Weco Pioneer Pulse 321MKS Instruction Manual
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Weco Pioneer Pulse 321MKS Instruction Manual

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Cod.006.0001.1520
11/07/2017 v2.8
ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36056 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.+39 0424 561943 – Fax +39 0424 561944
www.weco.it - E-mail info@weco.it
Pioneer Pulse 321MKS
Instruction manual
GB

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  • Page 1 Cod.006.0001.1520 11/07/2017 v2.8 ENGLISH WECO srl Via S. Antonio, 22 - BELVEDERE 36056 TEZZE SUL BRENTA (VICENZA) ITALY Tel.+39 0424 561943 – Fax +39 0424 561944 www.weco.it - E-mail info@weco.it Pioneer Pulse 321MKS Instruction manual...
  • Page 2 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 2/52...

  • Page 3: Table Of Contents

    USER INTERFACE ............. 9 TECHNICAL DATA ............37 UNIT POWER-UP.............. 11 SPARE PARTS..............38 RESET (LOAD FACTORY SETTINGS) ......11 16.1 PIONEER PULSE 321MKS ..........38 SET-UP (INITIAL SET-UP OF THE WELDING POWER 16.2 WIRE FEEDER MOTOR ............ 40 SOURCE)................12 16.3 WIRE FEEDER ROLLS ............

  • Page 4: Introduction

    This symbol accompanies important information concerning the execution of the relevant operations. Pioneer Pulse 321MKS is a professional three-phase inverter-based welding unit with 4-roll wire feeder designed to operate in extreme environmental conditions. This power source is ideal for workshop...

  • Page 5: Rear Panel

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH REAR PANEL 6: Power supply transformer fuse. Type Delayed acting (T) Amperage 3.15 A Voltage 500 V 7: Cooler power feeding connector. Voltage 230 V~ Current Output 0.8 A IP20 (cap open) IP protection rating...

  • Page 6: Connections To The Electrical Mains Network

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 3. Mount the cooler in the relevant location. 4. Fit the spool in the spool holder, ensuring it is located correctly. 4. Screw the cooler fixing bracket to the welding power source chassis using the supplied screws.

  • Page 7: Connections To Sockets

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH §. 16.3 WIRE FEEDER ROLLS 9. Connect the plug of the ground clamp to the welding socket on the basis of the polarity required.  The diameter of the roll groovemust be compatible with the 10.
  • Page 8 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH MIG/MAG installation 8/52...

  • Page 9: User Interface

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH USER INTERFACE CODE SYMBOL DESCRIPTION When this LED illuminates the following parameter can be set: WIRE FEED RATE The value appears on the following display: D1 Short-Spray, pulsed and synergic MIG/MAG welding: When this LED illuminates the following parameter can be set: WELDING CURRENT...
  • Page 10 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH Illumination shows that the following function has been activated: 3 levels procedure § 14.5 3 LEVEL - 2T B-LEVEL MIG/MAG WELDING / § 14.6 3 LEVEL - 2T SPOT MIG/MAG WELDING § 14.7 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING / § 14.8 3 LEVEL - 4T B-LEVEL MIG/MAG WELDING During illumination of the following LEDs: The display shows the value of the selected parameter.

  • Page 11: Unit Power-Up

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH UNIT POWER-UP Set the welding power source ON/OFF switch to “I” to switch on the unit. The message appears on the following displays: D4 MOTOR 321 PIONEER FW: YY.YY.YYY PROGRAM UPDATE YY.YY.YYY= power source software version.

  • Page 12: Set-Up (Initial Set-Up Of The Welding Power Source)

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH SET-UP (INITIAL SET-UP OF THE WELDING POWER SOURCE) With locked status active it is not possible to access this function. § 8.2 LOCKING PROCEDURE SET UP when device is switched on Set the welding power source ON/OFF switch to “O” to switch the unit off.

  • Page 13: Work Hours Counter

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 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.

  • Page 14: Locking Procedure

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 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.

