Cod
. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse
Instruction Manual
ENG
Translation of original instructions
Page 1: ...Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse Instruction Manual ENG Translation of original instructions...
Page 2: ...WELD THE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 2 ENGLISH...
Page 3: ...WELD THE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 3 ENGLISH...
Page 4: ...ACTIVATION 37 8 1 MIG MAG WELDING PARAMETERS 38 8 2 MMA WELDING PARAMETERS 43 8 3 TIG WELDING PARAMETERS 43 9 CHARACTERISTICS OF THE MENU LEVELS 44 9 1 1ST LEVEL 44 9 2 2ND LEVEL 44 9 3 3RD LEVEL 45...
Page 5: ...8 11 3 LOADING A USER JOB 69 11 4 DELETING A JOB 70 11 5 EXPORTING IMPORTING JOBs through a USB memory stick 71 11 6 EXPORTING A JOB 71 11 7 IMPORTING A JOB 73 11 8 SELECTING JOBS USING THE TORCH UP D...
Page 6: ...ocuments for future consultation KEY DANGER This pictogram warns of danger of death or serious injury WARNING This pictogram warns of a risk of injury or damage to property CAUTION This pictogram warn...
Page 7: ...ulsed synergic Pulsed Synergic and Double Pulsed Synergic modes ensure excellent appearance of the weld bead without spatter or deformation when welding aluminium stainless steel and regular steels A...
Page 8: ...iptions for use 2 1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK The characteristics of the mains power supply to which the equipment shall be connected are given in the section entitled TECHNICAL DATA...
Page 9: ...cket 4 EURO TORCH welding socket 5 Remote controller connector 6 Polarity selector cable 7 Welding power source ON OFF switch 8 Mains protection ON LED This LED illuminates if an incorrect operating c...
Page 10: ...e gas cylinder and the power source 3 Power cable Total length including internal part 4 5 m Number and Cross section of Wires 4 x 6 0 mm2 Power plug type Not supplied 2 4 WIRE FEEDER COMPARTMENT 2 1...
Page 11: ...nnect the plug of the polarity selector cable to the welding socket on the basis of the polarity required 8 Connect the earth clamp to the workpiece being processed 9 Set the welding power source ON O...
Page 12: ...e action on the user interface of the welding power source The system is ready to start welding POSITIONING THE SPOOL AND THE WIRE IN THE WIRE FEEDER WARNING Mechanical Hazards Read the warnings highl...
Page 13: ...heck that the feed rolls are suitable for the wire gauge The diameter of the roll groove must be compatible with the diameter of the welding wire The roll must be of suitable shape in relation to the...
Page 14: ...se the electrode based on the type of material and thickness of the workpiece to be welded 4 Insert the electrode in the electrode holder 5 Connect the electrode holder cable to the welding socket bas...
Page 15: ...nsert the electrode in the TIG torch 8 Connect the torch plug to the welding socket on the basis of the polarity required by the type of electrode in question 9 Connect the plug of the ground clamp to...
Page 16: ...g parameter values on the user interface i When the remote controller RC is connected and the relative locking screw is tightened welding current can be adjusted using the remote controller The system...
Page 17: ...parameter can be set WELDING THICKNESS Reference is made to T fillet welds on identical thicknesses The relative value is purely guideline The value appears on the following display D1 L4 Illuminates...
Page 18: ...ing voltage Welding The display shows the effective voltage value during welding HOLD function at welding end The display shows the latest measured voltage value D3 Data setting The display shows the...
Page 19: ...on the following display D2 E3 The encoder changes the setting of the selected parameter shown on the following display D3 The selected parameter is shown by the following symbol Not welding with a l...
Page 20: ...ce on this display Tab 1 Messages at power up MOTOR BOARD FW XX XX XXX XX XX XXX wire feeder software version PROGRAM UPDATE The welding power source is synchronising the wire feeder and power source...
