A-6 APPENDIX Manual 0463 413 001
Calibration
This section provides qualified service personnel detailed instructions to calibrate the Rebel control PCB when
in an assembled unit. The control PCB will require calibration when:
1. The Control PCB, PCB3 has been replaced,
2. The Wire Feed Mechanism M1 has been replaced,
3. The Output current sensor CS1 has been replaced.
Required Tools:
True RMS Volt Meter: Fluke Model 179 or equivalent
True RMS Current Clamp: Fluke Model 376 or equivalent
Hand Held Tachometer: Extech Instruments Model 461891 or equivalent
Load Bank: Capable of 200A continuous load
NOTE!
See CONTROL PCB 3 Layout for Trimpot locations
Output Amperage Calibration:
With unit connected to 230VAC primary line voltage, connect the output terminals of the power supply to a load
bank. The calibration will be checked at both Maximum and Minimum output current settings. Turn unit on and
set the machine into STICK (SMAW) Process and adjust for 180A (max) at 27.2VDC. Using a clamp on ammeter
read the actual output amperage on the positive output cable. Adjust Trimpot R34 on the Control PCB3 until
the measured output amperage on the clamp on meter reads 180A (+3A/- 0A). Next set the unit and load bank
up for 15A (min) @20.6VDC. The reading on the clamp on meter should be 15A (+0A/-1A). If necessary, adjust
R34 until both the max and min readings are both within the specified tolerances listed above.
Wire Feed Speed Calibration:
Set the power supply to MIG (GMAW) process and adjust Wire Feed Speed for 475 ipm on the power supply
display. The calibration will be checked at both Maximum and Minimum Wire Feed Speed settings. Using the
tachometer to measure the speed of the drive roll, trigger the unit and get actual speed measurement from
tachometer. Adjust the trimpot R642 on the Control PCB3 until the actual measured speed is 475 (max) ipm
(+/- 10 ipm). Then set Wire Feed Speed to 100 ipm and trigger the power supply. Actual measured speed
should be within +/- 8 ipm of power supply display reading. If necessary adjust R642 until both max and min
Wire Feed Speed measurements are within the specified tolerances listed above.
Voltmeter specification across the entire output range is +/- 0.5VDC.
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