Kemppi PROMIG EVOLUTION 511 User manual
Operation instructions • english
Gebrauchsanweisung • deutsch
Gebruiksaanwijzing • nederlands
Manuel d’utilisation • français
1923410E
0537
PROMIG
501, 511
PROMIG
501L
2 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
CONTENTS
1. PREFACE ........................................................................................................................ 3
1.1. Introduction ....................................................................................................................... 3
1.2. Product introduction ..........................................................................................................3
1.2.1. Operation control and connectors ................................................................................... 4
1.2.2. Parts of wire feed mechanism ......................................................................................... 6
1.2.3. Quick guide for operation of MC panel ............................................................................ 8
1.2.4. Quick guide for operation of ML panel ............................................................................ 9
1.3. Operation safety .............................................................................................................. 10
2. INSTALLATION ............................................................................................................. 11
2.1. Assembly of MIG system ................................................................................................ 11
2.2. Accessories corresponding to wire diameter .................................................................. 12
2.3. Mounting of MIG welding gun ......................................................................................... 12
2.4. Mounting and locking of wire reel .................................................................................... 13
2.5. Adjustment of pressure ...................................................................................................14
2.7. Adjustment of tightness of reel brake .............................................................................. 14
2.8. Burn back time ................................................................................................................14
2.9. Ground cable ...................................................................................................................14
2.10. Shielding gas ...................................................................................................................15
2.10.1. Installing gas bottle ....................................................................................................... 15
2.11. Main switch I/O ................................................................................................................16
2.12. Operation of cooling unit (Procool 10, Procool 30) ......................................................... 16
3. CONTROL PANELS OPERATIONS ............................................................................. 16
3.1. MC control panel ............................................................................................................. 16
3.1.1. Weld data / Gas test ...................................................................................................... 19
3.1.2. Selecto operations, MC panel ....................................................................................... 19
3.2. ML control panel .............................................................................................................. 20
3.2.1. Weld data ...................................................................................................................... 24
3.2.2. Synergic operations, ML panel ...................................................................................... 24
4. OPERATIONS OF REMOTE CONTROL UNITS IN
PROMIG 501 AND 511 WIRE FEED UNITS ................................................................. 27
5. PROMIG 501, 511 A001 JUMPER BLOCK FUNCTIONS ............................................ 28
6. ERROR CODES OF PANELS ....................................................................................... 30
7. SERVICE, OPERATION DISTURBANCES .................................................................. 31
8. DISPOSAL OF THE MACHINE ..................................................................................... 31
9. PROMIG 501L ............................................................................................................... 32
10. ORDERING NUMBERS ................................................................................................ 33
11. TECHNICAL DATA ........................................................................................................ 35
12. TERMS OF GUARANTEE ............................................................................................. 36
PROMIG 501, PROMIG 511/0537 – 3© KEMPPI OY
1. PREFACE
1.1. INTRODUCTION
Congratulations on having purchased this product. Properly installed Kemppi products should
prove to be productive machines requiring maintenance at only regular intervals. This manual
is arranged to give you a good understanding of the equipment and its safe operation. It also
contains maintenance information and technical specifications. Read this manual from front to
back before installing, operating or maintaining the equipment for the first time. For further
information on Kemppi products please contact us or your nearest Kemppi distributor.
The specifications and designs presented in this manual are subject to change without prior
notice.
In this document, for danger to life or injury the following symbol is used:
Read the warning texts carefully and follow the instructions. Please also study the Operation
safety instructions and respect them when installing, operating and servicing the machine.
1.2. PRODUCT INTRODUCTION
Promig 501 and Promig 511 are wire feeders designed for demanding professional use. Promig
501 and Promig 511 are based on same technical solutions. Promig 511 has as additional
characteristic an integrated swing arm for gun which makes working easier.