  • Page 15: Disabling

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH Disabling If a lock status is selected, you can only edit parameters permitted by the currently active lock status. If you cannot recall the password the only way to exit locked status is to perform the welding power source RESET procedure.

  • Page 16: Calibrating The Welding Circuit

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 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. CALIBRATING THE WELDING CIRCUIT When using the wire feed trolley with associated umbilical, it is advantageous practice to measure welding circuit impedance "r"...

  • Page 17: Alarms Management

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH ALARMS MANAGEMENT This LED illuminates if an incorrect operating condition occurs. An alarm message appears on the following display: D4 Tab. 3 - Alarm messages MESSAGE MEANING EVENT CHECKS Indicates tripping of the welding power source thermal - Make sure that the power required by the welding process All functions disabled.

  • Page 18: Parameters Activation

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 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.

  • Page 19: Welding Parameters

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 10.1 WELDING PARAMETERS Consequences of a lower value:  Cooler welding. Arc correction in Volts PRE GAS This parameter corrects the synergic voltage value relative to the synergic point of the synergic and pulsed MIG/MAG processes, while Time of gas delivery before the arc strike.
  • Page 20 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH POST GAS CRATER 3LEV Time of post gas delivery when the welding arc is extinguished. Crater in 3 levels operation This is useful when welding at high current values or with materials The parameter adjusts the 3rd level wire feed rate as a percentage of that oxidise readily to cool the weld pool in an uncontaminated the wire feed rate set for welding (2nd level).
  • Page 21 Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 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.

  • Page 22: Characteristics Of The Menu Levels

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH CHARACTERISTICS OF THE MENU LEVELS 11.1 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.

  • Page 23: 3Rd Level

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 11.3 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.
  • Page 24 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH CURVE HIGH CONTROL: the curves are available in HSL series power sources in PULSED MIG/MAG - DOUBLE PULSED MIG/MAG welding mode. The new pulsed HC (High Control) curve provides very fast arc control that allows to optimise the detachment of the droplet with greatly reduced energy.

  • Page 25: Manual Mig/Mag Welding

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 12.2 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.

  • Page 26: Synergic Mig/Mag Welding

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 12.3 SYNERGIC MIG/MAG WELDING Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding parameter, chosen from among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.

  • Page 27: Synergic Mig/Mag Parameters Setting (2Nd Level)

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 12.3.2 SYNERGIC MIG/MAG PARAMETERS SETTING (2ND LEVEL) Press the button to enter the 2nd level menu. Use these buttons to scroll through the list of parameters to edit. Using the encoder, edit the value of the selected parameter.

  • Page 28: Pulsed Synergic Mig/Mag Welding

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 12.4 PULSED SYNERGIC MIG/MAG WELDING Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding parameter, chosen from among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.

  • Page 29: Pulsed Synergic Mig/Mag Parameters Setting (2Nd Level)

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 12.4.2 PULSED SYNERGIC MIG/MAG PARAMETERS SETTING (2ND LEVEL) Press the button to enter the 2nd level menu. Use these buttons to scroll through the list of parameters to edit. Using the encoder, edit the value of the selected parameter.

  • Page 30: Double Pulsed Synergic Mig/Mag Welding

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 12.5 DOUBLE PULSED SYNERGIC MIG/MAG WELDING Set the welding data (material, wire diameter, gas type), shown on display D4 and just one welding parameter, chosen from among wire feed rate, Amperes, and workpiece Thickness, shown on display D1.

  • Page 31: Double Pulsed Synergic Mig/Mag Parameters Setting

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 12.5.2 DOUBLE PULSED SYNERGIC MIG/MAG PARAMETERS SETTING (2ND LEVEL) Press the button to enter the 2nd level menu. Use these buttons to scroll through the list of parameters to edit. Using the encoder, edit the value of the selected parameter.

  • Page 32: Jobs Management

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 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.

  • Page 33: Loading A User Job

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH Hold down the button for 3 seconds. The first letter of the name blinks. Use the encoder to change the letter. Press the button to confirm. Use these buttons to select the character to be modified.
  • Page 34 Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH Exit without confirmation Press the button. This action will automatically close the menu. Exit with confirmation Press the button. CONFIRM JOB ERASURE The message appears on the following displays: D4 Use the encoder to select the following setting: NO Press the button.