Page 21: ...e unit off Set the welding power source ON OFF switch to I to switch on the unit Simultaneously press the keys S1 and S10 This operation must be carried out before the wording PROGRAM UPDATE appears i...
Page 22: ...to switch the unit off Set the welding power source ON OFF switch to I to switch on the unit Simultaneously press the keys S1 and S10 This operation must be carried out before the wording PROGRAM UPD...
Page 23: ...to switch the unit off Set the welding power source ON OFF switch to I to switch on the unit Simultaneously press button S5 This operation must be carried out before the wording PROGRAM UPDATE appear...
Page 24: ...SET UP 4 10 CONTROL TYPE OFF OFF RC08 OFF No control RC03 n 1 potentiometer RC04 n 2 potentiometers RC05 n 1 UP DOWN RC06 n 2 UP DOWN RC08 SET UP 5 10 LOCK STATUS OFF OFF LOCK 2 OFF All adjustments e...
Page 25: ...run for 90 s plus a number of seconds equivalent to the average current value shown using the HOLD function 6 1 OPERATING HOUR COUNTER The menu page shows the processing hour counters POWER ON Total n...
Page 26: ...dures This setting enables the machine validation VAL and calibration CALIBRATION operations The SERVICE procedure is not described in this manual as it can be carried out only by specialised suitably...
Page 27: ...ds SET UP with machine on B Press keys S3 and S4 to select line SET UP 7 10 C Simultaneously hold down keys S3 and S4 for 3 seconds The value P ARC ON will be taken to 0 0 h 6 3 TRIGGER TYPE If T01 mo...
Page 28: ...isplay page 5 10 of the SETUP menu During the normal operation the operator can enter the SET UP menu by pressing the key S5 for 5 seconds SET UP can therefore be accessed with machine on HOLD m min m...
Page 29: ...torch trigger procedure button S7 Display of main welding parameters button S1 Arc correction encoder E2 Wire insertion button S10 Gas test button S9 Arc correction Potentiometer PoS6 Arc correction U...
Page 30: ...t the digit to be changed The selected digit will flash Use encoder E3 to set up the value C Exit without confirmation Press the S2 button This action will automatically close the menu Exit with confi...
Page 31: ...he checking procedure for an additional 30 sec onds If the problem persists rectify the cause of the alarm During this checking operation the setup menu can be accessed by pressing button S5 for 5 sec...
Page 32: ...buttons S3 and S4 TOUCH THE WORKPIECE WITH THE GUIDE WIRE TIP AND PRESS THE TORCH TRIGGER The message will appear on display D3 CAL The message will appear on display D1 Display D2 will show the weld...
Page 33: ...age will appear on display D3 The calibration value appears on display D2 You can make several subsequent calibrations by pressing and releasing the torch trigger In this case the last value revealed...
Page 34: ...ctions are disabled Exceptions the cooling fan Make sure the torch trigger is not pressed jammed or short circuiting Make sure the torch and MIG MAG torch connector are intact If the problem persists...
Page 35: ...g power source thermal cut out switch has tripped Leave the equipment running so that the overheated components cool as rapidly as possible When the problem is solved the welding power source will res...
Page 36: ...ource and if it is running Coo oFF the alarm is never signalled irrespective of the cir cumstances Coo Aut the alarm is signalled if the cooling unit is connected to the power source and if it is runn...
Page 37: ...G2 SG3 PF 2 Available selecting one of the PR curves e g SG2 SG3 PR 3 available in PIONEER PULSE MKS line power sources MENU MODE PROCEDURE PARAMETER Arc correction in Volts 3 3 3 3 3 3 Arc correction...
Page 38: ...es an increase in the length of the welding arc while a value 0 pro duces a shorter arc Arc correction with Power Root The parameter corrects the arc dynamics in the POWER ROOT process The default val...
