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Our support staff is available Monday thru Friday 8am to 5pm
7 days a week for IMG Customers
If you need support please call (714) 223-9981
You can also email Tech Support at support@imachinegroup.com
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Help for HAPPY HCS Voyager machines |
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.last
update: February, 2008 - new troubleshooting steps for USB
connection in "Troubleshooting"
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If you have an HCS Voyager machine, this section is devoted
to providing you with resources to help you keep your machine
"HAPPY" !
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Setting
Up and Configuring Voyager |
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Included
in this section are instructions and help files for HAPPY's
HCS Voyager machine. |
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| Your HCS Voyager machine
was carefully packed at the factory using quality packing materials
and procedures to assure that your machine is ready, right out
of the box to sew. By following the procedures carefully,
you can best-assure that your Voyager will be as "factory fresh"
as possible! |
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| Unpacking Voyager |
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| Instructions
for Unpacking Voyager |
| It
can be helpful, especially when first working with your
new Voyager machine to preserve the packaging materials
that protected your machine on its journey from the factory
to your home. This short illustrated guide will
help you not only preserve them but also help you set
your Voyager machine up more efficiently. |
FLASH movie: instructions for unpacking Voyager.
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| Assembling Voyager |
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| General
Diagram for Assembling Voyager |
| Be
sure to follow the instructions that are included in the
Voyager manual. Before doing so, it is important
to properly unpack Voyager. Be sure to follow the
instructions described in the FLASH movie above !! |
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| Your HCS Voyager machine
was carefully packed at the factory using quality packing materials
and procedures to assure that your machine is ready, right out
of the box to sew. Be sure to take the same care when un-boxing
Voyager and assembling it to run! |
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| Proper Threading |
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| Threading
the upper (Colored) Thread |
| Threading
your Voyager machine PROPERLY is VERY important
to prevent thread breaks and to ensure efficient operation!
Also - don't forget that needles need to be inserted and
oriented correctly! Below, we've provided an illustrated
diagram for threading your Voyager machine, which is also
provided in the manual that comes with Voyager. |
 PDF
file: properly threading Voyager.
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| Tension
Test |
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| Tension
Test for Voyager |
| Provided
below is a .dst file that you can download and use to
test-sew the tensions on your Voyager machine. |
Click HERE
to download the tension test in .dst format.
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| Problem
with lower
"thread holding spring" |
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| What
to do if this spring is pulled out of place |
| Sometimes
1 or more the thread-holding springs are dislodged from
their mounting points. You'll often find them caught
in the "up" position. Watch this short movie to
see how to remove the lower faceplate and mount back in
place. |
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Flash movie: fixing lower thread holding spring |
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Transferring Designs to Voyager
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| Transferring
Designs Using HAPPYLINK |
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Use the included HAPPYLINK
software to set up designs and send them to your Voyager machine. |
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Topic |
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Question |
Setting up a USB Connection |
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| How
to set up a USB Connection between your PC and HAPPYLINK |
| Follow
the directions below for setting up a USB connection between
your PC and a HAPPY Voyager machine. |
1.
Download the WINZIP file below that matches your Windows
operating system. These are very small files.
Open the file using WINZIP (if you have XP, you don't
need WINZIP). Extract the 2 driver files that are
inside the WINZIP file to the root c:\ directory.
2. Power on the Voyager machine. Upon
power-up, press ENT on the Voyager control panel to get
to the machine's default screen.
3. Connect a USB cable between the Voyager
machine and an available port on your PC. Do not
connect the USB cable to a USB hub - connect directly
to a PC.
4. The Windows "New Hardware" wizard will
start automatically upon detecting the HAPPY machine.
Follow the prompts, choosing the option to "Install driver
from a specific or known location". Browse to the
location where you stored the driver files in step (1)
above and highlight the HPYUSB01.INF or HPYUSB02.INF file
and continue. These steps should successfully set
up the USB connection.
5. Note: Perform these steps before starting
HAPPYLINK. Once the steps are completed, start
HAPPYLINK and go to File..Options and choose the USB connection
as well as correct options for the rest of the page. |
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Setting up a Serial Connection |
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| How
to set up a Serial connection between your PC and HAPPYLINK |
| Below
are a document contains the complete steps for setting
up a serial connection in between your PC and the HCS
Voyager machine using a serial cable. |
1.
