Husqvarna/Viking #1+ embroidery unit disengages when attempting to sew.
The embroidery unit slides into place and clicks loosely into its detent. The hoop is then installed, fabric feed is disengaged, presser foot is lowered and embroidery is attempted. As soon as sewing commences, the embroidery unit snaps out of its detent and shifts to the left about 1/4 inch.
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What make and model of sewing machine do you have? I have seen this problem with a Husqvarna Viking Designer I (or similar older Viking machine). In that case, the problem was corrosion on the contacts between the embroidery unit and the sewing machine. The solution was to use an electronic contact cleaner to clean the contacts; this is one product: http://www.amazon.com/CRC-05101-QD-Electronic-Cleaner/dp/B000CCMLD0 . Make sure that the machine is unplugged. Spray the contact cleaner on the contacts. (In some cases, you should then connect the embroidery unit to the machine and remove it a few times.) Allow the product to dry before you plug in the sewing machine again.
In another case, the solution was actually easier. The owner had two similar embroidery machines. She managed to mix up which embroidery unit went with which sewing machine. Neither embroidery unit could be properly seated on the machine that she attempting to use it with. Once the embroidery unit was paired with the correct machine, both pairs worked.
You can have replacement discs ordered from Husqvarna Viking. Visit an authorized Husqvarna Viking dealer for them to order the replacement discs. However, you might luck out and they have some already on hand from a scrapped machine or a trade-in. You can find your nearest dealer by visiting the Husqvarna Viking website - http://www.husqvarnaviking.com and clicking on dealer link down the left side of the page.
The bobbin tension sounds ok if regular sewing is ok. The upper tension unit may be the culprit in that there are loose threads or fluff causing the discs not to tighten enough for embroidery. The best solution is to have it serviced by an authorized husqvarna viking dealer. You can locate a dealer near you by visiting the husqvarna viking website and clicking on the Dealer link on the left-hand side of the page - http://www.husqvarnaviking.com
Remove the embroidery unit and see will come on then. If not, it is probably the PC board. If it does come back on, it may be the embroidery unit or the connection. Take to authorized Husqvarna Viking dealer for service or have them send it to Husqvarna Viking (SVP) Technical Service Department for repair. A list of authorized Husqvarna Viking dealers can be found at the Husqvarna Viking website - http://www.husqvarnaviking.com/us
Could be the design you're trying to stitch out is eroded. Try rewriting the design to the card and see if that helps. If not, take your machine along with the embroidery unit, peddle, hoops, etc. to your tech for a once over. It may just need an adjustment.
Four questions: What model Husqvarna sewing machine are you using? Are you using a Husqvarna formatted USB stick? Is the embroidery unit attached when you put in the stick? Is your machine using the latest version of its software?
I might be able to give some more specific help once I know the answers to the above. Pamsquilt