Weco Pioneer 403MSR User manual

Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR
Pioneer Pulse 503MSR
Instruction manual
ENG
Translation of original instructions

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
2
ENGLISH

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
3
ENGLISH
INDEX
1 INTRODUCTION.......................................................................................................................................... 4
1.1 INTRODUCTION.......................................................................................................................................... 5
2 INSTALLATION .......................................................................................................................................... 6
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK...................................................................... 6
2.2 FRONT PANEL............................................................................................................................................. 6
2.3 REAR PANEL............................................................................................................................................... 7
3 USER INTERFACE ...................................................................................................................................... 8
4 TECHNICAL DATA ...................................................................................................................................... 8
4.1 PIONEER 503 MSR / PIONEER PULSE 503 MSR ..................................................................................... 9
4.2 PIONEER 403 MSR / PIONEER PULSE 403 MSR ................................................................................... 10
5 PIONEER403/503MSR→WFCABLE....................................................................................................... 12
6 ELECTRICAL DIAGRAM .......................................................................................................................... 13
6.1 PIONEER 403-503MSR / PIONEER PULSE 403-503MSR....................................................................... 13
7 SPARE PARTS .......................................................................................................................................... 18
7.1 PIONEER 403-503MSR / PIONEER PULSE 403-503MSR....................................................................... 18

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
4
ENGLISH
1 INTRODUCTION
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.
LEGEND
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 warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution of the relevant operations.
 Thissymbolidentiesanactionthatoccursautomaticallyasaresultofapreviousaction.
 Thissymbolidentiesadditionalinformationorareferencetoadi󰀨erentsectionofthemanual
containing the associated information.
§ Thissymbolidentiesareferencetoachapterofthemanual.
*1 The symbol refers to the associated numbered note.
NOTES
Theguresinthismanualarepurelyguidelineandtheimagesmaycontaindi󰀨erenceswithrespectto
theactualequipmenttowhichtheyrefer.

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
5
ENGLISH
1.1 INTRODUCTION
PIONEER 403-503MSRisapowersourceforwelding.
WhencombinedwithawirefeederitcanbeusedforMIG/MAGwelding.
Fan. Thefanisturnedononlyduringwelding,attheendoftheweldingprocessitremainsonfora
xedperiodoftimeaccordingtoweldingconditions.
 Thefanisnonethelesscontrolledbyspecicthermalsensorsthatguaranteeacorrectcoolingof
the machine.
Accessories/ancillary devices that can be connected to the unit:
- Powersourcetrolleyformulti-functionconguration(MIG/MAG).
- LiquidcoolerforMIG/MAGtorches.
- Wire feeder.
Consultyourdealerforanupdatedlistofaccessoriesandthelatestnewproductsavailable.

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
6
ENGLISH
2 INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
2.1 CONNECTIONSTOTHEELECTRICALMAINSNETWORK
Themainspowersupplyfeaturestowhichtheequipmentshouldbeconnectedaregiveninchapter
“TECHNICAL DATA”.
Themachinecanbeconnectedtomotorgeneratorsprovidedtheirvoltageisstabilised.
Connect/disconnectthevariousdeviceswiththemachineswitchedo󰀨.
2.2 FRONT PANEL
1
3
2
○ WeldingpowersourceON/OFFswitch.[Item1].
○ MainsprotectionONLED[Item2].
○ Earthweldingsocket[Item3].

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
7
ENGLISH
2.3 REAR PANEL
1
3
2
4
5
6
○ Connectorforconnectiontotheprogrammer[Item1].Programmingconnectorforthe“pulsed”
circuitboard.Youcanupdatethesoftwareoftheequipmentusingtheprogrammingkit.
○ Coolergrouppowerfeedingconnector[Item2].
• Voltage: 400 V a.c.
• Currentoutput:1.0A
• IPprotectionrating:IP20(capopen)/IP66(capclosed)
DANGER!
High voltage!
If the socket is not connected to any devices always close cap
○ Powercable[Item3].
• Totallength(externalpart):4,3m
• Numberandcrosssectionofwires:4x6mm2
• Powerplugtype:notsupplied
○ Connectorofthebundleofcablesforconnectingthepowersourcetotheremotecontroldevice
[Item4].
○ Socketforconnectingthepowercablebetweenthepowersourceandtheremotecontroldevice
[Item5].
○ Signalsconnectorforautomaticapplication[Item6].

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
8
ENGLISH
3 USER INTERFACE
PIONEER 403-503MSR / PIONEER PULSE 403-503MSR
ON
L1
CODE SYMBOL DESCRIPTION
L1
ON
ThisLEDilluminatestoconrmthepresenceofpowerontheoutputsockets.
4 TECHNICAL DATA
Directives applied
Wasteelectricalandelectronicequipment(WEEE)
Electromagneticcompatibility(EMC)
Lowvoltage(LVD)
Restrictionoftheuseofcertainhazardoussubstances(RoHS)
Construction standards EN 60974-1; EN 60974-10 Class A
Conformity markings
EquipmentcompliantwithEuropeandirectivesinforce
Equipmentsuitableinanenvironmentwithincreasedhazardofelectricshock
EquipmentcompliantwithWEEEdirective
EquipmentcompliantwithRoHSdirective

