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First of all, THANK-YOU to everyone who gave me a suggestion to try....and yes Judy Iam always curious too as to what worked for someone........I just wish I could remember the solutions when I need them !!

My thread is a polyester (Guterman) 100 % I wasn't clear when I mentioned the 100 % good quality cotton.....I meant the material ! I changed the needle again to the suggested embroidery size, that helped a bit.....I didn't have any sewer's aid so will have to wait to try that, I reread the manual for the Sapphire 830 and rethreaded both machine and rewound the bobbin and tried to keep the machine speed at a moderate level but still ended up with problems......I am suspecting my thread might be older than I thought, because even on the old reliable Kenmore that always free motioned without any glitches I had a couple of thread breaks, but not as many as the Sapphire......so this weekend I am going to try the quilt shop just across the MN border to see if they might have Sewer's Aid but am going to do a bit of further research to make sure my machine won't be "scarred for life" if I use it.....my DH suggested maybe spraying the thread spool with WD-40 after hearing a few loud adjectives emitting from the sewing room !
Even he knew that wasn't an option but do give points for trying to solve the issue......after all he was the one who figured out how to thread the serger when I had given up !!

I have a quilting buddy who is very familar with the husqvarna machines and she is lined up to help figure out if it is the operator not the machine who is at fault.

Once again thanks for the insights......this board has been quiet of late......what is everyone up to.....we are finally feeling like we might be having some summer weather after weeks of cooler than norm temps and too too much rain.......I am trying to gear up my sewing to think forward to Christmas gifts, but not much motivation when it's nice outside !!