Versatile and easy to use operation functions of PROMIG units have been realized with
interchangeable control panels which point out different characteristics:
MC: basic controls and displays for MIG/MMA welding, Selecto memories
ML: basic controls and displays for MIG/MMA welding,Synergic MIG/PULSED MIG
Operations of wire feed unit are controlled and adjusted with microprocessor. Tacho generator of
wire feed motor enables accurate and even adjustment of wire feed speed.
These operation instructions handle Promig 501 and Promig 511 wire feed units, assembly and
installation of MIG system as well as operation functions of panels.
This equipment’s electromagnetic compatibility (EMC) is designed for use in an
industrial environment. Class A equipment is not intended for use in residential location
where the electrical power is provided by the public low-voltage supply system.
4 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
1.2.1. Operation control and connectors
Mounting opening for control panels
Warning lamp for thermal shield
Connection for control cable
Remote control unit
Connection of welding gun
EURO
Connection for control cable for sub-feeder
Accessory
Cooling liquid connections for gun
Accessory
Shielding gas connection
Supply Snap connector
Connection for control cable, MIG / TIG
Control cable, PRO power source
Inlet for cooling liquid hoses
Welding current cable, PRO power source
Wire inch
Selection of air/liquid cooling
Hook catch for keeping door open
Accessory drawer
PROMIG 501, PROMIG 511/0537 – 5© KEMPPI OY
PRO 3200
4200
5200
PRO 3200
4200
5200
PROCOOL 10
PROCOOL 30
PROMIG 511
PROMIG 501
PROMIG 511
PROMIG 501
PROMIG 511
PROMIG 511
PRO Power source
1 Control cable
8 Shielding gas hose Snap connector - 0
9a Welding current cable
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
22a MIG gun Air-cooled
PRO Power source
PROCOOL Cooling liquid circulation unit
1 Control cable
1a Control cable (Procool)
1b Mains cable (Procool)
5 Cooling liquid hose R3/8 - Snap connector
8 Shielding gas hose Snap connector - 0
9a Welding current cable
16d Extension cable for remote control
20 Earth cable
21 MMA welding cable
22b MIG gun liquid-cooled
6 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
1.2.2. Parts of wire feed mechanism
Promig 501
PROMIG 501, PROMIG 511/0537 – 7© KEMPPI OY
Promig 511
8 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
21 5
3
46
21 5
3
4
54
3
4
12 6
1 4
2
26
1.2.3. Quick guide for operation of MC panel
MIG welding with independent adjustments for wire feed and voltage
1. Select with selecting switch for method MIG two
sequence procedure or MIG four-sequence procedure
2. Select with SELECTO mode switch the position OFF
3. Select the control mode: local control, remote
control or gun control
4. Adjust required set values for wire feed speed
and voltage. Values are shown in displays
5. Set welding dynamics at zero position or at
required position
6. Weld and adjust wire feed speed and voltage when
needed
MIG welding with welding values stored in SELECTO memories
1. Select with selecting switch for method MIG two-
sequence procedure or MIG four-sequence
procedure
2. Select with SELECTO mode switch the position ON
3. Select the channel selection mode: local control,
remote control or gun control
4. Select required channel 1...5. Welding values stored
on channel are shown in displays
5. Weld and select another channel when needed. You
can change the channel also during welding
Programming of SELECTO memories
1. Select required channel 1...5
2. Select with SELECTO mode switch the position SET
3. Select the control mode: local control, remote control or gun control
4. Search by welding correct values for wire feed speed,
voltage and welding dynamics
5. Store them into memory by turning the SAVE switch.
Note! When necessary you can check the values stored on the
memory channel by turning the SELECTO mode switch on
position ON, then the displays show values which are in
memory of the channel in question.
6. Turn the SELECTO mode switch on position ON, then
channels are ready for welding.