Find a PC with a serial port. This is a 9-pin
port on the back of your PC that has 2 rows of pins, 5
in the first row, 4 in the second. Test-fit the
off-white serial cable that came with your Voyager machine.
2. Install the latest version of HAPPYLINK as
came with your Voyager machine.
3. Set up HAPPYLINK for a serial connection.
To do so, go to (1) File..Options, choose RS-232 for connection
type. Also choose in the same screen "Compatible
with HAPPYLINK", 12 needles, and No Borer if you're connecting
to a Voyager machine. Then go to (2) File...Port Settings
and choose the COM port you wish to use and speed.
If unsure, choose COM1 and a speed of 38,400kbps.
4. Set up the COM port in your PC by going
to the Windows Device Manager. In the Device Manager,
find the COM port settings under Ports (COM & LPT)
and choose a port # and speed to match what you did in
step (3) above.
5. Set up the transmission speed in Voyager.
Go to the Create menu in Voyager and change the 232C speed
to match the speed you chose in steps (3) and (4) above.
6. Try sending a design. You should
be set up following steps 1-5 above. Try opening
a design in HAPPYLINK and sending it across, trying the
different options available in the program.. |
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Downloads |
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Happylink Software |
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About HAPPYLINK |
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Transferring
Designs Using a Flash card |
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Using Flash-type memory
cards (the same kind found in many digital cameras) is a fast,
convenient way to transfer designs into the Voyager machine. |
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Topic |
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Question
and Answer |
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Illustrated Guide |
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What
types of cards work? |
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The
newest versions of Voyager (Generation 3) can employ 3 types of
Flash memory: CompactFlash, Memory Stick, and SmartMedia.
There are no known issues with any particular brands.
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What
types of cards work on older Voyager machines? |
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All versions of HAPPY's Voyager can read Sandisk(TM) brand CompactFlash
cards.
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What else do I need besides a FLASH card?
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You'll
need a PCMCIA adapter "sleeve" that the card fits into.
This adapter "sleeve" allows the card to be inserted into the
type of removable card slot found in laptops, which is the kind
of slot on the side of the Voyager control panel where the card
must be inserted. (note, the card CAN be inserted and/or
removed while the machine is powered on and while sewing - just
don't do this while a design is being transferred!) |
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Operating Voyager |
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Positioning
the Design in the Hoop |
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As complex as these
machines can seem, you should be able to expect a long lifetime
of trouble-free operation once you've learned how to use your
Voyager machine. Follow the simple maintenance needs of
your Voyager machine to keep it running smoothly! |
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Topic |
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Question |
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Centering the Design in the Hoop |
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The
design should sew in the center of the hoop by default.
However, if you've been moving the hoop around and are no longer
sure if this is the case, follow this simple procedure:
1. Hold the MENU key continuously until the
menu changes
to display
the 4 options: ORG TOP CNT POS
2. Press the arrow button corresponding to
the CNT button
(the down
arrow). The pantograph should move to center.
If the
center is off, re-start the machine.
3. With the pantograph positioned back on-center,
repeat step
(1) above,
then press the button associated with TOP.
This will
move the design center to the current pantograph
position,
which in this case is center, and also move the
sewing
position to the first stitch.
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Sewing the design in a position off-center in the Hoop |
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| Moving
the Design Off-Center |
Use
the arrow keys combined with the ENT key to position the
pantograph (based on the position of the presser foot)
to where you wish the design's center to be in the hoop's
sewing area. Then, press and hold MENU continuously
until the 4 options ORG, TOP, CNT, and POS appear.
Press the button corresponding to TOP. This will move
the design center to the area under the presser foot.
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Controlling Voyager while Sewing |
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| Common
Operations While Sewing |
| This
illustrated document describes the common operations that
can be performed while Voyager is in the middle of sewing
a design. |
Common sewing operations (PDF file)
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Using the HOOPTECH clamping system |
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Sewing designs on HCS
Voyager is a breeze once you've got everything set up correctly.
