Weco Pioneer 403MKS Instruction Manual

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Weco Pioneer 403MKS Instruction Manual | Manualzz
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer
Pioneer Pulse
403MKS
Instruction Manual
Translation of original instructions
ENG
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
2
WELD THE WORLD
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
WELD THE WORLD
ENGLISH
3
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
INDEX
1
1.1
INTRODUCTION........................................................................................................................................ 6
PRESENTATION........................................................................................................................................ 7
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
INSTALLATION ........................................................................................................................................ 8
CONNECTIONS TO THE ELECTRICAL MAINS NETWORK.................................................................... 8
FRONT PANEL........................................................................................................................................... 8
REAR PANEL............................................................................................................................................. 9
Wire feeder compartment......................................................................................................................... 10
MIG/MAG INSTALLATION....................................................................................................................... 11
PREPARING FOR MMA WELDING......................................................................................................... 14
PREPARING FOR TIG WELDING........................................................................................................... 15
3
USER INTERFACE.................................................................................................................................. 17
4
UNIT POWER-UP.................................................................................................................................... 20
5
5.1
5.2
RESET (LOAD FACTORY SETTINGS)................................................................................................... 20
PARTIAL RESET...................................................................................................................................... 21
TOTAL RESET......................................................................................................................................... 22
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)...................................................... 23
OPERATING HOUR COUNTER.............................................................................................................. 25
SERVICE MENU...................................................................................................................................... 25
TRIGGER TYPE....................................................................................................................................... 27
LOCKING PROCEDURE......................................................................................................................... 28
GAS FLOW ADJUSTMENT..................................................................................................................... 30
TORCH LOADING................................................................................................................................... 31
RESISTIVE CALIBRATION OF THE WELDING CIRCUIT...................................................................... 31
7
ALARM MANAGEMENT......................................................................................................................... 34
8
8.1
8.2
8.3
PARAMETERS ACTIVATION.................................................................................................................. 37
MIG/MAG WELDING PARAMETERS...................................................................................................... 38
MMA WELDING PARAMETERS.............................................................................................................. 43
TIG WELDING PARAMETERS................................................................................................................ 43
9
9.1
9.2
9.3
CHARACTERISTICS OF THE MENU LEVELS...................................................................................... 44
1ST LEVEL............................................................................................................................................... 44
2ND LEVEL.............................................................................................................................................. 44
3RD LEVEL.............................................................................................................................................. 45
10
10.1
10.1.1
10.2
10.2.1
10.2.2
10.3
10.3.1
10.3.2
10.4
10.4.1
10.4.2
10.5
10.5.1
WELDING SETTINGS............................................................................................................................. 45
WELDING CURVES SELECTION........................................................................................................... 45
Special curves: POWER FOCUS and POWER ROOT............................................................................ 45
MANUAL MIG/MAG WELDING................................................................................................................ 47
Manual MIG/MAG parameters setting (1st level): inductance setting..................................................... 48
MANUAL MIG/MAG PARAMETERS SETTING (2ND LEVEL)................................................................ 48
SYNERGIC MIG/MAG WELDING............................................................................................................ 49
Synergic MIG/MAG parameters setting (1st level): synergic curve setting............................................. 50
Manual MIG/MAG parameters setting (2nd level).................................................................................... 50
PULSED SYNERGIC MIG/MAG WELDING............................................................................................ 53
Pulsed Synergic MIG/MAG parameters setting (1st level): synergic curve setting................................. 54
Pulsed Synergic MIG/MAG parameters setting (2nd level)..................................................................... 55
DOUBLE PULSED SYNERGIC MIG/MAG WELDING............................................................................ 57
Double pulsed synergic MIG/MAG parameters setting (1st level): synergic curve setting...................... 58
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10.5.2
10.6
10.6.1
10.6.2
10.7
10.7.1
10.7.2
10.8
10.8.1
10.8.2
Double pulsed synergic MIG/MAG parameters setting (2nd level)......................................................... 58
MMA WELDING....................................................................................................................................... 61
MMA Parameters Setting (1st Level): welding current setting................................................................. 61
MMA Parameters Setting (2nd Level)...................................................................................................... 61
ARC AIR WELDING................................................................................................................................. 62
ARC AIR parameters setting (1st level): current setting........................................................................... 63
ARC AIR Parameters Setting (2nd Level)................................................................................................ 63
TIG WELDING......................................................................................................................................... 64
TIG Parameters Setting (1st Level): welding current setting.................................................................... 64
TIG Parameters Setting (2nd Level)........................................................................................................ 64
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
JOBS MANAGEMENT........................................................................................................................... 66
SAVING A JOB......................................................................................................................................... 66
NAMING JOBS........................................................................................................................................ 68
LOADING A USER JOB........................................................................................................................... 69
DELETING A JOB.................................................................................................................................... 70
EXPORTING/IMPORTING JOBs (through a USB memory stick)............................................................ 71
EXPORTING A JOB................................................................................................................................. 71
IMPORTING A JOB.................................................................................................................................. 73
SELECTING JOBS USING THE TORCH UP/DOWN BUTTONS............................................................ 74
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
TORCH TRIGGER MODES..................................................................................................................... 75
2T MIG/MAG WELDING.......................................................................................................................... 75
2T SPOT MIG/MAG WELDING................................................................................................................ 75
4T MIG/MAG WELDING.......................................................................................................................... 75
4T B-LEVEL MIG/MAG WELDING........................................................................................................... 75
2T - 3 LEVEL MIG/MAG WELDING........................................................................................................ 76
2T SPOT - 3 LEVEL MIG/MAG WELDING............................................................................................. 76
4T - 3 LEVEL MIG/MAG WELDING........................................................................................................ 76
4T B-LEVEL - 3 LEVEL MIG/MAG WELDING......................................................................................... 77
13
13.1
TECHNICAL DATA.................................................................................................................................. 78
PIONEER 403 MKS / PIONEER PULSE 403 MKS................................................................................. 79
14
14.1
14.1.1
14.1.2
14.1.3
14.1.4
WIRING DIAGRAM.................................................................................................................................. 80
REMOTE CONTROL CONNECTOR....................................................................................................... 85
RC03: Wiring diagram.............................................................................................................................. 85
RC04: Wiring diagram.............................................................................................................................. 85
RC05: Wiring diagram.............................................................................................................................. 86
RC06: Wiring diagram.............................................................................................................................. 86
15
15.1
15.2
SPARES................................................................................................................................................... 87
WIRE FEEDER MOTOR.......................................................................................................................... 91
WIRE FEEDER ROLLS........................................................................................................................... 93
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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 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
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 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.
*1 The symbol refers to the associated numbered note.
NOTES
The figures in this manual are purely guideline and the images may contain differences with respect to
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 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 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)
TWO STROKE (2T)
TIG
FOUR STROKE (4T)
MMA
ARC AIR
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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.
Connect/disconnect the various devices with the machine switched off.
2.2 FRONT PANEL
Pioneer Pulse 403MKS
2
1
3
5
6
7
8
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
1
3
1: Cooler power feeding connector.
• Voltage400 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)
• Number and Cross section of Wires
• Power plug type
4,5 m
4 x 6,0 mm2
Not supplied
2.4 WIRE FEEDER COMPARTMENT
1
2
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
L2
L1
L3
3P+T
3P4W
1.
2.
3.
4.
5.
6.
7.
Set the welding power source ON/OFF switch to “O” (unit switched off).
Connect the power source mains supply cable to the mains socket outlet.
Connect the gas hose from the welding gas cylinder to the relative socket.
Open the cylinder gas valve.
Connect the MIG/MAG torch plug to the EURO TORCH welding socket.
Connect the plug of the ground clamp to the welding socket on the basis of the polarity required.
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.
Use the flow control valve to adjust the flow of gas as required while the gas is flowing out.
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 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.
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 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.
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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.
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 composition of the wire material.
• The groove must be "U" shaped for soft materials (Aluminium and its alloys, CuSi3).
• The groove must be "V" shaped for harder materials (SG2SG3, stainless steels).
• Rolls with a knurled groove profile are available for fluxcored 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.
14. 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.
15. Refit the protective cover.
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
1.
2.
3.
4.
5.
Set the welding power source ON/OFF switch to “O” (unit switched off).
Plug the power cable plug into a mains socket outlet.
Choose the electrode based on the type of material and thickness of the workpiece to be welded.
Insert the electrode in the electrode holder.
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
current can be adjusted using the remote controller.
The system is ready to start welding.
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FRONT VIEW
(polarity to basic electrode)
REAR VIEW
REMOTE
CONTROL
L2
L1
L3
3P+T
3P4W
2.7 PREPARING FOR TIG WELDING
1.
2.
3.
4.
5.
6.
7.
8.
Set the welding power source ON/OFF switch to “O” (unit switched off).
Plug the power cable plug into a mains socket outlet.
Connect the gas hose from the welding gas cylinder to the rear gas connection.
Open the cylinder gas valve.
Connect the TIG torch plug to the EURO TORCH welding socket.
Choose the electrode based on the type of material and thickness of the workpiece to be welded.
Insert the electrode in the TIG torch.
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.
14. Use the flow control valve to adjust the flow of gas as required while the gas is flowing out.
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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
current can be adjusted using the remote controller.
The system is ready to start welding.
FRONT VIEW
(polarity for tungsten electrode)
REAR VIEW
L2
REMOTE
CONTROL
16
L1
L3
3P+T
3P4W
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3
USER INTERFACE
STOP
L7
HOLD
L4
L8
L1
L5
L2
D1
E1
S1
D2
E2
L6
L3
S2
m/min
mm
S10
S8
ESC
L9
0
L1
E3
D3
1
L1
S3
S4
CODE
S9
S5
SYMBOL
Menu
S6
Mode
S7
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
(Reference is made to "T" fillet welds on identical thicknesses. The relative value is purely
guideline).
The value appears on the following display: D1
L4
Illuminates 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 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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SYMBOL
DESCRIPTION
L8
This LED illuminates to confirm the presence of power on the output sockets.
L9
Illumination shows that the following function has been activated: 2 stroke procedure
§ “12.1 2T MIG/MAG WELDING”
A flashing signal means the following function is activated: 2 stroke procedure
§ “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 WELDING” / § “12.7 4T - 3 LEVEL MIG/MAG WELDING” / § “12.8 4T B-LEVEL - 3 LEVEL MIG/
MAG WELDING”.
A
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..
V
Data setting: The display shows the value, in Volts, of the selected welding voltage.
Welding: The display shows the effective voltage value during welding.
D2
HOLD function (at welding end): The display shows the latest measured voltage value.
Data setting: The display shows the various welding menus relative to the selected processes.
The display shows the selected parameter.
D3
Manual MIG/MAG mode: The button is not active.
S1
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
MODE
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 following display: D3
§ “11 JOBS MANAGEMENT”
E1
18
Data setting: The encoder adjusts the main welding (and synergy) parameter, shown on the
following display: D1
During welding operations with an active JOB: The encoder temporarily modifies the main
welding parameter, shown on the following display: D1
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CODE
SYMBOL
ENGLISH
DESCRIPTION
Manual MIG/MAG mode: The encoder adjusts the welding voltage, and the relative value is
shown, in volts, on the following display: D2
E2
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: The encoder temporarily modifies the main
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
This button opens the gas solenoid valve to fill the circuit and calibrate the pressure with the regulator 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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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
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: The following messages will appear in sequence on this display:
Tab. 1 - Messages at power-up
5
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.
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 settings set in the factory.
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.
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5.1 PARTIAL RESET
The reset procedure involves restoration of the parameter values and settings, except the following
settings:
- Settings of the SETUP menu.
- saved JOBS.
STOP
L7
L8
L1
ACTIVATION
HOLD
L4
B
S2
L5
S1
L2
A
D1
E1
m/min
D2
E2
L3
L6
ACTIVATION
mm
S10
S8
ESC
L9
EXIT
0
1
L1
S3
S4
S9
