Kemppi PROMIG EVOLUTION 501 User manual

TECHNICAL MANUAL FOR
PROMIG EVOLUTION
501, 501L, 511 & 530
(version 1.0)

Contents
Topic Page
General maintenance 3
Control card A001 4 - 14
ProSync 50 15 - 16
Troubleshooting 17 - 19
Measurements 20 - 29
Main circuit diagrams 30 - 31
Notes 32

General maintenance
Maintenance of the wire feeder will normally consist of:
•Visible checking for possible damages
•General cleaning of the wire feeder
•Checking and cleaning of wire feeding mechanism and especially
consumable parts like wire guide tubes, feed rolls, gear wheels,
etc.
•Checking and testing of controlling components like switches and
potentiometers.
•Function testing
•Test welding
NOTE !
Only person who have electrical engineering competence (fulfil the
requirements of local laws and rules) and trained by Kemppi Oy is allowed to
make maintenance and possible reparations for Kemppi -products.

Control card A001
Layout
EPROM D4
X5 X4
X3
X2X6
X1
H3
H1
H2
110
X11
X12

Control card A001
LED indicators
•H1: CONTROL CARD POWER SOURCE OPERATION. Indicates
the functioning of control card´s power source section.
•H2: REMOTE CONTROLLER VOLTAGE. Indicates the presence
of +5 Volts in the remote control circuit. If the LED is off there is a
short circuit in the remote control circuit.
•H3: SERIAL COMMUNICATION. Indicates serial communication
functioning in continuous state. Blinking at the moment of supply
voltage connection indicates, that the processor can´t detect the panel
type. Panel detection is run through connector X4 pins 5, 7 and 8.
Trimmer R113
•R113: BURNBACK TIME. Possibility to adjust burnback time.

Control card A001
Jumper functions (jumper block X7)
765 Factory setting
X7 8 9101234
765
X7 8 910123 4 Wire feeder 1 (address 102)
765 8 910
123 4 Wire feeder 2 (address 105)
X7
765
X7 8 910123 4 Wire feeder 3 (address 150)
765
X7 8 910
123 4 Wire feeder 4 (address 153)

Control card A001
Jumper functions (jumper block X7)
765
X7 8 9101234Gas/Water cooled gun selection switch by-
passing (always in water position).
Gas/Water cooled gun selection switch by-
passing (selection controlled by Gas/Water
selection switch).
765 8 91034Output is linear according to potentiometer
turning angle.
Output is linear according to control voltage:
Wire feeding: 0- 5V ⇒0 - 18, 25m/min.
Voltage: 0- 5V ⇒0 - 50V.
765
X7 8 9101234
X7 1 2
765 8 91034
X7 1 2
7658 9103 4
PMT and RMT 10 additional properties NOT
in operation (Err 11).
X7 1 2
76
58 9103 4
X7 1 2
PMT and RMT 10 additional properties in
operation.

Control card A001
Jumper functions (jumper block X7)
765
X7 8 9101234
765 8 9103 4 4T HOT START not in use (MC / ML -panel).
X7 1 2
765 89103 4
• Crater filling in 4T procedure with synergic
MIG/PULSMIG (ML –panel).
• Crater filling in 4T (MC –panel).
• 4T procedure (without panel).
X7 1 2
765 89103 4
X7 1 2
• No crater filling (MC / ML -panel).
• 2T procedure (without panel).
7
65 8 9103 4
X7 1 2
7
6
5 8 9103 4
X7 1 2
Local control function is switched on
automatically, when remote controller is
disconnected.
Remote control function stays on, when remote
controller is disconnected.
4T HOT START in use (MC / ML -panel).

Control card A001
Jumper functions (jumper block X7)
765
X7 89101234
765 8 9103 4 Wire feeding max. speed 18 m. / min.
X7 1 2
765 8 910 3 4
X7 1 2
765 8 9103 4
X7 1 2
Fe synergic MIG / PULSMIG (ML –panel).
AlSi synergic MIG / PULSMIG (ML –panel,
extra sticker).
Wire feeding max. speed 25 m. / min.

Control card A001
Jumper functions (jumper block X10 “software selection”)
X10
Promig INOX software
Promig Evolution software
Promig software
Promig Opel special software
10
11
X11
X10 10 11
X11
X10 10
11
X11
X10 10
11
X11