This section contains answers to the most common questions regarding
sewing designs on Voyager. |
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Using
the Cap Frame System |
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Voyager has an excellent
cap frame system, especially considering that Voyager was produced
to be lightweight and compact. Newer versions of HCS Voyager
can even employ the same wide-field cap frame that is used on
the large commercial HAPPY machines! Included in this
section are instructions on how to |
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Question |
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Answer |
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Hooping a Finished Cap |
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| Hooping
caps on the 180 Cap Frame |
1.
Align center seam on center mark
2. Sweat band should be unfolded and placed
under center mark plate.
3. Make sure teeth grip the seam all the way where
the base meets the riser.
4. Snap buckle into place.
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| Hooping
caps on the Wide Cap Frame
Note: Max cap field width approx. 275 mm. |
1.
Align center seam on center mark.
2. Sweat band should be unfolded and placed
under center mark plate.
3. Band strap: Make sure teeth grip the seam all
the way where the base meets the riser. If sewing on the
sides, make sure the sides are grabbed by the teeth as
well. Use free hand to hold back end of cap downwards.
4. Snap buckle into place. Note: Be ready
- cap will often shift towards buckle as buckle is closed,
pushing center seam off alignment. Compensate BEFORE
closing buckle.
5. Attach clips on rear of cap, pulling cap material
taut (but not overly tight).
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Care and Feeding (Maintenance) |
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As complex as these
machines can seem, you should be able to expect a long lifetime
of trouble-free operation once you've learned how to use your
Voyager machine. Follow the simple maintenance needs of
your Voyager machine to keep it running smoothly! |
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Topic |
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Question
& Solution |
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Oiling your
Voyager Machine |
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| Daily
Oiling |
| Your
Voyager machine needs daily oiling in one place - a small
"gutter" along the outer edge of the bobbin case "basket"
just inside the rotary hook. Place 1 drop of sewing machine
oil in this location once every 8 hours that the machine
is run. It is just as important to not over-oil
your machine, also - so if you don't run your machine
much, you won't have to oil it daily. Just follow
the 8-hour rule. |
To find the place to oil, open the rotary hook door (beneath
the needle plate on the sewing arm) and remove the bobbin
and bobbin case. You'll see the front face of the
rotary hook, as shown in the illustration on the right.
Place 1 drop of oil in the "gutter" or "race" of the hook,
which is indicated by the red arrow on the right.
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| Weekly
& Complete Oiling Schedule |
| In
the illustrated document below, you'll see the exact locations
to oil Voyager, for both daily and weekly schedules. |
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Oiling points for Voyager |
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Troubleshooting Voyager |
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Quick
Field Troubleshooting |
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You don't have to be
a skilled mechanic to keep Voyager up and running. But learning
some easy tips and tricks lets you keep right on sewing to get
you through the most common headaches that all embroiderers have,
like hoop strikes, thread breaks, and the like. |
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Topic |
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Question
& Solution |
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Fixing Design Transfer Problems/ Communication problems |
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| Troubleshooting
problems with Flash card transfers |
| Having
trouble sending your design by flash card to your Voyager
machine? We've listed the most common causes for
this here and how to avoid or fix them. |
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PDF instructions |
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USB
Connection Unsteady
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| USB
Connection is lost from time to time. |
Check
the following if you're having problems keeping a steady
USB connection in your HCS Voyager machine:
1. Update the firmware (control
panel program) to 3.02 or newer. You can
get this free
update from the support department at TEXMAC, along with
instructions.
The updated firmware has improved programming for USB
connections.
2. Ensure you're using a USB 2.0-compliant
cable. Purchase higher-quality
cables, limit
the length of the cable to about 12 feet. Ensure
that the cable
you purchase
is USB 2.0-compliant.