L1
E3
D3
A
S5
Menu
S6
Mode
S7
○ 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.
A
B
○ Simultaneously press the keys S1
and S10
[
This operation must be carried
out before the wording “PROGRAM UPDATE” appears in the following display: D3 ]
○
PARTIAL RESET SELECT TYPE OF RESET : The message will appear on display: D3
○ Exit without confirmation
- 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.
○ Exit with confirmation
to save the setting and quit the menu.
- Press S2
The display D3 will show the message: MEMORY CLEANING
- Wait for the memory clear procedure to terminate.
The unit restarts with the power-up procedure.
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5.2 TOTAL RESET
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!
STOP
ACTIVATION
HOLD
L7
L4
L8
L1
C
S2
L5
S1
L2
A
m/min
D1
E1
D2
E2
L6
L3
ACTIVATION
mm
S10
S8
ESC
L9
EXIT
S9
L1
0
E3
D3
A
1
L1
S3
S4
S5
IMPOSTAZIONE
Menu
S6
Mode
S7
B
○ 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.
A
and S10
[
This operation must be carried
○ Simultaneously press the keys S1
out before the wording “PROGRAM UPDATE” appears in the following display: D3 ]
PARTIAL RESET SELECT TYPE OF RESET : The message will appear on display: D3
B
○ Use the encoder E3
C
22
, to select the following “TOTAL RESET ”.
○ Exit without confirmation
- 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.
○ Exit with confirmation
to save the setting and quit the menu.
- Press S2
The display D3 will show the message: MEMORY CLEANING
- Wait for the memory clear procedure to terminate.
The unit restarts with the power-up procedure.
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6
SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)
With locked status active it is not possible to access this function.
§ “6.4 LOCKING PROCEDURE”.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
D
S2
S10
S8
ESC
L9
L1
0
E3
D3
1
L1
S3
B
S9
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
C
A
ACTIVATION
SET UP at machine power 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.
A
○ Simultaneously press button S5
[
This operation must be carried out before the
wording “PROGRAM UPDATE” appears on the following display: D3 ]
SET UP X/Y : The message will appear for a few seconds on display D3.
- X = number of the currently displayed menu page.
- Y = total number of menu pages.
B
○ Press buttons S3
and S4
to scroll down the list of settings to edit.
- Activation of the ADJUSTMENTS BLOCK calls for a specific procedure.
§ “6.4 LOCKING PROCEDURE”.
-
C
○ Using the encoder E3
D
to save the setting and quit the menu.
○ Press S2
- The unit restarts with the power-up procedure..
, edit the value of the selected setting.
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NOTE: During the normal operation, the operator can enter the SET UP menu by pressing the key S5
for 5 seconds (SET UP can therefore be accessed with machine on).
Tab. 2 - Setup settings
MENU
PAGE
SETTING
SET UP
1/10
SELECT LANGUAGE
SET UP
2/10
COOLING TYPE
SET UP
3/10
DISPLAY CONTRAST
SET UP
4/10
CONTROL TYPE
MIN
DEFAULT
MAX
NOTES
ENGLISH
ITALIANO
FRANÇAIS
DEUTSCH
ESPAÑOL
PORTUGUES
DUTCH
CESKY
SRBSKI
POLSKI
SUOMI
ON
AUTO
AUTO
0%
50 %
100 %
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
OFF
LOCK 1
SET UP
5/10
LOCK STATUS
SET UP
6/10
ARC CORRECTION
VOLTS
VOLTS
m/min
SET UP
7/10
HOUR COUNTER
0.0 h
0.0 h
0.0 h
SET UP
8/10
SERVICE
INFO
INFO
CALIB R A TION
SET UP
9/10
PUSH-PULL
OFF
OFF
ON
SET UP
10/10
24
OFF
OFF
LOCK 2
LOCK 2
TRIGGER TYPE
OFF
OFF
All adjustments enabled.
All adjustments are disabled
with the exceptions shown
in “- Functions not disabled
by Locks” on page 29
Access to the submenu of
the calibration and validation services
OFF
Normal operation of torch
button.
T01
Enable Job scroll function
in welding by pressing the
torch button.
T01
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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 plus
a number of seconds equivalent to the average current value shown using the HOLD function.
6.1 OPERATING HOUR COUNTER
The menu page shows the processing hour counters.
• POWER ON = Total number of hours the machine has been on (mains powered).
• T.ARC ON = Total number of hours of welding arc on.
• P.ARC ON = Partial number of hours of welding arc on.
SET UP
POWER ON
T. ARC. ON
P. ARC ON
7/10
7h 11’
2h 10’
2h 20’
6.2 SERVICE MENU
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
S2
E2
L6
L3
EXIT
E
D2
mm
S10
S8
ESC
L9
E3
D3
0
S3
1
L1
B D
L1
SELECTION
S9
S4
S5
Menu
S6
Mode
S7
VISUALIZATION
SELECTION
A
○ Press and hold down the key S5
C
A
ACTIVATION
CONFIRMATION
for 3 seconds (SET UP with machine on).
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B
○ Press keys S3
A
○ Press the button S5
to enter the 2nd level menu.
C
○ Use the encoder E3
, to select the requested item.
A
○ Press the S5
D
○ Press buttons S3
E
○ Press the S2 button
.
This action will automatically close the menu
and S4
to select line “SET UP 8/8”.
button to confirm.
and S4
to scroll down the pages to be displayed.
- INFO
The following information is displayed:
○ Software version and machine type (page 1/3)
○ Temperature measured by the thermal sensors inside the power generator (page 2/3)
○ Voltage display of the power generator 3 phases (page 3/3).
- ALARMS LIST
The last 12 alarm codes are displayed with the counter value POWER ON when the alarm is triggered. The list is display on 4 pages.
Service procedures
This setting enables the machine validation (VAL.) and calibration (CALIBRATION) operations.
The SERVICE procedure is not described in this manual as it can be carried out only by specialised,
suitably trained and equipped technical staff.
The testing methods and the equipment required are set out in the relevant technical standards.
- CURRENT VAL.
○ The validation procedure allows the current value (Ampere) to be correctly detected and displayed on the equipment display. The validation procedure requires the equipment to be connected to a suitable static load.
- VOLTAGE VAL.
○ The validation procedure allows the voltage value (Volt) to be correctly detected and displayed
on the equipment display. The validation procedure requires the equipment to be connected to a
suitable static load.
- WIRE S. VAL.
○ The validation procedure allows the wire feed rate (m/min) to be correctly detected and displayed
on the equipment display.
- CALIBRATION
○ The calibration procedure allows the machine current to be calibrated.
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STOP
L7
HOLD
L4
L8
L1
L5
L2
D1
E1
S1
D2
E2
L6
L3
S2
m/min
mm
S10
S8
ESC
L9
0
L1
SELECTION
E3
D3
S9
1
L1
S3
B C
S4
S5
Menu
S6
Mode
S7
SETTING
A
A
Partial count reset
○ Press and hold down the key S5
B
○ Press keys S3
C
○ Simultaneously hold down keys S3
and S4
The value P.ARC ON will be taken to 0.0 h
and S4
ACTIVATION
for 3 seconds (SET UP with machine on).
to select line “SET UP 7/10”.
for 3 seconds.
6.3 TRIGGER TYPE
If T01 mode is activated, the job scroll function in welding is enabled by pressing the torch button.
In T01 mode, the torch button operates in 4 strokes or 4 strokes 3 levels with Bilevel functions disabled.
Therefore, if jobs are saved with different modes, they are automatically provided according to these
conditions (which are not saved).
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6.4 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 (LOCK STATUS = OFF) and if you wish to set up a limitation on use of
the welding power source, display page 5/10 of the SETUP menu. During the normal operation, the
operator can enter the SET UP menu by pressing the key S5
for 5 seconds (SET UP can therefore
be accessed with machine on).
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
D
S2
S10
S8
ESC
L9
0
S3
1
L1
C
L1
E3
D3
S9
S4
S5
Menu
S6
Mode
S7
SETTING
SELECTION
A
○ Use the encoder E3
A
B
D
CONFIRMATION
EXIT
to select the required lock status.
B
○ Press the S5
button to confirm.
ENTER PASSWORD: 000 - The message wll appear on display: D3
Default password: 000
C
○ Enter a 4 digit numerical password.
and S4
to select the digit to be changed.
○ Use buttons S3
The selected digit will flash .
to set up the value.
○ Use encoder E3
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D
○ Exit without confirmation
- Press the S2
button.
This action will automatically close the menu
○ Exit with confirmation
- Press the S5
button.
The unit restarts with the power-up procedure.
The password becomes active. Make a note of the password you set!
Tab. 3 - Functions not disabled by Locks
TYPE OF REMOTE CONTROL
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
2
Selection of torch trigger
procedure (button S7)
Display of main welding
parameters (button S1)
Arc correction (encoder E2)
Wire insertion (button S10)
Gas test (button S9)
Selection of torch trigger
procedure (button S7)
Display of main welding
parameters (button S1)
Arc correction (encoder E2)
Synergy (encoder E1)
Wire insertion (button S10)
Gas test (button S9)
Arc correction
(Potentiometer
PoS6)
All
adjustments
enabled.
All adjustments
enabled.
NOTES
Arc correction
(UP/DOWN
lever 2)
All
adjustments
enabled.
All
adjustments
enabled.
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 lock status is to perform the welding power source
RESET procedure.
NOTE: The welding power source must be on and set up for welding.
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STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
S2
E2
L6
L3
C
EXIT
D2
mm
S10
S8
ESC
L9
0
L1
E3
D3
S9
1
L1
S3
B
S4
S5
Menu
S6
Mode
S7
SETTING
SETTING
B
A
C
SELECTION
EXIT
A
○ Press and hold down the button S5
for 5 second.
The SET UP menu will be accessed, with the machine on.
LOCK...WRITE PASSWORD : 000 - The message will appear on display: D3
○ Enter the active 4 digit numerical password.
B
○ Use buttons S3
and S4
to select the digit to be changed.
The selected digit will flash..
to set up the value.
○ Use encoder E3
C
○ Exit without confirmation
- Press the S2
button.
This action will automatically close the menu
○ Exit with confirmation
- Press the S5
button.
The unit restarts with the power-up procedure.
Quit lock status.
6.5 GAS FLOW ADJUSTMENT
When the unit is powered on the solenoid valve opens for 1 second.
This serves to fill the gas circuit.
○ Open the gas solenoid valve by pressing and releasing button S9
.
○ Adjust the pressure of gas flowing from the torch by means of the flow meter connected to the
gas cylinder.
.
○ Close the gas solenoid valve by pressing and releasing the button S9
○ The solenoid valve closes automatically after 30 seconds.
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6.6 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.
CHECK COOLING UNIT - The message will appear in display: D3
or torch trigger to repeat the checking procedure for an additional 30 sec○ Press button S2
onds.
• If the problem persists rectify the cause of the alarm.
• During this checking operation, the setup menu can be accessed by pressing button S5
for 5 seconds.
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.
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.
6.7 RESISTIVE CALIBRATION OF THE WELDING CIRCUIT
When the wire feeder is used with the associated cable bundle, the welding circuit “r” resistance must
be measured by using the calibration function. This allows to achieve a consistent welding quality when
the cable bundle length and the torch is changed. The welding circuit resistance depends on the cable
bundle and the torch used, therefore the calibration procedure must be repeated when these components are changed.
CALIBRATION after power source RESET
If the power source total RESET is carried out, the calibration value will be replaced by the default value.
If a partial RESET is carried out, the measured value will be stored.
Calibration is not compulsory therefore, should the user decide not to carry it out, the machine will keep
the default value.
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CALIBRATION PROCEDURE
STOP
L7
HOLD
L4
L8
L1
L5
L2
D1
E1
S1
m/min
L6
L3
S2
E2
mm
EXIT
C B
D2
S10
S8
ESC
L9
S3
S4
1
L1
A
0
L1
E3
D3
S9
S5
Menu
S6
Mode
S7
SETTING
B
EXIT
The welding power source must be on and not set up for welding.
The power source remote control must be enabled.
A
and S4
.
○ Press and hold down for 3 seconds buttons S3
TOUCH THE WORKPIECE WITH THE GUIDE WIRE TIP AND PRESS THE TORCH
TRIGGER- The message will appear on display: D3
CAL - The message will appear on display: D1
Display D2 will show the welding circuit resistance value (mΩ) measured during the last
calibration. After a total RESET, the default value will appear.
Remove the gas nozzle from the torch and lean the guide wire tip (without the wire) onto the surface
of the workpiece, making sure it sticks well; check that the contact between the guide wire tip and the
workpiece is on a clean area of the piece's surface. Press the torch button to perform the calibration.
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STOP
L7
HOLD
L4
L8
L1
L5
L2
D1
E1
S1
m/min
D2
E2
L6
L3
mm
EXIT
C B
S2
S10
S8
ESC
L9
S3
S4
1
L1
A
0
L1
E3
D3
S9
S5
Menu
S6
Mode
S7
SETTING
B
EXIT
Calibration carried out correctly
B
CALIBRATION SUCCESSFULLY COMPLETED - The message will appear on display:
D3.
The calibration value appears on display : D2.
You can make several subsequent calibrations by pressing and releasing the torch trigger. In
this case the last value revealed is memorized.
○ Exiting without saving
button.
- Press the S2
○ Exit and save
- Press the S5
button.
Calibration carried out incorrectly
C
CAL. Err. - The message will appear on display: D1 - D2.
REPEAT THE MEASUREMENT The message will appear on display: D3.
Press the torch trigger to perform the calibration.
○ Exiting without saving
button.
- Press the S2
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ALARM MANAGEMENT
This LED illuminates if an incorrect operating condition occurs.
An alarm message will appear on display D3.
Tab. 4 - Alarm messages
MESSAGE
MEANING
CODE
EVENT
CHECKS
E02
All functions are disabled.
ALARM NTC DISCONNECTED
Exceptions:
It indicates that at least one of the
• the cooling fan.
NTC is disconnected
• the cooling unit (if switched on)
Qualified technical personnel are
required.
E03
ALARM PRIMARY CURRENT
It indicates that the primary current cabling is disconnected
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (if switched on)
Qualified technical personnel are
required.
E04
All functions are disabled.
ALARM, OPEN CIRCUIT VOLTAExceptions:
GE NOT PRESENT
• the cooling fan.
Ensure the welding sockets are
not short circuiting before switching on the power source.
If the problem persists:
qualified technical personnel are
required for maintenance jobs.
E05
ALARM TRIGGER PRESSED
It indicates that at the welding
system power-up or after an
alarm reset, a short circuit was
detected on the torch trigger
input.
When the problem is solved, the
welding power source will reset
automatically.
All functions are disabled.
Exceptions:
• the cooling fan.
• Make sure the torch trigger is
not pressed, jammed, or short
circuiting.
• Make sure the torch and MIG/
MAG torch connector are intact.
• If the problem persists:
qualified technical personnel are
required.
E27
ALARM UNDERVOLTAGE
It indicates that the voltage on at
least one phase is lower than the
minimum threshold
The RED led next to the ON/OFF
switch turns on.
All functions are disabled.
Exceptions:
• the cooling fan.
Make sure that the welding system supply voltage complies with
the plate values.
E28
ALARM OVERVOLTAGE
It indicates that the voltage on at
least one phase is greater than
the maximum threshold
The led next to the ON/OFF
switch turns on.
All functions are disabled.
Exceptions:
• the cooling fan.
Make sure that the welding system supply voltage complies with
the plate values.
E29
ALARM PHASE MISSING
It indicates the absence of a
phase in the equipment power
supply line.
The led next to the ON/OFF
switch turns on.
All functions are disabled.
Exceptions:
• the cooling fan.
• Check if the equipment power
supply line has all the phases.
E30
ALARM PRIMARY OVERCURRENT
It indicates that the primary current surge protector has tripped.
Exit the alarm status by performing one of the following actions:
• Switch the power source off.
• Press the following button: ESC
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (if switched on)
Qualified technical personnel are
required.
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MESSAGE
MEANING
CODE
EVENT
CHECKS
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (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.
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (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.
E31
ALARM PRIMARY OVERTEMPERATURE
It indicates that the welding
power source thermal cut-out
switch has tripped.
Leave the equipment running so
that the overheated components
cool as rapidly as possible.
When the problem is solved, the
welding power source will reset
automatically.
E32
ALARM SECONDARY OVERTEMPERATURE
It indicates that the welding
power source thermal cut-out
switch has tripped.
Leave the equipment running so
that the overheated components
cool as rapidly as possible.
When the problem is solved, the
welding power source will reset
automatically.
E35
ALARM MAGNETIC OVERTEMPERATURE
It indicates that the welding
power source thermal cut-out
switch has tripped.
Leave the equipment running so
that the overheated components
cool as rapidly as possible.
When the problem is solved, the
welding power source will reset
automatically.
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (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.
E37
ALARM CURRENT LEVEL
EXCEEDED
It indicates that the welding power source current surge protector
has tripped.
Exit the alarm status by performing one of the following actions:
• Switch the power source off.
• Press the following button: ESC
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (if switched on)
• Check that the programmed
arc voltage value is not too high
in relation to the thickness of the
workpiece to be welded.
• Check the welding parameters.
• RESET the parameters.
E40
ALARM CAN BUS COMMUNICATION
It indicates a CAN communication
problem.
Exit the alarm status by performing one of the following actions:
• Press the following button: ESC
All functions are disabled.
Exceptions:
• the cooling fan.
• the cooling unit (if switched on)
• Check that the connecting cable
between power source and wire
feeder is intact and make sure the
connectors are securely tightened.
• If the problem persists:
qualified technical personnel are
required.
E49
ALARM DATA LOSS
It indicates a factory setting data
loss condition of the board
All functions are disabled.
Exceptions:
• the cooling fan.
Qualified technical personnel are
required.
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MESSAGE
MEANING
CODE
EVENT
CHECKS
E50
All functions disabled.
Exceptions:
• Cooling fan.
The alarm message persists on
the display until the first operation
is performed on the user interface.
Signalling of the alarm depends
on the following settings:
• Coo = on: the alarm is signalled
COOLER ALARM
if the cooling unit is connected
Indicates insufficient pressure in
to the power source and if it is
the torch liquid cooling circuit.
running.
• Coo = oFF: the alarm is never
signalled, irrespective of the circumstances.
• Coo = Aut: the alarm is signalled
if the cooling unit is connected
to the power source and if it is
running.
• 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, the fuse and the internal
connections of the cooler.
E58
ALARM INTERNAL POWER
SUPPLY
It indicates a power supply
problem in one of the electronic
boards
Qualified technical personnel are
required.
36
All functions are disabled.
Exceptions:
• the cooling fan.
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8
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)
2: Available selecting one of the "PR" curves (e.g.: SG2/SG3 PR)
3: available in PIONEER PULSE MKS line power sources
MODE
→
MENU
↓
PROCEDURE
→
PARAMETER
↓
-
Arc correction in Volts