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
9
ENGLISH
4.1 PIONEER 503 MSR / PIONEER PULSE 503 MSR
Supply voltage 3x400Va.c.±15%/50-60Hz
Mains protection 32 A 500 V Delayed
Zmax
Thisequipment complieswithIEC61000-3-12providedthatthemaximumpermis-
siblesystemimpedanceislessthanorequalto21mΩattheinterfacepointbetween
theuser’ssupplyandthepublicsystem.Itistheresponsibilityoftheinstalleroruser
oftheequipmenttoensure,byconsultationwiththedistributionnetworkoperatorif
necessary,thattheequipmentisconnectedonlytoasupplywithmaximumpermis-
siblesystemimpedancelessthanorequalto21mΩ.
Dimensions(DxWxH) 700x300x570(powersource)
Weight 46kg(powersource)
Insulation class H
Protection rating IP23
Cooling AF:Air-overcooling(fanassisted)
Static characteristic
MMA Falling characteristic
TIG Falling characteristic
MIG/MAG Flat characteristic
Weldingmode MIG/MAG TIG MMA
Current and voltage adjustment
range
10 A / 14.5 V
500 A / 39.0 V
10 A / 10.4 V
500 A / 30.0 V
10 A / 20.4 V
500 A / 40.0 V
Weldingcurrent/Working
voltage
30%(40°C) 500 A / 39.0 V 500 A / 40.0 V
35%(40°C) 500 A / 30.0 V
60%(40°C) 430 A / 35.5 V 450 A / 28.0 V 430 A / 37.2 V
100%(40°C) 400 A / 34.0 V 420 A / 26.8 V 400 A / 36.0 V
Maximum input power
30%(40°C) 25.1kVA-22.4kW 25.5kVA-22.3kW
35%(40°C) 19.3kVA-17.2kW
60%(40°C) 19.7kVA-17.0kW 16.2kVA-14.0kW 21.0kVA-18.0kW
100%(40°C) 17.7kVA-15.2kW 14.6kVA-12.6kW 19.3kVA-16.4kW
Maximum supply current
30%(40°C) 36.0 A 36.4 A
35%(40°C) 27.7 A
60%(40°C) 27.8 A 22.9 A 30.0 A
100%(40°C) 25.5 A 21.1 A 27.8 A
MaximumE󰀨ectiveSupply
Current
30%(40°C) 19.7 A 19.9 A
35%(40°C) 16.4 A
60%(40°C) 21.5 A 17.7 A 23.2 A
100%(40°C) 25.5 A 21.1 A 27.8 A
No-loadvoltage(U0) 62V
Reducedno-loadvoltage(Ur) 10V
Powersourcee󰀩ciency E󰀩ciency(500A/40,0V):88,8%
No-Loadconditionpowerconsumption(U1=400Va.c.):27W
Essential raw materials Accordingtotheinformationprovidedbyoursuppliers,thisproductdoesnotcontain
essentialrawmaterialsinquantitiesgreaterthan1gpercomponent.

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
10
ENGLISH
4.2 PIONEER 403 MSR / PIONEER PULSE 403 MSR
Supply voltage 3x400Va.c.±15%/50-60Hz
Mains protection 25 A 500 V Delayed
Zmax
Thisequipment complieswithIEC61000-3-12providedthatthemaximumpermis-
siblesystemimpedanceislessthanorequalto21mΩattheinterfacepointbetween
theuser’ssupplyandthepublicsystem.Itistheresponsibilityoftheinstalleroruser
oftheequipmenttoensure,byconsultationwiththedistributionnetworkoperatorif
necessary,thattheequipmentisconnectedonlytoasupplywithmaximumpermis-
siblesystemimpedancelessthanorequalto21mΩ.
Dimensions(DxWxH) 700x300x570(powersource)
Weight 46kg(powersource)
Insulation class H
Protection rating IP23
Cooling AF:Air-overcooling(fanassisted)
Static characteristic
MMA Falling characteristic
TIG Falling characteristic
MIG/MAG Flat characteristic
Weldingmode MIG/MAG TIG MMA
Current and voltage adjustment
range
10 A / 14.5 V
400 A / 34.0 V
10 A / 10.4 V
400 A / 26.0 V
10 A / 20.4 V
400 A / 36.0 V
Weldingcurrent/Working
voltage
30%(40°C) ---
65%(40°C) 400 A / 34.0 V - 400 A / 36.0 V
100%(40°C) 370 A / 32.5 V 400 A / 26.0 V 370 A / 34.8 V
Maximum input power
30%(40°C) ---
65%(40°C) 17.7kVA-15.2kW -19.3kVA-16.4kW
100%(40°C) 15.8kVA-13.4kW 13.7kVA-11.6kW 16.9kVA-14.3kW
Maximum supply current
30%(40°C) ---
65%(40°C) 25.5 A -27.8 A
100%(40°C) 23.0 A 19.9 A 24.6 A
MaximumE󰀨ectiveSupply
Current
30%(40°C) ---
65%(40°C) 20.6 A -22.4 A
100%(40°C) 23.0 A 19.9 A 24.6 A
No-loadvoltage(U0) 62V
Reducedno-loadvoltage(Ur) 10V
Powersourcee󰀩ciency E󰀩ciency(400A/36,0V):89%
No-Loadconditionpowerconsumption(U1=400Va.c.):27W
Essential raw materials Accordingtotheinformationprovidedbyoursuppliers,thisproductdoesnotcontain
essentialrawmaterialsinquantitiesgreaterthan1gpercomponent.