Note! You cannot store into memory MMA welding values and
MIG two-sequence/four-sequence selection
MMA welding
1. Select MMA welding with selecting switch for method
2. Select the control mode: local control, remote control
or gun control
3. Adjust required MMA current. Values are shown in
displays
4. Set welding dynamics on position zero or on required
position
5. Weld and adjust MMA current when needed
PROMIG 501, PROMIG 511/0537 – 9© KEMPPI OY
21 5
3
46
21 6
4
57
3
62 6
4
57
3
1 4
2
35
1.2.4. Quick guide for operation of ML panel
MIG welding with independent adjustments for wire feed and voltage
1. Select with selecting switch for method MIG two-
sequence procedure or MIG four-sequence procedure
2. Select with SYNERGIC mode switch the position MIG
3. Select the control mode: local control, remote control or
gun control
4. Adjust required set values for wire feed speed and
voltage. Values are shown in displays
5. Set welding dynamics at zero position or at required
position
6. Weld and adjust wire feed speed and voltage when
needed
SYNERGIC MIG welding
1. Select with selecting switch for method MIG two-
sequence procedure or MIG four-sequence procedure
2. Select with SYNERGIC mode switch the position 1-MIG
3. Set selecting switches for material and diameter
corresponding to filler wire used by you
4. Select the control mode: local control, remote control or
gun control
5. Adjust the required power with the potentiometer and
the arc length with the potentiometer. Values are shown
in displays
6. Set welding dynamics on zero or required position
7. Weld and adjust welding power and arc length when
needed
SYNERGIC PULSED MIG welding
1. Select with selecting switch for method MIG two-
sequence procedure or MIG four-sequence procedure
2. Select with SYNERGIC mode switch the position
3. Set selecting switches for material and diameter
corresponding to filler wire used by you
4. Select the control mode: local control, remote control
or gun control
5. Adjust the required power with the -potentiometer and
the arc length with the -potentiometer. Values are
shown in displays
6. Set welding dynamics on zero or required position
7. Weld and adjust welding power and arc length when needed.
MMA welding
1. Select MMA welding with selecting switch for method
2. Select the control mode: local control, remote control
or gun control
3. Adjust required MMA current. Values are shown in
displays
4. Set welding dynamics on position zero or on
required position
5. Weld and adjust MMA current when needed
10 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
1.3. OPERATION SAFETY
Please study these Operation safety instructions and respect them when installing, operating and
servicing the machine.
Welding arc and spatters
Welding arc hurts unprotected eyes. Be careful also with reflecting arc flash. Welding arc and
spatter burn unprotected skin. Use safety gloves and protective clothing.
Danger for fire or explosion
Pay attention to fire safety regulations. Remove flammable or explosive materials from welding
place. Always reserve sufficient fire-fighting equipment on welding place. Be prepared for
hazards in special welding jobs, eg. for the danger of fire or explosion when welding container
type work pieces. Note! Fire can break out from sparks even several hours after the welding
work has been finished!
Mains voltage
Never take welding machine inside a work piece (eg. container or truck). Do not place welding
machine on a wet surface. Always check cables before operating the machine. Change defect
cables without delay. Defect cables may cause an injury or set out a fire. Connection cable must
not be compressed, it must not touch sharp edges or hot work pieces.
Welding power circuit
Isolate yourself by using proper protective clothing, do not wear wet clothing. Never work on
a wet surface or use defect cables. Do not put MIG-gun or welding cables on welding machine
or on other electric equipment. Do not press MIG-gun switch, if the gun is not directed towards
a work piece.
Welding fumes
Take care that there is sufficient ventilation during welding. Take special safety precautions
when welding metals which contain lead, cadmium, zinc, mercury or beryllium.
PROMIG 501, PROMIG 511/0537 – 11© KEMPPI OY
JUMPER BLOCK
A001
2. INSTALLATION
2.1. ASSEMBLY OF MIG SYSTEM
Assemble the units in below-mentioned order and follow mounting and operation instructions
which are delivered in packages.
1. Installation of power source
Read paragraph: ”Installation” in operation instructions 1913170 for PRO power sources and
carry out the installation according to that.
