Weco Pioneer Pulse 321MKS User manual

Cod.006.0001.1520
11/07/2017 v2.8
ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36056 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.[phone] –Fax [phone]
www.weco.it - E-mail [e-mail]
Pioneer Pulse 321MKS
Instruction manual
GB

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1INTRODUCTION................................................................. 4
2FRONT PANEL................................................................... 4
3REAR PANEL..................................................................... 5
4INSTALLATION .................................................................. 5
4.1 UNIT ASSEMBLY................................................................ 5
4.2 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK 6
4.3 WIRE SPOOL POSITIONING .............................................. 6
4.4 POSITIONING THE WIRE IN THE WIRE FEEDER .............. 6
4.5 CONNECTIONS TO SOCKETS........................................... 7
5USER INTERFACE ............................................................. 9
6UNIT POWER-UP.............................................................. 11
7RESET (LOAD FACTORY SETTINGS) ............................. 11
8SET-UP (INITIAL SET-UP OF THE WELDING POWER
SOURCE).......................................................................... 12
8.1 WORK HOURS COUNTER ............................................... 13
8.2 LOCKING PROCEDURE................................................... 14
Enabling.......................................................................................14
Disabling......................................................................................15
8.3 GAS FLOW ADJUSTMENT ............................................... 15
8.4 TORCH LOADING............................................................. 15
8.5 CALIBRATING THE WELDING CIRCUIT.......................... 16
9ALARMS MANAGEMENT................................................. 17
10 PARAMETERS ACTIVATION............................................ 18
Arc correction in Volts...................................................................18
Arc correction in metres per minute...............................................18
Inductance ...................................................................................18
Inductance ...................................................................................18
Arc set .........................................................................................18
Pre gas ........................................................................................18
Soft start ......................................................................................18
Burn back.....................................................................................18
Post gas.......................................................................................18
Power focus .................................................................................18
Spot time......................................................................................18
B-level..........................................................................................18
10.1 WELDING PARAMETERS................................................. 19
11 CHARACTERISTICS OF THE MENU LEVELS.................. 22
11.1 1ST LEVEL ....................................................................... 22
11.2 2ND LEVEL....................................................................... 22
11.3 3RD LEVEL....................................................................... 23
12 WELDING SETTINGS....................................................... 23
12.1 WELDING CURVES SELECTION...................................... 23
12.1.1 SPECIAL CURVES: HIGH SPEED, HIGH CONTROL, POWER
FOCUS E POWER ROOT ............................................................23
12.2 MANUAL MIG/MAG WELDING.......................................... 25
12.2.1 MANUAL MIG/MAG PARAMETERS SETTING (1ST LEVEL):
INDUCTANCE SETTING..............................................................25
12.2.2 MANUAL MIG/MAG PARAMETERS SETTING (2ND LEVEL)........25
12.3 SYNERGIC MIG/MAG WELDING ...................................... 26
12.3.1 SYNERGIC MIG/MAG PARAMETERS SETTING (1ST LEVEL):
SYNERGIC CURVE SETTING......................................................26
12.3.2 SYNERGIC MIG/MAG PARAMETERS SETTING (2ND LEVEL) ....27
12.4 PULSED SYNERGIC MIG/MAG WELDING........................ 28
12.4.1 PULSED SYNERGIC MIG/MAG PARAMETERS SETTING (1ST
LEVEL): SYNERGIC CURVE SETTING........................................28
12.4.2 PULSED SYNERGIC MIG/MAG PARAMETERS SETTING (2ND
LEVEL) ........................................................................................29
12.5 DOUBLE PULSED SYNERGIC MIG/MAG WELDING......... 30
12.5.1 DOUBLE PULSED SYNERGIC MIG/MAG PARAMETERS SETTING
(1ST LEVEL): SYNERGIC CURVE SETTING................................30
12.5.2 DOUBLE PULSED SYNERGIC MIG/MAG PARAMETERS SETTING
(2ND LEVEL) ...............................................................................31
13 JOBS MANAGEMENT ...................................................... 32
13.1 SAVING A JOB.................................................................. 32
13.2 NAMING JOBS.................................................................. 32
13.3 LOADING A USER JOB..................................................... 33
13.4 DELETING A JOB ............................................................. 33
14 TORCH TRIGGER MODES................................................35
14.1 2T MIG/MAG WELDING.....................................................35
14.2 2T SPOT MIG/MAG WELDING...........................................35
14.3 4T MIG/MAG WELDING.....................................................35
14.4 4T B-LEVEL MIG/MAG WELDING......................................35
14.5 3 LEVEL - 2T B-LEVEL MIG/MAG WELDING .....................36
14.6 3 LEVEL - 2T SPOT MIG/MAG WELDING..........................36
14.7 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING .....................36
14.8 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING .....................36
15 TECHNICAL DATA............................................................37
16 SPARE PARTS..................................................................38
16.1 PIONEER PULSE 321MKS ................................................38
16.2 WIRE FEEDER MOTOR ....................................................40
16.3 WIRE FEEDER ROLLS......................................................42
16.3.1 STANDARD .................................................................................42
16.3.1 DOUBLE DRIVE...........................................................................42
17 ELECTRICAL DIAGRAM...................................................43
17.1 PIONEER PULSE 321MKS ................................................43
17.2 REMOTE CONTROLLER...................................................48
17.2.1 RC03: ELECTRICAL DIAGRAM....................................................48
17.2.2 RC04: ELECTRICAL DIAGRAM....................................................48
17.2.3 RC05: ELECTRICAL DIAGRAM....................................................49
17.2.4 RC06: ELECTRICAL DIAGRAM....................................................49
17.3 PUSH-PULL (OPTIONAL) ..................................................49

