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: 