2. Mounting of PRO power source to transport wagon
P40 6185261, air-cooled MIG system mounting / assembly instructions 4270450
P30W 6185262, liquid-cooled MIG system mounting / assembly instructions 4270460
3. Put the PROMIG onto the power source and lock it with bolts to handles of power source
4. Mounting of PROMIG control panel
MC 6263501, mounting instructions 4270950
ML 6263502, mounting instructions 4270950
5. Connecting cables
Connect cables according to figures on pages 6...7.
Air-cooled system on page 6. Liquid-cooled system on page 7.
You can change polarity of filler wire by interchanging the PROMIG welding current cable
and earth cable with welding cable connectors of PRO power source.
6. Max. wire feed speed
When the unit is delivered the max. wire feed speed is 18 m/min, which is enough for most
welding works. If you need a higher speed, you can increase the max. wire feed speed to 25
m/min by replacing the gear wheel on motor shaft to a bigger one. The big gear wheel D40 is
delivered with the feed unit in accessory drawer.
When necessary speed is changed according to follo-
wing:
– Open side plate and move JUMPER BLOCK’s
10 th coding piece on control card A001 to
point 25 m/min.
– Open tightening lever (20). Remove lower feed
rolls (21). Release screw (23) and its washer.
Remove gear wheel D28 (24) from motor shaft.
– Loosen screws (25) (3 pc) 1 twist. Mount the
D40 gear wheel onto motor shaft. Screw the
screw (23) with its washer back.
– Put feed rolls (21) back to their axles, however
don’t fasten yet fastening screws of feed rolls (22).
– Lift the motor so that the tooth gap between gear
wheel and both lower feed rolls is approx. 0,2 mm.
– Tighten screws (25). Check gear teeth gaps,
when necessary put the motor into a better position.
Screw on the mounting screws of feed rolls (22).
Too small gap between gear wheel and
feed rolls will overload motor.
Too big gap for its part might cause too
rapid wearing for teeth of feed rolls and
gear wheel.
12 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
7. Mounting of Promig 501 to boom
Wire feed unit must be mounted to boom in such a way that its chassis is galvanic
separated both from swing arm and boom.
Suspension angle of wire feed unit can be changed by moving fixing point in handle.
2.2. ACCESSORIES CORRESPONDING TO WIRE DIAMETER
PROMIG wire feed rolls are available with plain groove, knurled groove and with U groove
for different purposes.
Feed rolls with plain groove: Universal feed roll for welding of all kinds of wires.
Feed rolls with knurled groove: Special feed roll for cored wires and steel wires.
Feed rolls with U groove: Special feed roll for aluminium wires.
Trapezoid slotted , pivoted feed wheels: For heavy welding
PROMIG wire feed rolls have two grooves for different filler wire diameters. Correct wire
groove is selected by moving selecting washer (28) from one side to another in feed roll.
Feed rolls and wire guide tubes of wire feed unit have colour codes in order to make identifica-
tion easier.
feed rolls
colour filler wire ø mm (inch)
white 0.6 ja 0.8 (0.030)
red 0.9/1.0 ja 1.2 (0.035, 0.045 and 0.052)
yellow 1.4, 1.6 ja 2.0 (1/16 and 5/64)
black 2.4 (3/32)
guide tubes
colour filler wire ø mm (inch)
orange 0.6-1.6 (0.024-1/16)
blue over 1.6 (over 1/16)
In delivery Promig 501 and 511 are equipped with red feed rolls with plain groove and with
orange wire guide tubes for welding filler wires of 0.9-1.2 mm (0.035”, 0.045” and 0.052”).
2.3. MOUNTING OF MIG WELDING GUN
In order to ensure trouble-free welding check in operation instructions of gun used by you that
wire guide tube and contact tip of gun are according to manufacturer’s recommendation suitable
to be used for wire feed diameter and type in question. Too tight a wire guide tube might cause
for wire feed unit a bigger stress than normally as well as disturbances in wire feed.
