Support: Voyager 1-Head Embroidery Machine

side view 7 needle journeyfront view 7 needle journey
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May 15, 2018: New firmware v. 2.16 posted for all Touchscreen HAPPY machine models

HAPPY’s Tireless Quest for Perfection: Ongoing Updates

October 16, 2017: New Firmware v.214 posted for all Touchscreen HAPPY machine models

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Education

Tension Tests

Needle Diagram

June 16, 2015: New firmware v. 1.40 posted for HCH, HCS2, HCD2

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Using the Cap Frame System

Oiling and Cleaning For Journey

Tension Tests

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Quick Start guide


Chapter 2
Control Panel, More in-depth


Chapter 4
Maintenance and troubleshooting


Chapter 1
Introduction


Chapter 3
More QuickStart Guides; upper tension test


Chapter 5
Embroidering on finished ballcaps

Unpacking your Brand New Machine!
Please watch these videos on how to set up and start sewing on your brand new machine. **These Videos are showing the Journey, but the same methods apply to this machine.**





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Sewing with Your New Journey Machine
Please watch these videos on how to set up your machine for a typical embroidery job.



General Support/ Troubleshooting

General Support Topics

Switching Between Cap and Tubular Modes
Your machine should automatically detect when the cap driver is installed or not, displaying one of the cap hoops on screen as an indicator when the cap driver is detected. When the machine is started without the cap driver installed, the cap hoop should no longer be displayed as the selected hoop. To ensure that this works properly, be sure that the metal “finger” on the cap driver itself presses the plunger switch shown in the animation. Check to make sure the small metal strip and the small white “nub” of the microswitch (indicated by the red arrow) are pressed upwards as the plunger is pressed in. Conversely, when the machine is shut down and the cap driver is removed, the switch should return to the forward position, and the metal strip and white “nub” should come back down to their normal resting position. See the animation HERE

HAPPY’s Tireless Quest for Perfection: Ongoing Updates

Sept. 2016 Digitizing How-To: Adding borders to lettering in Stitch & Sew2

HAPPY Advantage: Japanese Manufacturing and Design Philosophy

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Downloads

maintenance manual for journey 1-head embroidery machineParts Manual

Voyager2 Parts Manual rev.AParts Manual for Rev. A models

 

Tension Test 

users manual for journey 1-head embroidery machineOperators Manual, Firmware Version 2.11
for HCS2-1201 Voyager2 embroidery machine, in PDF form.

Voyager2 Users Manual Users Manual Firmware version 1.40

Firmware update for Happy embroidery machinesFirmware Update 2.11 for HCH, HCS2 and HCD2
Released September 19, 2016.  Click the link above to download firmware 2.11 for your 1-head Happy embroidery machine.  This update adds the ability to load in designs and set them up (color sequence, etc) while the machine is running.  Click HERE for details on the release and instructions.

Firmware update for Happy embroidery machinesFirmware Update 2.00 for HCH, HCS2 and HCD2
Released May 24, 2016.  Quick instructions for updating firmware: (1) Download the ZIP file from the appropriate link to a folder in your PC and extract its contents to a USB thumb drive, resulting in a single folder called UpdateFile. (2) Insert the USB thumb drive into the machine, navigate to the main menu, choose OTHER, then VERSION. Press the UPDATE button to perform the update. (3) This should take several minutes. Update is finished when the machine auto-restarts.  New features: (1) extends max allowed designs in memory from 250 to 999.  (2) thread break messages also now display the needle number where the break occurred.  NOTE: If you use HAPPYLINK with your machine, you must also use HAPPYLINK 4.03 or newer.  The newest HAPPYLINK can be downloaded from the Support page for HAPPYLINK on this website.

