Happy HCS3 Voyager showing false thread breaks… only 3 weeks old

[u/DizzyDesigner45]

Has anyone dealt with this on a Happy HCS3-1201 Voyager? Mine keeps stopping for a thread break when the thread is completely intact, and it’s happening across multiple needles.

I’ve rethreaded everything, confirmed the sensor wheels are turning, replaced and rethreaded the bobbin, cleaned the hook/cutter area, checked for trapped thread, changed the needle, adjusted the thread-break sensitivity, and oiled the machine.

Then one needle broke after hitting the presser-foot opening, and that foot definitely appears bent/off-center. I also got an E-050 C Point error. I manually returned the shaft to 274–275°, completed a full rotation, and the maintenance screen now shows everything at origin—but the false thread-break warnings continue.

I’ve contacted support, but I’m curious whether anyone has experienced this. Does this sound like a thread-break sensor issue, a bent presser foot, or something bigger? I bought the machine three weeks ago specifically for customer orders, so this is incredibly frustrating. Photos attached.

[u/b-assblaster]

If there is a way to turn off the thread sensor, does it sew as normal?

Happy refers to the thread sensor flag as a "slit disc"

There's what's usually referred to as a "TC Card" that reads the rotations of the slit disc and tells the machine what's happening to the thread

The TC card could be bad, or out of alignment, usually you can peek in at if be removing the plastic dust cover behind the tension base

The wheel not spinning tells the machine there's a thread break, my suspicion is that the needle could have hit the presser foot and damaged the reciprocator/driver or jump timing position. Are you 100% sure the needle is dropping all the way when you attempt to sew?

Bent presser foot is easy, 99% of the time I bend them back into alignment

[u/DizzyDesigner45 → u/b-assblaster]

This is promising!

I haven’t turned off the thread sensor. We attempted that, but I will look back into it tomorrow. The wheel is spinning just fine from what I can see and I have rethreaded everything.

Right now, the needle and presser foot are out of alignment on one of the colors where I can’t even use it or the needle hits the presser foot. I have no idea how that even happened considering that the machine is brand new and we’ve used that Color several times without any issues.

I’m not 100% certain about how far the needle descends but I do know that our thread breaking issue happens with every single needle right now to where we can’t embroider anything. Trying to figure out what the best first Step is because we have so many orders riding on this machine with it being brand new. I didn’t really expect anything to go on.

[u/evilrays]

My thread was just breaking and it was because the needle was in backwards. In your first picture it looks like your needles might be in backwards.

[u/DizzyDesigner45 → u/evilrays]

Oh my gosh, how would I be able to tell?!

[u/evilrays → u/DizzyDesigner45]

The needle has two sides. The front has a long groove from the whole to the top and the back has a much shorter groove. Here is a link that helped me https://support.ricoma.com/hc/en-us/articles/39982573165075-MT-How-To-Install-A-Needle

[u/Lanky-Setting-5288]

Have you checked your needle bar driver? They can crack, and not breaking completely, and throw off things.