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
11
ENGLISH

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
12
ENGLISH
5 PIONEER403/503MSR→WFCABLE
cod. 006.0002.0031
cod. 016.5001.0822
cod. 016.5001.0823 cod. 016.5001.0822
cod. 016.5001.0823
cod. 006.0002.0031
cod. 021.0001.0169
cod. 021.0001.0069
cod. 045.0001.0013
G J H F
H
I
J
G F
A B D E C
A C D E B
cod. 021.0004.1002
cod. 021.0004.1006
cod. 021.0004.1006cod. 021.0004.1002
cod. 018.0002.0000
cod. 018.0002.0000
I
I
J
B
C
D
G
F
E
A
HAH
D
C
B
E
F
G
J
I
HA
G
F
E
C
D
B
J
I
D
C
B
A
E
G
F
J
I
H
cod. 021.0004.1500
cod. 021.0004.1500

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
13
ENGLISH
6 ELECTRICAL DIAGRAM
6.1 PIONEER 403-503MSR / PIONEER PULSE 403-503MSR
A B
CD
ELV1_C
ELV1_C
-DC
JP5
6 5 48 7
+DC
321
J1 J2
CN8
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
1234
+18V_PRI
78
GND_PRI
23456
CN7
+VBUS
1
GND
GND_SEC
10
10
-15V_SEC -15V_SEC GND_SEC
1314 11 12
-15V -15V
GND
1413 12 11
+15V_SEC +15V_SEC +24V_SEC +24V_SEC VENT3_C VENT12_C RELAY_C
67 9 8
CN6
ELV2_C
2 14 35
+24V +24V +15V +15V
J10
6789
VENT3_C VENT12C
RELAY_C
ELV2_C
12345
1234
J12
+5V GND USB_D+ USB_D-
NERO-BLACK ROSSO-RED ROSSO-RED NERO-BLACK
S
A
F
G
J
I
C
B
ED
H
PE
R T
VDC
M
VDC
M
J2
GND_CAN
CN3
J I
CN2
21
CN1
2 1 3456
+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
35 4 2 6
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
65432
J8
GND_CAN
78 65432
CN4
12 1
1
+48V_CAN
VENT_3
RELAY
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
1
1
J11
23456
AN3 OUT3 GND +5V IN0
5
J1
10 9 678 1234
DOWN
RIC_PED
+5V_CAN
AN_REM_IN2
GND_CAN
GND_CAN
PT
UP
4321
J6
+24V_CAN
HF
GND_CAN
GND_CAN
+48V_CAN GND_CAN
G EF H
CANH
AB
CANL GND_CAN
CD
+24V_CAN 400VAC-1
4 5
GND ISO
2 31
AL CU GIALLO/VERDE-YELLOW/GREEN 400VAC-2
RJ3 S TJ1
+48V_CAN VENT
1
1
2
2
+48V_CAN VENT
12
12
+L
1234
GND
HALL
-15V
+15V
CN8
321 4
NTC_SEC
RELAY
+48CAN
+15CAN
ELV_2
4321
J10 J7 J8
654321
R_OUT_GRUPPO
S_OUT
GND
J9
T_OUT_ISO R_OUT_ISO S_OUT_ISO
1 6
J4
5432
J5
11121314 9 8 710 5 4 36 2 1
T
R
N/O
S
S_SEZ
T_SEZ
R_SEZ
1615
65 2143
J7
+24V_CAN
+48V_CAN
GND_CAN
+24V_CAN
12 11
AN_REM_IN1
341256
J5J4
654213
GND_CAN
CAN_H1
+15V_CAN
+5V_CAN
CAN_L1
GND_CAN
312456
J3
654213
J2
12 8121110934 765
J9
USB_D-
USB_D+
RX2_RS232
TX2_RS232
+5V_CAN
GND_CAN
+5V_PROG
GND
TX1_RS232
RX1_RS232
J18
VOUT
GND
12
AL_CU
GND_CAN
J13
12
J19
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
1 3287654
LED-
LED+
J20
12
VS_ISO
VR_ISO
-V_BUS_ISO
+V_BUS_ISO
VT_ISO
J14
32876549110
DRV_D
DRV_A
DRV_C
DRV_B
4321
J15
+15V
-15V
HALL
GND
J17
1234
I_PONTE
GND
J16
12
87
C
B
A
D
2 1 4
JP1
3
J6
GND
I_PONTE
JP1
21
1234
JP4
JP1 JP7
CONN-ILME CU09
21 53 4
CONN-MIL_REMOTE
+DC -DC
+DC
+48CAN
T_OUT
S_OUT
R_OUT
050.XXXX.0156
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
GND_CAN
GND_CAN
INTERRUTTORE
T1 L1
N/O N/O
MAINS SWITCH
T2 L2
T3 L3
CAN_H0
+15V_CAN
+5V_CAN
CAN_L0
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
GND_CAN
GND_CAN
022.0002.0364
NTC_PRIM_1 NTC_PRIM_2
022.0002.0350
022.0002.0360
022.0001.0104
022.0001.0104
022.0001.0104
022.0002.0353
022.0002.0352
022.0010.0018 022.0010.0016
GND
NTC1
GND
1 65432
123456
NTC2
4
4
1 32
1 2 3
022.0002.0354
1 5
6 9
1 4 5
+5V_PROG
2 3
USB_D+
68 7 9
GND_CAN USB_D-
CONN-RS232
022.0002.0355
022.0002.0356 022.0002.0054
022.0002.0073
1
1
2
2
022.0002.0357
022.0002.0351
022.0002.0351
022.0002.0058
OUT2
022.0002.0361
050.XXXX.0158 050.XXXX.0157
050.XXXX.0155
022.0002.0359
050.0008.0129 050.XXXX.0159
050.XXXX.0096
045.0002.0023
TERMICO
NTC3
GND
+15V
050.XXXX.0151 050.XXXX.0174
WIRE 3 WIRE 2
MH1
WIRE 2
PE
PE
J2J1
2 1
GND REED
050.000X.0176
022.0002.0392
A
F
G
J
I
C
B
ED
H
J I
GND_CAN +24V_CAN
G EF H
+5V-CAN
AB
GND CAN CAN_H0
CD
CAN_L0
CONN-MIL_IR
022.0002.0404