Screw snap connector of gun tight that there won’t come any voltage losses on connecting
surface.
A loose connection will heat gun and wire feed unit.
When you are using liquid-cooled gun, mount water hoses according to figure on page 7.
Error signal lamp H11 of Promig 501 and 511 units have operations for overheating of liquid-
cooled PMT or WS gun and for overload of wire feed motor. Operation of signal lamp is as
follows (also see error codes on page 30):
1. Thermal release of the KEMPPI PMT or WS gun is operating. Then the equipment stops the
welding, yellow signal lamp H11 starts to blink and at the same time on (wire feed) display
of panel appears the text Err 8.
2. The wire feed motor is slightly overloaded e.g. due to a blocked gun. Then the error signal
lamp H11 starts to blink. If overload of motor is big, welding is stopped and on (wire feed)
display of panel appears the text Err 9.
PROMIG 501, PROMIG 511/0537 – 13© KEMPPI OY
28 28
Blinking of the H11 signal lamp followed by the error codes Err 8 and Err 9 is stopped by the
following start, if the reason of the error code has been abolished or if the gun has cooled down
or the motor is no more overloaded.
2.4. MOUNTING AND LOCKING OF WIRE REEL
– Release locking nails of wire reel hub by turning locking knob a quarter round.
– Mount the reel at its place. Note rotating direction of reel!
– Lock the reel with locking knob, locking nails of hub remain to outside position and will
lock the reel.
LOCKED OPEN
Check that in filler wire reel there are no parts sticking out, which could e.g.
chafe against chassis or door of wire feed unit. Dragging parts might expose
chassis of wire feed unit under voltage.
2.5. AUTOMATIC WIRE FEED TO GUN
Automatic wire feed in PROMIG wire feed units makes change of wire reel more rapid. In
reel change the pressure of feed rolls need not to be released and filler wire goes automatically
to correct wire line.
– Make sure that groove of feed roll match the diameter of welding wire used. Feed roll groove
is selected by moving the groove selecting washer (28).
– Release the wire end from reel and cut off the bent length. Be careful that the wire does
not spill from the reel to sides!
– Straighten about 20 cm of the wire and see that the end of it has no sharp edges (file off if
necessary). A sharp edge may damage the wire guide tube and contact tip of the welding gun.
Promig 501:
– Draw a bit of loose wire from wire reel. Feed wire through back liner to feed rolls. Don’t
release pressure of feed rolls!
– Press the gun switch and feed a bit wire until wire goes through feed rolls to gun. See that
wire is in grooves of both feed roll pairs!
– Press still the gun switch until wire has come through contact tip.
Automatic feed may sometimes fail with thin wires (Fe, Fc, Ss: 0,6...0,8 mm, Al: 0,8...1,0 mm).
Then it might be possible that you must open feed rolls and feed wire manually through feed
rolls.
Promig 511:
– Feed wire through wire cone and further until feed rolls. Don’t release pressure of feed rolls!
– Press the gun switch and feed a bit wire until wire goes through feed rolls to gun. See that
wire is in grooves of both feed roll pairs!
– Press still the gun switch until wire has come through contact tip.
14 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
41
2.6. ADJUSTMENT OF PRESSURE
Adjust the pressure of feed rolls with the control screw (20) so that the wire is fed into the
wire guide tube evenly and allows a little braking when coming out from the contact tip without
slipping at the feed rolls.
Excessive pressure causes flattening of the filler wire and damage to the coating.
It also causes undue wear of the feed rolls as well as friction.
2.7. ADJUSTMENT OF TIGHTNESS OF REEL BRAKE
Brake force is adjusted through hole in locking
device of reel hub by screwing the control screw (41)
with screwdriver.
Adjust brake force as so big that the wire is not allowed to become too loose on the reel so that
it would spill from the reel when the rotation of the reel stops. Need for brake force is increased
with increase of wire feed speed.