3
3
3
3
3
3
-
Arc correction in metres per minute



3
3
3
3
3
3
-
Arc correction with Power Root
2
2
2
1st
Inductance
2nd
Inductance



2nd
PR Start
2
2
2
2°
Arc Set
3
3
3
3
3
3
2°
Pre Gas





3
3
3
3
3
3
2°
Soft Start





3
3
3
3
3
3
2°
Burn back





3
3
3
3
3
3
2°
Post gas





3
3
3
3
3
3
2°
Power focus
1
1
1
2°
Spot time
2°
B-level
3
3
2°
Start 3lev

3
3
2°
Crater 3lev

3
3
2°
Slope 3lev 1

3
3
2°
Slope 3lev 2

3
3
2°
Corr. 3lev1

2°
Corr. 3lev2

2°
Freq 2puls
3
3
3
2°
Range 2puls
3
3
3
2°
Cycle 2puls
3
3
3
2°
Arc2 2puls
3
3
3
2°
Arc2 2puls
3
3
3



3



3
3
3
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8.1 MIG/MAG 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.
• Arc correction with Power Root
○ The parameter corrects the arc dynamics in the POWER ROOT process.
○ The default value is 0.
- NOTE Values >0 produce a «softer» weld, while values <0 produce a «harder» weld.
• INDUCTANCE (MIG/MAG manual 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.
• INDUCTANCE
○ The value SYN=0 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.
• PR START
○ The value SYN=0 denotes the optimal synergic inductance value chosen by the manufacturer.
○ IMPORTANT NOTE: This inductance value corresponds to start-up with the POWER ROOT
curves.
- Consequences of a higher value:
• Less positive starting.
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- Consequences of a lower value:
• 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.
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• BURN BACK
○ TheBURNBACKvalueisassociatedwiththequantityofwirethatisburntattheendofthewelding 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.
• 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
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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 slope in 3-level operation
○ The parameter controls the slope 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 slope in 3-level operation
○ The parameter controls the slope 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.
• CORR 3LEV 1
• Initial correction in 3-level operation
○ The parameter corrects the synergic value of the wire feed rate or of the arc tension during the
Hot Start time.
• CORR 3LEV 2
• Final correction in 3-level operation
○ The parameter corrects the synergic value of the wire feed rate or of the arc tension during the
down slope time.
• FREQ 2PULS
• Double pulsed frequency
○ This parameter adjusts the frequency of alternation of the two wire feed rates set with 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.
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○ 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 2PULS (on display D4), the wire feed rate will vary between 4 m/min (low
feed rate) and 6 m/min (high feed rate).
Wire speed (m/min)
10
9
Freq 2puls
8
7
High speed 6
Middle speed 5
Low speed 4
3
Cycle 2puls
2
1
1
2
3
4
5
6
minute
• CYCLE 2PULS
• Double pulsed duty cycle
○ The parameter adjusts the high feed rate time.
○ The value is expressed as a percentage over the pulse frequency period.
• ARC2 2PULS
• Arc2 voltage in double pulsed mode
○ The parameter corrects the synergic voltage value relative to the low wire feed rate of double
pulsed mode.
- NOTE: A value >0 produces an increase in the length of the welding arc, while a value <0 produces a shorter arc.
• ARC2 2PULS
• Arc2 wire feed rate in double pulsed mode
○ The parameter corrects the synergic value of the wire feed rate relative to the low voltage value
of double pulsed mode.
- NOTE: A value <0 produces an increase in the length of the welding arc, while a value >0 produces a shorter arc.
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8.2 MMA WELDING PARAMETERS
• WELDING CURRENT
○ This parameter regulates the primary welding current value.
• HOT-START
○ This parameter aids electrode melting at the time of arc striking. It is set as a percentage referred
to the value of the following parameter: WELDING CURRENT. The value is limited to 250A max.
- Consequences of a higher value:
• Ease of activation; Greater starting spatter; increase in the activation area.
• Consequences of a lower value:
• Difficulty of activation; Less starting splatter; Reduction in the activation area.
• ARC FORCE
○ This parameter helps to avoid electrode sticking during welding. It is set as a percentage referred
to the value of the following parameter: WELDING CURRENT
- Consequences of a higher value:
• Fluency factors in welding; Arc welding stability;Increased melting of the electrode within the
workpiece; More weld spatter.
- Consequences of a lower value:
• The arc is extinguished more easily, less welding spatter.
8.3 TIG WELDING PARAMETERS
• DOWN SLOPE
○ Time during which the current changes from the welding value to the end value by means of a
slope. Prevents the formation of craters in the process of turning off the arc. The parameter is not
used during the welding process when the following setting is present: MULTI TACK = ON
• FINAL CURRENT
○ During electrode welding the parameter makes it possible to obtain a uniform deposit of filler material from the start to the end of the welding process, closing the deposition crater with a current
such as to deposit a final droplet of filler material.
○ The value of this parameter can be set as a percentage of the welding current or as an absolute
value expressed in Amperes.
○ The parameter is displayed but it is not used during the welding process when the following setting is present: MULTI TACK = ON
○ By keeping the torch trigger pressed during the 3rd time, the crater filler current is maintained
thereby ensuring optimal crater filling, until the post gas time is started by releasing the torch trigger (4th time).
• POST GAS TIME
○ Time of post gas delivery when the welding arc is extinguished.
- 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).
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9
WELD THE WORLD
CHARACTERISTICS OF THE MENU LEVELS
9.1 1ST LEVEL
The menu shows the setting of the most important welding parameters (or synergic settings) relative to
the selected welding process.
SYN: This code indicates that parameters control is synergic.
MAN: This code indicates that parameters control is manual.
Acronym of the selected welding
process.
MAT: This parameter sets the
material of the welding wire utilised.
GAS: This parameter sets the
type of gas utilised for welding.
Name of loaded JOB.
SHORT/SPRAY
MAT 
SYN
Ø:1.2
SG2/SG3
GAS: 80% Ar / 20% CO2
R4
JOB : FE55 MARIO
K1
When the indicator is ““” the parameter value can be modified.
The value is saved automatically.
After pressing the torch trigger or after 10 seconds without any commands, the indicator
switches to “:”.
To reactivate the parameter value editing function press one of the following buttons:
.
Ø: This parameter sets the diameter of the wire utilised for
welding procedures.
R: Type of remote control enabled.
If no remote control is enabled
no message is displayed.
K: Type of lock enabled.
If no Lock is loaded no message
is displayed.
9.2 2ND LEVEL
For each process selection the menu shows the "secondary" welding parameters that can be modified
with respect to their synergic values.
If the type of wire, gas, or diameter is changed within a welding process, the second level parameters
return to their default values.
The changed parameters remain saved for the relative process selection (manual MIG/MAG, synergic,
pulsed synergic, double pulsed synergic ).
To save and retrieve the changes made, utilise the JOBs storage procedure.
When the message DEFAULT is replaced by the letters SYN this means that the value changes in relation
to the selected synergic curve.
Menu level
MENU 2
Selected parameter.
PRE GAS
Minimum value (MIN), maximum value (MAX) and factory
value (DEFAULT) of the selected parameter.
44
Arrow cursor.
x/y

