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SUNSTONE Linear DC, User Manual

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Chapter 1: Introduction:

Thank you for choosing Sunstone Welders and congratulations on your purchase!

You are now the proud owner of a Sunstone Linear DC Welder. This manual was designed to 
have you welding safely within minutes of unpacking your new welder. Please read and follow 
all safety precautions before proceeding with the welding process.

At Sunstone Engineering we are committed to producing quality products and ensuring com-
plete owner satisfaction. If you require assistance after reading this manual please contact us 
with the information provided below.

Sunstone Engineering R&D Corp.

1693 American Way Suite #5

Payson, UT 84651

Email: [email protected]

Voice: 801-658-0015

Fax: 866-701-1209

NOTE: The information contained in this manual is subject to change as improvements are 
made to our products. Visit www.SunstoneWelders.com for the latest version of this docu-
ment.

Sunstone Welders

Linear DC User Manual

3

Summary of Contents for Linear DC

Page 1: ...Sunstone Welders Linear DC User Manual...

Page 2: ...Button Save Button Load Button Video Tab Schedules Tab Operational States Button Weld On Weld Off Button Chapter 4 Start Welding Example Project Setup Perform a Weld Chapter 5 Automated Welding Overv...

Page 3: ...eering we are committed to producing quality products and ensuring com plete owner satisfaction If you require assistance after reading this manual please contact us with the information provided belo...

Page 4: ...not block WELDER INFO Welder information is found here TERMINALS Connect weld head or welding attachments cables here FUSE 20A Fuse DIN CONNECTION PORTS Connect welding attachment DIN Connections here...

Page 5: ...SETUP BACK PANEL CONNECTIONS Positive Terminal Connect one of the cables from weld head or welding hand attachment to the positive terminal with the included 20 screw Caution Terminal and or cable ca...

Page 6: ...o negative and positive terminals on the back of the Linear DC 2 Connect weld head actuation cable to Weld Head Actuation DIN connection port on the back of the welder 3 See weld head manual for instr...

Page 7: ...hment actuation cable to Weld Head Actuation DIN connection port on the back of the welder Precautions HANDLING PARTS BEING WELDED Caution Pieces that have been welded can be HOT Always use caution wh...

Page 8: ...D ON At this point engage the emergency stop button After this the welder should automatically go into a WELD OFF state The button on the top left of the screen will change from WELD ON to WELD OFF If...

Page 9: ...either type in their desired parameter in the numeric keypad or slide their finger on the slider bar to move the weld parameter value up or down The slider bar was designed to react to the speed of t...

Page 10: ...e in th root directory of the USB thumb drive follow the steps below 1 Insert the USB stick into the USB slot on the side of the welder 2 Touch the update welder button ENTER TEST SUITE This is used f...

Page 11: ...ettings After touching the save button follow these steps 1 Type in a name for the new setting or choose an existing saved setting on the left and it will be replaced with the current setting 2 Insert...

Page 12: ...tton Touch the Load Button to open previously saved weld parameters Simply scroll through the options on the left of the screen then select the desired previously saved weld parameter Then touch the l...

Page 13: ...13 Videos Tab Select from the tabs on the left to watch promotional settings and technique videos...

Page 14: ...ters are attainable with the connected weld path resistance The user has the option to have the welder stop operation when the Precheck fails or to continue welding with a warning message or signal Th...

Page 15: ...e precheck setup go to the weld head screen and set up the weld head in either manual or automatic mode See weld head section below for details about the parameters on this screen Resistance Resistanc...

Page 16: ...low heat is required Dual pulse welds are helpful when the piece is dirty or has oxides plating on it The first pulse preheats the part and burns off any oxides helping the second pulse to perform the...

Page 17: ...wer frequency is less pulses Upslope The length in milliseconds for the weld amount to increase to the weld voltage Weld Sets the duration of how long the max weld voltage is applied in milliseconds D...

Page 18: ...Monitored voltage current or power This displays the actual voltage current or power that was achieved on the previous weld The number will be 0 if the comparator was turned off on the previous weld...

