger the needle interval
V Speed display enable 0-1 0 0: OFF 1: ON
0：OFF 10：100VAC 11：110VAC12：120VAC 13：
R Low pressure alarm value 0、10-15 0
130VAC 14：140VAC15：150VAC
0：OFF 26：264VAC 27：274VAC28：284VAC 29：
Y High voltage alarm value 0、26-31 27
294VAC 30：304VAC31：314VAC
A Too thick afterburner switch 0-1 1 0：OFF 1：ON

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6、Reset
On the standby interface, long press the 11 key for 3 seconds to restore the factory settings, and the digital tube
displays "oK".

7、One key to clear error

When the system reports an error and displays an error alarm, press the 11 key to recheck whether the error exists,
if it does not exist, the error alarm will be cleared, and the alarm will continue if it exists (this function is only limited
to E4, E5, E6 and shutdown reminder OF); when the system reports an error E5 ( When the positioner signal is
abnormal) or E7 (machine head safety switch alarm), long press the 12 key to turn off the needle stop function or
the safety switch alarm function and release the alarm; if the alarm is not released, the alarm number will be
displayed until the fault is eliminated. For the detailed error code table, see the error code description table.

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8、Monitoring mode parameter description table
Long press 11 on the F interface for 3s to enter the monitoring mode, the first digital tube displays "J", and the second digital tube
does not display (hereinafter referred to as the monitoring interface). Short press 16 on the monitoring interface to change the serial
number, after pressing 12 the corresponding monitoring value will be displayed. Press 13 on the J5 interface to switch to display
the historical fault code. Short press 14 to return to the current serial number display interface, short press 15 on the J interface to
return to the P interface. Except for J1 and J2 after entering the display speed and power display interface, the real-time power and
speed will be displayed during operation, and the other monitoring interfaces will exit the J interface and return to the P interface when
the motor is running. The serial number of the monitoring interface is cycled according to the following table:

NO Function parameter Parameter Description

J1 speed Display the real-time speed in standby and running state, the displayed number*100 = actual speed
J2 power Display the real-time power in standby and running state, the displayed number*10 = actual power
J3 voltage Display the input voltage in standby state, the number displayed *10 = actual voltage
J4 Highest voltage in history Display the highest input voltage in history, the displayed number*10 = actual voltage
Display historical fault code (do not record dumping error E7, only display the latest 5, and display 00 when there is no fault
J5 Historical fault code
code), return to the standby interface without pressing the key for 8 seconds
J6 control box cumulative time Display the cumulative running time of the electronic control, the displayed number * 100 = actual time (Hour)
J7 Aging monitoring For factory test
J8 Model code 1/FF：F4type； 2：20Utype； 3：8558G/8560Gtype

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9、Digital tube display description

number

English Word

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三、Awareness of F4-25C motherboard
1、Awareness of motherboard interface

2、Understanding of components

3、Division and introduction of each functional circuit

4、Electronic control power supply trend distribution

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1、Awareness of motherboard interface

AC 220V
input Locator
interface interface
Motor Hall
interface
Locator
interface
Headlight
interface

Speed Locator
controller interface
interface
Locator
interface

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 2、Understanding of components

F1 fuse
Q1-Q6 IGBT
RV1 Varistor
CD1
RT1 Thermistor Electrolytic U1 Operational
capacitor Amplifier
D1 Rectifier bridge
U2 Drive core
K1 Relay FAN73892
U4 Power chip T1 transformer
TNY288PG
U6 Single chip
U7 817
microcomputer
Optocoupler

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3、Division and introduction of each functional circuit

High voltage
power circuit
Motor drive
circuit

Switching
power supply Signal
circuit processing loop

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Brief introduction of each functional circuit:

High-voltage power circuit: filter and rectify the input 220V alternating current to form 300V direct current, and
then output a relatively stable 300V direct current after filtering and energy storage by a large capacitor.
Switching power supply circuit: Step down the stable 300V, then form 15V, +5V, MCU+5V voltage after
rectification, and supply power to each circuit.
Motor drive circuit: Amplify and process the drive signal of the DSP chip to form each drive signal, control the
turn-on and turn-off of each IGBT, thereby controlling the rotation of the motor.
Signal processing loop: The single-chip microcomputer is the core of the whole part. The hall signal of the
motor, the needle stop signal, the speed controller signal, the setter signal, and the current feedback signal are all
input to the single-chip microcomputer for processing, and then the single-chip microcomputer will output according
to the collected signal The corresponding drive signal drives the motor to work.

