HAPPY SERVICE   information and customer resource page
 Welcome to the service page for HAPPY Embroidery Machines sold by Alarcon & Co., Inc.  This page is dedicated to customers, dealers and all others interested in the operation, maintenance, and repair of HAPPY embroidery machines.  Here on the Service page, you'll find useful information and resources to better help you with your HAPPY machine. 
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Self-Help Direct Links   Quick Access to Support Areas On This Page
Help with HAPPY HCA, HCG, and HCM machines If you need help with a HAPPY  HCA, HCG, or HCM machine, click on the icon on the right to go to that section for FAQ's, help files and other resources.
Help with HAPPY HCS Voyager machines  If you need help with a HAPPY  HCS Voyager compact embroidery  machine, click on the icon on the right to go to that section for FAQ's, help files and other resources.
Help with iPunch Software  If you need help with iPunch software click on the icon at the left to go to the iPunch website for FAQ's, help files, and other resources.
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Contacting the Service Department Directly     
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  Need to contact someone in the Service department right away?  We've listed the important contact information below, should you need to contact a technician.

phone 

1-800-497-3925   763-425-5173

fax 

 763-425-5179

e-mail 

 Alarcon
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  Help for HAPPY HCA, HCG, and HCM machines
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  HAPPY COMMERCIAL MACHINES
If you have an HCA, HCG, or HCM machine, this section is devoted to providing you with resources to help you keep your machine "HAPPY" !
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Sections    

back to top Help Files FAQ List Tech Tips  Error Codes
 
   Help Files for HCA/HCG/HCM
    In this section, you'll find useful files that you can download for your machine that can help you in many ways.
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  Machine Maintenance CD  Purchase our Happy Maintenance Guide for $49.99 on CD. This interactive movie will cover hook timing, head removal and timing, pressure foot replacement and adjustment, needle depth, common error codes, greasing and oiling! Contact the parts department and ask about the Happy Maintenance CD...  

To order, call
(800)497-3925  
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Control Panel Guide  Click here to view and print this useful guide for getting to know the control panel used in current HCA/HCG and HCM machines.
Cheat Sheet, old HCM machines  Click here to view and print this useful guide for earlier-model HAPPY HCM machines !!
Tension Test Designs

These designs, in .dst format, make testing upper thread tension a snap!   Both designs sew in a 320 x 320 hoop.  Set color sequence to 1, 2, 3, 4, 5... etc.   Download the design that matches your machine:

 Click
here to download a tension test for 12-needle machines.
 Click
here to download a tension test for 15-needle machines.

 
  FAQ List for HCA/HCG/HCM              

  

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Topic:  Floppy disk reader    
Question Answer
Can I copy designs from my HCA/HCG/HCM control panel back onto floppy diskette?  Yes!  Press  the Program [O] key, choose Floppy.  Using the Write option, you can save a design back onto the floppy diskette.  (Warning - write speed is very slow.  Be sure to allow adequate time for the design to be written to floppy.)
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What kind of floppy disk does my HCA/HCG/HCM machine read? 

 

Use a standard, PC-formatted floppy diskette.  You can use a double-density or high-density floppy. 
What formats can the disk reader on my HAPPY machine read?  HCA/HCG/HCM machines can read the following:  HAPPY (.tap), .dst, .exp, and FDR.   
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Topic:  Loading and Setting up Designs    
Question Answer
Can I program the needle colors on my monitor to match the order I've set up my thread cones on the machine?  Yes!  Press the Program [O] key and choose Color.  You'll see a list of 12 or 15 colors corresponding to each needle on your machine.  Use the arrow keys to select one, then press ENTER.  A new screen will appear in which you can use the left/right arrow keys to select an available color.  You can also adjust the brightness value of any color in the palette with the up/down arrow keys.  With the color and shade you've selected, press ENTER to set the current needle to that color.  Repeat the procedure until all needles are programmed.
I have a design in my control panel that took forever for me to set up the colors in.  If I want to load a new version of that design in, can  I keep the color sequence and transfer it to the new version?  Yes!  At the Needle sequence screen (from Program [O] key) press SHIFT+ the +/- key.  An option to either entry or load appears.  Choose the first option to put the color sequence in memory.  After you've done this, you can even delete the design.  Then, load the new design, go back to the needle sequence screen, press SHIFT / +/-, then choose Load to put the stored color list to the new design. 
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Topic:  Positioning the design    
Question Answer
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   Tech Tips for HCA/HCG/HCM

  

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Below, you'll find some technical help documents that will help you through some frequently-asked, common maintenance issues. We'll be adding to this section monthly, so be sure to check back for new, free tips to help keep your HAPPY machine HAPPY !!
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Upper Faceplate Adjustment   As your HCA or HCG machine ages, the needle engagement may get out of alignment and fail to sew.  This has been engineered to be an easy fix when it eventually happens.