Since the brake loads for its part the motor, you shouldn’t keep it unnecessarily tight.
2.8. BURN BACK TIME
Electronics of feed unit controls stopping of welding automatically so that the wire end does not
melt fastened to the contact tip or the work piece. Automatics work regardless of the wire feed
speed.
2.9. GROUND CABLE
Fasten earthing press of ground cable carefully, preferably direct to welding piece. Contact
surface of press always should be as large as possible.
Clean the fastening surface from paint and rust!
Use in your MIG equipment at least 70 mm2. Thinner cross-sectional areas might cause
overheating of connectors and insulations.
Make sure that the welding gun in your use is designed for max. welding current needed!
Never use a damaged welding gun!
PROMIG 501, PROMIG 511/0537 – 15© KEMPPI OY
E
B
D
C
AF
G
2.10. SHIELD GAS
Handle gas bottle with care. There is a risk for injury if gas bottle or bottle valve
is damaged!
For welding stainless steels, mixed gases are normally used. Check that the gas bottle valve
is suitable for the gas. The flow rate is set according to the welding power used in the job. A
suitable flow rate is normally 8 - 10 l/min. If the gas flow is not suitable, the welded joint will be
sporous. Contact your local Kemppi-dealer for choosing gas and equipment.
The following installing instructions are valid for most of the gas flow regulator types:
1. Step aside and open the bottle valve (A) for a while to blow out possible impurities from
the bottle valve.
2. Turn the press regulation screw (B) of the regulator until no spring pressure can be felt.
3. Close needle valve, if there is one in the regulator.
4. Install the regulator on bottle valve and tighten connecting nut (C) with a wrench.
5. Install hose spindle (D) and jacket nut (E) into gas hose and tighten with hose clamp.
6. Connect the hose with the regulator and the other end with the wire feed unit.
Tighten the jacket nut.
7. Open bottle valve slowly. Gas bottle pressure meter (F) shows the bottle pressure.
Note! Do not use the whole contents of the bottle. The bottle should be filled when the
bottle pressure is 2 bar.
8. Open needle valve if there is one in the regulator.
9. Turn regulation screw (B) until hose pressure meter (G) shows the required flow
(or pressure). When regulating flow amount, the power source should be in switched on and
the gun switch pressed simultaniously.
Close bottle valve after having finished welding. If the machine will be out of use for a long
time, unscrew the pressure regulation screw.
2.10.1. Installing gas bottle
Always fasten gas bottle properly in vertical position in a special holder on the
wall or on a carriage. Remember to close gas bottle valve after having finished
welding.
Parts of gas flow regulator
A Gas bottle valve
B Press regulation screw
C Connecting nut
D Hose spindle
E Jacket nut
F Gas bottle pressure meter
G Gas hose pressure meter
16 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
P21 R21 P22 R22 P23 S22
S21 S24 S25 S26 R23 S22
2.11. MAIN SWITCH I/O
When you turn the main switch of the PRO power source into I-position, pilot lamp close to it is lighted
and the equipment is ready for welding. The equipment is returned to that welding method with which
the welding was last carried out before the main switch was turned to zero position.
Always start and switch off the machine with the main switch, never use the
mains plug as a switch.
2.12. OPERATION OF COOLING UNIT
(PROCOOL 10, PROCOOL 30)
Operation of cooling unit is controlled in such a way that pump is started when welding is
started. After welding stop pump is rotating for approx. 5 min cooling the liquid to ambient
temperature.
Read in operation instructions for the PROCOOL 10 / 30 unit the trouble situations of the liquid
circulation system and protection against torch etc. damage.