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
14
ENGLISH
A B
CD
ELV1_C
ELV1_C
-DC
JP5
6 5 48 7
+DC
321
J1 J2
CN8
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
1234
+18V_PRI
78
GND_PRI
23456
CN7
+VBUS
1
GND
GND_SEC
10
10
-15V_SEC -15V_SEC GND_SEC
1314 11 12
-15V -15V
GND
14 13 12 11
+15V_SEC +15V_SEC +24V_SEC +24V_SEC VENT3_C VENT12_C RELAY_C
67 9 8
CN6
ELV2_C
2 14 35
+24V +24V +15V +15V
J10
6789
VENT3_C VENT12C
RELAY_C
ELV2_C
12345
1234
J12
+5V GND USB_D+ USB_D-
NERO-BLACK ROSSO-RED ROSSO-RED NERO-BLACK
S
A
F
G
J
I
C
B
ED
H
PE
R T
VDC
M
VDC
M
J2
GND_CAN
CN3
J I
CN2
21
CN1
2 1 3456
+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
35 4 2 6
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
65432
J8
GND_CAN
7
8
65432
CN4
12
1
1
+48V_CAN
VENT_3
RELAY
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
1
1
J11
23456
AN3 OUT3 GND +5V IN0
5
J1
10 9 678 1234
DOWN
RIC_PED
+5V_CAN
AN_REM_IN2
GND_CAN
GND_CAN
PT
UP
4321
J6
+24V_CAN
HF
GND_CAN
GND_CAN
+48V_CAN GND_CAN
G EF H
CANH
AB
CANL GND_CAN
CD
+24V_CAN 400VAC-1
4 5
GND ISO
2 31
AL CU GIALLO/VERDE-YELLOW/GREEN 400VAC-2
RJ3 S TJ1
+48V_CAN VENT
1
1
2
2
+48V_CAN VENT
12
12
+
L
1234
GND
HALL
-15V
+15V
CN8
321 4
NTC_SEC
RELAY
+48CAN
+15CAN
ELV_2
4321
J10 J7 J8
654321
R_OUT_GRUPPO
S_OUT
GND
J9
T_OUT_ISO R_OUT_ISO S_OUT_ISO
1 6
J4
5432
J5
11121314 9 8 710 5 4 36 2 1
T
R
N/O
S
S_SEZ
T_SEZ
R_SEZ
16 15
65 2143
J7
+24V_CAN
+48V_CAN
GND_CAN
+24V_CAN
12 11
AN_REM_IN1
341256
J5J4
654213
GND_CAN
CAN_H1
+15V_CAN
+5V_CAN
CAN_L1
GND_CAN
312456
J3
654213
J2
12 8121110934 765
J9
USB_D-
USB_D+
RX2_RS232
TX2_RS232
+5V_CAN
GND_CAN
+5V_PROG
GND
TX1_RS232
RX1_RS232
J18
VOUT
GND
12
AL_CU
GND_CAN
J13
12
J19
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
1 3287654
LED-
LED+
J20
12
VS_ISO
VR_ISO
-V_BUS_ISO
+V_BUS_ISO
VT_ISO
J14
32876549110
DRV_D
DRV_A
DRV_C
DRV_B
4321
J15
+15V
-15V
HALL
GND
J17
1234
I_PONTE
GND
J16
12
87
C
B
A
D
2 1 4
JP1
3
J6
GND
I_PONTE
JP1
21
1234
JP4
JP1 JP7
CONN-ILME CU09
21 53 4
CONN-MIL_REMOTE
+DC -DC
+DC
+48CAN
T_OUT
S_OUT
R_OUT
050.XXXX.0156
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
GND_CAN
GND_CAN
INTERRUTTORE
T1 L1
N/O N/O
MAINS SWITCH
T2 L2
T3 L3
CAN_H0
+15V_CAN
+5V_CAN
CAN_L0
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
GND_CAN
GND_CAN
022.0002.0364
NTC_PRIM_1 NTC_PRIM_2
022.0002.0350
022.0002.0360
022.0001.0104
022.0001.0104
022.0001.0104
022.0002.0353
022.0002.0352
022.0010.0018
022.0010.0016
GND
NTC1 GND
1 65432
123456
NTC2
4
4
1 32
1 2 3
022.0002.0354
1 5
6 9
1 4 5
+5V_PROG
2 3
USB_D+
68 7
9
GND_CAN USB_D-
CONN-RS232
022.0002.0355
022.0002.0356 022.0002.0054
022.0002.0073
1
1
2
2
022.0002.0357
022.0002.0351
022.0002.0351
022.0002.0058
OUT2
022.0002.0361
050.XXXX.0158 050.XXXX.0157
050.XXXX.0155
022.0002.0359
050.0008.0129
050.XXXX.0159
050.XXXX.0096
045.0002.0023
TERMICO
NTC3
GND
+15V
050.XXXX.0151 050.XXXX.0174
WIRE 3 WIRE 2
MH1
WIRE 2
PE PE
J2J1
2 1
GND REED
050.000X.0176
022.0002.0392
A
F
G
J
I
C
B
ED
H
J I
GND_CAN +24V_CAN
G EF H
+5V-CAN
AB
GND CAN CAN_H0
CD
CAN_L0
CONN-MIL_IR
022.0002.0404