Page 19: ...ill stop welding and alert the user anytime the voltage current or power goes out of the min max range that was set 3 Flag and continue weld The welder will continue welding but will alert the user th...

Page 20: ...ontrolling a weld head and the Linear DC with two separate foot pedals 3 Automatic Select this when controlling a weld head and the Linear DC with one foot pedal or when attaching to a PLC Weld Discha...

Page 21: ...r having made contact with the piece This allows the part to be settled well and give greater consistency between welds The Squeeze option must be selected in order to use this function Hold Time The...

Page 22: ...ere are two start trigger options One must be selected before entering welding parameters Foot Pedal Controlled by user pressing the foot pedal PLC Controlled Controlled by user using a PLC Programmab...

Page 23: ...when stored energy levels are too low and transitions from this state when sufficient stored energy levels have been reached Welder and user interface settings may be adjusted in this state however n...

Page 24: ...nality of the WELD state may be performed in this state COOLING NO WELD Many of the components inside the welding unit generate significant amounts of heat under various operational conditions that if...

Page 25: ...tions and discharge all stored energy in the welder as quickly as possible This state is activated by the user when the external emergency stop signal is sent to the welder or when the welder detects...

Page 26: ...26 Chapter 4 Start Welding Example Project Setup Below is an example project we preformed welding a piece of Nitinol Foil to a Tantalum plate PRECHECK PULSE 1 SETTINGS...

Page 27: ...27 COMPARATOR WELD HEAD...

Page 28: ...rt 3 With the Linear DC in a no weld state check the part height Check for obstructions or anything that could short between and electrodes 4 Verify that the weld head is actuating see chapter 1 Weldi...

Page 29: ...ngly Keep in mind that the effect that voltage has on a weld is not linear i e a weld made at 4 volts is not twice as powerful as a weld made at 2 volts It is closer to four times more powerful The we...

Page 30: ...d to Limited 12VDC for a 12VDC Logic signal active low Weld No Good If this signal Open Collector is closed grounded it indicates that the previous weld was considered out of limits on the comparator...

Page 31: ...C The user interface provides triggering options for when this signal is active Foot Trigger 1 and 2 These signals give weld delivery systems the ability to signal the Linear DC welding unit when to s...

Page 32: ...ce of the material The figure below shows an example of a micro scale surface profile On the micro scale material surfaces are rough and only contact in a limited number of locations In the first few...

Page 33: ...ent from weld to weld and is not dependent on the user ELECTRODE CONFIGURATIONS This figure shows several electrode configurations used in resistance welding Example A is called a direct weld Current...

Page 34: ...e Most of the time if this happens the unit can be turned off and back on and the problem will be resolved If the warnings keep on showing up then please contact support and we will gladly help resolv...

Page 35: ...0 1 10 0V at 10mV Step Power 0 01 20kW at 10W Step Peak Current 4000A Peak Voltage 10V Peak Power 20kW Weld Period Ranges weld time each section Squeeze hold Periods Ranges msec 0 100 0 5 Resolution...

Page 36: ...t the work area is clean and safe for welding before starting any weld job Wear appropriate eye protection while using the weld head Do not install or operate unit near combustible surfaces Do not ins...

Page 37: ...t of the welding path such as swapping electrodes or cables turn the unit off Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Properly install and ground th...

Page 38: ...heat rapidly Repetitive welds in the same location can also cause metal to heat rapidly Avoid touching weld spots immediately after the weld has been performed as they will be hot Do not touch hot wel...

Page 39: ...ng operation or storage Secure welding unit during transport so that it cannot tip or fall MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES Wearers of pacemakers and other implanted medical device...

Page 40: ...ion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Stan...

Page 41: ...41...

Page 42: ...SUNSTONE ENGINEERING R D CORPORATION 1693 American Way Suite 5 Payson UT 84651 1 877 786 9353 toll free 1 801 658 0015 international SunstoneWelders com...

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