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User Manual
250
i
Ω
MEGA
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Alarm: Gas Pressure Low:
This output will need to be enabled here or on the Active Alarms Screen
before a value is output. This output will go low (0V) when the gas pressure is less than or equal to your
preset threshold, and will remain low until the gas pressure raises above the threshold, or the threshold
is lowered. As insufficient gas pressure can negatively impact weld quality, this is primarily used to
monitor when gas tanks need replacing.
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Alarm: Gas Pressure High:
This output is enabled here or on the Active Alarms Screen before a value
is output. This output will go low (0V) when the gas pressure is greater than or equal to your preset
threshold value, and will remain low until the gas pressure is decreased, or the threshold is raised.
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Alarm: General Gas Pressure:
This output will need to be enabled here or on the Active Alarms Screen
before a value is output. This output will go low (0V) when the gas pressure is less than or equal to your
preset low threshold value, or greater than or equal to your preset high threshold value. This potentially
saves PLC pins for other needs.
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Error:
This output does not need to be enabled by you and will go low (0V) when an internal error
occurs. Such internal errors could include charge errors, too high of voltage on the welding terminals, or
potentially damaging internal temperatures. This is to signal you to turn off the machine, and if problems
persist, to contact Sunstone Support.
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Error: Electrode Stuck:
This output will go low (0V) when the welder detects the electrode is stuck to
the workpiece, and will stay low until the workpiece and electrode are separated. This is a critical error
when automating the welder, as trying to move a stuck electrode can cause damage to the workpiece.
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Error: Invalid Remote Schedule Selection:
This output will go low (0V) when an unassigned remote
schedule is selected. For more information, see the Remote Schedule Select section on page 29.
PLC Inputs
These two drop downs (pins 2.8 and 2.9) are used to customize what inputs the welder accepts. Click on one
of the arrows to open the drop-down and select one of the Sunstone PA250i’s 5 different inputs. The Sunstone
PA250i’s PLC operates in an active-low configuration, so a value of 0V corresponds with true, and a nonzero
value (12V typical) corresponds with false. Inputs have an internal pull-up resistance to +12VDC limiting current
to 25mA. Pins 2.1 and 2.10 can be used to pull the inputs to 0VDC (GND). The available inputs are:
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Toggle Weld On/Off:
Drive this input to 0V to toggle the weld state between Weld On and Weld Off. For
those using Weld Head mode, this input does not toggle to Dry Run state.
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Reset Weld Count 1:
Drive this input to 0V to reset the first weld count.
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Reset Weld Count 2:
Drive this input to 0V to reset the second weld count.
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Reset Both Weld Counts:
Drive this input to 0V to reset both weld counts.
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Purge Gas:
Drive this input to 0V to purge the shielding gas (typically Argon). This is beneficial if there
are breaks between welding, or if you are noticing black residue around your weld sites.
The Sunstone PA250i also has a dedicated Weld Trigger input, assigned to pin 1.9. This pin also operates in an
active-low configuration, drive this input to 0V to trigger a weld. (if in Arc or Tack mode make sure your trigger
method is set to Foot Pedal).