X = number of the currently displayed menu page.
Y = total number of menu pages.
0.0s
MIN
DEFAULT
MAX
0.0s
0.0s
10.0s
Set value.
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9.3 3RD LEVEL
The menu contains the settings and values that are changed infrequently and are to be set up the first
time the unit is powered up.
The changed parameters remain saved until the next modification or reset of the unit.
§ “6 SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE)”.
Menu level
Selected parameter.
SET UP
x/y
COOLING TYPE
ON
x = number of the currently displayed menu page.
y = total number of menu pages.
Set value.
10 WELDING SETTINGS
10.1 WELDING CURVES SELECTION
SHORT/SPRAY
MAT 
SG2/SG3
SYN
Ø:1.2
GAS: 80% Ar / 20% CO2
R4
JOB : FE55 MARIO
K1
○ Select parameter MAT by pressing buttons S3
and S4
.
, edit the value of the selected parameter.
- Using the encoder E3
and S4
.
○ Select parameter Ø by pressing buttons S3
, edit the value of the selected parameter.
- Using the encoder E3
and S4
.
○ Select parameter GAS by pressing buttons S3
- Using the encoder E3
, edit the value of the selected parameter.
10.1.1 Special curves: POWER FOCUS and POWER ROOT
No specific procedures are required to activate these curves. The special curves appear in the list together with the standard curves.
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POWER FOCUS CURVES: the curves are available in HSL series power sources in SYNERGIC
SHORT SPRAY MIG/MAG welding mode.
The difference between a standard MIG MAG and Power Focus is its concentration and pressure.
The POWER FOCUS arc concentration allows the welder to focus the high temperature of the arc in
the central section of the deposition, thus avoiding to overheat the sides of the welding. The thermally
changed area with the Power Focus arc is less widespread.
These curves differ from the other standard curves because of the acronym PF which is displayed after
the reference to the welding wire material.
Example:
SHORT/SPRAY
MAT 
SG2/SG3
SYN
PF
Ø:1.2
GAS: 80% Ar / 20% CO2
R4
JOB : FE55 MARIO
K1
POWER ROOT CURVES: the curves are available in SYNERGIC SHORT SPRAY MIG/MAG welding
mode.
Power Root is an optimised short arc transfer with the feature of having a cold drop transfer. Power Root
allows to achieve a very high quality in root passes.
These curves differ from the other standard curves because of the acronym PR which is displayed after
the reference to the welding wire material.
Example:
SHORT/SPRAY
MAT 
46
SG2/SG3
SYN
PR
Ø:1.2
GAS: 80% Ar / 20% CO2
R4
JOB : FE55 MARIO
K1
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10.2 MANUAL MIG/MAG WELDING
Welding is of the Short/Spray type.
Adjustment of the main welding parameters, wire feed rate and voltage is entirely at the discretion of the
operator. The optimal work point must be identified for the required welding type.
During a welding operation with an active JOB, it is possible to temporarily change the parameters
shown in the displays D1 and D2 with their encoders to test the temporary changes made to the welding operation. At the end of the welding operation (and HOLD is quit) the values of the loaded JOB are
reset.
When the welding operation is not being carried out and a JOB is active through encoder E3, the JOBs
belonging to its sequence can be scrolled.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
E2
L6
L3
S2
D2
mm
S10
S8
ESC
L9
L1
0
E3
D3
1
L1
S3
D
S9
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
S6
MODE
B
C
SELECTION
A
A
SELECTION
This button serves to select the following welding mode:
MANUAL MIG/MAG
A
S7
Use this button to select one of the following torch trigger procedures:
2 STROKE
2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value other
than “OFF”.
4 STROKE
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Tab. 5 - Main settings and displays in MANUAL MIG/MAG mode
DISPLAY D1
DISPLAY D2
Data setting
Shows the wire feed rate setting in m/
min, which can be altered by means of
the following encoder: (E1).
Shows the set welding voltage, which
can be adjusted with the following
encoder: (E2).
Welding
Shows the average current measured
during welding.
Shows the average voltage measured
during welding.
HOLD function
(At welding end)
Shows the average current measured
during the last welding procedure
performed.
Shows the average voltage measured
during the last welding procedure
performed.
10.2.1 Manual MIG/MAG parameters setting (1st level): inductance setting.
B
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
SHORT/SPRAY
IND 100
IND: This parameter allows electronic adjustment of the welding inductance from the main
menu.
MAN
10.2.2 MANUAL MIG/MAG PARAMETERS SETTING (2ND LEVEL)
C
○ Press the button S5
D
○ Scroll down the list of parameters to be edited by pressing buttons S3
B
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
to enter the 2nd level menu.
and S4
Tab. 6 - 2nd level menu parameters in MANUAL MIG/MAG mode
PROCEDURE
2 STROKE
2 STROKE SPOT
4 STROKE
48
PARAMETER
MIN
DEFAULT
MAX
INDUCTANCE
(row 1/6)
-100
0
100
PRE GAS
(row 2/6)
0.0 s
0.0 s
10.0 s
SOFT START
(row 3/6)
1%
35 %
100 %
BURN BACK
(row 4/6)
1%
25 %
200 %
POST GAS
(row 5/6)
0.0 s
1.0 s
10.0 s
SPOT TIME
(row 6/6)
0.1 s
OFF
25.0 s
INDUCTANCE
(row 1/5)
-100
0
100
PRE GAS
(row 2/5)
0.0 s
0.0 s
10.0 s
SOFT START
(row 3/5)
1%
35 %
100 %
BURN BACK
(row 4/5)
1%
25 %
200 %
POST GAS
(row 5/5)
0.0 s
1.0 s
10.0 s
NOTES
The parameter value is saved for each
welding mode.
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
10.3 SYNERGIC MIG/MAG WELDING
Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding
parameter, chosen among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.
NOTE: The synergic curves were created with reference to a fillet weld in position PB (horizontal-vertical) with 10 mm stick-out (distance from torch to workpiece).
In general, the parameter set is the wire feed rate (associated with the deposition of filler material) and
the synergic welding power source automatically sets the most suitable welding voltage.
Encoder E2 can be adjusted to correct the arc shown on display D3, in order to make minor adjustments
in accordance with requirements.
During a welding operation with an active JOB, it is possible to temporarily change the parameters
shown in the displays D1 and D2 with their encoders to test the temporary changes made to the welding operation. At the end of the welding operation (and HOLD is quit) the values of the loaded JOB are
reset.
When the welding operation is not being carried out and a JOB is active through encoder E3, the JOBs
belonging to its sequence can be scrolled.
The welding power source also automatically adjusts several secondary parameters that are relevant
for welding quality.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
E2
L6
L3
S2
D2
mm
S10
S8
ESC
L9
L1
0
E3
D3
S9
1
L1
S3
B
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
C
D
A
A
SELECTION
SELECTION
49
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
S6
WELD THE WORLD
MODE
This button serves to select the following welding mode:
SYNERGIC MIG/MAG
S7
A
Use this button to select one of the following torch trigger procedures:
2 STROKE
2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value other
than “OFF”.
4 STROKE
4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value other
than “OFF”
3 LEVEL 2 STROKE
3 LEVEL 2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value
other than “OFF”. If the "SPOT TIME" parameter is active in the 3 LEVELS procedure, its value denotes
the time for which the main welding current is supplied.
3 LEVEL 4 STROKE
3 LEVEL 4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value
other than “OFF”
Tab. 7 - Main settings and displays in SYNERGIC MIG/MAG mode
DISPLAY D1
DISPLAY D2
Data setting
Shows the main synergy parameter
(wire feed rate, Amperes, recommended thickness), which can be adjusted
with the following encoder: (E1).
Shows the set welding voltage, which
can be adjusted with the following
encoder: (E2).
Shows the arc correction executed by
the operator with encoder (E2).
Shows the arc correction executed by
the operator with encoder (E2).
Welding
Shows the average current measured
during welding.
Shows the average voltage measured
during welding.
HOLD function
(At welding end)
Shows the average current measured
during the last welding procedure
performed.
Shows the average voltage measured
during the last welding procedure
performed.
10.3.1 Synergic MIG/MAG parameters setting (1st level): synergic curve setting
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
and S4
10.3.2 Manual MIG/MAG parameters setting (2nd level)
D
○ Press the button S5
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
50
to enter the 2nd level menu.
and S4
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
Tab. 8 - 2nd level menu parameters in SYNERGIC MIG/MAG mode
PROCEDURE
2 STROKE
2 STROKE
SPOT
4 STROKE
4 STROKE
B-LEVEL
PARAMETER
DEFAULT
MAX
INDUCTANCE
(row 1/6)
-100
SYN
100
PR START
(row 1/6)
1
SYN
200
PRE GAS
SOFT START
BURN BACK
POST GAS
(row 2/6)
(row 3/6)
(row 4/6)
(row 5/6)
0.0 s
1%
1%
0.0 s
0.0 s
SYN
SYN
1.0 s
10.0 s
100 %
200 %
10.0 s
SPOT TIME
(row 6/6)
0.1 s
OFF
25.0 s
INDUCTANCE
(row 1/6)
-100
SYN
100
PR START
(row 1/6)
1
SYN
200
PRE GAS
SOFT START
BURN BACK
POST GAS
(row 2/6)
(row 3/6)
(row 4/6)
(row 5/6)
0.0 s
1%
1%
0.0 s
0.0 s
SYN
SYN
1.0 s
10.0 s
100 %
200 %
10.0 s
B-LEVEL
(row 6/6)
1%
OFF
200 %
INDUCTANCE
(row 1/14)
-100
SYN
100
PR START
(row 1/14)
1
SYN
200
PRE GAS
SOFT START
START 3LEV
START TIME
SLOPE 3LEV
1
(row 2/14)
(row 3/14)
(row 4/14)
(row 5/14)
0.0 s
1%
10 %
0.0 s
0.0 s
SYN
130 %
0.5 s
10.0 s
100 %
200 %
10.0 s
(row 6/14)
0.1 s
0.5 s
10.0 s
3 LEVEL
2 STROKE CORR.3LEV1
3 LEVEL
2 STROKE
SPOT
MIN
(row 7/14)
SLOPE 3LEV
2
(row 8/14)
CORR.3LEV2
(row 9/14)
CRATER 3LEV
CRATER TIME
BURN BACK
POST GAS
(row 10/12)
(row 11/14)
(row 12/14)
(row 13/14)
SPOT TIME
(row 14/14)
-9.9 V
0.0 V
-4.0 m/min 0.0 m/min
0.1 s
0.5 s
-9.9 V
0.0 V
-4.0 m/min 0.0 m/min
10 %
80 %
0.0 s
0.5 s
1%
SYN
0.0 s
1.0 s
0.1 s
OFF
NOTES
This parameter is present exclusively with
POWER ROOT.
The parameter value is saved for each
welding mode.
This parameter is present exclusively with
POWER ROOT.
The parameter value is saved for each
welding mode.
This parameter is present exclusively with
POWER ROOT.
9.9 V
4.0 m/min
10.0 s
9.9 V
4.0 m/min
200 %
10.0 s
200 %
10.0 s
25.0 s
The parameter value is saved for each
welding mode.
51
Pioneer 403MKS
Pioneer Pulse 403MKS
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02/09/2020 V.1.0
ENGLISH
PROCEDURE
WELD THE WORLD
PARAMETER
52
DEFAULT
MAX
INDUCTANCE
(row 1/10)
-100
SYN
100
PR START
(row 1/12)
1
SYN
200
PRE GAS
SOFT START
START 3LEV
SLOPE 3LEV
1
(row 2/12)
(row 3/12)
(row 4/12)
0.0 s
1%
10 %
0.0 s
SYN
130 %
10.0 s
100 %
200 %
(row 5/12)
0.1 s
0.5 s
10.0 s
3 LEVEL
4 STROKE CORR.3LEV1
3 LEVEL
4 STROKE
B-LEVEL
MIN
(row 6/12)
SLOPE 3LEV
2
(row 7/12)
CORR.3LEV2
(row 8/12)
B-LEVEL
(row 12/12)
-9.9 V
0.0 V
-4.0 m/min 0.0 m/min
0.1 s
0.5 s
-9.9 V
0.0 V
-4.0 m/min 0.0 m/min
CRATER 3LEV (row 9/12)
10 %
80 %
BURN BACK (row 10/12)
1%
SYN
POST GAS
(row 11/12)
0.0 s
1.0 s
1%
OFF
NOTES
This parameter is present exclusively with
POWER ROOT.
9.9 V
4.0 m/min
10.0 s
9.9 V
4.0 m/min
200 %
200 %
10.0 s
200 %
The parameter value is saved for each
welding mode.
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
10.4 PULSED SYNERGIC MIG/MAG WELDING
(available in PIONEER PULSE MKS line power sources)
Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding
parameter, chosen among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.
NOTE: The synergic curves were created with reference to a fillet weld in position PB (horizontal-vertical) with 10 mm stick-out (distance from torch to workpiece).
In general, the parameter set is the wire feed rate (associated with the deposition of filler material) and
the synergic welding power source automatically sets the most suitable welding voltage.
Encoder E2 can be adjusted to correct the arc shown on display D3, in order to make minor adjustments
in accordance with requirements.
During a welding operation with an active JOB, it is possible to temporarily change the parameters
shown in the displays D1 and D2 with their encoders to test the temporary changes made to the welding operation. At the end of the welding operation (and HOLD is quit) the values of the loaded JOB are
reset.
When the welding operation is not being carried out and a JOB is active through encoder E3, the JOBs
belonging to its sequence can be scrolled.
The welding power source also automatically adjusts several secondary parameters that are relevant
for welding quality.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
E2
L6
L3
S2
D2
mm
S10
S8
ESC
L9
0
S3
1
L1
B
L1
E3
D3
S9
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
C
D
A
A
SELECTION
SELECTION
53
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
S6
WELD THE WORLD
MODE
This button serves to select the following welding mode:
PULSED SYNERGIC MIG/MAG
S7
Use this button to select one of the following torch trigger procedures:
2 STROKE
2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value other
than “OFF”.
4 STROKE
4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value other
than “OFF”
3 LEVEL 2 STROKE