3. Ensure you're not connecting
through a USB Hub. At this time, USB
connection
for your Voyager machine is not supported through hubs. |
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| Windows
XP crashes when sending files through USB. |
You
probably have the wrong driver either installed or somewhere
in your PC. Setting up the USB connection
from your PC to the HCS Voyager machine requires 2 driver
files. There is a set of 2 driver files for Windows
98, and a set of 2 drivers files for computers with Windows
2000 or Windows XP. The files are as follows:
Windows 98 Driver files: hpyusb01.inf, hpyusb01.sys
Windows XP Driver files: hpyusb02.inf, hpyusb02.sys
To fix this problem, do a search for all files named "hpyusb"
using Start..Search... etc. Make sure you enable
the options to search hidden files, system files, and
subfolders, and search all of your local disk C:\.
Delete all files, then re-download the XP drivers from
the Help Files section above.
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| "Machine
is Busy" message when attempting to transfer designs |
Check
to make sure that the version of your Voyager's control
panel software is at least 1.06 or newer. The currently-installed
version appears on the first line of text when the Voyager
is powered on. Be ready! The version number
is displayed for barely 2 seconds. The message will
show "Version A X.XX". If you have a version previous
to 1.06, you can get the 1.06 updater in the Help Files
section above. Be careful! If you are unsure
of what you're doing, you may permanently corrupt your
control panel software. If in doubt, contact the
service department with any questions
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| I
have the correct Flash card but Voyager isn't reading
any designs on the card. |
Make
sure of the following: that (1) the card is formatted
in FAT and not FAT32; (2) that none of your designs
are located in any sub-folders within the card; and finally
(3) Ensure that after saving designs to the flash card
from PC, that you Stop the card from the Stop Hardware
icon in the bottom-right corner of your Windows screen
(next to the clock). Failure to do so may cause
the design not to save at all to the card.
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Fixing
thread breaks
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| Basic
thread Break Fix |
Follow
this short procedure to clear a thread break. (Note:
this procedure does not address troubleshooting the cause
of the break, only to teach how to re-thread and continue
sewing. Problem may re-occur without proper
troubleshooting.
1. Press T.CUT to cut thread still attached to
garment
2. Repair thread break by re-threading upper
thread or replacing bobbin.
3. Press or press and hold STOP to move sewing
position to just before the break
4. Press START to continue sewing.
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| Troubleshooting
Thread Breaks |
Follow
this procedure to troubleshoot thread breaks:
1. Bobbin . Check to see if the upper
thread is actually broken. If it isn't,
and the bobbin has not
been changed for a while, check bobbin and replace.
A remote possibility may
be that the thread break sensor is defective for
that needle, but this is
the least likely of the causes listed here.
2. Thread Path. If upper thread
is actually broken, check carefully along the
entire thread
path to make sure that needle is threaded correctly.
Pull the
thread through the
needle and ensure the thread pulls smoothly through the
entire thread path.
There is an excellent diagram in your manual on how the
thread should flow
through the tensioners, grommets, etc from thread cone
down to the needle.
3. Design or thread. If the thread
path appears correct and the thread seems to
be pulling smoothly,
and this still doesn't solve the problem, check to see
if the
break seems to be
occurring in either (a) the same point in a given design,
[i.e. poor digitizing]
or (b) with that particular thread [old or otherwise inferior
thread will be more
brittle than newer/quality thread].
4. Needle depth/proper needle orientation.
Did you know that the needle
MUST be installed
in a specific way? The long groove must be facing forward,
and the scarf (cutout
section behind the eye) must be facing directly
backwards. Incorrect
needle depth is also a cause (i.e. was the needle inserted
all the way into
place? Does the depth appear correct compared to
the
position of the rest
of the needles?). Check your manual for the
procedure
to set needle depth
for the ultimate procedure. Also, check to ensure
that
the needle is entering
the hole in the needle plate in the center or close
enough to the center that
it isn't physically contacting the needle.
5. Check for burred/jagged surfaces.
The normal wear of sewing operations
can cause surfaces that
the thread contacts to become damaged/jagged.
Check the following places.
Crocus cord or crocus cloth, which can be
purchased at any hardware
store, can be used to polish away these surfaces.
a. Surface of the rotary hook (diagrams will follow)
b. Needle plate - ensure that the edges of the hole
are smooth
c. Damaged needle - when in doubt, replace the needle,
inserting as shown
in (4) above.