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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the
manufacturer or from your dealer.
Retain these documents for future consultation.
KEY
This symbol identifies an action that occurs automatically as
a result of a previous action.
This symbol identifies additional information or a reference to
a different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
This symbol accompanies important information concerning
the execution of the relevant operations.
Pioneer Pulse 321MKS is a professional three-phase inverter-based
welding unit with 4-roll wire feeder designed to operate in extreme
environmental conditions. This power source is ideal for workshop
applications and the metalworking, automotive and transport
industries requiring high quality construction work and it can be easily
transported in difficult work areas thanks to its rugged frame.
Available MIG/MAG mode: manual, synergic, pulsed synergic and
double pulsed 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 broad range of synergic MIG-MAG programs facilitates the selection
of precise welding parameters rapidly and using all types of wire.
The welding modes and procedures available are those indicated in
the table.
MODE
PROCEDURE
MANUAL MIG/MAG
TWO STEP (2T)
TWO SPOT TIME (2T-SPOT)
FOUR STEP (4T)
SYNERGIC MIG/MAG
TWO STEP (2T)
TWO SPOT TIME (2T-SPOT)
PULSED SYNERGIC MIG/MAG
FOUR STEP (4T)
DOUBLE PULSED SYNERGIC
MIG/MAG
THREE LEVEL (3T)
2FRONT PANEL
6 7 8 1 2 3
4 5
1: Remote controller connector.
2: Provision for connection of the push pull torch (purchasing and
installing the relative kit).
3: EURO TORCH welding socket.
4: Connector for coolant hose.
Torch Power source
5: Connector for coolant hose.
Power source Torch
6: Welding power source ON/OFF switch.
7: Mains protection ON LED.
This LED illuminates if an incorrect operating condition occurs:
Absence of a phase in the power supply line.
8: Earth welding socket.

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3REAR PANEL
8 7 6 1 2 3
4 5
1: Connector for connection to the programmer.
(Programming connector for the process circuit board.)
You can update the software of the equipment using the
programming kit.
2: Connector for connection to the programmer.
(Programming connector for the motor circuit board.)
You can update the software of the equipment using the
programming kit.
3: Gas rear connector. This is for the connection of the gas pipe
coming from the bundle of cables.
4: Connector for coolant hose.
Cooler Power source
5: Connector for coolant hose.
Power source Cooler
6: Power supply transformer fuse.
Type
Delayed acting (T)
Amperage
3.15 A
Voltage
500 V
7: Cooler power feeding connector.
Voltage
230 V~
Current Output
0.8 A
IP protection rating
IP20 (cap open)
IP66 (cap closed)
WARNING!
High voltage!
If the socket is not connected to any devices always close the cap:
presence of hazardous voltage levels!
8: Power cable.
Total length
(including internal part)
4,5 m
Number and Cross section of Wires
4 x 4,0 mm2
Power plug type
Not supplied
4INSTALLATION
WARNING!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
4.1 UNIT ASSEMBLY
1. Fit the front swivel wheels with the supplied screws.
2. Screw the fixed rear wheels to the studs in the base of the unit
and secure them with the supplied nuts.

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3. Mount the cooler in the relevant location.
4. Screw the cooler fixing bracket to the welding power source
chassis using the supplied screws.
5. Screw the base of the cooler to the unit base using the supplied
screws.
4.2 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” on
page 37.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
4.3 WIRE SPOOL POSITIONING
1. Open the unit side door to gain access to the spool compartment.
2. Unscrew the cap of the spool holder.
3. If necessary, fit an adapter for the wire spool.
4. Fit the spool in the spool holder, ensuring it is located correctly.
5. Adjust the spool holder braking system by tightening/loosening the
screw in such a way that the wire feed force is not excessive and
when the spool stops rotating no excess wire is released.
6. Refit the plug.
4.4 POSITIONING THE WIRE IN THE WIRE FEEDER
1. Lower the wire feeder pressure devices.
2. Raise the wire feeder pressure arms.
3. Remove the protective cover.
4. Check that the feed rolls are suitable for the wire gauge.