3 LEVEL 2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value
other than “OFF”. If the "SPOT TIME" parameter is active in the 3 LEVELS procedure, its value denotes
the time for which the main welding current is supplied.
3 LEVEL 4 STROKE
3 LEVEL 4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value
other than “OFF”
A
Tab. 9 - Main settings and displays in PULSED SYNERGIC MIG/MAG mode
DISPLAY D1
DISPLAY D2
DISPLAY D3
Data setting
Shows the main synergy parameter (wire feed rate, Amperes,
recommended thickness), which
can be adjusted with the following
encoder: (E1).
Shows the set welding voltage,
which can be adjusted with the
following encoder: (E2).
Shows the arc correction
executed by the operator with
encoder (E2). Displays D2
and D3 change simultaneously, but while display D2 shows
the absolute value, display
D3 shows the correction with
respect to the standard and
optimal value proposed by the
manufacturer.
Shows the arc correction
executed by the operator with
encoder (E2). Displays D2
and D3 change simultaneously, but while display D2 shows
the absolute value, display
D3 shows the correction with
respect to the standard and
optimal value proposed by the
manufacturer. The parameter
corrects the arc dynamics in
the POWER ROOT process.
Welding
Shows the average current measured during welding.
Shows the average voltage
measured during welding.
Shows the arc correction
executed by the operator.
HOLD function
(At welding end)
Shows the average current
measured during the last welding
procedure performed.
Shows the average voltage
measured during the last welding procedure performed.
Shows the arc correction
executed by the operator.
10.4.1 Pulsed Synergic MIG/MAG parameters setting (1st level): synergic curve setting.
54
Cod. 006.0001.2230
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Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
and S4
10.4.2 Pulsed Synergic MIG/MAG parameters setting (2nd level).
D
○ Press the button S5
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
to enter the 2nd level menu.
and S4
Tab. 10 - 2nd level menu parameters in PULSED SYNERGIC MIG/MAG mode
PROCEDURE
2 STROKE
2 STROKE SPOT
4 STROKE
4 STROKE B-LEVEL
3 LEVEL 2 STROKE
2 STROKE SPOT
PARAMETER
MIN
DEFAULT
MAX
ARC SET
(row 1/6)
1
SYN
200
PRE GAS
(row 2/6)
0.0 s
0.0 s
10.0 s
SOFT START
(row 3/6)
1%
SYN
100 %
BURN BACK
(row 4/6)
1%
SYN
200 %
POST GAS
(row 5/6)
0.0 s
1.0 s
10.0 s
SPOT TIME
(row 6/6)
0.1 s
OFF
25.0 s
ARC SET
(row 1/6)
1
SYN
200
PRE GAS
(row 2/6)
0.0 s
0.0 s
10.0 s
SOFT START
(row 3/6)
1%
SYN
100 %
BURN BACK
(row 4/6)
1%
SYN
200 %
POST GAS
(row 5/6)
0.0 s
1.0 s
10.0 s
B-LEVEL
(row 6/6)
1%
OFF
200 %
ARC SET
(row 1/12)
1
SYN
200
PRE GAS
(row 2/12)
0.0 s
SYN
10.0 s
SOFT START
(row 3/12)
1%
SYN
100 %
START 3LEV
(row 4/12)
10 %
130 %
200 %
START TIME
(row 5/12)
0.0 s
0.5 s
10.0 s
SLOPE 3LEV 1
(row 6/12)
0.1 s
0.5 s
10.0 s
SLOPE 3LEV 2
(row 7/12)
0.1 s
0.5 s
10.0 s
CRATER 3LEV
(row 8/12)
10 %
80 %
200 %
CRATER TIME
(row 9/12)
0.0 s
0.5 s
10.0 s
BURN BACK
(row 10/12)
1%
SYN
200 %
POST GAS
(row 11/12)
0.0 s
1.0 s
10.0 s
SPOT TIME
(row 12/12)
0.1 s
OFF
25.0 s
NOTES
The parameter value is saved
for each welding mode.
The parameter value is saved
for each welding mode.
The parameter value is saved
for each welding mode.
55
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
PROCEDURE
3 LEVEL 4 STROKE
4 STROKE B-LEVEL
56
WELD THE WORLD
PARAMETER
MIN
DEFAULT
MAX
ARC SET
(row 1/10)
1
SYN
200
PRE GAS
(row 2/10)
0.0 s
SYN
10.0 s
SOFT START
(row 3/10)
1%
SYN
100 %
START 3LEV
(row 4/10)
10 %
130 %
200 %
SLOPE 3LEV 1
(row 5/10)
0.1 s
0.5 s
10.0 s
SLOPE 3LEV 2
(row 6/10)
0.1 s
0.5 s
10.0 s
CRATER 3LEV
(row 7/10)
10 %
80 %
200 %
BURN BACK
(row 8/10)
1%
SYN
200 %
POST GAS
(row 9/10)
0.0 s
1.0 s
10.0 s
B-LEVEL
(row 10/10)
1%
OFF
200 %
NOTES
The parameter value is saved
for each welding mode.
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
10.5 DOUBLE PULSED SYNERGIC MIG/MAG WELDING
(available in PIONEER PULSE MKS line power sources)
Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding
parameter, chosen among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.
NOTE: The synergic curves were created with reference to a fillet weld in position PB (horizontal-vertical) with 10 mm stick-out (distance from torch to workpiece).
In general, the parameter set is the wire feed rate (associated with the deposition of filler material) and
the synergic welding power source automatically sets the most suitable welding voltage. Encoder E2
can be adjusted to correct the arc shown on display D3, in order to make minor adjustments in accordance with requirements. During a welding operation with an active JOB, it is possible to temporarily
change the parameters shown in the displays D1 and D2 with their encoders to test the temporary
changes made to the welding operation. At the end of the welding operation (and HOLD is quit) the
values of the loaded JOB are reset.
When the welding operation is not being carried out and a JOB is active through encoder E3, the JOBs
belonging to its sequence can be scrolled. The welding power source also automatically adjusts several
secondary parameters that are relevant for welding quality. This mode involves a variable frequency
pulse between two parameters of the Pulsed Synergic curve.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
E2
L6
L3
S2
D2
mm
S10
S8
ESC
L9
S3
1
L1
B
0
D3
S9
L1
E3
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
C
D
A
A
SELECTION
SELECTION
57
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
S6
WELD THE WORLD
This button serves to select the following welding mode:
MODE
DOUBLE PULSED SYNERGIC MIG/MAG
S7
Use this button to select one of the following torch trigger procedures:
2 STROKE
2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value other
than “OFF”.
4 STROKE
4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value other
than “OFF”
3 LEVEL 2 STROKE
3 LEVEL 2 STROKE SPOT: The procedure is active when the “SPOT TIME” parameter is set to a value
other than “OFF”. If the "SPOT TIME" parameter is active in the 3 LEVELS procedure, its value denotes
the time for which the main welding current is supplied.
3 LEVEL 4 STROKE
3 LEVEL 4 STROKE B-LEVEL: The procedure is active when the “B-LEVEL” parameter is set to a value
other than “OFF”
A
Tab. 11 - Main settings and displays in DOUBLE PULSED SYNERGIC MIG/MAG mode
DISPLAY D1
DISPLAY D2
DISPLAY D3
Data setting
Shows the main synergy parameter (wire feed rate, Amperes,
recommended thickness), which
can be adjusted with the following
encoder: (E1).
Shows the set welding voltage,
which can be adjusted with the
following encoder: (E2).
Shows the arc correction
executed by the operator with
encoder (E2). Displays D2
and D3 change simultaneously, but while display D2 shows
the absolute value, display
D3 shows the correction with
respect to the standard and
optimal value proposed by the
manufacturer.
Welding
Shows the average current measured during welding.
Shows the average voltage
measured during welding.
Shows the arc correction
executed by the operator.
HOLD function
(At welding end)
Shows the average current
measured during the last welding
procedure performed.
Shows the average voltage
measured during the last welding procedure performed.
Shows the arc correction
executed by the operator.
10.5.1 DoublepulsedsynergicMIG/MAG parameterssetting(1stlevel):synergiccurvesetting.
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
and S4
10.5.2 Double pulsed synergic MIG/MAG parameters setting (2nd level).
D
○ Press the button S5
B
○ Scroll down the list of parameters to be edited by pressing buttons S3
58
to enter the 2nd level menu.
and S4
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
C
○ Using the encoder E3
, edit the value of the selected parameter
The value is saved automatically.
Tab. 12 - 2nd level menu parameters in DOUBLE PULSED SYNERGIC MIG/MAG mode
PROCEDURE
MIN
DEFAULT
MAX
ARC SET
PRE GAS
SOFT START
BURN BACK
POST GAS
(row 1/10)
(row 2/10)
(row 3/10)
(row 4/10)
(row 5/10)
1
0.0 s
1%
1%
0.0 s
SYN
0.0 s
SYN
SYN
1.0 s
200
10.0 s
100 %
200 %
10.0 s
2 STROKE
SPOT TIME
(row 6/10)
0.1 s
OFF
25.0 s
2 STROKE
SPOT
FREQ 2PULS
RANGE 2PULS
CYCLE 2PULS
(row 7/10)
(row 8/10)
(row 9/10)
ARC2 2PULS
(row 10/10)
0.1 Hz
10 %
10 %
- 9.9 V
1.5 Hz
50 %
50 %
0.0 V
10.0 Hz
90 %
90 %
9.9 V
- 4.0 m/min
0.0 m/min
4.0 m/min
ARC SET
PRE GAS
SOFT START
BURN BACK
POST GAS
(row 1/10)
(row 2/10)
(row 3/10)
(row 4/10)
(row 5/10)
1
0.0 s
1%
1%
0.0 s
SYN
0.0 s
SYN
SYN
1.0 s
200
10.0 s
100 %
200 %
10.0 s
B-LEVEL
(row 6/10)
1%
OFF
200 %
FREQ 2PULS
RANGE 2PULS
(row 7/10)
(row 8/10)
0.1 Hz
10 %
1.5 Hz
50 %
10.0 Hz
90 %
CYCLE 2PULS
(row 9/10)
4 STROKE
4 STROKE
B-LEVEL
3 LEVELS
2 STROKE
2 STROKE
SPOT
PARAMETER
10 %
50 %
90 %
0.0 V
0.0 m/min
SYN
SYN
SYN
130 %
0.5 s
0.5 s
0.5 s
80 %
0.5 s
SYN
1.0 s
9.9 V
4.0 m/min
200
10.0 s
100 %
200 %
10.0 s
10.0 s
10.0 s
200 %
10.0 s
200 %
10.0 s
ARC2 2PULS
(row 10/10)
ARC SET
PRE GAS
SOFT START
START 3LEV
START TIME
SLOPE 3LEV 1
SLOPE 3LEV 2
CRATER 3LEV
CRATER TIME
BURN BACK
POST GAS
(row 1/16)
(row 2/16)
(row 3/16)
(row 4/16)
(row 5/16)
(row 6/16)
(row 7/16)
(row 8/16)
(row 9/16)
(row 10/16)
(row 11/16)
- 9.9 V
- 4.0 m/min
1
0.0 s
1%
10 %
0.0 s
0.1 s
0.1 s
10 %
0.0 s
1%
0.0 s
SPOT TIME
(row 12/16)
0.1 s
OFF
25.0 s
FREQ 2PULS
RANGE 2PULS
CYCLE 2PULS
(row 13/16)
(row 14/16)
(row 15/16)
ARC2 2PULS
(row 16/16)
0.1 Hz
10 %
10 %
- 9.9 V
1.5 Hz
50 %
50 %
0.0 V
10.0 Hz
90 %
90 %
9.9 V
- 4.0 m/min
0.0 m/min
4.0 m/min
NOTES
The parameter value is saved for each
welding mode.
The parameter value is saved for each
welding mode.
The parameter value is saved for each
welding mode.
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PROCEDURE
3 LEVELS
4 STROKE
4 STROKE
B-LEVEL
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PARAMETER
ARC SET
(row 1/14)
PRE GAS
(row 2/14)
SOFT START
(row 3/14)
START 3LEV
(row 4/14)
SLOPE 3LEV 1
(row 5/14)
SLOPE 3LEV 2
(row 6/14)
CRATER 3LEV
(row 7/14)
BURN BACK
(row 8/14)
POST GAS
(row 9/14)
MIN
1
0.0 s
1%
10 %
0.1 s
0.1 s
10 %
1%
0.0 s
DEFAULT
SYN
SYN
SYN
130 %
0.5 s
0.5 s
80 %
SYN
1.0 s
MAX
200
10.0 s
100 %
200 %
10.0 s
10.0 s
200 %
200 %
10.0 s
B-LEVEL
(row 10/14)
1%
OFF
200 %
FREQ 2PULS
RANGE 2PULS
CYCLE 2PULS
(row 11/14)
(row 12/14)
(row 13/14)
ARC2 2PULS
(row 14/14)
0.1 Hz
10 %
10 %
- 9.9 V
- 4.0 m/min
1.5 Hz
50 %
50 %
0.0 V
0.0 m/min
10.0 Hz
90 %
90 %
9.9 V
4.0 m/min
NOTES
The parameter value is saved for each
welding mode.
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10.6 MMA WELDING
SETTING
B
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
F
S2
S10
S8
ESC
L9
0
L1
E3
D3
S9
1
L1
S3
D
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
E
C
A
SELECTION
SELECTION
A
S6
MODE
This button serves to select the following welding mode: MMA
Tab. 13 - Main settings and displays in MMA mode
DISPLAY D1
DISPLAY D2
Data setting
Shows the preset welding current
Shows the tension between the welding sockets.
Welding
Shows the average current measured
during welding.
Shows the average voltage measured
during welding.
HOLD function
(At welding end)
Shows the average current measured during the last welding procedure
performed.
Shows the average voltage measured during the last welding procedure
performed.
10.6.1 MMA Parameters Setting (1st Level): welding current setting
B
○ Using the encoder E1
, edit the value of the welding current.
The value is saved automatically.
10.6.2 MMA Parameters Setting (2nd Level)
C
○ Press the button S5
to enter the 2nd level menu.
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D
○ Scroll down the list of parameters to be edited by pressing buttons S3
E
○ Using the encoder E3
, edit the value of the selected parameter.
The value is saved automatically.
F
Exit with confirmation
○ Press the S2 button
.
This action will automatically close the menu.
and S4
.
Tab. 14 - Parameters of the 2nd level menu in MMA mode
PROCEDURE
PARAMETER
VRD
HOT START
ARC FORCE
MMA
(riga 1/3)
(riga 2/3)
(riga 3/3)
MIN
DEFAULT
MAX
NOTES
OFF
0%
0%
OFF
50 %
30 %
ON
100 %
100 %
10.7 ARC AIR WELDING
SETTING
B
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
F
S2
S10
S8
ESC
L9
L1
0
E3
D3
S9
1
L1
S3
D
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
E
C
A
SELECTION
SELECTION
A
S6
MODE
This button serves to select the following welding mode: ARC AIR
Tab. 15 - Main settings and displays in ARC AIR mode
Data setting
62
DISPLAY D1
DISPLAY D2
Shows the preset welding current
Shows the tension between the welding sockets.
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DISPLAY D1
DISPLAY D2
Welding
Shows the average current measured
during welding.
Shows the average voltage measured
during welding.
HOLD function
(At welding end)
Shows the average current measured during the last welding procedure
performed.
Shows the average voltage measured during the last welding procedure
performed.
10.7.1 ARC AIR parameters setting (1st level): current setting
B
○ Using the encoder E1
, edit the current value
The value is saved automatically.
10.7.2 ARC AIR Parameters Setting (2nd Level)
C
○ Press the button S5
D
○ Scroll down the list of parameters to be edited by pressing buttons S3
E
○ Using the encoder E3
, edit the value of the selected parameter.
The value is saved automatically.
F
Exit with confirmation
○ Press S2
.