Firmware update for Happy embroidery machinesFirmware Update 1.60 for HCH, HCS2 and HCD2
Released December 18, 2015

Hoop Maps for 3rd Party Hoops

Current model Happy machines provide an impressive ability to load hoop maps for just about any hoop that will fit on the machine.  Why is this a big deal?  This gives the operator a visual map of the design position and fit inside the usable sewing area unique to that hoop, just like the pre-programmed Happy brand hoops.  In this way, even new operators have a good visual check on design fit, and can re-position the hoop on the spot, watching the actual hoop move along with the animation on screen.  And since different hoops enable a machine to do different kinds of jobs, Happy machine operators can adapt to the very wide variety of hoops available with relatively little fuss!  Works on all new Happy embroidery machines (including single and multi-head models), as well as with first generation color Voyager and HCD-1501 models.

General instructions: Download the hoop files you wish to install.  Since each is a ZIP files containing a single hoop map, you’ll have to extract the map file after downloading it, saving it onto your CompactFlash card or USB thumb drive (if your machine has a USB thumb drive port.).  After doing so, follow the instructions appropriate for your machine, below, right.

Hoopmaps for Durkee Hoops (updated 7/6/2016)

Hoop map, Durkee 15x30cm “jeans” hoop – zip file contains maps for both  vertical and horizontal orientations.

Hoop map, Durkee 10x30cm “sleeve” hoop – zip file contains maps for both vertical and horizontal orientations.

Hoop map, Durkee 12x24cm (5x9in) hoop – note that this is a vertically-oriented hoop.

Hoop map, Durkee 15cm square hoop

Hoop map, Durkee 24cm square hoop

Hoop map, Durkee 30cm square hoop

Hoop map, Durkee 9cm round hoop

Hoop map, Durkee Cap Frame

Instructions for Touch Screen Happy machines

Instructions for most 3rd party hoops
(updated August 11, 2014)

Instructions for Color Voyager1, HCD1, HCR machines

Instructions for most 3rd party hoops

Instructions for Hooptech clamp windows

Instructions for Hooptech 8-in-1 windows

Hoopmaps for Hooptech Products: Clamps & the 8-in-1  Updated 8/11/14

Note: When using these maps, be sure to enter the correct Y-offset (X can stay at zero). For ITCS2 (large), offset is -80mm.  For ITCS1 (small base), offset is -60.3mm.

Hoop map, Hooptech Clamp ITCS1 (small base), 2.5″w x 4″h window

Hoop map, Hooptech Clamp ITCS1 (small base), 3.5″w x 4″h window

Hoop map, Hooptech Clamp ITCS1 (small base), 4.5″ square window

Hoop map, Hooptech Clamp ITCS2 (large base), 5.5″ square  window

Hoop map, Hooptech Clamp ITCS2 (large base), 4.5″w x 6″h hoop

Hoop map, Hooptech Clamp ITCS2 (large base), 7.5″w x 6″h hoop

Hoop map, Hooptech 8-in-1 System 7 window sizes included in this file (cap attachment not included)  Updated Wednesday, June 4, 2014.

Hoop map, Hooptech Clamp ITCS1 (window), 6″w x 6″h

Hoopmaps for Magnetic Mighty Hoops from Hoopmaster (updated 7/23/18)

Hoop map, Mighty Hoop 4.25 inch square hoop

Hoop map, Mighty Hoop 5.5 inch square hoop

Hoop map, Mighty Hoop 6.5 inch square hoop

Hoop map, Mighty Hoop 8inch x 9inch  hoop

Hoop map, Mighty Hoop 10 inch square hoop

Hoop map, Mighty Hoop 7.25 inch square hoop

Hoop map, Mighty Hoop 8.25 x 6.25 in hoop

 

Hooptech Hoops (conventional tubular hoops)

Hoop map, Hooptech square 7.5 inch hoop

TEMPLATE for making your own Hoopmaps

You can download and print. For large hoopmaps, you can print this to a sheet of 11″x 17″ paper. Follow the directions in your machine’s manual for making your own hoopmaps (for compatible HAPPY machine models).