3. CONTROL PANELS OPERATIONS
3.1. MC CONTROL PANEL 6263501
MIG basic operations
Welding method selection (S21): MIG two-sequence procedure, MIG four-sequence
procedure, MMA
Control mode selection (S22): local, remote, gun
Local controls: wire feed speed/MMA current (R21), welding voltage (R22)
Controls for MIG and MMA welding dynamics (R23)
Digital displays: wire feed speed (P21), current (P22), voltage (P23)
Retrieval of last used welding values (S23)
PROMIG 501, PROMIG 511/0537 – 17© KEMPPI OY
SELECTO operations
SELECTO mode switch S24
OFF: Normal MIG/MAG welding
ON: Welding with memory stored values (5 channels)
SET: Welding parameters selection and storage SAVE (S25), for selected channel CH 1...5 (S26).
Welding method selecting switch S21
MMA
MMA welding with stepless welding current control
MIG two-sequence procedure
MIG/MAG welding with two-sequence procedure of welding gun start switch
1. switch pressed: welding starts
2. switch open: welding stops
MIG four-sequence procedure
MIG/MAG welding with four-sequence procedure of welding gun start switch
1. switch pressed: shielding gas flow starts
2. switch open: welding starts
3. switch pressed: welding stops
4. switch open: shielding gas flow stops
Control mode selecting switch S22
Local control:
Control potentiometers R21 and R22 on panel are used.
Remote control:
Adjustments are carried out from remote control unit R20 which is connected to
remote control connector X11 of wire feed unit.
If you use the remote control unit R10, adjust wire feed speed or MMA welding
current with potentiometer of the R10 and voltage with potentiometer U on panel.
Gun control:
Wire feed speed is adjusted with control module RMT 10 which is connected to
KEMPPI PMT or WS welding gun and welding voltage is adjusted with potentio-
meter.
Note! If the remote control unit or the gun control unit is not connected to the
PROMIG and you have selected remote control or gun control, then controls
operate with local controlpotentiometers like in local control position.
Local controls R21, R22
potentiometer
SELECTO OFF:
Local control for wire feed speed 0...18 m/min or 0...25 m/min
SELECTO ON: No operation
SELECTO SET:
Local control for wire feed speed 0...18 m/min or 0...25 m/min
MMA welding: Welding current control, 10 A...max. current of
power source
potentiometer
SELECTO OFF:
local control for voltage of PRO power source, 10 V...max.
MIG voltage of power source
SELECTO ON: No operation
SELECTO SET: local control for voltage of PRO power
source, 10 V...max. MIG voltage of power source
MMA welding: No operation
18 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
Control of welding dynamics R23
MIG and MMA welding dynamics are adjusted with the same potentiometer.
When you adjust welding dynamics the adjustment value -9...0...9 is shown in
display V, which otherwise shows set value/welding voltage. Value of dynamics is
shown in display still for approx. 3 s after stopping the adjustments.
Control of MIG welding dynamics:
With control of MIG welding dynamics you can influence on how stable the arc is and how
much spatter there is. With this control you can also optimize the welding result for wire type
and shielding gas mixture you are using.
-9...-1 Softer arc. Object: minimizing spatter
0 Recommendable basic setting for all wires
1...9 Harder arc. Object: e.g. maximizing stability of the arc on short circuit and welding
of steel with 100 % CO2 shielding gas (settings 7...9).
Control of MMA dynamics:
With control of MMA dynamics you can influence on arc in different situations.
When you make the arc harder, blow and at the same time spatter is increased.
-9...-1 Softer arc. Object: Minimizing spatter in welding at upper end of recommended
currents for electrode.
0 Factory setup. Normal setting for all electrode types.
1...9 Harder arc. Object: e.g. cellulose covered electrodes (9) and thin stainless electrodes
in welding at lowerend of recommended currents for electrode.
Digital display for wire feed speed, current and voltage P21, P22, P23
m/min display
MIG welding:
Display shows set value for wire feed speed and true value 0.0...18.0 m/min or 0.0...25.0 m/min
during welding depending on selection of wire feed speed range.
MMA welding:
Display is blank at MMA welding.
A display
MIG welding:
Display shows in setting state 0 A and true value for welding current during welding.