Click here to download and print this illustrated techtip for a quick easy fix!
Connecting multiple HAPPY machines

 

  We've had a lot of inquiries recently about connecting several HAPPY machines to your computer.  We've provided an information page for those needing to know how to do it ! 

Click here to learn more!
   
 
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  Error Code List for HCA/HCG/HCM 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.
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 Main shaft motor overload, short, trouble w/main shaft drive unit or other main shaft motor related abnormality Cut power and turn main shaft by hand.  If turns normally, power on again.
016 X-assembly alarm X-motor-related trouble, i.e. x-motor 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.
017 Y-assembly alarm X-motor-related trouble, i.e. x-motor 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.
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.  
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 to have it set at center of fixed position (range within which needle bar selector doesn't move).
021 Needle move Motor for needle bar selection unit has stopped partway through its path. After fixing malfunction of needle and thread take-up lever, turn needle bar selector shaft with wrench to have it set at center of fixed position (range within which needle bar selector doesn't move)
022 Needle move No movement due to malfunction of thread take-up lever or trouble of position-detecting circuit board After fixing malfunction of needle and thread take-up lever, turn needle bar selector shaft with wrench to have it set at center of fixed position (range within which needle bar selector doesn't move)
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 to have it set at center of fixed position (scope within which needle bar selector doesn't move).
025 Needle over Needle # out of range of actual needles on given machine. Turn needle bar selector with 3mm hex wrench to have it set at center of fixed position (scope within which needle bar selector doesn't move).
026 Needle differ   Turn needle bar selector with 3mm hex wrench to have it set at center of fixed position (scope within which needle bar selector doesn't move).
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. 
050 C point error Main shaft is stopped in a position other than "C" point Turn grip on main shaft upwards (forward) and set to C point mark. 
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. 
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. 
070 Safety sensor Needle safety sensor has been tripped. Remove any object/substance obstructing needle area of moving head.
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.
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.
102 Tape set During reading phase, tape holder knocked out of place. Read tape again from the beginning.
103 Tape format While reading, tape holder knocked out of place Check tape format or data format of pattern data.  In relation to setting of pattern data reading, set tape fvormat or data format properly.
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.
105 Dual function Data has been detected in the tape that has ambiguous/dual function. Check physical condition of tape.  Read tape again from the beginning.
106 No function Physical distance between initial point in tape data and actual start point of pattern data is too great. Leave less than 1 mm between reading unit of tape reader and first part of tape data.
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.
116 Not found ID Specified pattern does not exist. Check setting.
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120 Memory error Fault in retaining contents of pattern memory If this occurs frequently, it is likely that CPU is faulty.
130 Disk error Incapable of disposing data disk continuously Power down machine and after a 10 seconds, power on again.  If error remains, there is a problem with the disk drive unit.
131 Disk no ready Disk is not set Check if data disk is properly inserted into disk drive.
132 Write protect Disk write protected Disable write protect on disk.
133 Bad disk Improper or faulty data disk Data disk that disk drive unit can't read or faulty data disk or uninitialized disk
134 Disk unit Trouble in disk drive unit Power down machine and after a 10 seconds, power on again.  If error remains, there is a problem with the disk drive unit.
140 Entry over Disk capacity full Clear unnecessary patterns or use alternate disk.
141 Not found name Designated pattern is not found Data disk is not correct.
142 Disk full Disk capacity full Clear unnecessary patterns or use alternate disk.
143      
190 Cut blade Thread cut knife is not at stop position. Check if the stop position limit switch on the thread cut actuation unit on the left side under the machine table contacts the dog. 