Page 39: ...eby eliminating contaminants at the start of the welding pass SOFT START MIG MAG manual welding mode The SOFT START is the wire approach speed to the workpiece The value is expressed as a percentage o...
Page 40: ...wer value Lower gas consumption Oxidation of electrode tip more difficult arc strike POWER FOCUS The parameter changes the concentration of the electric arc increasing or reducing the energy transferr...
Page 41: ...necting the HOT START level and the welding level The setting is dependent on the specific needs of the operator Values from 0 5 s to 1 0 s are suitable for the vast majority of applications SLOPE 3LE...
Page 42: ...w feed rate and 6 m min high feed rate 1 1 3 5 7 9 2 4 6 8 10 Wire speed m min High speed Middle speed Low speed 2 3 4 5 6 minute Cycle 2puls Freq 2puls CYCLE 2PULS Double pulsed duty cycle The parame...
Page 43: ...nges from the welding value to the end value by means of a slope Prevents the formation of craters in the process of turning off the arc The parameter is not used during the welding process when the f...
Page 44: ...ssage is displayed K Type of lock enabled If no Lock is loaded no message is displayed GAS This parameter sets the type of gas utilised for welding Name of loaded JOB SHORT SPRAY SYN MAT SG2 SG3 1 2 G...
Page 45: ...of menu pages SET UP x y COOLING TYPE ON 10 WELDING SETTINGS 10 1 WELDING CURVES SELECTION SHORT SPRAY SYN MAT SG2 SG3 1 2 GAS 80 Ar 20 CO2 R4 JOB FE55 MARIO K1 Select parameter MAT by pressing butto...
Page 46: ...er Focus arc is less widespread These curves differ from the other standard curves because of the acronym PF which is displayed after the reference to the welding wire material Example SHORT SPRAY SYN...
Page 47: ...es made to the weld ing operation At the end of the welding operation and HOLD is quit the values of the loaded JOB are reset When the welding operation is not being carried out and a JOB is active th...
Page 48: ...the selected parameter The value is saved automatically IND This parameter allows electronic adjust ment of the welding inductance from the main menu SHORT SPRAY MAN IND 100 10 2 2 MANUAL MIG MAG PARA...
Page 49: ...r E2 can be adjusted to correct the arc shown on display D3 in order to make minor adjustments in accordance with requirements During a welding operation with an active JOB it is possible to temporari...
Page 50: ...the main synergy parameter wire feed rate Amperes recommend ed thickness which can be adjusted with the following encoder E1 Shows the set welding voltage which can be adjusted with the following enc...
Page 51: ...10 0 s SOFT START row 3 6 1 SYN 100 BURN BACK row 4 6 1 SYN 200 POST GAS row 5 6 0 0 s 1 0 s 10 0 s B LEVEL row 6 6 1 OFF 200 The parameter value is saved for each welding mode 3 LEVEL 2 STROKE 3 LEVE...
Page 52: ...T PRE GAS row 2 12 0 0 s 0 0 s 10 0 s SOFT START row 3 12 1 SYN 100 START 3LEV row 4 12 10 130 200 SLOPE 3LEV 1 row 5 12 0 1 s 0 5 s 10 0 s CORR 3LEV1 row 6 12 9 9 V 4 0 m min 0 0 V 0 0 m min 9 9 V 4...
Page 53: ...itable welding voltage Encoder E2 can be adjusted to correct the arc shown on display D3 in order to make minor adjustments in accordance with requirements During a welding operation with an active JO...
Page 54: ...Amperes recommended thickness which can be adjusted with the following encoder E1 Shows the set welding voltage which can be adjusted with the following encoder E2 Shows the arc correction executed by...
Page 55: ...10 0 s SOFT START row 3 6 1 SYN 100 BURN BACK row 4 6 1 SYN 200 POST GAS row 5 6 0 0 s 1 0 s 10 0 s SPOT TIME row 6 6 0 1 s OFF 25 0 s The parameter value is saved for each welding mode 4 STROKE 4 ST...