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§. 16.3 WIRE FEEDER ROLLS
The diameter of the roll groovemust be compatible with the
diameter of the welding wire.
The roll must be of suitable shape in relation to the composition of
the wire material.
The groove must feature a "U" profile for soft materials
(Aluminium and its alloys, CuSi3).
The groove must be "V" shaped for harder materials (SG2-SG3,
stainless steels).
Rolls with a knurled groove profile are available for flux-cored
wire.
5. Feed the wire between the wire feeder rolls and insert it into the
MIG/MAG TORCH connector plug.
6. Make sure the wire is located correctly in the roll grooves.
7. Close the wire feeder pressure arms.
8. Adjust the pressure system so that the arms press the wire with a
force that does not deform it while also ensuring constant feed
rate without slipping.
9. Refit the protective cover.
10. Set the welding power source ON/OFF switch to “I” (unit
powered).
11. Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit front panel.
4.5 CONNECTIONS TO SOCKETS
1. Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2. Plug the power cable plug into a mains socket outlet.
3. Connect the gas hose from the welding gas cylinder to the relative
socket.
4. Open the cylinder gas valve.
5. Connect the power supply cable of the cooling unit to the auxiliary
power socket on the power source.
6. Attach the coolant hoses to the relevant connectors on the cooler
and on the power source rear panel.
7. Connect the MIG/MAG torch plug to the EURO TORCH welding
socket.
8. Attach the coolant hoses of the MIG/MAG torch to the relevant
connectors on the power source front panel.
9. Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
10. Connect the earth clamp to the workpiece being processed.
11. Set the welding power source ON/OFF switch to “I” (unit
powered).
12. Feed the wire through the torch until it protrudes from the tip,
pressing button on the unit front panel.
13. Select the torch trigger procedure on the user interface.
14. Press the torch trigger with the torch well clear of any metal parts.
This serves to open the gas solenoid valve without striking the
welding arc.
15. Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
16. Set the required welding parameter values on the user interface.
On connecting and enabling a remote controller [RC] certain
settings can be modified from said controller without having to
take action on the user interface of the welding power source.
The system is ready to start welding.

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MIG/MAG installation

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5USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
When this LED illuminates the following parameter can be set: WIRE FEED RATE
The value appears on the following display: D1
L2
Short-Spray, pulsed and synergic MIG/MAG welding:
When this LED illuminates the following parameter can be set: WELDING CURRENT
HOLD function (at welding end):
Illuminates to show a value in the following unit of measurement: AMPERES
The value appears on the following display: D1
L3
This LED illuminates to show an anomaly in the operating conditions.
An alarm message appears on the following display: D4
§ 9 ALARMS MANAGEMENT
L4
When this LED illuminates the following 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
L5
Illuminates to show a value in the following unit of measurement: MILLIMETRES
Illuminates together with the following LED:
The value appears on the following display: D1
L6
Illuminates to show a value in the following unit of measurement: METRES PER MINUTE
Illuminates together with the following LED:
The value appears on the following display: D1
L7
Illuminates to show the last voltage and current values measured during welding.
The LED switches off when a new welding procedure is started, or when any of the welding settings is modified.
The value appears on the following displays: D1-D2
L8
This LED illuminates to confirm the presence of power on the output sockets.
L9
This LED illuminates to show that the following welding mode is selected: MANUAL MIG/MAG
L10
This LED illuminates to show that the following welding mode is selected: SYNERGIC MIG/MAG
L11
This LED illuminates to show that the following welding mode is selected: PULSED SYNERGIC MIG/MAG
L12
This LED illuminates to show that the following welding mode is selected: DOUBLE PULSED SYNERGIC MIG/MAG
L13
Illumination shows that the following function has been activated: 2 times procedure
§ 14.1 2T MIG/MAG WELDING
A flashing signal means the following function is activated: 2 times procedure
§ 14.2 2T SPOT MIG/MAG WELDING
L14
Illumination shows that the following function has been activated: 4 times procedure
§ 14.3 4T MIG/MAG WELDING / § 14.4 4T B-LEVEL MIG/MAG WELDING

