When sMIG Has No Voltage Limits

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My sMIG has been kind of acting strange on one of my Rebels, voltage has been jumping for no reason. Well today it decided to go into full on beast mode at 37.7 volts when set for 14ga, burned the wire back into the tip then shot out a flaming ball across the shop, picture was taken right after the fireworks, amps dropped off. Blew a hole right through one of the awning braces I was making also. I am sure it's going to die soon, it's jumped to 29 volts before but this is getting crazy!I will give ESAB a call this week and see what might be the problem.

Attached Images

ESAB Rebels 215 and 235, ESAB HELIARC 281i, ESAB ET 301i, Hypertherm 85 and 45XP, Thermal Arc 185, TD 60i, HTP PRO PULSE 300
Reply:That is pretty crazy.  I have had the opposite happen with mine.  Voltage drops way to low causing very cold or poppy welds.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:ESAB had not heard of my problem, but did learn there is a system reset in the setup options (probably should have looked first). I did the reset and welded with it a few hours and did not have any problems so far. I got some good info on the Rebel boards and software. ESAB Technical service is top notch, said if I did have more problems to take it in and they would load bank it, update the software if needed, and check the boards.ESAB Rebels 215 and 235, ESAB HELIARC 281i, ESAB ET 301i, Hypertherm 85 and 45XP, Thermal Arc 185, TD 60i, HTP PRO PULSE 300
Reply:what is load bank it?  Max it's load and see what it does?Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:

Originally Posted by N2 Welding

what is load bank it?  Max it's load and see what it does?
Reply:

Originally Posted by Slob

Exactly but not only to ensure it will make current, but hold it too.
Reply:Any updates after the reset?  Did you reset it from the control panel?Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.
Reply:

Originally Posted by N2 Welding

Any updates after the reset?  Did you reset it from the control panel?
Reply:Ok just checking.  Think I will try a reset next time I use it.Lincoln, ESAB, Thermal Dynamics, Victor, Miller, Dewalt, Makita, Kalamzoo.  Hand tools, power tools, welding and cutting tools.