Page 56: ...SET row 1 10 1 SYN 200 PRE GAS row 2 10 0 0 s SYN 10 0 s SOFT START row 3 10 1 SYN 100 START 3LEV row 4 10 10 130 200 SLOPE 3LEV 1 row 5 10 0 1 s 0 5 s 10 0 s SLOPE 3LEV 2 row 6 10 0 1 s 0 5 s 10 0 s...
Page 57: ...ted to correct the arc shown on display D3 in order to make minor adjustments in accord ance with requirements During a welding operation with an active JOB it is possible to temporarily change the pa...
Page 58: ...nded thickness which can be adjusted with the following encoder E1 Shows the set welding voltage which can be adjusted with the following encoder E2 Shows the arc correction executed by the operator w...
Page 59: ...10 0 s SOFT START row 3 10 1 SYN 100 BURN BACK row 4 10 1 SYN 200 POST GAS row 5 10 0 0 s 1 0 s 10 0 s B LEVEL row 6 10 1 OFF 200 The parameter value is saved for each welding mode FREQ 2PULS row 7 1...
Page 60: ...START 3LEV row 4 14 10 130 200 SLOPE 3LEV 1 row 5 14 0 1 s 0 5 s 10 0 s SLOPE 3LEV 2 row 6 14 0 1 s 0 5 s 10 0 s CRATER 3LEV row 7 14 10 80 200 BURN BACK row 8 14 1 SYN 200 POST GAS row 9 14 0 0 s 1...
Page 61: ...AY D2 Data setting Shows the preset welding current Shows the tension between the wel ding sockets Welding Shows the average current measured during welding Shows the average voltage measured during w...
Page 62: ...enu in MMA mode PROCE DURE PARAMETER MIN DEFAULT MAX NOTES MMA VRD riga 1 3 OFF OFF ON HOT START riga 2 3 0 50 100 ARC FORCE riga 3 3 0 30 100 10 7 ARC AIR WELDING HOLD m min mm Menu D1 S1 L4 L7 L8 D2...
Page 63: ...7 1 ARC AIR parameters setting 1st level current setting B Using the encoder E1 edit the current value The value is saved automatically 10 7 2 ARC AIR Parameters Setting 2nd Level C Press the button...
Page 64: ...AY D2 Data setting Shows the preset welding current Shows the tension between the wel ding sockets Welding Shows the average current measured during welding Shows the average voltage measured during w...
Page 65: ...ing the encoder E3 edit the value of the selected parameter The value is saved automatically F Exit with confirmation Press the S2 button This action will automatically close the menu Tab 18 Parameter...
Page 66: ...IVATION A B SELECTION C C A Hold down button S8 to activate the job menu The job menu appears in display D3 B Press buttons S3 and S4 to select parameter OPT The selected parameter is shown by the fol...
Page 67: ...ss the S2 button This action will automatically close the menu Exit with confirmation Press the S8 button This action will automatically close the menu E Save by overwriting Using the encoder E3 selec...
Page 68: ...D B SELECTION C C C ACTIVATION CONFIRMATION SELECTION SELECTION A Hold down button S8 to activate the job menu The job menu appears in display D3 B Press buttons S3 and S4 to select parameter OPT The...
Page 69: ...urn encoders E1 E2 to change the welding current or voltage press the welding mode selection button button S6 Press the following button If there are no JOBS loaded the UP DOWN buttons on the torch se...
Page 70: ...rmation Press the S2 button This action will automatically close the menu Exit with confirmation Press the S8 button This action will automatically close the menu 11 4 DELETING A JOB This function is...
Page 71: ...JOBs through a USB memory stick By using a USB memory stick the JOBs saved on the panel can be imported into another panel When a USB memory stick is connected the JOB MENU will display the items rela...