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Types
of Machine "Jams"
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| Fixing
error E-018 main shaft error: When if shaft unable
to turn between 180 and 280 degree mark (approximately) |
| This
error indicates that resistance or obstruction has prevented
the main shaft from turning, either momentarily or a solid
jam. Click on the link below to view a video on
one of the common causes of this type of jam to see if
this is your problem, and also to see a fix for that problem. |
Video: Fixing this type of jam |
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FLASH movie: Fixing this type of jam. Interactive! |
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Sometimes your problems
may require more than a quick turn of a screw or an adjustment
knob. For those of you who want to take on more in-depth
repairs yourselves, we've provided some useful information below. |
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Topic |
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Question
& Solution |
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Removing Voyager's
Outer Covers |
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| How
to Remove the Covers |
| This
illustrated guide can help you if you need to perform
any maintenance on Voyager that requires removing the
outer covers. |
PDF instructions
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Adjusting Thread Cut Timing |
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| Adjusting
Thread Cut Timing |
| This
illustrated guide teaches you how to adjust thread cut
timing on Voyager. . |
PDF instructions
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Error Code List HCS Voyager machines |
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Below,
you'll find a list of the possible error codes displayed by the
machine, and an explanation of each, with suggested solutions. |
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Error
Code |
Error |
Description |
Resolution |
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001 |
Circuit
Board |
Abnormality
detected in control circuit board |
Power
down machine and, after 10 seconds, power on again. |
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004 |
System
Memory |
System
memory fault |
Power
down machine and, after 10 seconds, power on again. |
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015 |
Inverter
Trip |
Sewing
motor-related problem, i.e. overload or short circuit, trouble
with motor drive unit |
Cut
power and turn main shaft by hand. If turns normally, power
on again. |
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018 |
Main
shaft error |
Main
shaft will not turn. |
Turn
main shaft manually to verify full movement through complete 360
degree turn. Troubleshoot for anything that may block this
motion i.e. jam at rotary hook shaft, needle bar, etc. Also
re-initialize system, speed from MENU...OTHER. |
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020 |
Needle
Detect |
Machine
not detecting current needle # correctly, or needle bar selection
unit is off its stop position. Trouble with position-detecting
circuit board. |
Turn
needle bar selector with 3mm hex wrench (or on Gen III Voyager
machines, with large thumbscrews) to have it set at center of
fixed position (range within which needle bar selector doesn't
move). Align red arrows with indicator sticker on case.
1/2 turn = one full color change position.
Failing that, follow procedure in Maintenance Manual to correct
this. You'll need to re-start machine in Maintenance Mode
and go to OTHER...MAINTE (enter code)...MACHINE... and options
(D), (E) and (F). |
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021 |
Needle
move |
Motor
for needle bar selection unit has stopped partway through its
path. |
After
resolving initial cause of incident, turn needle bar selector
(or in new HCS machines, silver knob) with wrench to have it set
at center of fixed position (range within which needle bar selector
doesn't move). Test again. |
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022 |
Needle
move |
No
movement due to malfunction of thread take-up lever or trouble
of position-detecting circuit board |
After
resolving initial cause of incident, turn needle bar selector
(or in new HCS machines, silver knob) with wrench to have it set
at center of fixed position (range within which needle bar selector
doesn't move). Test again. |
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024 |
Needle
center |
Needle
bar stop position is off-center; needle bar stop position is out
of place. |
Turn
needle bar selector with 3mm hex wrench (or in new HCS machines,
silver knob) to have it set at center of fixed position (scope
within which needle bar selector doesn't move). |
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025 |
Needle
over |
Needle
# out of range of actual needles on given machine. |
Turn
needle bar selector with 3mm hex wrench (or in new HCS machines,
silver knob) to have it set at center of fixed position (scope
within which needle bar selector doesn't move). |
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026 |
Needle
differ |
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Turn
needle bar selector with 3mm hex wrench (or in new HCS machines,
silver knob) to have it set at center of fixed position (scope
within which needle bar selector doesn't move). |
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030 |
Slow
speed mismatch |
Improper
speed adjustment at low speed. Speed does not decrease below
100rpm at low speed. |
Adjustment
or replacement required of speed control VR on CPU circuit board.