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
15
ENGLISH
A B
CD
ELV1_C
ELV1_C
-DC
JP5
6 5 48 7
+DC
321
J1 J2
CN8
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
1234
+18V_PRI
78
GND_PRI
23456
CN7
+VBUS
1
GND
GND_SEC
10
10
-15V_SEC -15V_SEC GND_SEC
1314 11 12
-15V -15V
GND
14 13 12 11
+15V_SEC +15V_SEC +24V_SEC +24V_SEC VENT3_C VENT12_C RELAY_C
67 9 8
CN6
ELV2_C
2 14 35
+24V +24V +15V +15V
J10
6789
VENT3_C VENT12C
RELAY_C
ELV2_C
12345
1234
J12
+5V GND USB_D+ USB_D-
NERO-BLACK ROSSO-RED ROSSO-RED NERO-BLACK
S
A
F
G
J
I
C
B
ED
H
PE
R T
VDC
M
VDC
M
J2
GND_CAN
CN3
J I
CN2
21
CN1
2 1 3456
+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
35 4 2 6
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
65432
J8
GND_CAN
78 65432
CN4
12 1
1
+48V_CAN
VENT_3
RELAY
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
1
1
J11
23456
AN3 OUT3 GND +5V IN0
5
J1
10 9 678 1234
DOWN
RIC_PED
+5V_CAN
AN_REM_IN2
GND_CAN
GND_CAN
PT
UP
4321
J6
+24V_CAN
HF
GND_CAN
GND_CAN
+48V_CAN GND_CAN
G EF H
CANH
AB
CANL GND_CAN
CD
+24V_CAN 400VAC-1
4 5
GND ISO
2 31
AL CU GIALLO/VERDE-YELLOW/GREEN 400VAC-2
RJ3 S TJ1
+48V_CAN VENT
1
1
2
2
+48V_CAN VENT
12
12
+
L
1234
GND
HALL
-15V
+15V
CN8
321 4
NTC_SEC
RELAY
+48CAN
+15CAN
ELV_2
4321
J10
J7 J8
654321
R_OUT_GRUPPO
S_OUT
GND
J9
T_OUT_ISO R_OUT_ISO S_OUT_ISO
1 6
J4
5432
J5
11121314 9 8 710 5 4 36 2 1
T
R
N/O
S
S_SEZ
T_SEZ
R_SEZ
16 15
65 2143
J7
+24V_CAN
+48V_CAN
GND_CAN
+24V_CAN
12 11
AN_REM_IN1
341256
J5J4
654213
GND_CAN
CAN_H1
+15V_CAN
+5V_CAN
CAN_L1
GND_CAN
312456
J3
654213
J2
12 8121110934 765
J9
USB_D-
USB_D+
RX2_RS232
TX2_RS232
+5V_CAN
GND_CAN
+5V_PROG
GND
TX1_RS232
RX1_RS232
J18
VOUT
GND
12
AL_CU
GND_CAN
J13
12
J19
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
1 3287654
LED-
LED+
J20
12
VS_ISO
VR_ISO
-V_BUS_ISO
+V_BUS_ISO
VT_ISO
J14
32876549110
DRV_D
DRV_A
DRV_C
DRV_B
4321
J15
+15V
-15V
HALL
GND
J17
1234
I_PONTE
GND
J16
12
87
C
B
A
D
2 1 4
JP1
3
J6
GND
I_PONTE
JP1
21
1234
JP4
JP1 JP7
CONN-ILME CU09
21 53 4
CONN-MIL_REMOTE
+DC -DC
+DC
+48CAN
T_OUT
S_OUT
R_OUT
050.XXXX.0156
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
GND_CAN
GND_CAN
INTERRUTTORE
T1 L1
N/O N/O
MAINS SWITCH
T2 L2
T3 L3
CAN_H0
+15V_CAN
+5V_CAN
CAN_L0
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
GND_CAN
GND_CAN
022.0002.0364
NTC_PRIM_1 NTC_PRIM_2
022.0002.0350
022.0002.0360
022.0001.0104
022.0001.0104
022.0001.0104
022.0002.0353
022.0002.0352
022.0010.0018
022.0010.0016
GND
NTC1 GND
1 65432
123456
NTC2
4
4
1 32
1 2 3
022.0002.0354
1 5
6 9
1 4 5
+5V_PROG
2 3
USB_D+
68 7 9
GND_CAN USB_D-
CONN-RS232
022.0002.0355
022.0002.0356 022.0002.0054
022.0002.0073
1
1
2
2
022.0002.0357
022.0002.0351
022.0002.0351
022.0002.0058
OUT2
022.0002.0361
050.XXXX.0158 050.XXXX.0157
050.XXXX
.0155
022.0002.0359
050.0008.0129 050.XXXX.0159
050.XXXX.0096
045.0002.0023
TERMICO
NTC3
GND
+15V
050.XXXX.0151 050.XXXX.0174
WIRE 3 WIRE 2
MH1
WIRE 2
PE PE
J2J1
2 1
GND REED
050.000X.0176
022.0002.0392
A
F
G
J
I
C
B
ED
H
J I
GND_CAN +24V_CAN
G EF H
+5V-CAN
AB
GND CAN CAN_H0
CD
CAN_L0
CONN-MIL_IR
022.0002.0404