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L15
Illumination shows that the following function has been activated: 3 levels procedure
§ 14.5 3 LEVEL - 2T B-LEVEL MIG/MAG WELDING / § 14.6 3 LEVEL - 2T SPOT MIG/MAG WELDING
§ 14.7 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING / § 14.8 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING
D1
During illumination of the following LEDs: / /
The display shows the value of the selected parameter.
Welding: The display shows the effective amperes value during welding.
HOLD function (at welding end): The display shows the latest measured current value.
D2
Data setting: The display shows the value, in Volts, of the selected welding 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
Manual MIG/MAG welding: The display is not active. The display shows “- - - “.
Synergic MIG/MAG welding: The display shows the arc correction value imposed by the operator with respect to the default value of the
synergic curve.
D4
Data setting: The display shows the various welding menus relative to the selected processes.
The display shows the selected parameter.
S1
Manual MIG/MAG mode: The button is not active.
Synergic MIG/MAG mode: The button cycles through the following LEDs in sequence, selecting only one: / /
S2
This button selects the welding mode.
S3
This button selects the torch trigger procedure.
§ 14 TORCH TRIGGER MODES
S4
The button restores the main menu of display D4, starting from any other page.
The button serves to exit any menu without saving any changes.
S5
The button scrolls the selection made on the menus upwards or to the right.
S6
The button scrolls the selection made on the menus downwards or to the left.
S7
The button selects the various submenus visible in the following display: D4
S8
The button enables management of the personalised programs that can be shown on the following display: D4
§ 13 JOBS MANAGEMENT
S9
This button opens the gas solenoid valve to fill the circuit and calibrate the pressure with the regulator on the gas cylinder.
§ 8.4 TORCH LOADING
S10
This button activates wire feed to insert it through the MIG/MAG torch.
The insertion speed is 2 m/min for 3 seconds, subsequently increasing to 10 m/min.
This function produces a slower feed rate and hence greater precision when inserting the wire when it enters the torch nozzle.
E1
Data setting: The encoder adjusts the main welding (and synergy) parameter, shown on the following display: D1
E2
Manual MIG/MAG mode: The encoder adjusts the welding voltage, and the relative value is shown, in volts, on the following display: D2
Synergic MIG/MAG mode: The encoder is used to correct the factory-set value of the selected synergic curve, the value of which is shown on
the following display: D3
E3
The encoder changes the setting of the selected parameter shown on the following display: D4
The selected parameter is shown by the following symbol: 

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6UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
The message appears on the following displays: D4
MOTOR 321 PIONEER
FW: YY.YY.YYY
PROGRAM UPDATE
PIONEER POWER PULSE ZZZ
FW: YY.YY.YYY
POWER SOURCE OK
YY.YY.YYY= power source software version.
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory presets.
Subsequent power-ups
The welding power source sets up for welding in the latest stable welding configuration that was active at the time of power-off.
During power-up all functions are inhibited and the following displays remain blank: D1, D2, D3
7RESET (LOAD FACTORY SETTINGS)
The reset procedure involves complete restoration of the default values, parameters and memory settings set in the factory.
All memory locations will be reset and hence all your personal welding settings will be lost!
The reset procedure is useful in the following cases:
too many changes made to the welding parameters so user finds it difficult to restore defaults.
unidentified software problems that prevent the welding power source from functioning correctly.
Set the welding power source ON/OFF switch to “O” to switch the unit off.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
S1
S10
Hold down both buttons simultaneously.
PERFORM THIS OPERATION BEFORE THE MESSAGE
“SYNCHRONISATION” APPEARS ON THE FOLLOWING DISPLAY: D4
FACTORY SETUP
MEMORY CLEANING
The message appears on the following displays: D4
S1
S10
Release buttons.
Wait for the memory clear procedure to terminate.
The unit restarts with the power-up procedure.

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8SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
With locked status active it is not possible to access this function.
§ 8.2 LOCKING PROCEDURE
SET UP when device is switched on
Set the welding power source ON/OFF switch to “O” to switch the unit off.
Set the welding power source ON/OFF switch to “I” to switch on the unit.
S7
Hold down the button.
PERFORM THIS OPERATION BEFORE THE MESSAGE
“SYNCHRONISATION” APPEARS ON THE FOLLOWING DISPLAY: D4
SET UP x/y
The message appears on the following displays: D4
x=
number of the currently displayed menu page.
y=
total number of menu pages.
S5
S6
Use these buttons to scroll through the list of settings to edit.
Activation of the ADJUSTMENTS BLOCK calls for a specific procedure.
§ 8.2 LOCKING PROCEDURE
E3
Using the encoder, edit the value of the selected setting.
S4
Press any button to save the setting and quit the menu.
The unit restarts with the power-up procedure.
NOTE: During normal use of the generator, to enter SET UP menu, press S7 for 5 seconds (enter SET UP with machine switched on).
Tab. 1 - Setup settings
MENU PAGE
SETTING
MIN
DEFAULT
MAX
SET UP 1/8
SELECT LANGUAGE:
ENGLISH
ITALIANO
FRANÇAIS
DEUTSCH
ESPAÑOL
PORTUGUES
DUTCH
CESKY
SRBSKI
POLSKI
SUOMI
SET UP 2/8
COOLING TYPE
OFF
AUTO
ON
SET UP 3/8
DISPLAY CONTRAST
0 %
50 %
100 %
SET UP 4/8
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 5/8
LOCK STATUS
OFF
OFF
LOCK 3
OFF
All adjustments enabled.
LOCK 1
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
LOCK 2
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
LOCK 3
All adjustments are disabled with the exceptions shown in
Tab. 2 page 14.
SET UP 6/8
ARC CORRECTION
m/min
Volts
Volts
SET UP 7/8
PUSH-PULL
OFF
OFF
ON
SET UP 8/8
COUNTER
0.0 h
0.0 h
0.0 h

