Maleah, I could be way off track, but I have an idea we are in the same boat. I have a Orchidea and my plus hoop has P1, P2, and P3 marked on the hoop. This means if I want to stitch out a "large" design it has to be split in 3 and saved in 3 bits under P1, P2 and P3. Then when it comes to the stitching out I have to adjust the hoop at the end of each bit. A all in one finished design does not work on the machine, I've asked my dealer if there was hope, maybe a new program that the Husq can use to overcome this problem, but he said that there is no hope, its the machine itself and the way it was made jonks ago. All hope is not lost. Buzztools have software with a free trail period of 21 days that you may try out, with the software you can cut designs. I don't have Embird, this software can also do the same job. I'll come back with an Embird link, buzztools you can visit under www.buzztools.com, look under downloads and free trails.

Mops (Black hat with pretty flowers avatar) told me that she uses Husq/viking software and that the 3D software has got a designer splitter in it, spliting and saving the design in one easy go.

I also have a Rose, which I like except that the 4x4 area is all the machine can do. No, you don't need a new card. If you want to take advantage of the larger area, you need new designs and/or to plan to use multiple designs for a border, for example. The plus hoop has 3 positions as mentioned and you can sew 3 overlapping designs to get a 4 x 7 area in one hooping, but you can still only sew 4 x 4 in any one position. I have done Train borders for my GS, but it requires some fussing to get the pieces to line up. I have not yet acquired software to split designs. I do have some 3-part designs that came with the Plus hoop, but have not tried them yet - been concentrating on little boy and little girl things. Good luck with the new hoop. Don't know what error you might have - can you give us more information? Are all the designs on the card you are trying 4x4 or smaller?