This action will automatically close the menu.
to enter the 2nd level menu.
and S4
.
Tab. 16 - Parameters of the 2nd level menu in ARC AIR mode
PROCEDURE
ARC AIR
PARAMETER
VRD
(row 1/1)
MIN
DEFAULT
MAX
OFF
OFF
ON
NOTES
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10.8 TIG WELDING
SETTING
B
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
F
S2
S10
S8
ESC
L9
0
L1
E3
D3
S9
1
L1
S3
D
S4
S5
Menu
S6
Mode
S7
SELECTION
SETTING
E
C
A
SELECTION
SELECTION
A
S6
MODE
This button serves to select the following welding mode: TIG
Tab. 17 - Main settings and displays in TIG mode
DISPLAY D1
DISPLAY D2
Data setting
Shows the preset welding current
Shows the tension between the welding sockets.
Welding
Shows the average current measured
during welding.
Shows the average voltage measured
during welding.
HOLD function
(At welding end)
Shows the average current measured during the last welding procedure
performed.
Shows the average voltage measured during the last welding procedure
performed.
10.8.1 TIG Parameters Setting (1st Level): welding current setting
B
○ Using the encoder E1
, edit the value of the welding current.
The value is saved automatically.
10.8.2 TIG Parameters Setting (2nd Level)
C
64
○ Press the button S5
to enter the 2nd level menu.
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D
○ Scroll down the list of parameters to be edited by pressing buttons S3
E
○ Using the encoder E3
,edit the value of the selected parameter.
The value is saved automatically..
F
Exit with confirmation
○ Press the S2 button
.
This action will automatically close the menu.
and S4
.
Tab. 18 - Parameters of the 2nd level menu in TIG mode
PROCEDURE
TIG
PARAMETER
DOWN SLOPE
I FINAL
POST GAS
(row 1/3)
(row 2/3)
(row 3/3)
MIN
DEFAULT
MAX
0.0 s
5%
0.0 s
0.0 s
5%
10.0 s
25.0 s
80 %
10.0 s
NOTES
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11
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JOBS MANAGEMENT
Personalised welding settings, or JOBs, can be saved in memory locations and subsequently uploaded.
Up to 99 jobs can be saved (j01-j99).
The settings of the SETUP menu are not saved.
11.1 SAVING A JOB
This function is available when welding mode is not active.
STOP
L7
HOLD
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
ACTIVATION
S2
S10
S8
ESC
L9
C
S4
E3
D3
0
S3
S9
L1
B
A
1
L1
S5
Menu
S6
Mode
S7
SELECTION
C
SELECTION
A
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
○ Press buttons S3
and S4
to select parameter OPT.
The selected parameter is shown by the following symbol “  ”.
C
○ Use the encoder E3
, to select the SAVE function.
and S4
to select parameter JOB.
○ Press buttons S3
The first free memory location is displayed.
If all the memory locations are occupied, the word JOB flashes and the first JOB is displayed.
If the memory location is already occupied by another job, when a new JOB is written to
the location it will overwrite the existing JOB.
The names of unnamed jobs are “-“ after a space following the number corresponding to
the memory location by default
§ “11.2 NAMING JOBS”.
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STOP
L7
HOLD
L4
L8
L1
L5
L2
D1
E1
S1
S2
D2
E2
L6
L3
D
m/min
mm
S10
S8
ESC
L9
EXIT
EXIT
0
L1
E3
D3
S9
D
E
1
L1
S3
S4
S5
SELECTION
D E
Menu
S6
Mode
S7
SELECTION
D
Save and keep original
○ Using the encoder E3
, select one of the unoccupied jobs.
Exit without confirmation
button.
○ Press the S2
This action will automatically close the menu
Exit with confirmation
○ Press the S8 button.
This action will automatically close the menu
E
Save by overwriting
○ Using the encoder E3
, select one of the occupied jobs.
○ Press the S8 button.
CONFIRM JOB CHANGE: The message will appear on display D3
Exit without confirmation
Use the encoder E3
, to select the “NO” function
○ Press the S8 button.
This action will automatically close the menu
Exit with confirmation
Use the encoder E3
, to select the “YES” function
○ Press the S8 button.
This action will automatically close the menu
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11.2 NAMING JOBS
JOBS can be named and renamed (maximum 9 characters) in the JOB MENU, LOAD, or SAVE. This
function is available when welding mode is not active.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
mm
EXIT
D
S2
S10
S8
ESC
L9
SELECTION
S4
S5
Menu
S6
Mode
S7
SELECTION
SELECTION
C
A
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
and S4
to select parameter OPT.
○ Press buttons S3
The selected parameter is shown by symbol “  ”.
C
68
, to select the LOAD/SAVE function.
Use the encoder E3
Press buttons S3
and S4
to select parameter JOB.
Use the encoder E3
to select the position of the job to be renamed.
Hold down for 3 seconds button S8
.
The first letter of the name blinks.
○ Use the encoder E3
to change the letter.
to confirm.
○ Press button S8
and S4
to select the character to be changed.
○ Press buttons S3
○
○
○
○
A
ACTIVATION
D
EXIT
1
L1
C
0
B
S9
L1
E3
D3
S3
C
ACTIVATION
CONFIRMATION
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D
Exit without confirmation
button.
○ Press the S2
Return to the job menu.
button to exit.
○ Press the S2
Exit with confirmation
○ Hold down for 3 seconds button S8
Return to the job menu.
○ Press button S8
again.
.
11.3 LOADING A USER JOB
If using a torch with UP/DOWN buttons you can scroll through the uploaded JOBs.
You can quit the uploaded job with the following methods:
• turn encoders E1 - E2 to change the welding current or voltage.
• press the welding mode selection button (button S6).
• Press the following button:
If there are no JOBS loaded, the UP/DOWN buttons on the torch serve to adjust the welding current.
This function is available when welding mode is not active.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
ACTIVATION
mm
EXIT
D
S2
S8
ESC
L9
C
S4
S9
D
EXIT
1
L1
S3
A
0
E3
D3
B
L1
SELECTION
S10
S5
Menu
S6
Mode
S7
SELECTION
SELECTION
C
A
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
○ Press buttons S3
and S4
to select parameter OPT.
The selected parameter is shown by symbol “  ”.
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C
, to select the LOAD function.
○ Use the encoder E3
○ Press buttons S3
and S4
to select parameter JOB.
The JOB displayed is the one that was most recently used.
When there are no saved jobs the following message appears on the bottom line: NO JOB
○ Using the encoder E3
, select one of the jobs displayed.
D
Exit without confirmation
○ Press the S2
button.
This action will automatically close the menu
Exit with confirmation
○ Press the S8 button.
This action will automatically close the menu
11.4 DELETING A JOB
This function is available when welding mode is not active.
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
ACTIVATION
mm
S10
A
S9
D
EXIT
D
S2
S8
ESC
L9
SELECTION
C
S4
1
L1
S3
0
B
L1
E3
D3
S5
Menu
S6
SELECTION
SELECTION
C
D
A
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
○ Press buttons S3
and S4
to select parameter OPT.
The selected parameter is shown by symbol “  ”.
70
Mode
S7
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C
○ Use the encoder E3
, to select the DELETE function.
○ Press buttons S3
and S4
to select parameter JOB.
The JOB displayed is the one that was most recently used.
When there are no saved jobs the following message appears on the bottom line: NO JOB
, select one of the jobs displayed.
○ Using the encoder E3
D
Exit without confirmation
○ Press the S2
button.
This action will automatically close the menu
Exit with confirmation
○ Press the S8 button.
The message “CONFIRM JOB ERASURE” appears on display D3.
, to select the NO function”
○ Use the encoder E3
○ Press the S8 button.
This action will automatically close the menu
Exit with confirmation
, to select the NO function”
○ Use the encoder E3
○ Press the S8 button.
This action will automatically close the menu
11.5 EXPORTING/IMPORTING JOBs (through a USB memory stick)
By using a USB memory stick, the JOBs saved on the panel can be imported into another panel.
When a USB memory stick is connected, the JOB MENU will display the items related to the importing
and exporting procedure.
WARNING! The JOBs are exported to the USB memory stick with the name of the location
where they are saved on the panel. If the file names of the JOBs saved onto the USB memory stick are
changed by using a PC, after they are imported into the destination panel, they will still be saved in their
original location. This means that, if the destination panel already contains JOBs saved in the same
location as those exported to the memory stick, they will be overwritten.
We recommend not to change the name of the files exported to the USB memory stick. The file
extension (.bin) must never be changed.
JOBs to be kept must be moved in a location of the destination panel different from the location
of the JOBs exported to the USB memory stick.
To be usable, the memory stick must be formatted as FAT32.
11.6 EXPORTING A JOB
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STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
ACTIVATION
mm
EXIT
D
S2
S10
S8
ESC
L9
B
D
EXIT
0
L1
E3
D3
S9
A
1
L1
S3
SELECTION
S4
S5
SELECTION
Menu
S6
Mode
S7
C
A
○ Insert the memory stick in the USB port.
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
○ Press buttons S3
and S4
to select parameter OPT.
The selected parameter is shown by symbol “  ”.
C
○ Use the encoder E3
, to select the USB EXPORT function.
When there are no saved jobs the following message appears on the bottom line: NO JOB
D
Exit without confirmation
button.
○ Press the S2
This action will automatically close the menu
Exit with confirmation
○ Press the S8 button.
Tab. 19 - JOB exporting operation messages
MESSAGE
MEANING
CHECKS
USB DEVICE NOT FOUND
USB device not found
- incorrectly inserted memory stick
- memory stick removed before completing the operation.
EXPORT FAILED
- USB not formatted as FAT32.
- memory stick removed before - unidentifiable generic error: re-insert the memory
completing the operation.
stick and retry.
- the connected USB drive is damaged.
EXPORT IN PROGRESS
The JOBs saved on the panel
are being exported
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MESSAGE
MEANING
CHECKS
EXPORT COMPLETE
Exporting procedure completed
11.7 IMPORTING A JOB
STOP
HOLD
L7
L4
L8
L1
L5
L2
m/min
D1
E1
S1
D2
E2
L6
L3
ACTIVATION
mm
EXIT
D
S2
S10
S8
ESC
L9
EXIT
0
B
D
L1
E3
D3
S9
A
1
L1
S3
SELECTION
S4
S5
SELECTION
Menu
S6
Mode
S7
C
A
○ Insert the memory stick in the USB port.
○ Hold down button S8
to activate the job menu.
The job menu appears in display: D3.
B
○ Press buttons S3
and S4
to select parameter OPT.
The selected parameter is shown by symbol “  ”.
C
○ Use the encoder E3
D
Exit without confirmation
button.
○ Press the S2
This action will automatically close the menu
Exit with confirmation
○ Press the S8 button.
, to select the USB IMPORT function.
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Tab. 20 - JOB importing operation messages
MESSAGE
MEANING
CHECKS
USB DEVICE NOT FOUND
USB device not found
- incorrectly inserted memory stick
- memory stick removed before completing
the operation.
FILE NOT FOUND
File not found
- there are no JOBs loaded onto the USB
memory stick.
IMPORT FAILED
Importing procedure
failed.
- USB not formatted as FAT32.
- unidentifiable generic error: re-insert the
memory stick and retry.
- the connected USB drive is damaged.
IMPORT IN PROGRESS
The JOBs saved on the
USB memory stick are
being imported
IMPORT COMPLETE
Importing procedure
completed
11.8 SELECTING JOBS USING THE TORCH UP/DOWN BUTTONS
When an UP/DOWN torch is installed, JOBs can be selected in a JOB sequence using the buttons on
the welding torch.
JOBs can be scrolled only when the welding operation is not being carried out.
During the welding operation (with an active JOB) the parameter values displayed can be temporarily
changed with the UP/DOWN keys; at the end of the welding operation, the original values are restored.
When a DIGIMANAGER torch is installed the operations described above can be carried out, with the
following differences:
- a job can be loaded directly from the torch
- jobs can be scrolled regardless of the sequence they belong to.
Sequence 1
J.01
J.02
J.03
JOB not
saved
Sequence 2
J.05
J.06
J.07
JOB not
saved
Sequence 3
J.09
J.10
J.11
Select and upload one of the JOBs belonging to the desired sequence (e.g. J.06) through the power
source user interface.
Use the torch buttons to scroll through the JOBs of sequence 2 (J.05, J.06, J.07).
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12 TORCH TRIGGER MODES
12.1 2T MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) and keep the torch trigger pressed.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The arc strikes and the wire feeder accelerates to the set feed rate value.
3. Release (2T) trigger to start the weld completion procedure.
Gas flow continues for the time set in the post gas parameter (adjustable time).
12.2 2T SPOT MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) and keep the torch trigger pressed.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The arc strikes and the wire feeder accelerates to the set feed rate value.
The welding procedure continues, at the preset current, for the time set with the spot time parameter.
The welding completion procedure starts.
The arc is extinguished.