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 4、Introduction to the trend of electronic control power supply
J1Power connector 220V AC F1 fuse
voltage input RV1Varistor RT1 Thermistor D1 Rectifier bridge CD1 Electrolytic capacitor DC330V

reley

Driver chip

Switching
power Operational amplifier
supply microcontroller
circuit

Headlight assembly

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四、Maintenance of F4-25C motherboard

1、Visual inspection
2、Static measurement
3、Power-on measurement
4、Error repair
5、Motor and speed controller repair

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 1、Visual inspection
① Check whether the fuse and varistor are damaged or burst,
if they are damaged, replace and check the high-voltage
① ④ power supply related components.
②
③ ② Check whether the common mode inductor has broken
feet; if there are broken feet, replace the common mode
inductor.
③. Whether the CD1 electrolytic capacitor has bulging,
liquid leakage, etc., if so, replace the corresponding
electrolytic capacitor and check the high-voltage power
supply related components.
④ Check whether the driving IGBT and sampling resistor
are obviously damaged, if so, replace the damaged
components

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 2. Static measurement
AC_L ①, AC channel measurement
As shown in the picture on the left, first set the
AC_N multimeter to the buzzer position, put the two test
1 leads on the AC_L pin of the power plug and the 2
pins of the rectifier bridge respectively, the buzzer is
2
normal; then put the two test leads on the AC_N of
3 the power plug respectively The resistance value of
4 80~120Ω measured by buzzer is normal.
If the above values are not normal, check whether
the circuit is complete, whether the fuse is normal,
and whether the common mode inductor pin is
disconnected.

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 2、Static measurement

②、Rectifier bridge measurement

1
Multimeter diode file
2
3
4 Black test lead Red test lead normal
1 2 0.400~0.500V
1 3 0.400~0.500V
2 4 0.400~0.500V
3 4 0.400~0.500V

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 2、Static measurement
1 2 3
③、Spindle IGBT measurement（Multimeter diode file）

Black test Red test

normal
lead lead

2 3 around 0.450V

1 3 around 0.780V

If pins 2 and 3 are short-circuited, it means that the IGBT itself is damaged and needs to be replaced. If the value of pins 1 and 3
is abnormal, first check whether the relevant resistance under the IGBT is normal. If the resistance value is normal, replace U2. (If
the value is close to 0, it means that pins 1 and 3 of IGBT are broken down, just replace the IGBT)Note: Depending on the
multimeter used, the peripheral measurement value will be different, but basically the peripheral value of the upper bridge IGBT is
basically the same, and the peripheral value of the lower bridge is basically the same. The spindle drives the upper bridge IGBT
(Q1, Q3, Q5), and the lower bridge IGBT (Q2, Q4, Q6).
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3、Power-on detection
If the static measurement is normal, it can be powered on for testing. We can narrow the scope of the fault point by observing
the reflection after power-on and the reported fault code, and by measuring the voltage at some key points in the power-on state, we
can help us solve the problem faster.
*There is a certain degree of danger during the power-on process, so please pay attention to safety!
Turn the switch to the off position before powering on, plug in the power cord, make sure that there are no conductive objects
on the circuit board and underneath, so as not to cause a short circuit, then turn on the switch and observe the status of the circuit
board. After the normal circuit board is energized, the sound of the relay can be heard, and the LED light is always on.
Power-on voltage measurement point:
220V AC measuring point-No. 2 and No. 3 pins of the rectifier bridge
BUS+ (310V) DC point-rectifier bridge 1, 4 pins
15V DC measuring point-both ends of TVS3
L+5V DC measuring point-both ends of CD5
MCU+5V DC measurement point-both ends of TVS2
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15V measuring point

MCU+5V measuring point

L+5V measuring point

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AC_L 3.1、High-voltage power supply failure repair
①. There is no obvious damage to the electronic control by visual
AC_N inspection, such as blown fuse, damaged varistor, bulging CD1
electrolytic capacitor, if there is, please replace it first;
② Turn on the power and use a multimeter to measure whether
there is an AC 220V input at both ends of the J1 plug. If not, please
check the power cord or the switch for damage;
③. Check if the common mode inductance has broken feet or poor
contact
④ Check whether the rectifier bridge is normal

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 3.2. Low-voltage power supply failure repair
①. When the power is on, use the multimeter voltage file to
measure whether the voltage at both ends of the C29
capacitor is about 6V, if it is not normal, first replace the
power chip U4 (288PG)
② When the power is off, use a multimeter diode to
measure whether the 15V, MCU+5V measuring points are
short-circuited. If so, please replace the short-circuited
components first, check D14, TVS3, and drive chip for 15V
short-circuit; check D13, U1 for MCU+5V short-circuit ,
U6, TVS2, TVS4;
③. Replace transformer T1
U4 Power chip D14
288PG D13
C29（100NF）