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Cooler activation
ON= The cooler is always running when the power source is switched on. This mode is preferable for heavy duty and automatic welding
procedures.
OFF= The cooler is always disabled because an air-cooled torch is in use.
AUT= When the unit is switched on the cooler is switched on for 15 s. During welding procedures the cooler runs constantly. When welding is
terminated the cooler continues to run for 90 s + a number of seconds equivalent to the average current value shown using the HOLD
function.
8.1 WORK HOURS COUNTER
The menu page shows the work hours counters.
POWER ON= number of hours during which the machine was powered on (supplied from the mains).
T.ARC ON= number of hours during which the welding arc was powered on.
T.ARC ON= partial count of the number of hours during which the welding arc was powered on.
S
E
T
U
P
8
/
8
P
O
W
E
R
O
N
7.
2
h
T
.
A
R
C
O
N
5.
3
h
P
.
A
R
C
O
N
0.
7
h
Partial count reset
To enter SET UP menu, press S7 for 3 seconds ( SET UP with machine switched on).
S5
S6
Use these buttons to select the following line: SET UP 8/8
S5
S6
Hold down these buttons simultaneously for 3 seconds.
The P.ARC ON value is taken to 0.0 h
The readings are taken at the
following times:
7 hours and (0.2x60) 12 minutes.

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8.2 LOCKING PROCEDURE
The procedure inhibits unit adjustments, allowing the user to modify only certain settings depending on the selected lock status.
The procedure is used to prevent accidental alteration of the unit settings and welding settings by the operator.
Enabling
If no locking status is selected (LOCKED STATUS = OFF) and if you wish to set up a limitation on use of the welding power source, display page
5/8 of the SETUP menu.
E3
Use the encoder to select the required lock status.
S7
Press the button to confirm.
WRITE PASSWORD
0000
The message appears on the following displays: D4
Default password: 0000
Enter the 4 digit numerical password.
S5
S6
Use these keys to select the digit to be modified.
The selected digit blinks.
E3
Use this encoder to select the value.
Exit without confirmation
S4
Press the button.
This action will automatically close the menu.
Exit with confirmation
S7
Press the button.
The unit restarts with the power-up procedure.
The password becomes the active password. Make a note of the password you set!
Tab. 2 - Functions not disabled by Locks
LOCK
USER INTERFACE/ RC08
RC03
RC04
RC05
RC06
OFF
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
1
Selection of torch trigger procedure (button S3)
Display of main welding parameters (button S1)
Arc correction (encoder E2)
Wire insertion (button S10)
Gas test (button S9)
Arc correction
(Potentiometer Pot2)
Arc correction (UP/DOWN
lever 2)
2
Selection of torch trigger procedure (button S3)
Display of main welding parameters (button S1)
Arc correction (encoder E2)
Synergy (encoder E1)
Wire insertion (button S10)
Gas test (button S9)
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
All adjustments enabled.
3 (*1)
Selection of torch trigger procedure (button S3)
Display of main welding parameters (button S1)
JOB selection (encoder E2)
Wire insertion (button S10)
Gas test (button S9)
Scroll JOBS (UP/DOWN
lever 1)
Scroll JOBS (UP/DOWN
lever 1)
*1: The LOCK 3 setting becomes active only when a JOB is loaded. When no JOB is loaded, the user interface is completely unlocked.