When the stop position limit switch is no longer in contact, return switch to previous position, in the following manner:

(It is recommended that you reference the diagrams in your manual to continue)
1.  Remove solenoid cover on the left side under the machine table (2 screws).
2.  Insert flathead screwdriver between solenoid stopper and plunger and turn the main shaft toward arrow mark by bringing plunger up.
3.  Insert flathead screwdriver to the hilt.  
4.  Turn main shaft toward indicator arrow amrk and set to 10 deg. beyond "C" on the adjustment wheel.  If the main shaft appears abnormally heavy while turning, remove needle plate and check thread cut knife.
5.  Remove the flathead screwdriver from the solenoid.
6.  Replace solenoid cover and needle plate cover.
7.  Turn main shaft position to "C" mark on adjustment wheel.
193 Catcher Thread catch hook is off its properly-retracted position.  Limit switch to detect position is not "OFF". 1. Check if one of the heads that is not trimming properly.  If so, cut and return thread catch hook to retracted position.
2.  If threads are all cut, check to verify that thread catch hook on head has returned to its position completely. 
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201      
202      
  Help for HAPPY HCS Voyager machines
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VOYAGER
If you have an HCS Voyager machine, this section is devoted to providing you with resources to help you keep your machine "HAPPY" !

Sections

back to top Help Files FAQ List Tech Tips  Error Codes
 
   Help Files for HCS Voyager
HappyLink 2.01 This is the latest version of the HAPPYLINK software that you can download and install into a PC.  HAPPYLINK lets you open up embroidery files, set them up for the machine including color changes, offset, rotate & other features before sending them through a cable directly to your HCS, HCA, or HCG machine.
E-mail the Service department for download instructions.
USB Drivers, Windows XP  For those with the HAPPY HCS-1201 Voyager compact embroidery machine, this is appropriate driver for Windows XP/2000 driver for the USB connection that offers smoother operation, and solves some known issues regarding interrupted design transfers and Windows instability. 

Click here to download the ZIP file containing the 2 driver files.
HCS 1.06 Updater Program  

 

This program will update the internal program of the HAPPY HCS 1201 Voyager machine from Version 1.05 to 1.06.  Note: If you are unsure about the update process, Do NOT download this program or attempt to perform the update without consulting Alarcon technical staff.  An improperly-performed update can cause the Voyager machine to malfunction.

Click hereto download the ZIP file containing the instructions and necessary files..
Tension Test Design for Voyager  This design, in .dst format, makes testing upper thread tension a snap!   Fits in a  320 x 320 hoop.  Set color sequence to 1, 2, 3, 4, 5... etc.   

 Click
here to download a tension test for 12-needle machines.
 
 
 
   FAQ List for HCS Voyager

  

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Topic:  Flash memory card    
Question Answer
What kind of FLASH memory card do you recommend?  The most reliable card, so far, has been a Compact Flash memory card, brand name SanDisk.  It is also recommend that the PCMCIA adapter that the memory card plugs into also be of the same brand.
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I have the correct FLASH card, but Voyager is not 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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Topic:  USB Connection    
Question Answer
My Windows XP operating system  crashes with the USB connection.  How do I fix the problem? 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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I keep getting "Machine is Busy" or "USB not ready" even after having correctly set up the USB connection.  How do I fix this? 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.
Topic:  Positioning the design    
Question Answer
After loading my design, how do I make sure that the design will sew in the center of the hoop? 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.  
After loading my design, how do I sew the design somewhere other than 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.
 
   Tech Tips  for HCS Voyager

  

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Topic:  Procedure
Fixing Needle Detect/Needle Change problems If you get an error 020 or 024 indicating that Voyager either thinks that the needle isn't on-center over the needle plate, or that the wrong needle is selected, there is an easy fix:  
 
 
  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.
Error Code  Error Description Resolution

001

Circuit Board Abnormality detected in control circuit board 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 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.
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.
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).  
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.
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.
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).
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).
026 Needle differ   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).
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. 
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.  . 
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 takeup 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. HCS adds 1024 to the stitch count of any design loaded into memory; this is the trace data.  Error occurs when maximum stitch length settings is  unusual value.   
120 Memory error Fault in retaining contents of pattern memory If this occurs frequently, it is likely that CPU is faulty.
130 Disk error Incapable of disposing data disk continuously Power down machine and after a 10 seconds, power on again.  If error remains, there is a problem with the disk drive unit.
131 Disk no ready Disk is not set Check if data disk is properly inserted into disk drive.
133 Bad card Memory card faulty Memory card unreadable or broken or not initialized.  Make sure that card is formatted in FAT and not FAT32 format.
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. 1. Check to verify that machine not trimming properly.  If so, cut and return thread catch hook to retracted position.
2.  If threads are cut, check to verify that thread catch hook has returned to its position completely. 
193 Catcher Thread catch hook is off its properly-retracted position.  Limit switch to detect position is not "OFF". 1. Check to verify that machine not trimming properly.  If so, cut and return thread catch hook to retracted position.
2.  If threads are cut, check to verify that thread catch hook has returned to its position completely. 

(Be sure to check back frequently for updates!)