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
16
ENGLISH
A B
CD
ELV1_C
ELV1_C
-DC
JP5
6 5 48 7
+DC
321
J1 J2
CN8
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
1234
+18V_PRI
78
GND_PRI
23456
CN7
+VBUS
1
GND
GND_SEC
10
10
-15V_SEC -15V_SEC GND_SEC
1314 11 12
-15V -15V
GND
14 13 12 11
+15V_SEC +15V_SEC +24V_SEC +24V_SEC VENT3_C VENT12_C RELAY_C
67 9 8
CN6
ELV2_C
2 14 35
+24V +24V +15V +15V
J10
6789
VENT3_C VENT12C
RELAY_C
ELV2_C
12345
1234
J12
+5V GND USB_D+ USB_D-
NERO-BLACK ROSSO-RED ROSSO-RED NERO-BLACK
S
A
F
G
J
I
C
B
ED
H
PE
R T
VDC
M
VDC
M
J2
GND_CAN
CN3
J I
CN2
21
CN1
2 1 3456
+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
35 4 2 6
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
65432
J8
GND_CAN
78 65432
CN4
12 1
1
+48V_CAN
VENT_3
RELAY
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
1
1
J11
23456
AN3 OUT3 GND +5V IN0
5
J1
10 9 678 1234
DOWN
RIC_PED
+5V_CAN
AN_REM_IN2
GND_CAN
GND_CAN
PT
UP
4321
J6
+24V_CAN
HF
GND_CAN
GND_CAN
+48V_CAN GND_CAN
G EF H
CANH
AB
CANL GND_CAN
CD
+24V_CAN 400VAC-1
4 5
GND ISO
2 31
AL CU GIALLO/VERDE-YELLOW/GREEN 400VAC-2
RJ3 S TJ1
+48V_CAN VENT
1
1
2
2
+48V_CAN VENT
12
12
+
L
1234
GND
HALL
-15V
+15V
CN8
321 4
NTC_SEC
RELAY
+48CAN
+15CAN
ELV_2
4321
J10 J7 J8
654321
R_OUT_GRUPPO
S_OUT
GND
J9
T_OUT_ISO R_OUT_ISO S_OUT_ISO
1 6
J4
5432
J5
11121314 9 8 710 5 4 36 2 1
T
R
N/O
S
S_SEZ
T_SEZ
R_SEZ
16 15
65 2143
J7
+24V_CAN
+48V_CAN
GND_CAN
+24V_CAN
12 11
AN_REM_IN1
341256
J5
J4
65
42
13
GND_CAN
CAN_H1
+15V_CAN
+5V_CAN
CAN_L1
GND_CAN
312456
J3
654213
J2
12 8121110934 765
J9
USB_D-
USB_D+
RX2_RS232
TX2_RS232
+5V_CAN
GND_CAN
+5V_PROG
GND
TX1_RS232
RX1_RS232
J18
VOUT
GND
12
AL_CU
GND_CAN
J13
12
J19
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
1 3287654
LED-
LED+
J20
12
VS_ISO
VR_ISO
-V_BUS_ISO
+V_BUS_ISO
VT_ISO
J14
32876549110
DRV_D
DRV_A
DRV_C
DRV_B
4321
J15
+15V
-15V
HALL
GND
J17
1234
I_PONTE
GND
J16
12
87
C
B
A
D
2 1 4
JP1
3
J6
GND
I_PONTE
JP1
21
1234
JP4
JP1 JP7
CONN-ILME CU09
21 53 4
CONN-MIL_REMOTE
+DC -DC
+DC
+48CAN
T_OUT
S_OUT
R_OUT
050.XXXX.0156
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
GND_CAN
GND_CAN
INTERRUTTORE
T1 L1
N/O N/O
MAINS SWITCH
T2 L2
T3 L3
CAN_H0
+15V_CAN
+5V_CAN
CAN_L0
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
GND_CAN
GND_CAN
022.0002.0364
NTC_PRIM_1 NTC_PRIM_2
022.0002.0350
022.0002.0360
022.0001.0104
022.0001.0104
022.0001.0104
022.0002.0353
022.0002.0352
022.0010.0018
022.0010.0016
GND
NTC1 GND
1 65432
123456
NTC2
4
4
1 32
1 2 3
022.0002.0354
1 5
6 9
1 4 5
+5V_PROG
2 3
USB_D+
68 7 9
GND_CAN USB_D-
CONN-RS232
022.0002.0355
022.0002.0356 022.0002.0054
022.0002.0073
1
1
2
2
022.0002.0357
022.0002.0351
022.0002.0351
022.0002.0058
OUT2
022.0002.0361
050.XXXX.0158 050.XXXX.0157
050.XXXX.0155
022.0002.0359
050.0008.0129 050.XXXX.0159
050.XXXX.0096
045.0002.0023
TERMICO
NTC3
GND
+15V
050.XXXX.0151 050.XXXX.0174
WIRE 3 WIRE 2
MH1
WIRE 2
PE PE
J2J1
2 1
GND REED
050.000X.0176
022.0002.0392
A
F
G
J
I
C
B
ED
H
J I
GND_CAN +24V_CAN
G EF H
+5V-CAN
AB
GND CAN CAN_H0
CD
CAN_L0
CONN-MIL_IR
022.0002.0404