Gas flow continues for the time set in the post gas parameter (adjustable time).
12.3 4T MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) and release (2T) the torch trigger.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The arc strikes and the wire feeder accelerates to the set feed rate value.
3. Press (3T) the trigger to start the weld completion procedure.
Gas flow continues until the torch trigger is released.
4. Release (4T) the torch trigger to start the post gas procedure (adjustable time).
12.4 4T B-LEVEL MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) and release (2T) the torch trigger.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The arc strikes and the wire feeder accelerates to the set feed rate value.
During normal speed welding, press and immediately release the torch trigger to switch to the
second welding current.
The trigger must not be pressed for more than 0.3 seconds; otherwise, the weld completion stage
will start.
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WELD THE WORLD
When the trigger is pressed and released immediately, the system returns to the welding current.
3. Press (3T) trigger and keep it pressed to start the weld completion procedure.
Gas flow continues until the torch trigger is released.
4. Release (4T) torch trigger to start the post gas procedure (adjustable time).
12.5 2T - 3 LEVEL MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) torch trigger.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The welding arc strikes and the wire feed rate changes to the first welding level (hot start), which
is set as a percentage of the normal welding feed rate.
This first level is used to create the weld pool: for example, when welding aluminium a value of
130 % is recommended.
The hot start level continues for the start time, which is settable in seconds; then switch to normal
welding speed is performed in accordance with the start slope, which can be set in seconds.
3. Release (2 T) the torch trigger to switch to the third welding level (crater filler), which is set as a
percentage of the normal welding feed rate.
The switch of welding current level in terms of crater filling is performed in accordance with the
crater slope, which can be set in seconds.
This third level is used to complete the weld and fill the final crater (crater filler) in the weld pool:
for example, when welding aluminium a value of 80 % is recommended.
4. The crater filler level continues for the crater time, which is settable in seconds; at the end of this
time welding is interrupted and the post gas stage is performed.
12.6 2T SPOT - 3 LEVEL MIG/MAG WELDING
The welding process is the same as the 2T - 3 LEVELS process, except that the welding procedure
continues, at the preset current, for the time set with the spot time parameter.
The weld is closed in the same way as with the 2T - 3 LEVELS process.
12.7 4T - 3 LEVEL MIG/MAG WELDING
1. Bring the torch up to the workpiece.
2. Press (1T) torch trigger.
The wire advances at the approach speed until making contact with the material. If the arc does
not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are deenergized.
The welding arc strikes and the wire feed rate changes to the first welding level (hot start), which
is set as a percentage of the normal welding feed rate.
This first level is used to create the weld pool: for example, when welding aluminium a value of
130 % is recommended.
3. Release (2T) trigger to switch to normal welding speed; then switch to normal welding speed is
performed in accordance with the start ramp, which can be set in seconds.
4. Press the torch trigger again (Level 3) to switch to the third welding level (crater filler), which is set
as a percentage of the normal welding feed rate.
The switch of welding current level in terms of crater filling is performed in accordance with the
crater slope, which can be set in seconds.
This third level is used to complete the weld and fill the final crater (crater filler) in the weld pool:
for example, when welding aluminium a value of 80 % is recommended.
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Pioneer Pulse 403MKS
WELD THE WORLD
ENGLISH
5. Release the torch trigger a second time (4T) to close the weld and run the post gas procedure.
12.8 4T B-LEVEL - 3 LEVEL MIG/MAG WELDING
The welding process is the same as the 4T - 3 LEVELS process except that during normal speed
welding pressing and immediately releasing the torch trigger switches the unit to the second welding current.
The trigger must not be pressed for more than 0.3 seconds; otherwise, the weld completion stage
will start.
When the trigger is pressed and released immediately, the system returns to the welding current.
1. Press (3T) trigger and keep it pressed to start the crater filler procedure.
The weld is closed in the same way as with the 4T - 3 LEVELS process.
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Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
13 TECHNICAL DATA
Waste electrical and electronic equipment (WEEE)
Directives applied
Electromagnetic compatibility (EMC)
Low voltage (LVD)
Restriction of the use of certain hazardous substances (RoHS)
Construction standards
EN 60974-5; EN 60974-10 Class A
Equipment compliant with European directives in force
Conformity markings
Equipment suitable in an environment with increased hazard of electric shock
Equipment compliant with WEEE directive
Equipment compliant with RoHS directive
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13.1 PIONEER 403 MKS / PIONEER PULSE 403 MKS
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 permissible 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 permissible system impedance less than or equal to 21 mΩ.
Dimensions ( D x W x H )
700 x 300 x 570 (power source)
Weight
90.4 kg (power source)
Insulation class
H
Protection rating
IP23
Maximum gas pressure
0,5 MPa (5 bar)
Motor speed
1.0-24.0 m/min
Wire spool: (dimensions/weight)
200 mm / 5 kg – 300 mm / 15 kg
Cooling
AF: Air-over cooling (fan assisted)
Static characteristic
MMA
Falling characteristic
TIG
Falling characteristic
MIG/MAG
Flat characteristic
Welding mode
Current and voltage adjustment
range
Welding current / Working
voltage
Maximum input power
Maximum supply current
Maximum Effective Supply
Current
MIG/MAG
TIG
MMA
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
40% (40° C)
400 A / 34.0 V
400 A / 26.0 V
400 A / 36.0 V
60% (40° C)
350 A / 31.5 V
350 A / 24.0 V
350 A / 34.0 V
100% (40° C)
320 A / 30.0 V
320 A / 22.8 V
320 A / 32.8 V
40% (40° C)
18.3 kVA - 15.5 kW
14.4 kVA - 12.1 kW
18.9 kVA - 16.3 kW
60% (40° C)
15.3 kVA - 12.7 kW
12.2 kVA - 9.9 kW
16.2 kVA - 13.6 kW
100 % (40° C)
13.6 kVA - 11.1 kW
11.0 kVA - 8.7 kW
14.7 kVA - 12.0 kW
40% (40° C)
26.4 A
20.8 A
27.3 A
60% (40° C)
22.1 A
17.7 A
23.3 A
100 % (40° C)
19.6 A
15.9 A
21.1 A
40% (40° C)
16.7 A
13.2 A
17.3 A
60% (40° C)
17.1 A
13.7 A
18.0 A
100 % (40° C)
19.6 A
15.9 A
21.1 A
No-load voltage (U0)
66V
Reduced no-load voltage (Ur)
10V
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Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
14 WIRING DIAGRAM
A
B
022.0002.0390
N ML K J I H GF E D C B A
+5V-ISO
AN_REM_IN2
AN_REM_IN1
GND-ISO
DIG_REM_IN1
AN_REM_IN1/10V
DIG_CMD_OUT
AN_REM_IN2/10V
DIG_REM_IN2
EV
MIG
12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2 1
J7
BLACK
RED
M
050.XXXX.0078
+5V
GND
DISP_SEL
CONTRAST_OUT
DISP_EN
DISP_RW
DISP_D5
DISP_D4
DISP_D7
DISP_D6
BKL_K
BKL_A
ENC_3A
ENC_3B
ENC_1B
ENC_1A
ENC_2A
ENC_2B
MUX_COL0
MUX_COL1
MUX_COL2
MUX_COL3
GND
GND
LED-SEG1/KEY-RAW1
LED-SEG0/KEY-RAW0
LED-SEG5
LED-SEG7
LED-SEG2/KEY-RAW2
LED-SEG6
LED-SEG3/KEY-RAW3
LED-SEG4/KEY-RAW4
+8V
+8V
1
3
2
4
J10
1 2 3 4
+5V_PROG
DD+
GND
+5V
GND
ENC_OUT_1
RX1-RS232
TX1-RS232
GND
RX2-RS232
TX2-RS232
J10
1 2 3 4
+5V
DD+
GND
050.XXXX.0189
J10
1 2 3 4
J19
1 2 3 4 5 6 7 8
S5
KEY-RAW3
KEY-RAW3
S2
022.0010.0014
A K J
I
L N H
M
G
F
E
050.XXXX.0168
GND
+5V_PROG
TX2-RS232
RX2-RS232
4 3 2 1
J1
343332313029282726252423 222120191817161514131211 10 9 8 7 6 5 4 3 2 1
J1
D
343332313029282726252423 22212019181716151413121110 9 8 7 6 5 4 3 2 1
34V-REM
GND_CAN
GND-CAN
CANH
+5V-CAN
CANL
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
4 3 2 1
PANEL_DIG_OUT_3
GND
PANEL_DIG_IN1
B-RS485
+34V-REM
CANL
PANEL_DIG_OUT_1
PANEL_DIG_OUT_2
PANEL_DIG_IN2
A-RS485
GND-CAN
CANH
2 1
CN2
PT2-GND
B
C
JP1
21
GND-ISO
DIG_CMD_OUT
DIG_REM_IN2
DIG_REM_IN1
AN_REM_IN2/10V
AN_REM_IN1/10V
ELV-2
GND-ISO
AN_REM_IN1
AN_REM_IN2
PT-2
PT-1
+5V-ISO
GND_CAN
+24V_CAN
6 5 4 3 2 1
-12V
+15V
MOT/GND_CAN
+48V_CAN
MOT/+
24VDC
4 3 2 1
PT1-DATA
PT1-DATA
PT2-GND
050.XXXX.0171
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
6 5 4 3 2 1
6 5 4 3 2 1
J3
J4
J5
4 3 2 1
6 5 4 3 2 1
USB_D-
6
5
9
5
9
CONN-RS232
1
6
CONN-RS232
GND_CAN
GND_CAN
GND_CAN
+48V_CAN
+24V_CAN
+24V_CAN
6 5 4 3 2 1
J2
+24V_CAN
HF
GND_CAN
GND_CAN
6 5 4 3 2 1
J1
USB_D+
GND_CAN
+5V_PROG
1
J7
J6
USB_D+
USB_DGND
+5V_PROG
022.0010.0025
12 11 10 9 8 7 6 5 4 3 2 1
TX2_RS232
RX2_RS232
+5V_CAN
GND_CAN
TX1_RS232
RX1_RS232
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
AN_REM_IN1
DOWN
RIC_PED
CN5
65 4 3 2 1
CN4
+5V_CAN
8 7 6 5 4 3 2 1
CN3
AN_REM_IN2
UP
PT
GND_CAN
GND_CAN
6 5 4 3 2 1
J8
RELAY
VENT_3
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
+48V_CAN
2 1
CN2
65 4 3 2 1
+48V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
GND_CAN
VENT
+48V_CAN
2 1
CN1
VENT
+48V_CAN
022.0002.0355
CONN-RS232
GND
+5V_PROG
TX2-RS232
RX2-RS232
D-
022.0002.0386
CONN-RS232
D+
TX1-RS232
RX1-RS232
9 8 7 6 5 4 3 21
022.0002.0153
9 8 7 6 5 4 3 21
022.0002.0122
+48V_CAN
VENT
GND
USB_D+
USB_D+5V
J16
1 2
J17
1 2 3 4
J18
1 2
J19
1 2 3 4 5 6 7 8
J20
1 2
I_PONTE
GND
+15V
-15V
HALL
GND
VOUT
GND
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
LEDLED+
AL_CU
GND_CAN
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
J15
1 2 3 4
022.0002.0359
022.0002.0389
400VAC-2
GIALLO/VERDE-YELLOW/GREEN
AL CU
400VAC-1
1
3
2
4
5
5 4 3 2
1
CONN-ILME CU09
J14
1 2 3 4 5 6 7 8 9 10
DRV_B
DRV_C
DRV_A
DRV_D
J13
1 2
CN8
1 2 3 4
-V_BUS_ISO
+24V
+24V
+15V
+15V
GND
GND
-15V
-15V
+V_BUS_ISO
+24V_SEC
+24V_SEC
+15V_SEC
+15V_SEC
GND_SEC
GND_SEC
-15V_SEC
-15V_SEC
VR_ISO
ELV1_C
ELV2_C
RELAY_C
VENT12C
VENT3_C
VT_ISO
022.0010.0024
VS_ISO
ELV1_C
ELV2_C
RELAY_C
VENT12_C
VENT3_C
1413121110 9 8 7 6 5 4 3 2 1
J10
CN6
1413121110 9 8 7 6 5 4 3 2 1
CN7
87 65 4 3 2 1
+VBUS
GND_PRI
OUT2
OUT3
GND
+5V
IN0
AN3
050.XXXX.0159
050.XXXX.0129
+18V_PRI
J11
12 3 4 5 6 7 8
ROSSO-RED
NERO-BLACK
21
21
M
VDC
+48V_CAN
VENT
21
21
J9
ROSSO-RED
NERO-BLACK
J12
12 3 4
1 2 3 4 5 6 7 8 9 10 11 12
M
VDC
INTERRUTTORE
MAINS SWITCH
T2
L2
022.0002.0241
GND ISO
T3
L3
T1
L1
N/O
N/O
022.0002.0393
045.0002.0022
T
J1
T
S
J2
S
R
J3
R
J2
J4
12 3 4 5 6
J9
1 2 3 4 5 6
J7
J8
S_OUT_ISO
R_OUT_ISO
T_OUT_ISO
022.0002.0055
NTC1
NTC2
GND
GND
GND
+15V
NTC3
TERMICO
WIRE 2
JP4
+DC
MH1
-DC
JP5
-DC
87 65 4 3 2 1
4 3 2 1
+DC
050.XXXX.0151
022.0002.0350
12 3 4
12 3 4
12 3 4 5 6
12 3 4 5 6
022.0002.0388
J6
R_OUT
J10
1 2 3 4
ELV_2
+15CAN
+48CAN
RELAY
+48CAN
T_OUT
T
050.XXXX.0155
S_OUT
S
GND
N/O
R
S_OUT
T_SEZ
EURO
S_SEZ
R_OUT_GRUPPO
R_SEZ
022.0002.0387
PE
REED
GND
16151413121110 9 8 7 6 5 4 3 2 1
J5
21
J1
050.000X.0176
PE
+DC
JP1
JP7
+15V
-15V
HALL
GND
NTC_PRIM_1
J2
1 2 3 4
JP1
B
C
A
D
4 3 2 1
050.XXXX.0156
050.XXXX.0157
050.XXXX.0158
NTC_SEC
NTC_PRIM_2
WIRE 3
I_PONTE
GND
WIRE 2
050.XXXX.0190
J1
JP1
1 2
L
C
80
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Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
A
EV
MIG
-12V
+15V
MOT/GND_CAN
+48V_CAN
MOT/+
24VDC
6 5 4 3 2 1
2 1
CN2
BLACK
RED
M
1
3
2
4
RX1-RS232
1
022.0002.0122
AN_REM_IN2
UP
PT
GND_CAN
GND_CAN
AN_REM_IN1
DOWN
RIC_PED
12 11 10 9 8 7 6 5 4 3 2 1
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
022.0010.0025
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
J1
USB_D+
USB_DGND
+5V_PROG
CN5
65 4 3 2 1
CN4
TX2_RS232
RX2_RS232
+5V_CAN
GND_CAN
TX1_RS232
RX1_RS232
8 7 6 5 4 3 2 1
CN3
+5V_CAN
6 5 4 3 2 1
J8
RELAY
VENT_3
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
+48V_CAN
2 1
CN2
65 4 3 2 1
+48V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
GND_CAN
2 1
CN1
VENT
+48V_CAN
VENT
+48V_CAN
022.0002.0386
1 2 3 4 5 6 7 8 9 10 11 12
M
VDC
ROSSO-RED
NERO-BLACK
21
21
ROSSO-RED
NERO-BLACK
+48V_CAN
VENT
21
21
J9
M
VDC
+48V_CAN
VENT
3
2
022.0002.0389
400VAC-2
GIALLO/VERDE-YELLOW/GREEN
AL CU
400VAC-1
4
5
GND ISO
81
045.0002.0022
J15
1 2 3 4
DRV_B
DRV_C
DRV_A
DRV_D
+V_BUS_ISO
-V_BUS_ISO
J14
1 2 3 4 5 6 7 8 9 10
VT_ISO
J13
1 2
VS_ISO
+24V
+24V
+15V
+15V
GND
GND
-15V
-15V
VR_ISO
ELV1_C
ELV2_C
RELAY_C
VENT12C
VENT3_C
1413121110 9 8 7 6 5 4 3 2 1
J10
+24V_SEC
+24V_SEC
+15V_SEC
+15V_SEC
GND_SEC
GND_SEC
-15V_SEC
-15V_SEC
022.0010.0024
1
1
5 4 3 2
CONN-ILME CU09
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
CN8
1 2 3 4
ELV1_C
ELV2_C
RELAY_C
VENT12_C
VENT3_C
AL_CU
GND_CAN
CN6
1413121110 9 8 7 6 5 4 3 2 1
GND_PRI
+18V_PRI
CN7
+VBUS
87 65 4 3 2 1
050.XXXX.0129
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
022.0002.0390
+5V-ISO
AN_REM_IN2
AN_REM_IN1
GND-ISO
DIG_REM_IN1
AN_REM_IN1/10V
DIG_CMD_OUT
AN_REM_IN2/10V
DIG_REM_IN2
12 11 10 9 8 7 6 5 4 3 2 1
6 5 4 3 2 1
050.XXXX.0078
+5V
GND
DISP_SEL
CONTRAST_OUT
DISP_EN
DISP_RW
DISP_D5
DISP_D4
DISP_D7
DISP_D6
BKL_K
BKL_A
ENC_3A
ENC_3B
ENC_1B
ENC_1A
ENC_2A
ENC_2B
MUX_COL0
MUX_COL1
MUX_COL2
MUX_COL3
GND
GND