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Disabling
If a lock status is selected, you can only edit parameters permitted by the currently active lock status.
If you cannot recall the password the only way to exit locked status is to perform the welding power source RESET procedure.
NOTE: the generator has to be powered on and ready for welding.
S7
Hold down the button for 5 seconds.
Enter the SET UP menu when the machine is switched on.
LOCK …
WRITE PASSWORD
0000
The message appears on the following displays: D4
Enter the active 4 digit numerical password.
S5
S6
Use these keys to select the digit to be modified.
The selected digit blinks.
E3
Use this encoder to select the value.
Exit without confirmation
S4
Press the button.
This action will automatically close the menu.
Exit with confirmation
S7
Press the button.
The unit restarts with the power-up procedure.
Quit locked status.
8.3 GAS FLOW ADJUSTMENT
When the unit is powered on the solenoid valve opens for 1 second.
This serves to fill the gas circuit.
S9
Open the gas solenoid valve by pressing and releasing the button.
Adjust the pressure of gas flowing from the torch by means of the flow meter connected to the gas cylinder.
S9
Close the gas solenoid valve by pressing and releasing the button.
The solenoid valve closes automatically after 30 seconds.
8.4 TORCH LOADING
WARNING!
Make sure the torch in use is correctly sized in relation to the welding current required and for the available and selected cooling type. This
prevents the risk of burns to which the operator is potentially exposed, potential faults, and irreversible damage to the torch and the system.
If a torch is installed or replaced while the unit is running, the circuit of the newly installed must be filled with coolant to avoid the risk of damage
to the torch in the case of high voltage arc strikes without any liquid in the circuit.
Power-up with operation of the cooler set to "ON" or "AUTO" mode
A check is performed automatically of the presence of liquid in the cooling circuit and the cooler is switched on for 30 seconds.
If the coolant circuit is full, the power source sets up in the most recent stable welding configuration.
If the coolant circuit is not full, all functions are inhibited and there will be no output power present.
Power-up with operation of the cooler set to "OFF"
Operation of the cooler and the cooler alarm are disabled.
Welding is performed without liquid cooling of the torch.
COOLING SYSTEM TEST
The message appears on the following displays: D4
S4
Press the button or torch trigger to repeat the checking procedure for an additional 30 seconds.
If the problem persists rectify the cause of the alarm.
During checking, in order to enter the set up menu press S7 for 5 seconds.

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Torch change-over with operation of the cooler set to "AUTO"
Press and release the torch trigger.
This serves to start the cooler for 80 seconds to fill the torch cooling circuit.
8.5 CALIBRATING THE WELDING CIRCUIT
When using the wire feed trolley with associated umbilical, it is advantageous practice to measure welding circuit impedance "r" using the
calibration function. This makes it possible to achieve constant welding quality irrespective of the length of the umbilical and torch. Welding circuit
impedance depends on the umbilical and torch installed, so the calibration procedure must be repeated whenever these components are
changed.
CALIBRATION following a power source RESET
If you perform a total power source RESET the calibration value will return to the default setting.
In the case of a partial RESET the last measured value will remain saved in the memory.
Calibration is not therefore obligatory, and if the user decides to dispense with the procedure the unit will simply operate on the basis of a default
value.
CALIBRATION PROCEDURE
The power source must be powered on and must not be in welding mode.
Power source management with remote controller must be enabled.
S5
S6
Hold down these buttons simultaneously for 3 seconds.
TOUCH THE WORKPIECE WITH THE WIRE
GUIDE TIP AND PRESS THE TORCH TRIGGER
The message appears on the following displays: D4
CAL
The message appears on the following displays: D1
Display D2 will show the welding circuit impedance value (mΩ) measured at the time of the most recent calibration.
After a total RESET the default value will be displayed.
Remove the torch gas nozzle and place the wire guide tip (without protruding wire) on the surface of the workpiece ensuring it is firmly located;
check that the wire guide tip is in contact with a clean area of the workpiece surface. Press the torch button to perform the calibration.
Calibration performed correctly
CALIBRATION COMPLETED SUCCESSFULLY
The message appears on the following displays: D4
The calibration value is shown on the following displays: D2
You can make several subsequent calibrations by pressing and releasing the torch button. In this case the last value revealed is memorized.
Output wihout memorizing
S4
Press the button.
Output with memorizing
S7
Press the button.
Calibration not performed correctly
CAL. Err.
The message appears on the following displays: D1-D2
REPEAT MEASUREMENT
The message appears on the following displays: D4
Press the torch button to perform the calibration.
Output wihout memorizing
S4
Press the button.