Contact service department. |
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050 |
C
point error |
Main
shaft is stopped in a position other than "C" point |
To
clear automatically: Press ENT. Select Auto and press
ENT again. Main shaft should turn to correct position.
Failing that, move timing wheel clockwise to 270 degree position.
Check full rotation to ensure that shaft is able to turn full
360 degrees without significant resistance. . |
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051 |
L
sensor |
Timing
detection board fault, or marred photo-sensor. Malfunction
of "Lowest needle position" sensor on detection circuit board. |
Check
to see if photo sensor is clean or if the slit plate contacts
sensor. |
|
052 |
C
sensor |
Timing
board detection fault, or marred photo-sensor. Malfunction
of "Color change position" sensor on timing detection circuit
board. |
Check
to see if photo sensor is clean or if the slit plate contacts
sensor. |
|
055 |
Take-up
cover |
Safety
cover over take up levers is open. |
Close
safety cover. If cover is broken, cover can be removed and
sensor may be clipped to bypass this safety feature, although
this is not recommended. |
|
060 |
X
limit |
Frame/pantograph
has moved beyond sewing area along X-axis. |
Return
frame within sewing area using the frame movement keys on the
control panel. Check pattern size and center mark to ensure
that it is within size range of selected hoop and also properly
centered. |
|
061 |
Y-limit |
Frame/pantograph
has moved beyond sewing area along Y-axis. |
Return
frame within sewing area using the frame movement keys on the
control panel. Check pattern size and center mark to ensure
that it is within size range of selected hoop and also properly
centered. |
|
090 |
Miss
reception |
Error
has occurred during data transfer (via cable) between machine
and PC. |
Try
reading pattern data again. Verify that transmission speed
setting is correct at (1) transfer software; (2) device manager
of PC and (3) RS-232C speed of machine. Or if USB connection,
check USB connection. If necessary, shutdown HCS and HAPPYLINK
and re-load USB driver in device manager. Then, restart HCS machine,
bring to default screen, then re-start HAPPYLINK. |
|
091 |
No
send |
Machine
has not received data for > 10 seconds during data transfer. |
Try
reading pattern data again. Verify that transmission speed
setting is correct at (1) transfer software; (2) device manager
of PC and (3) RS-232C speed of machine. Or if USB connection,
check USB connection. If necessary, shutdown HCS and HAPPYLINK
and re-load USB driver in device manager. Then, restart HCS machine,
bring to default screen, then re-start HAPPYLINK. |
|
103 |
Data
format |
Machine
unable to determine data format of design |
Verify
that design is in .dst or .tap format and attempt to re-send and/or
reload. |
|
104 |
Miss
function |
Timing
to read tape does not conform. |
Try
reading pattern data again. Verify that transmission speed
setting is correct at (1) transfer software; (2) device manager
of PC and (3) RS-232C speed of machine. Or if USB connection,
check USB connection. If necessary, shutdown HCS and HAPPYLINK
and re-load USB driver in device manager. Then, restart HCS machine,
bring to default screen, then re-start HAPPYLINK. |
|
105 |
Dual
function |
Data
has been detected in the design that has ambiguous/dual function. |
Delete
design from control panel and re-load design from cable or card
again. |
|
108 |
Improper
read |
While
reading pattern data, error has occurred in internal processing. |
Try
reading pattern data again. |
|
110 |
Memory
full |
During
disk or tape read, memory has filled to capacity. |
Delete
unnecessary patterns from machine memory and try again. |
|
111 |
Change
over |
While
reading pattern data, # of color changes has exceeded 250. |
Divide
pattern data such that number of color changes of each segment
is less than 250. |
|
112 |
Data
error |
Pattern
data of current design is damaged. |
Try
loading pattern data again. |
|
114 |
Id
over |
#
of patterns in control panel memory has exceeded the maximum of
99 |
Delete
unnecessary patterns from machine memory and try again. |
|
118 |
Trace
Data Over |
Over
1024 stitches of trace data were created while the pattern data
was being read in. |
| |
USB Drivers for Windows 98