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

Control card A001
Error codes
Error 1:
• MMA/2T/4T -selection switch is turned into MMA position when source is
already welding with another method (MMA local control from power source or
from TIG).
• MMA/2T/4T -selection switch is turned into MMA position and there is
malfunction in connection between power source and wire feeder (intermediate
cable or connectors).
Error 2:
Error 3:
• Torch switch is pressed down when the power source is already welding.
COOLER Error 4:
COOLER Error 5:
• This error message appears if the the water/gas selection switch has been turned
into “water” position. Possible reason for this error message can be:
– Disconnection of the supply voltage to the cooling unit
– Cooling unit is not switched on (Procool 10)
– Probus is not connected (Procool 10)
– Pressure switch and/or cooling liquid PTC is not connected (Procool 30)
– Cooling liquid is too hot
– Cooling liquid pressure is too low
– Pressure switch is dirty

Control card A001
Error codes
Error 8:
• PMT torch has overheated. This function can be disabled by removing jumper
5 when using standard MIG guns (without RMT-10 and overheat protection
facilities).
Error 9:
• Overload of wire feed motor.
Error 10:
• Power source does not start, when start message is sent. This error can be
caused by following reasons (for example):
– Power source overheated
– Power source faulty
– Two wire feeders with same address (jumpers 1 & 2) has been connected
to the Probus.
Error 11:
• Jumper 5 (which prevents PMT-torches RMT-10 and overheat protection
facilities) has been removed from control card and and PMT torch has been
connected to wire feed unit.
Error 12:
• The link between X3,4 and X3,6 is open.

Control card A001
Error codes
Error 14:
• Wire feeder supply voltage >70 VDC
Error codes removal
•ErrorcodeError 1 is removed, when Promig Evolution feeder is set to MIG
mode.
•ErrorcodeError 2…4 is automatically removed in 5s, if the trigger is not
pulled. The cause of this error code should be eliminated before next start.
•ErrorcodesError 5…14 are removed during next start, if the causes of these
error codes are eliminated.

Control card A001
Arc ON/OFF -signal
Arc on/off-signal can be used to control for example
mechanization devices ON/OFF.

Prosync 50 (6263121)
Mounting instruction
• Install synchronisation card A002 (Prosync 50) to the Promig. See next page.
• Install connector XW501 (“military-type”) to the machines front panel. Use 3,5 x
9,5 mm. screws (included to the delivery).
• Connect connector XW502 (6-pole) from the XW501 to the connector X2 on the
synchronisation card A002.
• Connect connector XW503 (12-pole) to the connector X1 on the synchronisation
card A002. Connect connector XW504 (12-pole) to the connector X6 on the control
card A001.
• NOTE !! 2-pole connector is used only with Promig AVS models.
Connections

Prosync 50 (6263121)

Troubleshooting
PROBLEM POSSIBLE CAUSE REMEDY
Fuse F2 6,3A in the
power source is blown. Change the fuse and check that there are not
any short circuits in
control cable.
The control cable is not
properly connected or
connector X1 in the
control card A001 is
loose or broken.
Check Promig operation
voltage +50 VDC from
the connector X1/1 and
X1/3. Check that all LED
indicators are
illuminating.
The Promig Evolution
doesn't work at all. Wire
feeding motor or
solenoid valve is not
operating. Panel displays
are not working.
Control card A001 is
faulty Replace the control card A001, if needed.
Connection cables
between panel and
control card A001 are
loose or they are cross
connected.
Check that the connection
cables are connected
according to main circuit
diagram.
Faulty EPROM D4
(M27C4001).Replace the faulty EPROM.
The panel P001 (MC,
ML, MXE) in Promig
Evolution is not
operating properly or
control of the Promig
Evolution is not working.
Faulty panel P001. Replace the faulty panel.
The wire feeding motor
M001 does not start,
when torch switch is
closed.
Faulty switch, poor
connection in start lines
or problem with start line
wire insulators.
Check the switch and
start line wires of the
MIG gun. Replace if
needed.

Troubleshooting
PROBLEM POSSIBLE CAUSE REMEDY
The wire feeding motor
M001 does not start,
when MIG gun switch is
pressed.
Start line wires are cross
connected. Locate the cross connection to the MIG
gun or to the Promig
Evolution and correct it.
Wire feeding can not be
stopped, when PMT gun
with RMT-10 remote
controller is connected to
the feeder.
Start line wires are cross
connected. Locate the cross connection to the MIG
gun or to the Promig
Evolution and correct it.
Defective remote
controller or short circuit
in the remote controller
cable.
Change or repair the
remote controller.
Remote controller (R10,
R20) does not work.
LOCAL/GUN/REMOTE
-switch is in wrong
position or broken.
Check and correct
position of the
LOCAL/GUN/ REMOTE
–switch. Replace switch
if needed.
Solenoid valve Y001 is
not working: gas is
flowing all the time or
the gas is not flowing at
all.
Faulty solenoid valve or
malfunction in the control
card A001.
Check the control voltage
(24 VDC) of the solenoid
valve from connectors
X2/10 and X2/13. If
voltage exist, the solenoid
valve is faulty.

Troubleshooting
PROBLEM POSSIBLE CAUSE REMEDY
Welding is breaking
when the welding wire is
touching the piece.
Short circuit between
cables inside of the torch. Check is there galvanic connection between
welding current cable and
start lines. Repair or
replace cables if galvanic
connection exist.
Disturbance in start or
welding is interrupted
without any error
message.
The start line wire may
be in contact with the
brass body of quick
coupling (EURO -
connector). Also moisture
could cause this problem.
Measure resistance
between start lines and
body of the quick coup-
ling (EURO -connector).
Resistance should be
higher than 2.5 Mohm. If
resistance is lower, repair
the MIG gun or change
the body of the quick
coupling (EURO –
connector).

Measurements
Wire feed motor M001 control (1)
Wire feed speed: 1 m/min
Wire feed motor control
Wire feed speed: 1 m/min
Upeak: 57 V
Uaverage: 2,26 V
Frequency: approx. 11 000 Hz