MMA welding:
Display shows set value for MMA welding current 10 A ...max. current of power source and
true value during welding.
V display
MIG welding:
Display shows set value for welding voltage and true value during welding.
MMA welding:
Display shows in setting state open circuit voltage of power source and true value during
welding for MMA welding voltage.
PROMIG 501, PROMIG 511/0537 – 19© KEMPPI OY
Note! Display shows terminal voltage of power source. Depending on length and copper cross-
section of welding cables as well as on that of MIG guns real arc voltage and display might
differ many volts from each other, see table below.
Cable 50 mm2 70 mm2 95 mm2
Voltage loss / 10 m 0,35 V / 100 A 0,25 V / 100 A 0,18 V / 100 A
When you adjust welding dynamics, display shows adjustment value for welding dynamics
-9...0...9 and value is kept on display still for approx. 3 s after end of adjustment. After that
display returns to show voltage.
3.1.1. WELD DATA / GAS TEST
Retrieval of welding parameters to displays,
Use of WELD DATA switch retrieves to displays those welding parameters, wire
feed speed, welding current, welding voltage which were used when welding was
stopped last. Welding values are indicated in display for so long as you are using
the WELD DATA switch and are kept in memory until you press again the start
switch for gun.
Testing the gas flow
A short press on the switch starts the flow of the shielding gas. The shielding gas flows for
approximately 20 seconds, or until the switch is pressed again.
3.1.2. SELECTO operations, MC panel
SELECTO is the name for the operation in which you can store welding parameters for memory
channels for reutilization. You can store to memory five sets of MIG/MAG welding values.
Parameters which can be stored are wire feed speed, welding voltage and welding dynamics.
Stored values are kept in memory though power is switched off from unit.
Note! You cannot store MMA welding values and MIG 2-sequence/4-sequence selection.
In SELECTO operations are three different operating modes:
SELECTO OFF:
Normal MIG/MAG welding with independent adjustments for wire feed speed and voltage,
SELECTO functions are not in use.
SELECTO ON:
Welding with stored welding values, wire feed speed, welding voltage and welding dynamics.
Only channel selection, channels 1...5 from panel is operating. Channel is selected, depending
on position of control mode, either with CH switch on panel, remote control unit or with regula-
ting module RMT 10 of PMT or WS gun. You can change the channel also during welding.
Digital displays indicate values for wire feed speed and voltage which are stored on the channel
in question. Stored value for welding dynamics can be brought to display by turning a little the
adjustment potentiometer for welding dynamics.
SELECTO SET:
Search of welding data for storage. Welding data are stored for wished channel by using the
SAVE switch. Those values for wire feed speed, voltage and welding dynamics are stored,
which were set before using the SAVE switch.
20 – PROMIG 501, PROMIG 511/0537 © KEMPPI OY
P31 R31 P32 R32 P33 S32
S31 S34 S35 S36 R33 S33
Programming of memory channel:
1. Select channel 1...5
2. Set SELECTO mode switch on position SET.
3. Find by welding correct values for wire feed speed, voltage and welding dynamics.
4. Store them by using the SAVE switch.
Note! If you want to you can check data which you have stored on memory channel by
setting SELECTO mode switch on position ON, when displays show values which are in
memory of the channel in question.
5. Set SELECTO mode switch on position ON and channels are in welding use.
From SELECTO operations go to normal MIG/MAG welding by setting the SELECTO mode
switch on position OFF.
3.2. ML CONTROL PANEL 6263502
MIG basic operations
Welding method selection (S31): MIG two-sequence procedure, MIG four-sequence procedure,
MMA
Control mode selection (S32): local, remote, gun
Local controls: wire feed speed/welding power/MMA current (R31), welding voltage (R32)
Controls for MIG and MMA welding dynamics (R33)
Digital displays: wire feed speed (P31), current (P32), voltage (P33)
Retrieval of last used welding values (S33)
This manual suits for next models
2
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