Weco Pioneer 403MKS User manual

Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse
Instruction Manual
ENG
Translation of original instructions

WELD THE WORLD
Cod. 006.0001.2230
02/09/2020 V.1.0 Pioneer 403MKS
Pioneer Pulse 403MKS
2
ENGLISH

WELD THE WORLD
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
3
ENGLISH

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INDEX
1 INTRODUCTION....................................................................................................................................... 6
1.1 PRESENTATION....................................................................................................................................... 7
2 INSTALLATION ....................................................................................................................................... 8
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK................................................................... 8
2.2 FRONT PANEL.......................................................................................................................................... 8
2.3 REAR PANEL............................................................................................................................................ 9
2.4 Wire feeder compartment........................................................................................................................ 10
2.5 MIG/MAG INSTALLATION ...................................................................................................................... 11
2.6 PREPARING FOR MMA WELDING........................................................................................................ 14
2.7 PREPARING FOR TIG WELDING.......................................................................................................... 15
3 USER INTERFACE................................................................................................................................. 17
4 UNIT POWER-UP ................................................................................................................................... 20
5 RESET (LOAD FACTORY SETTINGS).................................................................................................. 20
5.1 PARTIAL RESET..................................................................................................................................... 21
5.2 TOTAL RESET ........................................................................................................................................ 22
6 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE) ..................................................... 23
6.1 OPERATING HOUR COUNTER............................................................................................................. 25
6.2 SERVICE MENU..................................................................................................................................... 25
6.3 TRIGGER TYPE...................................................................................................................................... 27
6.4 LOCKING PROCEDURE ........................................................................................................................ 28
6.5 GAS FLOW ADJUSTMENT .................................................................................................................... 30
6.6 TORCH LOADING .................................................................................................................................. 31
6.7 RESISTIVE CALIBRATION OF THE WELDING CIRCUIT ..................................................................... 31
7 ALARM MANAGEMENT ........................................................................................................................ 34
8 PARAMETERS ACTIVATION ................................................................................................................. 37
8.1 MIG/MAG WELDING PARAMETERS..................................................................................................... 38
8.2 MMA WELDING PARAMETERS............................................................................................................. 43
8.3 TIG WELDING PARAMETERS............................................................................................................... 43
9 CHARACTERISTICS OF THE MENU LEVELS ..................................................................................... 44
9.1 1ST LEVEL..............................................................................................................................................44
9.2 2ND LEVEL............................................................................................................................................. 44
9.3 3RD LEVEL............................................................................................................................................. 45
10 WELDING SETTINGS ............................................................................................................................ 45
10.1 WELDING CURVES SELECTION .......................................................................................................... 45
10.1.1 Special curves: POWER FOCUS and POWER ROOT........................................................................... 45
10.2 MANUAL MIG/MAG WELDING............................................................................................................... 47
10.2.1 Manual MIG/MAG parameters setting (1st level): inductance setting. ................................................... 48
10.2.2 MANUAL MIG/MAG PARAMETERS SETTING (2ND LEVEL) ............................................................... 48
10.3 SYNERGIC MIG/MAG WELDING........................................................................................................... 49
10.3.1 Synergic MIG/MAG parameters setting (1st level): synergic curve setting ............................................ 50
10.3.2 Manual MIG/MAG parameters setting (2nd level)................................................................................... 50
10.4 PULSED SYNERGIC MIG/MAG WELDING ........................................................................................... 53
10.4.1 Pulsed Synergic MIG/MAG parameters setting (1st level): synergic curve setting. ............................... 54
10.4.2 Pulsed Synergic MIG/MAG parameters setting (2nd level).................................................................... 55
10.5 DOUBLE PULSED SYNERGIC MIG/MAG WELDING ........................................................................... 57
10.5.1 Double pulsed synergic MIG/MAG parameters setting (1st level): synergic curve setting..................... 58