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 Fault code table

E1 Motor stalled E2 Controller exception

E4 Motor Hall signal failure E5 Needle stop Hall signal failure

E6 Speed controller signal failure E7 Head safety switch alarm

EA Software overcurrent Eb System overvoltage

EC System undervoltage EJ Current detection circuit failure

Machine head needle compensation button

OF OFF erro EZ
failure

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E1Motor blocked/E2 controller abnormal
Fault description: If it is detected that the motor cannot rotate after starting up,
it will report E1. When the machine head is stuck or the signal part fails, the
motor may be blocked. The signal part failure mainly manifests in the signal
line disconnection and chip damage.
Solution:
1. Determine whether the mechanical shaft or the motor cable is off and cause
E1 to be reported. If so, remove the fault first.
2. Visually inspect whether there are any obvious damaged components on the
circuit board. If so, replace it first, and then use the diode file to measure
whether the IGBT (Q1, Q2, Q3, Q4, Q5, Q6) and the surrounding resistance
are damaged. If the IGBT is damaged, replace it. , And then test.
If no IGBT damage is found or an error is still reported after replacing the bad
IGBT, proceed to the next maintenance step.
Note: For the measurement method of IGBT, please refer to the
measurement of IGBT in static inspection.

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E1 motor is blocked / E2 controller is abnormal

3. Check the boost bootstrap circuit, including three resistors

R30, R42, R43 (33R0), three diodes D7, D8, D9 (RS1M), and
three capacitors C3, C4, C5 (10UF);
4. When the circuit board is energized, use the multimeter's DC
voltage gear to check whether the 15V voltage is normal or not
to repair the switching power supply circuit abnormally;

U2 5. Use the buzzer file to measure whether the sample constantan

wire R15 (0.025mR) is normal
6. Replace the driver chip U2 (FAN73892).
7. Check the 6 signal resistances R54-R57, R61, R62 (200Ω)
15V voltage measuring point under the drive chip
Constantan wire

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E4 Motor Hall signal is abnormal
Fault description: The single-chip microcomputer does not detect the
hall signal of the motor, or the hall signal of the motor is abnormal.
When E4 is reported, the spare motor can be replaced to check whether
the electronic control is damaged or the motor is damaged;
If it is an electrical control problem, follow the steps below to
troubleshoot:
1. Check whether the Hall wire of the motor and the J2 plug are in poor
contact;
2. Check whether the resistance and capacitance of the motor Hall
circuit are soldered, as shown on the left, where the resistances are R25,
R27, R28 (4.7KΩ), R35, R37, R38 (10KΩ), C13, C14, C15 (1nf).
3. Repair welding of single chip microcomputer

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E5 Abnormal Hall signal when the needle is stopped

Fault description: The single-chip microcomputer does not detect

the motor needle stop signal, or the motor Hall signal is abnormal.
(When E5 is reported, long press the right button to close the
needle stop function, which can be used temporarily)
Solution:
1. Check whether the magnetic steel on the handwheel falls off;
2. Check whether the needle-stopped Hall wire and J3 interface are
in poor contact;
3. Check whether the resistance and capacitance of the pin-stop
Hall circuit are soldered, such as R34, R36 (1KΩ), R24, R26
(4.7KΩ), C11, C12 (1nf) in the picture on the left.
4. Replace the Hall (4401) on the Hall plate of the needle stop

Stop needle Hall 4401

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E6 Speed controller connection abnormal

Fault description: caused by poor contact between the speed controller

and the electric control box;

Solution:

1. Check whether the plug pins of the speed controller are in poor

contact or are loose or fall off;

2. Replace the speed controller, and check whether the speed controller

is the problem or the electronic control problem;

3. Check if resistance R84 (56KΩ), R69 (4.7KΩ), capacitor C27

(100nf), and inductor L5 are damaged.

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E7 Head safety switch alarm
When the safety switch of the machine head is turned on, this alarm will appear when the machine head is
overturned; turn off the safety switch or restore the position of the machine head. If the alarm cannot be
eliminated, please contact the maintenance personnel.

EZ Machine head needle compensation button failure

Please check whether the needle compensating button of the machine head can be normally closed and
bounced. If it is always in the closed state, please replace the needle compensating button of the machine
head.
(The alarm will automatically turn off the needle compensation function, but it will not affect the
operation of the motor. The alarm will be automatically cleared after 30s or can be cleared by manual
short keypress)

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EA Software overcurrent/EJ current detection circuit failure

Fault description: EA is mainly due to the MCU detecting

that the output voltage of the op amp exceeds the set value.
Solution:
1. Check whether the 6 IGBTs are damaged. If they are
damaged, you need to replace and check the damaged
resistors around them before testing; (Generally, E2 is caused
by a short circuit of an IGBT);
2. Use the buzzer file to measure whether the sample
U1 constantan wire R15 (0.025mR) is normal;
U2 3. Replace the U1 operational amplifier and check whether
the surrounding resistors and capacitors are damaged,
including R29 (1KΩ), R32 (1KΩ), R33 (40.2KΩ);
4. Replace U2 (FAN73892).