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
17
ENGLISH
A B
CD
ELV1_C
ELV1_C
-DC
JP5
6 5 48 7
+DC
321
J1 J2
CN8
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
1234
+18V_PRI
78
GND_PRI
23456
CN7
+VBUS
1
GND
GND_SEC
10
10
-15V_SEC -15V_SEC GND_SEC
1314 11 12
-15V -15V
GND
14 13 12 11
+15V_SEC +15V_SEC +24V_SEC +24V_SEC VENT3_C VENT12_C RELAY_C
67 9 8
CN6
ELV2_C
2 14 35
+24V +24V +15V +15V
J10
6789
VENT3_C VENT12C
RELAY_C
ELV2_C
12345
1234
J12
+5V GND USB_D+ USB_D-
NERO-BLACK ROSSO-RED ROSSO-RED NERO-BLACK
S
A
F
G
J
I
C
B
ED
H
PE
R T
VDC
M
VDC
M
J2
GND_CAN
CN3
J I
CN2
21
CN1
2 1 3456
+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
35 4 2 6
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
65432
J8
GND_CAN
78 65432
CN4
12 1
1
+48V_CAN
VENT_3
RELAY
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
1
1
J11
23456
AN3 OUT3 GND +5V IN0
5
J1
10 9 678 1234
DOWN
RIC_PED
+5V_CAN
AN_REM_IN2
GND_CAN
GND_CAN
PT
UP
4321
J6
+24V_CAN
HF
GND_CAN
GND_CAN
+48V_CAN GND_CAN
G EF H
CANH
AB
CANL GND_CAN
CD
+24V_CAN 400VAC-1
4 5
GND ISO
2 31
AL CU GIALLO/VERDE-YELLOW/GREEN 400VAC-2
RJ3 S TJ1
+48V_CAN VENT
1
1
2
2
+48V_CAN VENT
12
12
+
L
1234
GND
HALL
-15V
+15V
CN8
321 4
NTC_SEC
RELAY
+48CAN
+15CAN
ELV_2
4321
J10 J7 J8
654321
R_OUT_GRUPPO
S_OUT
GND
J9
T_OUT_ISO R_OUT_ISO S_OUT_ISO
1 6
J4
5432
J5
11121314 9 8 710 5 4 36 2 1
T
R
N/O
S
S_SEZ
T_SEZ
R_SEZ
16 15
65 2143
J7
+24V_CAN
+48V_CAN
GND_CAN
+24V_CAN
12 11
AN_REM_IN1
341256
J5J4
654213
GND_CAN
CAN_H1
+15V_CAN
+5V_CAN
CAN_L1
GND_CAN
312456
J3
654213
J2
12 8121110934 765
J9
USB_D-
USB_D+
RX2_RS232
TX2_RS232
+5V_CAN
GND_CAN
+5V_PROG
GND
TX1_RS232
RX1_RS232
J18
VOUT
GND
12
AL_CU
GND_CAN
J13
12
J19
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
1 3287654
LED-
LED+
J20
12
VS_ISO
VR_ISO
-V_BUS_ISO
+V_BUS_ISO
VT_ISO
J14
32876549110
DRV_D
DRV_A
DRV_C
DRV_B
4321
J15
+15V
-15V
HALL
GND
J17
1234
I_PONTE
GND
J16
12
87
C
B
A
D
2 1 4
JP1
3
J6
GND
I_PONTE
JP1
21
1234
JP4
JP1 JP7
CONN-ILME CU09
21 53 4
CONN-MIL_REMOTE
+DC -DC
+DC
+48CAN
T_OUT
S_OUT
R_OUT
050.XXXX.0156
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
GND_CAN
GND_CAN
INTERRUTTORE
T1 L1
N/O N/O
MAINS SWITCH
T2 L2
T3 L3
CAN_H0
+15V_CAN
+5V_CAN
CAN_L0
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
GND_CAN
GND_CAN
022.0002.0364
NTC_PRIM_1 NTC_PRIM_2
022.0002.0350
022.0002.0360
022.0001.0104
022.0001.0104
022.0001.0104
022.0002.0353
022.0002.0352
022.0010.0018
022.0010.0016
GND
NTC1 GND
1 65432
123456
NTC2
4
4
1 32
1 2 3
022.0002.0354
1 5
6 9
1 4 5
+5V_PROG
2 3
USB_D+
68 7 9
GND_CAN USB_D-
CONN-RS232
022.0002.0355
022.0002.0356 022.0002.0054
022.0002.0073
1
1
2
2
022.0002.0357
022.0002.0351
022.0002.0351
022.0002.0058
OUT2
022.0002.0361
050.XXXX.0158 050.XXXX.0157
050.XXXX.0155
022.0002.0359
050.0008.0129 050.XXXX.0159
050.XXXX.0096
045.0002.0023
TERMICO
NTC3
GND
+15V
050.XXXX.0151 050.XXXX.0174
WIRE 3 WIRE 2
MH1
WIRE 2
PE PE
J2J1
2 1
GND REED
050.000X.0176
022.0002.0392
A
F
G
J
I
C
B
ED
H
J I
GND_CAN
+24V_CAN
G EF
H
+5V-CAN
AB
GND CAN CAN_H0
CD
CAN_L0
CONN-MIL_IR
022.0002.0404