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10.5.2 Double pulsed synergic MIG/MAG parameters setting (2nd level). ....................................................... 58
10.6 MMA WELDING ...................................................................................................................................... 61
10.6.1 MMA Parameters Setting (1st Level): welding current setting ................................................................ 61
10.6.2 MMA Parameters Setting (2nd Level) ..................................................................................................... 61
10.7 ARC AIR WELDING ................................................................................................................................ 62
10.7.1 ARC AIR parameters setting (1st level): current setting.......................................................................... 63
10.7.2 ARC AIR Parameters Setting (2nd Level) ............................................................................................... 63
10.8 TIG WELDING ........................................................................................................................................ 64
10.8.1 TIG Parameters Setting (1st Level): welding current setting................................................................... 64
10.8.2 TIG Parameters Setting (2nd Level) ....................................................................................................... 64
11 JOBS MANAGEMENT .......................................................................................................................... 66
11.1 SAVING A JOB........................................................................................................................................ 66
11.2 NAMING JOBS ....................................................................................................................................... 68
11.3 LOADING A USER JOB .......................................................................................................................... 69
11.4 DELETING A JOB ................................................................................................................................... 70
11.5 EXPORTING/IMPORTING JOBs (through a USB memory stick)........................................................... 71
11.6 EXPORTING A JOB ................................................................................................................................ 71
11.7 IMPORTING A JOB................................................................................................................................. 73
11.8 SELECTING JOBS USING THE TORCH UP/DOWN BUTTONS........................................................... 74
12 TORCH TRIGGER MODES.................................................................................................................... 75
12.1 2T MIG/MAG WELDING ......................................................................................................................... 75
12.2 2T SPOT MIG/MAG WELDING............................................................................................................... 75
12.3 4T MIG/MAG WELDING ......................................................................................................................... 75
12.4 4T B-LEVEL MIG/MAG WELDING.......................................................................................................... 75
12.5 2T - 3 LEVEL MIG/MAG WELDING ....................................................................................................... 76
12.6 2T SPOT - 3 LEVEL MIG/MAG WELDING ............................................................................................ 76
12.7 4T - 3 LEVEL MIG/MAG WELDING ....................................................................................................... 76
12.8 4T B-LEVEL - 3 LEVEL MIG/MAG WELDING ........................................................................................ 77
13 TECHNICAL DATA ................................................................................................................................. 78
13.1 PIONEER 403 MKS / PIONEER PULSE 403 MKS ................................................................................ 79
14 WIRING DIAGRAM................................................................................................................................. 80
14.1 REMOTE CONTROL CONNECTOR ...................................................................................................... 85
14.1.1 RC03: Wiring diagram............................................................................................................................. 85
14.1.2 RC04: Wiring diagram............................................................................................................................. 85
14.1.3 RC05: Wiring diagram............................................................................................................................. 86
14.1.4 RC06: Wiring diagram............................................................................................................................. 86
15 SPARES.................................................................................................................................................. 87
15.1 WIRE FEEDER MOTOR......................................................................................................................... 91
15.2 WIRE FEEDER ROLLS .......................................................................................................................... 93

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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 manual before install-
ing 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
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.
 
 󰀨
containing the associated information.
 
*1 The symbol refers to the associated numbered note.
NOTES
󰀨
the actual equipment to which they refer.

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1.1 PRESENTATION
Pioneer Pulse 403MKS is a professional three-phase inverter-based welding unit with 4-roll wire fee-
der 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 construc-
󰀩
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 STROKE (2T)
TWO SPOT STROKE (2T-SPOT)
FOUR STROKE (4T)
SYNERGIC MIG/MAG TWO STROKE (2T)
TWO SPOT STROKE (2T-SPOT)
PULSED SYNERGIC MIG/MAG
(available in PIONEER PULSE MKS line power
sources)
FOUR STROKE (4T)
DOUBLE PULSED SYNERGIC MIG/MAG
(available in PIONEER PULSE MKS line power
sources)
THREE LEVEL (3T)
TIG
TWO STROKE (2T)
FOUR STROKE (4T)
MMA
ARC AIR

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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 characteristics of the mains power supply to which the equipment shall be connected are given in
the section entitled “TECHNICAL DATA” on page 78.
The machine can be connected to motorgenerators provided their voltage is stabilised.
󰀨
2.2 FRONT PANEL
Pioneer Pulse 403MKS
1
2
5
3 4
6
7
8

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1: Port provided to connect a USB memory stick to export/import JOBs.
2: Negative pole welding socket.
3: Positive pole welding socket.
4: EURO TORCH welding socket.
5: Remote controller connector.
6: Polarity selector cable.
7: Welding power source ON/OFF switch.
8: Mains protection ON LED.
This LED illuminates if an incorrect operating condition occurs:
- absence of a phase in the power supply line.
2.3 REAR PANEL
Pioneer Pulse 403MKS
2
3
1
1: Cooler power feeding connector.
• Voltage 400 V~
• Current Output 1.53 A
• IP protection rating IP20 (cap open) / IP66 (cap closed)

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WARNING!
High voltage!
If the socket is not connected to any devices always close the cap: presence of hazardous voltage levels!
2: Connector for gas feed hose between the gas cylinder and the power source.
3: Power cable.
• Total length (including internal part) 4,5 m
• Number and Cross section of Wires 4 x 6,0 mm2
• Power plug type Not supplied
2.4 WIRE FEEDER COMPARTMENT
21
1: PROG-1: (Programming connector for the process circuit board). You can update the software of
the equipment using the programming kit.
2: PROG-2: (Programming connector for the motor circuit board). You can update the software of
the equipment using the programming kit.