Constantan wire

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EB Overvoltage protection/EC undervoltage protection
Fault analysis: When the single-chip microcomputer detects that
the 220V AC voltage input exceeds 280V, the single-chip
microcomputer will report the Eb fault code; when the single-
chip microcomputer detects that the 220V AC voltage output is
lower than 150V, the single-chip microcomputer will report the
EC fault code. Generally, it is caused by problems with the
components of the bus sampling circuit.
Solution:
1. Check whether the AC input voltage is relatively stable AC
220V;
2. Check whether the MCU+5V voltage is normal. If it is not
normal, please repair the switching power supply first;
3. Check whether the components of the bus voltage detection
circuit are normal, as shown in the red box, the resistances R46,
R64, R71 (200KΩ), R78 (5.6KΩ)

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0FF erro
Fault description: The single-chip microcomputer does
not detect the AC 220V voltage input after the power is
turned on, or the relay does not pull in.
Approach:
1. Replace the switch (poor contact)
2. Check the components of the relay circuit and the
vulnerable resistance
R92 (4.7KΩ),
Q7 (5551 triode),
R59 (100Ω),
R89 (2KΩ).
3. Replace K1 relay.

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5、Repair of motors and speed controllers

Common faults of Zhongbang motors are generally divided into three types:
First, the coil is burnt out (E2 will be reported); Second, the Hall of the motor will
be damaged (E4 will be reported); Third, the rotor is worn.
If the coil is found to be burnt, send it directly to the manufacturer for repair. If
the electronic control reports the E4 code and it is determined that the motor is
faulty, first determine whether the connection wire at the motor plug is connected
properly. If the motor connection is normal, check whether the motor Hall is normal.
The following is the motor Hall detection method.

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composition of the motor

Motor coil Motor rotor Motor handwheel

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Motor repair

Motor Hall detection:

As shown in the left picture: plug the motor to be tested, turn on the
power supply and turn on the switch, adjust the multimeter to DC 20V,
insert the black test lead of the multimeter into the socket where the thin
black wire is located, and insert the red pen into the white, One of the
sockets where the thin brown and yellow lines are located, turn the motor
handwheel by hand and observe the value displayed by the multimeter. If
0 and 5 alternately appear, it means that the Hall corresponding to the
line is normal. If the value remains 0 or 5 No change, it means that the
motor Hall (41F) corresponding to the color line has been damaged. Test
the white, brown, and blue wires in sequence, and write down the color
of the abnormal line. Disassemble the motor to find the Hall
corresponding to the line. You can replace it.

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 Repair of speed controller

As shown in the picture on the left: if the

speed controller does not move or the
electronic control is in the closed needle
Hexagon stop position, please move slowly, first
socket loosen the screw with the No. 3 hexagon
screw No. socket, and then adjust the magnet angle
3 appropriately. Until the speed controller
can work normally, if the adjustment
Magnet, speed position is invalid, first check whether the
control hall
cable is normal, if it is normal, please
replace the speed control hall (50B), and
Speed then adjust the magnet position.
controller
plug
Note: positive pole (red wire), negative
pole (black wire), S pole (green wire)
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 Consumable parts list
Material Material
Tag Material model Tag Materil model
code code
- Right angle switch 99000024 U14 Power chip PNY288PG 98400037

F1 Fuse 10A/250V 199000008 U3、U7 817Optocoupler 98400067

D1 Rectifier bridge 99000002 U8 Controllable precision regulator 431 98300004

RT1 Thermal PTC100D10 98600009 U1 Operational amplifier 20072 98400038

RV1 Varistor 98600001 CD2 35V100UF electrolytic capacitor 98700006

CD1 Electrolytic capacitor 450V470UF 98700021 TVS2、TVS4 Transient suppression diode 98200047

U2 Driver chip 73892 98400073 - Sampling constantan wire/25mR 198600014

Q1-
IGBT 98900008 - Motor Hall 41F 98900037
Q6

H1 Switch Hall 4401 98900025 - Speed control hall 50B 98900027

U6 Single chip microcomputerHC32L130J8TA 198400284

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*Source: Frost & Sullivan's research based on the number of industrial sewing machines sold by major global industrial sewing machine companies in each year between 2010 and 2023, market research completed in September 2024.

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