  • Page 35: Torch Trigger Modes

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH TORCH TRIGGER MODES 14.1 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 work.

  • Page 36: Level - 2T B-Level Mig/Mag Welding

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 14.5 3 LEVEL - 2T B-LEVEL MIG/MAG WELDING 1. Bring the torch up to the workpiece. 2. Press (1T) the torch trigger. The wire advances at the approach speed until making contact with the work. If the arc does not strike after 10 cm wire protrusion, wire feeding is locked and the welding unit outputs are de-energized.

  • Page 37: Technical Data

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH TECHNICAL DATA Model Pioneer Pulse 321MKS EN 60974-1 Construction standards EN 60974-5 EN 60974-10 Class A Supply voltage 3 x 400 V~± 15 %/ 50-60 Hz This equipment complies with IEC 61000-3-12 provided that the maximum permissible system impedance is less than or equal to 33 mΩ...

  • Page 38: Spare Parts

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH SPARE PARTS 16.1 PIONEER PULSE 321MKS 38/52...
  • Page 39 Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH N° CODE DESCRIPTION N° CODE DESCRIPTION 011.0006.0030 RIGHT HANDLE 050.0025.0080 PULSE BOARD 014.0002.0010 KNOB WITHOUT POINTER 041.0006.0006 AUXILIARY TRANSFORMER 013.0021.0901 FRONT PANEL LABEL 045.0006.0082 DIODES-SOCKET COPPER BRACKET 013.0000.8032 LOGIC BOARD PLATE 045.0006.0081 DIODE-DIODE BRACKET 050.5070.0000...

  • Page 40: Wire Feeder Motor

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 16.2 WIRE FEEDER MOTOR 40/52...
  • Page 41 Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH N° CODE DESCRIPTION 002.0000.0254 MOTOR COIL 002.0000.0308 SPACER RING 002.0000.0306 COUNTERSUNK SCREW M6x12 002.0000.0307 SCREW M6x20 002.0000.0295 FEED PLATE 002.0000.0318 SCREW M4x8 002.0000.0291 INSULATION MOUNTING KIT 002.0000.0300 MAIN GEAR DRIVE 002.0000.0298 SHAFT 002.0000.0299 GEAR ADAPTOR FEED ROLL (BRONZE BUSHING) 002.0000.0309...

  • Page 42: Wire Feeder Rolls

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 16.3 WIRE FEEDER ROLLS 16.3.1 STANDARD D = 37mm d = 19mm N° CODE WIRE DIAMETER GROOVE TYPE 002.0000.0140 0.6-0.8 002.0000.0141 0.8-1.0 V groove Solid wire 002.0000.0142 1.0-1.2 002.0000.0143 1.2-1.6 002.0000.0149 1.0-1.2 002.0000.0150 1.2-1.6...

  • Page 43: Electrical Diagram

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH ELECTRICAL DIAGRAM 17.1 PIONEER PULSE 321MKS 43/52...
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  • Page 48: Remote Controller

    Cod.006.0001.1520 11/07/2017 v2.8 Pioneer Pulse 321MKS ENGLISH 17.2 REMOTE CONTROLLER 17.2.1 RC03: ELECTRICAL DIAGRAM Name Voltage Input/Output +5 V 5 V d.c. B AN2 (5 V) 0-5 V C AN1 (5 V) 0-5 V 10 kOhm - 100 kOhm potentiometer 17.2.2 RC04: ELECTRICAL DIAGRAM...

  • Page 49: Rc05: Electrical Diagram

    Cod.006.0001.1520 Pioneer Pulse 321MKS 11/07/2017 v2.8 ENGLISH 17.2.3 RC05: ELECTRICAL DIAGRAM 17.3 PUSH-PULL (OPTIONAL) Name Voltage 42 V d.c. 17.2.4 RC06: ELECTRICAL DIAGRAM 49/52...
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