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9ALARMS MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message appears on the following display: D4
Tab. 3 - Alarm messages
MESSAGE
MEANING
EVENT
CHECKS
WARNING POWER SOURCE
Indicates tripping of the welding power source thermal
protection.
Leave the unit running so that the overheated
components cool as rapidly as possible.
When the unit has cooled, the welding power source will
reset automatically.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched
on).
-Make sure that the power required by the welding process
is lower than the maximum rated power output.
-Check that the operating conditions are in compliance with
the welding power source data plate specifications.
-Check for the presence of adequate air circulation around
the welding power source.
WARNING NO
COMUNICATIONS
Indicates the presence of problems in data
communication between the power source and wire
feeder.
When the unit has cooled, the welding power source will
reset automatically.
Exit the alarm state by performing one of the following
actions:
-Switch the power source off.
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched
on).
-Check that the connecting cable between power source
and wire feeder is intact and make sure the connectors are
securely tightened.
-Check the data transmission wiring inside the power
source and the wire feeder.
-Check for correct operation of the Control Board in the
power source and the Motor Board in the wire feeder.
WARNING TRIGGER
Indicates that when the wire feeder was powered up a
short circuit was detected on the torch trigger input.
When the unit has cooled, the welding power source will
reset automatically.
All functions disabled.
-Make sure the torch trigger is not pressed, jammed, or
short circuiting.
-Make sure the torch and MIG/MAG torch connector are
intact.
WARNING COOLING SYSTEM
Indicates insufficient pressure in the torch liquid cooling
circuit.
To exit the alarm condition and perform an operating
check of the cooling unit press the following button:
All functions disabled.
Exceptions:
-cooling fan.
-Check that the connection to the cooler is correct.
-Check that the O/I switch is set to I and that it illuminates
when the pump is running.
-Check that the cooler is filled with coolant.
-Check that the cooling circuit is liquid tight, notably the
torch hoses and the internal connections of the cooler.
WARNING PROTECTION
CURRENT
Indicates tripping of the welding power source current
surge protection.
Exit the alarm state by performing one of the following
actions:
-Switch the power source off.
-Press the following button:
All functions disabled.
Exceptions:
-cooling fan.
-cooler (if switched
on).
-Check that the programmed arc voltage value is not too
high in relation to the thickness of the work to be welded.

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10 PARAMETERS ACTIVATION
The welding parameters are available in accordance with the selected welding mode and procedure.
Certain parameters are available only after other parameters or functions of the unit have been enabled or set.
The table shows the settings required to enable each parameter.
: always available
1: available in HSL line power sources on selecting one of the "PF" curves (e.g.: SG2/SG3 PF)
MENU
MODE 

PROCEDURE 
PARAMETER 
-
Arc correction in Volts









-
Arc correction in metres per
minute









1°
Inductance


2°
Inductance



2°
Arc set






2°
Pre gas











2°
Soft start











2°
Burn back











2°
Post gas











2°
Power focus
1
1
1
2°
Spot time




2°
B-level






2°
Start 3lev



2°
Crater 3lev



2°
Slope 3lev 1



2°
Slope 3lev 2



2°
Freq 2puls



2°
Range 2puls



2°
Cycle 2puls



2°
Arc2 2puls



2°
Arc2 2puls




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10.1 WELDING PARAMETERS
Arc correction in Volts
This parameter corrects the synergic voltage value relative to the
synergic point of the synergic and pulsed MIG/MAG processes, while
it manages correction of the voltage of the high value in the MIG/MAG
double pulsed process.
The default value for horizontal and frontal welding is 0.0 V.
NOTE: A value >0 produces an increase in the length of the welding
arc, while a value <0 produces a shorter arc.
Arc correction in metres per minute
This parameter corrects the wire feed rate synergic value relative to
the synergic point of the synergic and pulsed MIG/MAG processes,
while it manages the wire feed rate of the high value in the MIG/MAG
double pulsed process.
The default value for horizontal and frontal welding is 0.0 V.
NOTE: A value <0 produces an increase in the length of the welding
arc, while a value >0 produces a shorter arc.
INDUCTANCE (MIG/MAG manual welding mode)
Consequences of a higher value:
"Softer welding".
Less spatter.
Less positive starting.
Consequences of a lower value:
"Harder welding".
More spatter.
More reliable starting.
INDUCTANCE
The value SYN=100 denotes the optimal synergic inductance value
chosen by the manufacturer.
IMPORTANT NOTE: This inductance value does not correspond to
the equivalent number set in manual MIG/MAG welding.
Consequences of a higher value:
"Softer welding".
Less spatter.
Less positive starting.
Consequences of a lower value:
"Harder welding".
More spatter.
More reliable starting.
ARC SET
In pulsed synergic welding this parameter directly influences the size
of the welding pulses.
The value SYN=100 denotes the optimal synergic value chosen by
the manufacturer.
IMPORTANT NOTE: This parameter should be adjusted as little as
possible. To correct synergy it is advisable to use arc correction by
means of the voltage parameter. This parameter can be useful if the
material or gas used is different from that of the synergic curve.
If you set a value other than SYN, this value is stored and fixed.
Consequences of a higher value:
Hotter welding.
Consequences of a lower value:
Cooler welding.
PRE GAS
Time of gas delivery before the arc strike.
CAUTION: an excessively long value will slow the welding procedure.
Other than in the presence of special requirements the value should
generally be kept at 0.0 s or anyway very low.
Consequences of a higher value:
This parameter allows a shielded environment to be created, thereby
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 of the set feed rate.
Consequences of a lower value:
The start of welding is "softer".
Consequences of a higher value:
The welding start may prove difficult.
SOFT START
The SOFT START is the wire approach speed to the workpiece.
The value is expressed as a percentage of the set feed rate.
In synergic welding the optimal SOFT START value (indicated with
SYN) varies in general with variations of the synergic parameters.
In synergic welding, if the value SOFT START = SYN is selected the
welding power source will always have the optimal SOFT START
value set when the main welding parameter changes.
If you set a value other than SYN, this value is stored and fixed.
Consequences of a lower value:
The start of welding is "softer".
Consequences of a higher value:
The welding start may prove difficult.
BURN BACK (MIG/MAG manual welding mode)
The BURN BACK value is associated with the quantity of wire that is
burnt at the end of the welding procedure.
Consequences of a higher value:
Wire significantly retracted into the torch nozzle.
Consequences of a lower value:
Stick-out at welding start is longer.
BURN BACK
The BURN BACK value is associated with the quantity of wire that is
burnt at the end of the welding procedure.
In synergic welding the optimal BURN BACK value (indicated with
SYN) varies in general with variations of the synergic parameters.
In synergic welding, if the value BURN BACK = SYN is selected the
welding power source will always have the optimal BURN BACK value
set when the main welding parameter changes.
If you set a value other than SYN, this value is stored and fixed.
Consequences of a higher value:
Wire significantly retracted into the torch nozzle.
Consequences of a lower value:
Stick-out at welding start is longer.

