As soon as i put power to the pedal the cotton breaks
Install a brand new needle. Make sure you are using thread and needle that are compatible with the fabric you are sewing.
Change the type of thread you are using. Old or bargain bin threads will frequently cause problems.
Clean the tension disks to make sure there is nothing stuck that is preventing the thread from feeding.
Remove all the thread and re-thread from the beginning. FIRST raise the presser foot so the tension disks will allow the thread to seat properly. Make sure you are threading everything in the proper sequence and not missing any steps.
Set the upper tension at the halfway point between the high and low number.
Stitch a test on a piece of your scrap fabric from your project.
The ideal tension is when the upper thread and bobbin thread meet in the middle of the fabric. If the bobbin thread is appearing at the top of the fabric, your upper tension is too tight and needs to be loosened. If the upper thread is appearing under the fabric or forming a loopy mess, the upper thread is too loose.
Keep adjusting and testing until the tension appears correct.
If the thread continues to break, then there may be a burr that is catching the thread and breaking it. Or the timing could be off. Take it for service.
http://www.schmetzneedles.com/all-about-needles/
http://www.sewingandcraftcorner.com/why-does-my-thread-keep-breaking-while-i-sew/
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Could be the cotton is too old ( cotton has an additive in it to stop it unraveling and this additive deteriorates with age and weakens the cotton--makes it rough and so it will not slide easily through the eye )
go up an needle eye size
check that the thread is not jamming rather than between he tension plates
check that you have the needle in correctly ( groove in the needle facing the thread )
SOURCE: no zig and cotton keeps breaking
Make sure you have a new sharp needle installed for both problems and sometimes you need a particular kind of needle for the fabric. Also some machines don't deal well with 100% cotton thread. For some reason it gets caught up in the machine somewhere and breaks. Gutterman and Metrosene make excellent although slightly more expensive threads. Coats and Clark thread is good too. They make an all cotton thread but it doesn't come in as many colors. If you have the old spools of cotton thread from Walmart, just use them for topstitching if you need the color. Other wise, use them for hand stitching or throw them away. One more thing that I can think of off hand, one of my machines does not like lining fabric. For some reason the thread breaks if I stitch really fast. If you have to use that thread, you may try sewing slowly. One more thing, when was the last time your machine was serviced? This can make a huge difference if it's been awhile and you use the machine a lot. Good luck. Hope any of this helps.
SOURCE: cotton breaking when sewing into thicker material
Try a different needle, matched to the weight of your fabric.
SOURCE: needle breaks
The tension may be too tight causing the needle to break or the needle is hitting the bobbin case cam causing it to break. Suggest you take it to an authorized husqvarna viking dealer for service if the problem still exists. 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
Good luck.
SOURCE: cotton breaks on Brother Embroidery Galaxie 2100 machine
Try turning down your top tension setting a bit. If its at 4 or 5, i would turn it down to about 3 ish. Cotton thread is more brittle than polyester and rayon thread.
Hope that helps :)
Chris
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