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2.5 MIG/MAG INSTALLATION
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
FRONT VIEW REAR VIEW
REMOTE
CONTROL
L1L1
L2L2
L3L3
3P+T
3P4W
 󰀨
2. Connect the power source mains supply cable to the 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 MIG/MAG torch plug to the EURO TORCH welding socket.
6. Connect the plug of the ground clamp to the welding socket on the basis of the polarity required.
7. Connect the plug of the polarity selector cable to the welding socket on the basis of the polarity
required.
8. Connect the earth clamp to the workpiece being processed.
9. Set the welding power source ON/OFF switch to “I” (unit powered).
10. Select the following welding mode on the user interface: MIG/MAG
11. Press the key to feed the wire until it protrudes from the torch tip. The insertion speed is
2.0 m/min for 3 seconds, subsequently increasing to 15 m/min. When the button is released wire
feed is interrupted. This function produces a slower feed rate and hence greater precision when
inserting the wire when it enters the torch nozzle.
12. Select the torch trigger procedure on the user interface.
13. Open the gas solenoid valve by pressing and releasing the button . 14.
 
15. Close the gas solenoid valve by pressing and releasing the button.

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16. Set the required welding parameter values on the user interface.
i

controller without having to take action on the user interface of the welding power source.
The system is ready to start welding.
POSITIONING THE SPOOL AND THE WIRE IN THE WIRE FEEDER
WARNING!
Mechanical Hazards
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
1. Open the unit side door to gain access to the spool com-
partment.
2. Unscrew the cap of the spool holder.
 
4. Fit the spool in the spool holder, ensuring it is located
correctly.

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        
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.
 
7. Lower the wire feeder pressure devices.
8. Raise the wire feeder pressure arms.
9. Remove the protective cover.
10. Check that the feed rolls are suitable for the wire gauge.
• The diameter of the roll groove must be compatible with
the diameter of the welding wire.
• The roll must be of suitable shape in relation to the compo-
sition of the wire material.
• The groove must be "U" shaped for soft materials (Alu-
minium and its alloys, CuSi3).
• The groove must be "V" shaped for harder materials (SG2-
SG3, stainless steels).
    
cored wire.
11. Feed the wire between the wire feeder rolls and insert it
into the MIG/MAG TORCH connector plug.
12. Make sure the wire is located correctly in the roll grooves.

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13. Close the wire feeder pressure arms.

wire with a force that does not deform it while also en-
suring constant feed rate without slipping.

16. Set the welding power source ON/OFF switch to “I” (unit
switched on).
17. Feed the wire through the torch until it protrudes from
the tip, pressing button on the unit front panel.
18. Close the spool compartment door in the side of the unit.
2.6 PREPARING FOR MMA WELDING
 󰀨
2. Plug the power cable plug into a mains socket outlet.
3. Choose the electrode based on the type of material and thickness of the workpiece to be welded.
4. Insert the electrode in the electrode holder.
5. Connect the electrode holder cable to the welding socket based on the polarity requested by the
type of electrode used.
6. Connect the plug of the ground clamp to the welding socket on the basis of the polarity required.
7. Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
8. Set the welding power source ON/OFF switch to “I” (unit powered).
9. Select the following welding mode on the user interface: MMA
10. Set the required welding parameter values on the user interface.
i
When the remote controller [RC] is connected and the relative locking screw is tightened, welding

The system is ready to start welding.

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FRONT VIEW
(polarity to basic electrode) REAR VIEW
REMOTE
CONTROL
L1L1
L2L2
L3L3
3P+T
3P4W
2.7 PREPARING FOR TIG WELDING
 󰀨
2. Plug the power cable plug into a mains socket outlet.
3. Connect the gas hose from the welding gas cylinder to the rear gas connection.
4. Open the cylinder gas valve.
5. Connect the TIG torch plug to the EURO TORCH welding socket.
6. Choose the electrode based on the type of material and thickness of the workpiece to be welded.
7. Insert the electrode in the TIG torch.
8. Connect the torch plug to the welding socket on the basis of the polarity required by the type of
electrode in question.
9. Connect the plug of the ground clamp to the welding socket on the basis of the polarity required.
10. Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the “General prescriptions for use”.
11. Set the welding power source ON/OFF switch to “I” (unit powered).
12. Select the following welding mode on the user interface: DC TIG
13. 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.