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
18
ENGLISH
7 SPARE PARTS
7.1 PIONEER 403-503MSR / PIONEER PULSE 403-503MSR
1
23
4
5
6
7
8
9
11
12
16
17 1819 20 21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
39
40
41
42
43
44
45
46
47
48
49
13
38
50
14
15
10

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6
Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
19
ENGLISH
N° CODE DESCRIPTION
1013.0021.1001 FRONTPANELLABEL(403MSR)
013.0021.1101 FRONTPANELLABEL(503MSR)
2013.0000.8044 FRONTAL PANEL PLATE
3050.0002.0096 LED BOARD
4012.0007.0010 FRONT PLASTIC
5011.0013.0021 FRONT PLATE
6012.0007.0020 PLASTIC LOUVRE
7011.0000.1171 LEFT COVER
8011.0013.0258 COVER PANEL SUPPORT PLATE
9050.0001.0157 PRIMARY BOARD
10 050.0001.0158 DRIVERBOARD+IGBTMODULE
11 050.0001.0156 ELECTROLYTIC CAPACITOR
BOARD
12 032.0001.8216 THREE PHASE RECTIFIER BRID-
GE
13 040.0003.1011 THERMAL CUT-OUT 2 NTC 10K
14 015.0001.0026 HEAT SINK
15
050.5097.0000 COMPLETEFRONTPANEL(403
MSR)
050.5098.0000 COMPLETEFRONTPANEL(503
MSR)
16 011.0013.0259 FRONT SOCKETS PANEL
17 016.4107.0001 LED HOLDER
18 022.0002.0364 LEDWIRING
19 040.0001.0016 FOUR-POLE SWITCH
20 021.0001.0279 OUTPUT SOCKET
21 042.0003.0053 POWER TRANSFORMER
22 011.0013.0251 HEAT SINK SUPPORT PLATE
23 011.0013.0250 LOWER COVER
24 016.0009.0003 RUBBER FOOT
25 011.0000.1191 RIGHTCOVER
26 011.0013.0254 INTERNAL FAN SUPPORT
27 011.0013.0253 SEPARATION PLATE
28 045.0006.0117 DIODES-TRANSFORMER COP-
PER BRACKET
29 040.0003.1012 THERMAL CUT-OUT NTC 10K
30 041.0004.0502 HALL EFFECT SENSOR
31 045.0006.0116 OUT COPPER BRACKET
32 044.0004.0029 OUTPUT INDUCTOR
33 011.0013.0252 UPPER PLATE
34 022.0002.0356 10 PIN CONNECTOR CABLE
35 022.0002.0404 CABL. REMOTE 403/503 ROBOT
36 003.0002.0017 FAN
37 011.0013.0255 FRONT PLATE
38 022.0002.0073 CU SUPPLY CABLE
39 021.0013.0007 ILME CONNECTOR CAP
40 045.0002.0023 SUPPLY CABLE
N° CODE DESCRIPTION
41 021.0014.0303 RS-232 CONNECTOR CAP
42 022.0002.0355 RS-232WIRING
43 045.0000.0017 CABLE CLAMP
44 050.0008.0129 SUPPLIES BOARD
45
050.0001.0159 CONTROLBOARD(403MSR)
050.0002.0159 CONTROLBOARD(503MSR)
050.0006.0159 CONTROLBOARD(403MSR
PULSE)
050.0007.0159 CONTROLBOARD(503MSR
PULSE)
46 011.0013.0257 RIGHTSUPPORTBOARDPLATE
47 011.0013.0256 LEFT SUPPORT BOARD PLATE
48 050.0001.0155 MAINS FILTER BOARD
49 011.0013.0260 UPPER COVER
50 032.0002.2403 ISOTOP DIODE
51 050.0001.0176 REED SENSOR BOARD

WELD T H E W O R L D
Cod. 006.0001.2120
22/07/2022 V.2.6 Pioneer 403MSR/503MSR
Pioneer Pulse 403MSR/503MSR
20
ENGLISH