Videos

Unpacking your Brand New Machine!
Please watch these videos on how to set up and start sewing on your brand new machine. **These Videos are showing the Journey, but the same methods apply to this machine.**

Assembling the optional Machine Stand

Unboxing your new Happy Embroidery Machine

Happy Journey Embroidery Machine Setup 1 of 3

Happy Journey Embroidery Machine Setup 2 of 3

Happy Journey Embroidery Machine Setup 3 of 3

Happy Journey Embroidery Machine Sewing Setup 1 of 4

Happy Journey Embroidery Machine Sewing Setup 2 of 4

Happy Journey Embroidery Machine Sewing Setup 3 of 4

Happy Journey Embroidery Machine Sewing Setup 4 of 4

Error Codes

Error Codes

 Below, you’ll find a list of the possible error codes displayed by the machine, and an explanation of each, with suggested solutions.
Error Code  Error Description Resolution

001

 Circuit Board Abnormality detected in control circuit board Power down machine and, after 10 seconds, power on again.
002 Power Source Power failure or abnormal voltage Power down machine and, after 10 seconds, power on again.
004 System Memory System memory fault Power down machine and, after 10 seconds, power on again.
015 Inverter Trip Not applicable to this machine. Not applicable to this machine.
  016 X-assembly alarm X-motor related trouble, i.e. overload, short circuit, problem with motor drive unit. Power off machine, test pantograph movement manually.  Check for any abnormality throughout full range of motion.  If none found, power on and test.  May need to check PMD (pulse motor driver).
  017 Y-assembly alarm Y-motor related trouble, i.e. overload, short circuit, problem with motor drive unit Power off machine, test pantograph movement manually.  Check for any abnormality throughout full range of motion.  If none found, power on and test.  May need to check PMD (pulse motor driver).
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.  Check for jams between needle bar boss on back of moving head and reciprocator assembly on front face of fixed head. 
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. Restart the machine.  Upon re-start and pressing the NEXT button, the machine should perform a self-check and re-calibrate the needle numbers and positions. 
022 Needle move No movement due to malfunction of thread take-up lever or trouble of position-detecting circuit board Follow same procedure for listed error 020
024 Needle center Needle bar stop position is off-center; needle bar stop position is out of place. Follow same procedure for listed error 020
025 Needle over Needle # out of range of actual needles on given machine. Follow same procedure for listed error 020
026 Needle differ Mismatch between actual selected needle position and needle number showing in the control panel. Restart the machine.  Upon re-start and pressing the NEXT button, the machine should perform a self-check and re-calibrate the needle numbers and positions. 
030 Slow speed mismatch Improper speed adjustment at low speed.  Speed does not decrease below 100 rpm at low speed. Perform automatic speed re-set: (1) Choose “OTHER” from the main menu, then select “SPEED”.  After warning, machine will turn main shaft slowly from stop to max speed (needle will not sew).
050 C point error Main shaft is stopped in a position other than “C” point  On error, choose the “AUTO” option if available (instead of manual.) Main shaft should turn to correct position. Failing that, go to the back of the machine, remove the circular black rubber cap, and move the timing wheel clockwise to 275 degrees.  Check full rotation to ensure that shaft is able to turn full 360 degrees without significant resistance.
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. Also check rotary hook area for bird-nesting and clear thread/blockage as necessary.
052 C sensor  Timing board detection fault, or marred photo-sensor.  Malfunction of “Color change position” sensor on timing detection circuit board.  Follow same procedure listed for error 051
055 Take-up cover Safety cover over take-up levers is open. Not applicable for this machine.
060 X limit  Frame/pantograph has moved beyond sewing area along X-axis (extreme left or right).  Check to make sure current pattern is digitized center-center. Re-check design position and size against currently-selected hoop and re-adjust as necessary.
061 Y-limit  Frame/pantograph has moved beyond sewing area along Y-axis. Check to make sure current pattern is digitized center-center. Re-check design position and size against currently-selected hoop and re-adjust as necessary.
090 Miss reception Not applicable to this machine. Not applicable to this machine.
091 No send Not applicable to this machine. Not applicable to this machine.
103 Data format Machine unable to determine data format of design Verify that design is in .dst, .tap, or .exp format and attempt to re-send and/or reload.
104 Miss function Timing to read tape does not conform. Re-transfer design and try again.
105 Dual function Data has been detected in the design that has ambiguous/dual function. Re-load design again into memory.
108 Improper read Not implemented Not implemented
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 99. 
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 Not applicable to this machine. Not applicable to this machine.
120 Memory error Fault in retaining contents of pattern memory Try performing a SYSTEM, then SPEED reset (main menu -> OTHER -> SYSTEM, then SPEED).  This should reset the machine.  Failing this, try dumping the machine memory from Maintenance mode.
130 Disk error Incapable of disposing data disk continuously Re-seat memory card and try again.  Ensure that you are using a compatible memory card.
131 Disk no ready Disk is not set Same procedure as for error 130
133 Bad card Memory card faulty Same procedure as for error 130
141 Not found name Designated pattern is not found Memory card incorrect type or format.
190 Cut blade Thread cut knife is not at stop position. Look for bird’s nest or other obstruction to moving knife. Clean out throat /needle plate and rotary hook area. Perform thread cut to attempt to clear. Failing that, press manual engagement lever and manually turn main shaft to check that knife opens and closes properly, continuing until knife re-seats properly. In doing so, check moving knife timing, verifying that knife opens at approx. 116 degrees. If needed, reset knife according to the service manual.
193 Catcher Thread catch hook is off its properly-retracted position.  Limit switch to detect position is not “OFF”. Check if not trimming properly.  If thread is cut, ensure that catcher has returned to position, selecting either auto or manual. If so, cut and return thread catch hook to retracted position. If problem recurs, troubleshoot position of thread holder, which may mis-guide catcher and cause it to miss the thread. 