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POST GAS
Time of post gas delivery when the welding arc is extinguished.
This is useful when welding at high current values or with materials
that oxidise readily to cool the weld pool in an uncontaminated
atmosphere.
In the absence of specific requirements the value should generally be
kept low.
Consequences of a higher value:
More effective pickling (improved appearance of workpiece at the
end of the welding pass).
Higher gas consumption.
Consequences of a lower 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 transferred to the workpiece.
Consequences of a higher value:
Welding arc concentration.
Penetration increase.
SPOT TIME
When the torch trigger is pressed the welding arc persists for the time
set in the parameter.
Press the torch trigger again to resume the welding process.
The welding process cannot be interrupted once it has been started.
When the torch trigger is pressed, if the arc does not strike within 10
seconds, the process is deactivated.
The welding parameters can be modified during the welding process.
B-LEVEL
The parameter enables a special torch trigger function.
Pressing and releasing the torch trigger rapidly in welding mode (in
time 2) serves to switch from the main welding current to a secondary
current.
Pressing and releasing the torch trigger again switches from the
secondary current to the main current. This switching can be
performed repeatedly at the discretion of the operator.
To close the welding cycle (time 3) operate the torch trigger with a
prolonged press. When the trigger is released the welding cycle will
close (time 4).
START 3LEV
Start in 3 levels operation
The parameter adjusts the 1st level wire feed rate as a percentage of
the wire feed rate set for welding (2nd level).
The time is determined by the operator on the basis of the time he
presses the torch trigger during the third time.
This is helpful to start the weld run with different heat input compared
to steady state welding conditions.
High values (e.g. 130%) are generally required by aluminium alloys to
create a weld pool.
CRATER 3LEV
Crater in 3 levels operation
The parameter adjusts the 3rd level wire feed rate as a percentage of
the wire feed rate set for welding (2nd level).
The time is determined by the operator on the basis of the time he
presses the torch trigger during the third time.
This is helpful to finish the weld run with different heat input compared
to steady state welding conditions.
This function is generally required with aluminium alloys, in which the
final crater must be filled.
Consequences of a lower value:
Less formation of the welding final crater (crater filler).
SLOPE 3LEV 1
Initial ramp in 3-level operation
The parameter controls the ramp time connecting 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 3LEV 2
Final ramp in 3-level operation
The parameter controls the ramp time connecting the welding level
and the crater filler 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.
FREQ 2PULS
Double pulsed frequency
This parameter adjusts the frequency of alternation of the two wire
feed rates set with the RANGE 2PULS parameter.
The setting is dependent on the specific needs of the operator.
The best results are obtained with frequencies of approximately 1.5
Hertz.
RANGE 2PULS
Double pulsed range
This parameter generates the two wire feed rates (high and low)
utilised in double pulsed mode, which alternate with the frequency
defined by the parameter FREQ 2PULS.
Values that are not excessively high are preferable for stability of the
welding arc.
This value is expressed as a percentage of the set wire feed rate and
it determines the high and low feed rate values in compliance with the
following rule:
High wire feed rate= wire feed rate (D1) + [wire feed rate
(D1)*RANGE 2PULS]/2
Low wire feed rate= wire feed rate (D1) + [wire feed rate (D1)*RANGE
2PULS]/2
Example: if a rate of 5 m/min is set on the main adjustment (on
display D1) (average feed rate) and 40 % on RANGE 2PULSED (on
display D4), the wire feed rate will vary between 4 m/min (low feed
rate) and 6 m/min (high feed rate).