Page 72: ...3 to select the USB EXPORT function When there are no saved jobs the following message appears on the bottom line NO JOB D Exit without confirmation Press the S2 button This action will automatically...
Page 73: ...L 3 E1 E2 E3 S T O P ESC Mode ACTIVATION EXIT EXIT A D D B C SELECTION SELECTION A Insert the memory stick in the USB port Hold down button S8 to activate the job menu The job menu appears in display...
Page 74: ...When an UP DOWN torch is installed JOBs can be selected in a JOB sequence using the buttons on the welding torch JOBs can be scrolled only when the welding operation is not being carried out During th...
Page 75: ...The welding completion procedure starts The arc is extinguished Gas flow continues for the time set in the post gas parameter adjustable time 12 3 4T MIG MAG WELDING 1 Bring the torch up to the workpi...
Page 76: ...iller in the weld pool for example when welding aluminium a value of 80 is recommended 4 The crater filler level continues for the crater time which is settable in seconds at the end of this time weld...
Page 77: ...ss except that during normal speed welding pressing and immediately releasing the torch trigger switches the unit to the second weld ing current The trigger must not be pressed for more than 0 3 secon...
Page 78: ...magnetic compatibility EMC Low voltage LVD Restriction of the use of certain hazardous substances RoHS Construction standards EN 60974 5 EN 60974 10 Class A Conformity markings Equipment compliant wit...
Page 79: ...Pa 5 bar Motor speed 1 0 24 0 m min Wire spool dimensions weight 200 mm 5 kg 300 mm 15 kg Cooling AF Air over cooling fan assisted Static characteristic MMA Falling characteristic TIG Falling characte...
Page 80: ...2_RS232 TX2_RS232 5V_CAN GND_CAN 5V_PROG GND TX1_RS232 RX1_RS232 8 7 C B A D 2 1 4 JP1 3 GND I_PONTE JP1 2 1 1 2 3 4 JP4 JP1 JP7 CONN ILME CU09 2 1 5 3 4 DC 48CAN 050 XXXX 0156 CAN_L1 5V_CAN 15V_CAN C...
Page 81: ...CAN CN3 CN2 2 1 CN1 2 1 3 4 5 6 48V_CAN 48V_CAN VENT VENT 48V_CAN 48V_CAN 48V_CAN GND_CAN 15V_CAN 15V_CAN GND_CAN 15V_CAN GND_CAN 15V_CAN CN5 3 5 4 2 6 15V_CAN GND_CAN 15V_CAN GND_CAN 6 5 4 3 2 J8 GND...
Page 82: ...32 TX2 RS232 RX2 RS232 GND RX1 RS232 1 3 2 6 5 4 J19 8 7 ENC_1B 022 0010 0014 LED SEG1 KEY RAW1 LED SEG6 LED SEG4 KEY RAW4 LED SEG3 KEY RAW3 8V 8V LED SEG2 KEY RAW2 LED SEG0 KEY RAW0 LED SEG7 LED SEG5...
Page 83: ...CN1 2 1 3 4 5 6 48V_CAN 48V_CAN VENT VENT 48V_CAN 48V_CAN 48V_CAN GND_CAN 15V_CAN 15V_CAN GND_CAN 15V_CAN GND_CAN 15V_CAN CN5 3 5 4 2 6 15V_CAN GND_CAN 15V_CAN GND_CAN 6 5 4 3 2 J8 GND_CAN 7 8 6 5 4...
Page 84: ...0387 050 XXXX 0159 022 0002 0359 J1 15V_CAN 15V_CAN GND_CAN 15V_CAN GND_CAN 6 5 4 3 2 J8 GND_CAN 1 J11 4 5 6 OUT3 GND 5 J1 10 9 6 7 8 1 2 3 4 DOWN RIC_PED 5V_CAN AN_REM_ GND_CAN GND_CAN PT UP 4 3 2 1...