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15. Set the required welding parameter values on the user interface.
i
When the remote controller [RC] is connected and the relative locking screw is tightened, welding

The system is ready to start welding.
FRONT VIEW
(polarity for tungsten electrode) REAR VIEW
REMOTE
CONTROL
L1L1
L2L2
L3L3
3P+T
3P4W

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3 USER INTERFACE
HOLD
m/min
mm
Menu
D1
S1
L4L7 L8
D2
D3
L9
L10
L11
S2
S3
S4 S5 S6 S7
S10
S9
S8
L2
L1
L6
L5
L3
E1 E2
E3
S T O P
ESC
Mode
CODE SYMBOL DESCRIPTION
L1 illumination shows that 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:
illumination shows that 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
illumination shows that the following parameter can be set: WELDING THICKNESS
              
guideline).
The value appears on the following display: D1
L4
Illuminates to show the last voltage and current values measured during welding.
󰀨

The value appears on the display : D1-D2
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
This LED illuminates to show an anomaly in the operating conditions.
An alarm message appears on the following display: D3
§ “7 ALARM MANAGEMENT”

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CODE SYMBOL DESCRIPTION
L8 
L9
Illumination shows that the following function has been activated: 2 stroke procedure
§ “12.1 2T MIG/MAG WELDING”

§ “12.2 2T SPOT MIG/MAG WELDING”
L10 Illumination shows that the following function has been activated: 4 stroke procedure
§ “12.3 4T MIG/MAG WELDING” / § “12.4 4T B-LEVEL MIG/MAG WELDING”
L11
Illumination shows that the following function has been activated: 3 levels procedure
§ “12.5 2T - 3 LEVEL MIG/MAG WELDING” / § “12.6 2T SPOT - 3 LEVEL MIG/MAG WEL-
DING” / § “12.7 4T - 3 LEVEL MIG/MAG WELDING” / § “12.8 4T B-LEVEL - 3 LEVEL MIG/
MAG WELDING”.
D1
ADuring illumination of the following LEDs: / /
The display shows the value of the selected parameter.
Welding:󰀨
HOLD function (at welding end): The display shows the latest measured current value..
D2
VData setting: The display shows the value, in Volts, of the selected welding voltage.
Welding:󰀨
HOLD function (at welding end): The display shows the latest measured voltage value.
D3 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, select-
ing only one: / /
S2 The button restores the main menu of display D3, starting from any other page.
The button serves to exit any menu without saving any changes.
S3 The button scrolls the selection made on the menus upwards or to the right.
S4 The button scrolls the selection made on the menus downwards or to the left.
S5 The button selects the various submenus visible in the following display: D3
S6
MODEMODE
This button selects the welding mode.
S7 This button selects the torch trigger procedure.
§ “12 TORCH TRIGGER MODES”
S8
The button enables management of the personalised programs that can be shown on the fol-
lowing display: D3
§ “11 JOBS MANAGEMENT”
E1
Data setting:
following display: D1
During welding operations with an active JOB:
welding parameter, shown on the following display: D1

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CODE SYMBOL DESCRIPTION
E2
Manual MIG/MAG mode: 
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: D2
During welding operations with an active JOB: 
welding parameter, shown on the following display: D2
E3
The encoder changes the setting of the selected parameter shown on the following display: D3
The selected parameter is shown by the following symbol: .
Not welding, with a loaded JOB: Scrolling of JOBs belonging to the same sequence.
KEYS PROVIDED INSIDE THE WIRE FEEDER
S9
-
tor on the gas cylinder.
§ “6.3 TRIGGER TYPE”
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.

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4 UNIT POWER-UP
Set the welding power source ON/OFF switch to “I” to switch on the unit.
First power-up or power-ups following a RESET procedure
The welding power source sets up for welding with the factory preset values..
Subsequent power-ups
 
󰀨
During power-up all functions are inhibited and the following displays remain blank: D1, D2
D3: The following messages will appear in sequence on this display:
Tab. 1 - Messages at power-up
MOTOR BOARD
FW: XX.XX.XXX XX.XX.XXX= wire feeder software version.
PROGRAM UPDATE The welding power source is synchronising the wire feeder and
power source software.
PIONEER ZZZ
FW: YY.YY.YYY
WELDING MACHINE OK
ZZZ= Ampere value of the power source.
YY.YY.YYY= power source software version.
5 RESET (LOAD FACTORY SETTINGS)
To perform a reset the power source must be managed via the remote control.
The reset procedure involves complete restoration of the default values, parameters and memory set-
tings set in the factory.
The reset procedure is useful in the following cases:
- 󰀩
- 