LED-SEG1/KEY-RAW1
LED-SEG0/KEY-RAW0
LED-SEG5
LED-SEG7
LED-SEG2/KEY-RAW2
LED-SEG6
LED-SEG3/KEY-RAW3
LED-SEG4/KEY-RAW4
+8V
+8V
6 5 4 3 2 1
6 5 4 3 2 1
J3
J4
J5
GND_CAN
GND_CAN
GND_CAN
+48V_CAN
+24V_CAN
+24V_CAN
6 5 4 3 2 1
J2
4 3 2 1
6 5 4 3 2 1
J6
USB_D-
J7
J11
12 3 4 5 6 7 8
J9
OUT2
OUT3
GND
+5V
IN0
AN3
J12
12 3 4
1 2 3 4 5 6 7 8 9 10 11 12
GND
USB_D+
USB_D+5V
J15
1 2 3 4
J16
1 2
J17
1 2 3 4
J18
1 2
J19
1 2 3 4 5 6 7 8
J20
1 2
DRV_B
DRV_C
DRV_A
DRV_D
I_PONTE
GND
+15V
-15V
HALL
GND
VOUT
GND
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
LEDLED+
+V_BUS_ISO
-V_BUS_ISO
VT_ISO
J14
1 2 3 4 5 6 7 8 9 10
VS_ISO
J13
1 2
VR_ISO
+24V
+24V
+15V
+15V
GND
GND
-15V
-15V
AL_CU
GND_CAN
ELV1_C
ELV2_C
RELAY_C
VENT12C
VENT3_C
1413121110 9 8 7 6 5 4 3 2 1
J10
050.XXXX.0159
022.0002.0359
022.0002.0241
82
022.0002.0393
INTERRUTTORE
MAINS SWITCH
T2
L2
T3
L3
T1
L1
N/O
N/O
6
6
5
9
5
9
CONN-RS232
1
USB_D+
USB_DGND
+5V_PROG
TX2_RS232
RX2_RS232
+5V_CAN
GND_CAN
TX1_RS232
RX1_RS232
6 5 4 3 2 1
J1
USB_D+
GND_CAN
+5V_PROG
+24V_CAN
HF
GND_CAN
GND_CAN
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
CAN_L0
+5V_CAN
+15V_CAN
CAN_H0
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CAN
CAN_H1
GND_CAN
GND_CAN
AN_REM_IN2
UP
PT
GND_CAN
GND_CAN
+5V_CAN
12 11 10 9 8 7 6 5 4 3 2 1
J8
65 4 3 2 1
AN_REM_IN1
DOWN
RIC_PED
022.0002.0355
1
CONN-RS232
GND
+5V_PROG
TX2-RS232
RX2-RS232
D-
CONN-RS232
D+
TX1-RS232
RX1-RS232
050.XXXX.0171
CONN-RS232
GND
+5V_PROG
TX2-RS232
RX2-RS232
022.0002.0153
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
A K J
I
L N H
M
G
F
E
050.XXXX.0168
4 3 2 1
+5V
GND
ENC_OUT_1
J10
1 2 3 4
+5V_PROG
DD+
GND
J10
1 2 3 4
GND
RX2-RS232
TX2-RS232
RX1-RS232
TX1-RS232
J10
1 2 3 4
+5V
DD+
GND
050.XXXX.0189
J19
1 2 3 4 5 6 7 8
S5
KEY-RAW3
KEY-RAW3
S2
022.0010.0014
9 8 7 6 5 4 3 21
J7
9 8 7 6 5 4 3 21
J1
343332313029282726252423 222120191817161514131211 10 9 8 7 6 5 4 3 2 1
J1
D
343332313029282726252423 22212019181716151413121110 9 8 7 6 5 4 3 2 1
34V-REM
GND_CAN
GND-CAN
CANH
+5V-CAN
CANL
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B
C
JP1
PANEL_DIG_OUT_3
GND
PANEL_DIG_IN1
B-RS485
+34V-REM
CANL
PANEL_DIG_OUT_1
PANEL_DIG_OUT_2
PANEL_DIG_IN2
A-RS485
GND-CAN
CANH
2 1
CN2
4 3 2 1
GND-ISO
DIG_CMD_OUT
DIG_REM_IN2
DIG_REM_IN1
AN_REM_IN2/10V
AN_REM_IN1/10V
ELV-2
GND-ISO
AN_REM_IN1
AN_REM_IN2
PT-2
PT-1
+5V-ISO
GND_CAN
+24V_CAN
21
-12V
+15V
MOT/GND_CAN
+48V_CAN
MOT/+
6 5 4 3 2 1
PT2-GND
4 3 2 1
PT1-DATA
PT1-DATA
PT2-GND
N ML K J I H GF E D C B A
B
+5V_CAN
AN_REM_
UP
PT
GND_CAN
GND_CAN
AN_REM_
DOWN
RIC_PED
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
J1
Cod.
006.0001.2230
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN 02/09/2020 V.1.0
022.0010.0025
GND_CAN
+15V_CAN
WELD THE WORLD
ENGLISH
USB_D+
USB_DGND
+5V_PROG
12 11 10 9 8 7 6 5 4 3 2 1
CN4
TX2_RS232
RX2_RS232
+5V_CAN
GND_CAN
TX1_RS232
RX1_RS232
8 7 6 5 4 3 2 1
CN3
J8
RELAY
VENT_3
ELV2
ELV1
+15V_CAN
+48V_CAN
+48V_CAN
+48V_CAN
6 5 4 3 2 1
65 4 3 2 1
+48V_CAN
+48V_CAN
+48V_CAN
GND_CAN
GND_CAN
GND_CAN
2 1
CN2
CN5
65 4 3 2 1
CN1
VENT
+48V_CAN
VENT
+48V_CAN
2 1
Pioneer 403MKS
Pioneer Pulse 403MKS
1 2 3 4 5 6 7 8 9 10 11 12
M
VDC
ROSSO-RED
NERO-BLACK
21
21
ROSSO-RED
NERO-BLACK
+48V_CAN
VENT
21
21
J9
M
VDC
+48V_CAN
VENT
AL_CU
GND_CAN
+18V_PRI
GND_PRI
-18V_PRI
GND_PRI
J15
1 2 3 4
022.0002.0389
400VAC-2
GIALLO/VERDE-YELLOW/GREEN
AL CU
400VAC-1
1
3
2
4
5
5 4 3 2
1
CONN-ILME CU09
J14
1 2 3 4 5 6 7 8 9 10
DRV_B
DRV_C
DRV_A
DRV_D
J13
1 2
CN8
1 2 3 4
-V_BUS_ISO
+24V
+24V
+15V
+15V
GND
GND
-15V
-15V
+V_BUS_ISO
+24V_SEC
+24V_SEC
+15V_SEC
+15V_SEC
GND_SEC
GND_SEC
-15V_SEC
-15V_SEC
VT_ISO
ELV1_C
ELV2_C
RELAY_C
VENT12C
VENT3_C
VS_ISO
022.0010.0024
VR_ISO
+18V_PRI
ELV1_C
ELV2_C
RELAY_C
VENT12_C
VENT3_C
1413121110 9 8 7 6 5 4 3 2 1
J10
GND_PRI
CN7
87 65 4 3 2 1
+VBUS
CN6
1413121110 9 8 7 6 5 4 3 2 1
050.XXXX.0129
GND ISO
045.0002.0022
T
J1
T
S
J2
S
R
J3
R
J2
PE
REED
GND
J4
12 3 4 5 6
J9
1 2 3 4 5 6
J6
J7
R_OUT_ISO
J8
12 3 4 5 6
022.0002.0388
ELV_2
+15CAN
+48CAN
RELAY
J10
1 2 3 4
S_OUT_ISO
T_OUT_ISO
R_OUT
T
+48CAN
T_OUT
S
S_OUT
N/O
R
050.XXXX.0155
GND
T_SEZ
S_OUT
S_SEZ
R_OUT_GRUPPO
R_SEZ
16151413121110 9 8 7 6 5 4 3 2 1
J5
21
J1
050.000X.0176
PE
022.0002.0350
JP4
+DC
-DC
JP5
-DC
87 65 4 3 2 1
4 3 2 1
+DC
+DC
JP1
JP7
NTC_PRIM_1
JP1
B
C
A
D
4 3 2 1
050.XXXX.0156
050.XXXX.0157
050.XXXX.0158
NTC_PRIM_2
I_PONTE
GND
JP1
1 2
C
83
6 5 4 3 2 1
6 5 4 3 2 1
6 5 4 3 2 1
J2
J3
J4
J5
ENGLISH
5
9
CONN
6
Pioneer 403MKS
Pioneer Pulse 403MKS
J7
J6
1
CONN
6 5 4 3 2 1
9 8 7 6 5
4 3 2 1
USB_D-
USB_D+
USB_DGND
+5V_PROG
TX2_RS232
RX2_RS232
+5V_CAN
GND_CAN
TX1_RS232
RX1_RS232
Cod. 006.0001.2230
02/09/2020 V.1.0
GND_CAN
GND_CAN
GND_CAN
+48V_CA
+24V_CA
+24V_CA
6 5 4 3 2 1
J1
+24V_CA
HF
GND_CAN
GND_CAN
CAN_L0
+5V_CAN
+15V_CA
CAN_H0
GND_CAN
GND_CAN
CAN_L0
+5V_CAN
+15V_CA
CAN_H0
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CA
CAN_H1
GND_CAN
GND_CAN
CAN_L1
+5V_CAN
+15V_CA
CAN_H1
GND_CAN
GND_CAN
AN_REM_
UP
PT
GND_CAN
GND_CAN
AN_REM_
DOWN
RIC_PED
+5V_CAN
12 11 10 9 8 7 6 5 4 3 2 1
J8
65 4 3 2 1
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+15V_CAN
GND_CAN
+5V_PROG
WELD THE WORLD
J11
12 3 4 5 6 7 8
J9
OUT2
OUT3
GND
+5V
IN0
AN3
J12
12 3 4
1 2 3 4 5 6 7 8 9 10 11 12
GND
USB_D+
USB_D+5V
J15
1 2 3 4
J16
1 2
J17
1 2 3 4
J18
1 2
J19
1 2 3 4 5 6 7 8
J20
1 2
DRV_B
DRV_C
DRV_A
DRV_D
I_PONTE
GND
+15V
-15V
HALL
GND
VOUT
GND
NTC1
NTC2
NTC3
TERMICO
GND
GND
GND
+15V
LEDLED+
+V_BUS_ISO
-V_BUS_ISO
J14
1 2 3 4 5 6 7 8 9 10
VT_ISO
AL_CU
GND_CAN
J13
1 2
VS_ISO
+24V
+24V
+15V
+15V
GND
GND
-15V
-15V
VR_ISO
ELV1_C
ELV2_C
RELAY_C
VENT12C
VENT3_C
1413121110 9 8 7 6 5 4 3 2 1
J10
050.XXXX.0159
022.0002.0359
INTERRUTTORE
MAINS SWITCH
T2
L2
022.0002.0241
T3
L3
T1
L1
N/O
N/O
022.0002.0387
S_OUT_ISO
R_OUT_ISO
T_OUT_ISO
EURO
022.0002.0055
NTC1
NTC2
GND
GND
+15V
NTC3
TERMICO
WIRE 2
MH1
050.XXXX.0151
GND
12 3 4
12 3 4
12 3 4 5 6
12 3 4 5 6
NTC_PRIM_1
+15V
-15V
HALL
GND
J2
1 2 3 4
050.XXXX.0157
NTC_SEC
NTC_PRIM_2
J1
WIRE 3
WIRE 2
050.XXXX.0190
J4
12 3 4 5 6
022.0002.0393
L
D
84
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
14.1 REMOTE CONTROL CONNECTOR
14.1.1 RC03: Wiring diagram
Potenziometro 10 kOhm - 100 kOhm
10 kOhm - 100 kOhm potentiometer
Pin
Name
Voltage
A
+5 V
5 V d.c.
Input/Output
Out
B AN2 (5 V)
0-5 V
In
C AN1 (5 V)
0-5 V
In
D
GND
E
D1-IN
GND
Out
0-5 V
In
F AN2 (10 V)
0-10 V
In
G
0-5 V
D3-OUT
Out
H AN1 (10 V)
0-10 V
In
I
D2-IN
0-5 V
In
J
RC
-
Not used
K
-
-
Not used
L
-
-
Not used
M
-
-
Not used
N
-
-
Not used
14.1.2 RC04: Wiring diagram
Potenziometro 10 kOhm - 100 kOhm
10 kOhm - 100 kOhm potentiometer
85
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
14.1.3 RC05: Wiring diagram
86
WELD THE WORLD
14.1.4 RC06: Wiring diagram
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
15 SPARES
39
38
16
15
17 18
19
36
21
14
12 13
7
37
35 34
20
8
33
22
32
6
31
27
1
9
2
10 11
29
28
3
4
25 26
23
24
5
30
87
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
42
40
43
41
44
45
46
47
49
48
54
55
56
52
50 51 53
58
57
59
61
60
WELD THE WORLD
62
ENGLISH
88
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
WELD THE WORLD
No. CODE
DESCRIPTION
1
050.5184.0000
COMPLETE FRONT PANEL (403 MKS)
2
013.0000.8042
FRONTAL PANEL PLATE
3
013.0018.1501
FRONT PANEL LABEL (403 MKS)
4
014.0002.0002
KNOB
5
012.0007.0020
PLASTIC LOUVRE
6
012.0007.0010
FRONT PLASTIC
7
011.0013.0021
FRONT PLATE
8
040.0001.0016
FOUR-POLE SWITCH
9
016.4107.0001
LED HOLDER
10
022.0002.0359
LED WIRING
11
012.0019.0010
PLASTIC HOUSING
12
021.0001.0259
OUTPUT SOCKET
13
022.0002.0055
MOVABLE PLUG
14
021.0004.2994
TAPPO PER CONNETTORE MS-20
15
022.0002.0390
RS-232 WIRING
16
021.0015.0002
USB(A) CAP
17
011.0014.0076
USB PLATE
18
050.0001.0171
USB(A) BOARD
19
050.0001.0190
OUTPUT VOLTAGE BOARD
20
042.0003.0052
POWER TRANSFORMER
21
043.0002.0676
VAC TOROID
22
050.0001.0189
KEY BOARD
23
016.0009.0003
RUBBER FOOT
24
021.0001.2022
CAPILLARY TUBE
25
021.0001.2000
COUPLING EURO
26
011.0002.0041
WIRE FEED MOTOR-STING BLOCK BRACKET
27
021.0001.2010
CURRENT CLAMP FOR BRASS GUIDE FOR EURO CONNECTOR
28
021.0001.2017
STING
29
002.0000.0025
WIRE FEEDER
30
011.0006.0002
SLIDE CLOSURE
31
011.0000.1181
RIGHT COVER
32
002.0000.0287
CAP FOR SPOOL HOLDER
33
011.0006.0062
COMPLETE SPOOL SUPPORT
34
022.0002.0153
RS-232 WIRING (1)
35
022.0002.0355
RS-232 WIRING (2)
36
003.0002.0020
FAN
37
017.0001.5542
SOLENOID VALVE
38
011.0013.0211
UPPER COVER
39
011.0006.0007
PLASTIC HINGE
40
045.0002.0022
SUPPLY CABLE
41
045.0000.0017
CABLE CLAMP
42
021.0013.0007
ILME CONNECTOR CAP
43
022.0002.0389
CU SUPPLY CABLE
44
011.0013.0210
REAR PLATE
45
044.0004.0029
OUTPUT INDUCTOR
46
050.0001.0155
MAINS FILTER BOARD
ENGLISH
89
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
No. CODE
DESCRIPTION
47
050.0001.0176
REED SENSOR BOARD
48
050.0001.0156
ELECTROLYTIC CAPACITOR BOARD
49
032.0001.8216
THREE PHASE RECTIFIER BRIDGE
50
040.0003.1012
THERMAL CUT-OUT NTC 10K
51
041.0004.0501
HALL EFFECT SENSOR
52
045.0006.0122
OUTPUT BRACKET
53
050.0001.0158
DRIVER BOARD
54
050.0001.0157
PRIMARY BOARD
55
032.0002.2403
ISOTOP DIODE
56
045.0006.0114
DIODES-TRANSFORMER COPPER BRACKET
57
050.0002.0151
EMI CAPACITORS BOARD
58
011.0000.1171
LEFT COVER
59
050.0008.0129
SUPPLIES BOARD
050.0008.0159
CONTROL BOARD (403MKS)
050.0009.0159
CONTROL BOARD (403MKS PULSE)
050.0032.0078
MOTOR BOARD
60
61
90
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
14
13
12
11
5 10
22
2
4
1
3
27
8
33
5
6
7
34
9
28
26 25
24 23
20
21
29
31
30
15
16
17
18
19
15.1 WIRE FEEDER MOTOR
91
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
N° CODE
DESCRIPTION
1
002.0000.0254
MOTOR COIL
2
002.0000.0062
COMPLETE WIRE FEEDER
3
002.0000.0391
SPACER RING
4
016.0300.0411
COUNTERSUNK SCREW M6x12
5
002.0000.0349
M6 HEXAGONAL NUT
6
002.0000.0384
M5 HEXAGONAL NUT
7
002.0000.0373
FEED PLATE
8
002.0000.0297
INLET GUIDE WITH SOFT LINER
9
002.0000.0385
M6 SQUARE NUT
10 002.0000.0324
SCREW M5x10
11 002.0000.0387
SCREW M6x25
12 002.0000.0294
INTERMEDIATE GUIDE
13 002.0000.0300
MAIN GEAR DRIVE
14 002.0000.0374
SHAFT
15
002.0000.0299
GEAR ADAPTOR FEED ROLL (BRONZE BUSHING)
002.0000.0309
GEAR ADAPTOR FEED ROLL (BALL BEARING)
16 002.0000.0142
FEED ROLL
17 002.0000.0383
RETAINING SCREW M4
18 002.0000.0382
SCREW M5x30
19 002.0000.0388
INTERNAL PROTECTION
20 002.0000.0386
M5 SQUARE NUT
21 002.0000.0315
DISTANCE RING 1
22 002.0000.0303
SMOOTH DRIVE ROLL
23 002.0000.0314
DISTANCE RING 2
24 002.0000.0318
SCREW M4x8
25 002.0000.0377
RIGHT PRESSURE ARM
26 002.0000.0317
SPRING
27 002.0000.0376
LEFT PRESSURE ARM
28 002.0000.0375
JOINT AXLE
29 002.0000.0381
COMPLETE PRESSURE DEVICE
30 002.0000.0319
PIN
31 002.0000.0380
PRESSURE ROLL AXLE
32 002.0000.0304
SCREW M4x10
33 002.0000.0395
COMPLETE LEFT PRESSURE ARM
34 002.0000.0396
COMPLETE RIGHT PRESSURE ARM
92
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
15.2 WIRE FEEDER ROLLS
CODE
Ø WIRE
002.0000.0140
0.6-0.8
002.0000.0141
0.8-1.0
002.0000.0142
1.0-1.2
002.0000.0143
1.2-1.6
002.0000.0144
0.6-0.8
002.0000.0145
1.0-1.2
002.0000.0146
1.2-1.6
002.0000.0147
1.6-2.0
002.0000.0148
2.4-3.2
002.0000.0149
1.0-1.2
002.0000.0150
1.2-1.6
002.0000.0151
2.4-3.2
TYPE
d
D
Standard
Ø ROLL
GROOVE
V groove
Solid wire
D=37x12/d=19 V
35° V
U shape
Aluminium wire
D=37x12/d=19 U
90° V
D=37x12/d=19 VK
90° V
VK shape
Arm with standard roll
CODE
002.0000.0303
Smooth
Ø ROLL
D=37x12/d=12 Smooth standard
93
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
CODE
Ø WIRE
Ø ROLL
002.0000.0168
1.0-1.2
D=37x12/d=19 U DOUBLE D.
002.0000.0169
1.2-1.6
D=37x12/d=19 U DOUBLE D.
002.0000.0171
1.0-1.2
D=37x12/d=19 UT TEFLON.
002.0000.0172
1.2-1.6
D=37x12/d=19 UT TEFLON
d
D
Double driving roll (4 roll with groove) - RECOMMENDED CONFIGURATION
GEAR ADAPTOR FEED ROLL
002.0000.0299
GEAR ADAPTOR FEED ROLL (BRONZE BUSHING)
002.0000.0309
GEAR ADAPTOR FEED ROLL (BALL BEARING)
94
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
ENGLISH
WELD THE WORLD
CODE
Ø WIRE
Ø ROLL
002.0000.0168
1.0-1.2
D=37x12/d=19 U DOUBLE D.
002.0000.0169
1.2-1.6
D=37x12/d=19 U DOUBLE D.
002.0000.0171
1.0-1.2
D=37x12/d=19 UT TEFLON.
002.0000.0172
1.2-1.6
D=37x12/d=19 UT TEFLON
d
D
Double driving roll (2 roll with groove + 2 flat roll)
GEAR ADAPTOR FEED ROLL
002.0000.0299
GEAR ADAPTOR FEED ROLL (BRONZE BUSHING)
002.0000.0309
GEAR ADAPTOR FEED ROLL (BALL BEARING)
Arm with double driving roll
CODE
002.0000.0152
Smooth
Ø ROLL
D=37x12/d=19 SMOOTH double driving
CODE
002.0000.0153
Knurled
Ø ROLL
D=37x12/d=19 KNURLED double
driving
95
Pioneer 403MKS
Pioneer Pulse 403MKS
Cod. 006.0001.2230
02/09/2020 V.1.0
ENGLISH
WELD THE WORLD
Transformation KIT from STANDARD wire feeder to Double driving roll wire feeder
Standard
Double driving roll
If you want to change the configuration ot the STANDARD wire feeder to DOUBLE DRIVE ROLL configuration, you
need to order the following items:
N° 4 Special rolls “U DOUBLE D” (see Part. A)
N° 2 Gear adaptor feed rolls (see Part. B) [it is recommended with bronze bushing]
CODE
Ø WIRE
Ø ROLL
002.0000.0168
1.0-1.2
D=37x12/d=19 U DOUBLE D.
002.0000.0169
1.2-1.6
D=37x12/d=19 U DOUBLE D.
A
x4
GEAR ADAPTOR FEED ROLL for Double driving roll
002.0000.0299
GEAR ADAPTOR FEED ROLL (BRONZE
BUSHING)
002.0000.0309
GEAR ADAPTOR FEED ROLL (BALL BEARING)
96
B
x2
Cod. 006.0001.2230
02/09/2020 V.1.0
Pioneer 403MKS
Pioneer Pulse 403MKS
WELD THE WORLD
ENGLISH
97
Cod. 006.0001.2230
02/09/2020 V.1.0
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