Potentiometer Calibration - KLC FLEX-MATE K500 Service Manual

3. Thread the cable through the opening for the potentiometer. For CPM units with a serial number beginning
with the number '1', compress the Heyco strain relief and insert it into the opening to secure the
potentiometer cable. For CPM units with a serial number that begin with the number '2', insert the molded
strain relief into the key-hole and turn it 90° counter-clockwise to engage the locking mechanism.
4. Connect the potentiometer connector to the header on the Motor PCB labeled J4.
5. Turn the CPM on at the power switch to allow viewing of the angle on the controller. Turn the potentiometer
by hand to 0°. Slowly turn the potentiometer clockwise, while viewing the display, to assure that the
component is reading the correct -10° - 120° range. Turn the potentiometer in the opposite direction to return
it to the 0°position.
6. Place potentiometer bracket into the slot on the potentiometer and install the socket head cap screws using
the 3/32" Allen wrench. Do not tighten screws until 0 degree mark has been set in Steps 8 and 9.
7. Plug transformer into wall and start the unit into extension mode until the bars of both the thigh and calf
supports are in alignment. This step can also be done by hand. Use a straight edge to verify.
8. Once alignment has been confirmed, carefully turn potentiometer until readout on the controller reads 0
degrees.
9. Tighten the screws with a 3/32" Allen Wrench by alternating half turns until the potentiometer is secured.
10. Attach the potentiometer housing with the #4-40 flat head screws provided and tighten snugly with a Phillips
screwdriver. The strain relief pigtail from the potentiometer assembly should slide into the slot in the housing.
NOTE: Once the screws for the bracket have been tightened, perform the 120° calibration process defined below.
11. Replace housing and reinstall push rivets.
Sec 8.3.3
NOTE: The calibration process described below is to be performed with the Thigh Support Adjustment set at its lowest position.
Failure to properly position the thigh support will make the distance adjustment of 1-1/4" difficult an may possibly damage
the CPM unit.
1. With the power on, start the CPM into full (120°) flexion. Stop the carriage.
2. Position the ruler onto the unit to measure the distance between the yoke and the end of the extrusion
(aluminum rail).
3. Move the yoke by turning the pulley until the yoke is 1-1.4" from the back of the extrusion. If the display reads
120° and the display is not flashing, then the calibration process is complete.
4. If the display does not read 120°, or if it is flashing between angles, the flexion limit will need to be set.
5. Locate the 'R5' variable resistor. With a small flat screwdriver, turn the adjustment screw until the display on
the pendent reads a steady 120°
6. Once the 120° position has been set, start the CPM and allow it to run down to the 0° position. Verify the 0°
position.
P/N 1.00060 Revision A
Calibration of the 120° position:
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