Non-Touch Screen Models

  HCS Voyager User's Manual   User’s Manual, standard control panel

Voyager LCD Monitor User Manual   User’s Manual, color LCD monitor

Voyager Maintenance Manual   Maintenance Manual, color LCD addendum

Voyager Parts Manual   Parts Manual, color LCD addendum

Voyager Parts Manual   Parts Manual, Standard Panel

Voyager LCD Monitor User Manual   Dec. 10, 2008:  User’s Manual, color LCD monitor, jump drive, collars

Voyager Parts Manual   April 2010:  User’s Manual, color LCD monitor, includes instructions for custom hoo

Learning Workbooks for HCS Voyager (for firmware 1.16)

Click on the links below to view/print the 5 chapters on learning your HCS-1201 Voyager single-head machine.  You can also try the animated, guided tour through your machine as well.  Includes update for USB jump drive versiion of Voyager
Voyager chapter 1
Introduction to the machine, embroidery basics
Voyager Chapter 2 
Learning the most important tasks, transferring designs
Voyager Chapter 3
Sewing Checklist, adjusting upper tension

Voyager Chapter 4
Maintenance,, troubleshooting, key adjustments

Voyager Chapter 5 
Learning how to sew on finished ballcaps with Voyager

 Voyager animated learning guide
Transferring Designs Using a Flash card
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. 

Topic

Question and Answer

Illustrated Guide

Everything you need to know about CompactFlash cards and Voyager 
Provided below is a PDF document illustrating the most popular FLASH cards used with Voyager
  View/print information about CompactFlash
cards for use with HAPPY Voyager.
What types of cards work? The newest versions of Voyager (Generation 3 and color LCD) 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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Are there any card memory size limitations? While we have seen cards up to 1Gb (1024Mb) work well, the official recommendation is 256Mb max, which is still large enough to hold thousands of average and large sized designs.
What types of cards work on older Voyager machines?
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?

 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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Controlling Voyager while Sewing

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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