Page 85: ...2 5 V 0 5 V C AN1 5 V 0 5 V D GND GND Out E D1 IN 0 5 V F AN2 10 V 0 10 V G D3 OUT 0 5 V Out H AN1 10 V 0 10 V I D2 IN 0 5 V J RC Not used K Not used L Not used M Not used N Not used In In In In In In...
Page 86: ...WELD THE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 86 ENGLISH 14 1 3 RC05 Wiring diagram 14 1 4 RC06 Wiring diagram...
Page 87: ...E WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 87 ENGLISH 15 SPARES 36 20 9 13 14 7 6 5 1 3 4 2 12 8 10 11 18 17 16 15 19 22 35 34 37 38 24 32 21 31 30 25 26 29 28 27 2...
Page 88: ...WELD THE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 88 ENGLISH 41 40 43 42 44 47 48 46 45 60 61 62 52 53 57 49 51 56 54 59 58 55 50...
Page 89: ...UT VOLTAGE BOARD 20 042 0003 0052 POWER TRANSFORMER 21 043 0002 0676 VAC TOROID 22 050 0001 0189 KEY BOARD 23 016 0009 0003 RUBBER FOOT 24 021 0001 2022 CAPILLARY TUBE 25 021 0001 2000 COUPLING EURO 2...
Page 90: ...0003 1012 THERMAL CUT OUT NTC 10K 51 041 0004 0501 HALL EFFECT SENSOR 52 045 0006 0122 OUTPUT BRACKET 53 050 0001 0158 DRIVER BOARD 54 050 0001 0157 PRIMARY BOARD 55 032 0002 2403 ISOTOP DIODE 56 045...
Page 91: ...HE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 91 ENGLISH 15 1 WIRE FEEDER MOTOR 21 28 33 34 1 3 4 5 6 8 7 9 5 10 11 12 13 14 15 16 17 18 19 20 31 30 29 22 24 23 27 25...
Page 92: ...0000 0374 SHAFT 15 002 0000 0299 GEAR ADAPTOR FEED ROLL BRONZE BUSHING 002 0000 0309 GEAR ADAPTOR FEED ROLL BALL BEARING 16 002 0000 0142 FEED ROLL 17 002 0000 0383 RETAINING SCREW M4 18 002 0000 0382...
Page 93: ...d 19 V 35 V 002 0000 0141 0 8 1 0 002 0000 0142 1 0 1 2 002 0000 0143 1 2 1 6 002 0000 0144 0 6 0 8 U shape Aluminium wire D 37x12 d 19 U 90 V 002 0000 0145 1 0 1 2 002 0000 0146 1 2 1 6 002 0000 0147...
Page 94: ...DED CONFIGURATION d D CODE WIRE ROLL 002 0000 0168 1 0 1 2 D 37x12 d 19 U DOUBLE D 002 0000 0169 1 2 1 6 D 37x12 d 19 U DOUBLE D 002 0000 0171 1 0 1 2 D 37x12 d 19 UT TEFLON 002 0000 0172 1 2 1 6 D 37...
Page 95: ...000 0169 1 2 1 6 D 37x12 d 19 U DOUBLE D 002 0000 0171 1 0 1 2 D 37x12 d 19 UT TEFLON 002 0000 0172 1 2 1 6 D 37x12 d 19 UT TEFLON GEAR ADAPTOR FEED ROLL 002 0000 0299 GEAR ADAPTOR FEED ROLL BRONZE BU...
Page 96: ...feeder to DOUBLE DRIVE ROLL configuration you need to order the following items N 4 Special rolls U DOUBLE D see Part A N 2 Gear adaptor feed rolls see Part B it is recommended with bronze bushing CO...
Page 97: ...WELD THE WORLD Cod 006 0001 2230 02 09 2020 V 1 0 Pioneer 403MKS Pioneer Pulse 403MKS 97 ENGLISH...
Page 98: ...www weco it Cod 006 0001 2230 02 09 2020 V 1 0...
