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Direct Current Resistance Welder Users Guide

20210615 • PART #1230

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Summary of Contents for PicoDC

Page 1: ...Direct Current Resistance Welder Users Guide 20210615 PART 1230 Pic...

Page 2: ...CTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES WITHOUT LIMITING THE FOREGOING YOU UNDERSTAND AND...

Page 3: ...ld Schedules 13 Trigger Weld 13 Comparator Monitoring 14 Displacement Monitoring 14 Weld Head Position 14 Force 14 Weld Head Control Screen Operation 15 Mode Select 15 Force 16 Position 17 Timing 18 S...

Page 4: ...Users Guide Pic...

Page 5: ...tion settings the welder has basic PLC protocols A cloning feature provides a simplified method to set up multiple identical welders Cloning copies all parameters and settings from one welder and quic...

Page 6: ...the weld DC RESISTANCE WELD FORMATION Resistive spot welding relies on metal resistivity to heat and fuse metal Current is generated by the DC power supply and is passed through the workpiece metal En...

Page 7: ...As previously discussed the resistivity of the materials and contact resistance play a major role Other important factors include the force being applied the weld discharge energy the weld discharge...

Page 8: ...adjustable gap electrodes can be used to weld thin foils and strips and offer flexibility in gap distance also allowing for a step configuration if required They are available with a variety of tip s...

Page 9: ...tion requires more weld ener gy than a direct weld would See Figure 5 3 Thermocompression In a thermocompression configuration the current does not pass through the materials being welded but rather t...

Page 10: ...no impediments to shaft movement Make sure all the screws and connectors are tight Make sure the weld head is placed on a stable level surface that does not wobble Try to make sure the materials being...

Page 11: ...nd the power supply is adequate for welding operations Ensure there is sufficient clearance around the sides and rear of the power supply for cables to run freely Good ventilation is important to keep...

Page 12: ...d To turn the welder off press the button again to unlatch it and start the power down sequence Warning Do NOT turn the welder off during boot up Allow the welder to complete the boot process before t...

Page 13: ...to communicate with external accessories such as the Micro E weld head PLC Port The PLC Port C includes logic inputs and outputs that can be used to communicate with a PLC E Stop The E Stop Bypass Plu...

Page 14: ...r safety the Pico uses a 5mm x 20mm 15amp fuse J rated for up to 250VAC Power Inlet The Pico Power Inlet K requires an IEC 320 C13 power cord and can accept 90 250VAC 50 60Hz Exploring the Side Panel...

Page 15: ...cables coming from the weld head or hand piece firmly to the copper terminals on the back panel of the welder One cable should be attached to the negative one cable should be attached to the posi tive...

Page 16: ...m Settings Run Screen A Touch the Run Screen icon A in the Navigation Bar to display the current settings of the weld dis charge and servo weld head See page 13 to learn how to use the Run Screen Weld...

Page 17: ...harge and weld head Additionally the achieved results from the previous weld are displayed here as well The Run Screen is equivalent to a home screen and should be the active screen when triggering a...

Page 18: ...splacement results were within set bounds A red dot indicates something was out of bounds WELD HEAD POSITION N In the lower right hand side of the Run Screen the weld head s current position is displa...

Page 19: ...d The Mode Se lect icon A in Figure 15 2 is identical to the Weld Head Control Screen icon due to it being an extension of the weld head controls The weld head has two modes available Direct Control a...

Page 20: ...d then en ter the desired force using the slider bar or number pad that will appear in a pop up window See Figure 16 2 The weld head will attempt to achieve this force with each weld actuation An uppe...

Page 21: ...ve the Weld Point to which the weld head will return after the weld process is complete The Hover Point value will always be smaller than the Weld Point You cannot set a hover point that is larger tha...

Page 22: ...lliseconds by using the slider bar or by entering the number using the number pad Press the Enter Button to close the box Hold Time Once the weld discharge is complete the servo will maintain position...

Page 23: ...the travel speed between the Hover Point and the Approach Point Set the Weld to Hover Speed Use the slider bar to set the travel speed between the Weld Point and the Hover Point Once the desired spee...

Page 24: ...Button to the Off Position To set displacement limits touch the Minimum or Max imum Displacement box A pop up box will appear Use the slider bar or the number pad to set the displace ment limit Press...

Page 25: ...separate times with each weld trigger initiation The first pulse is useful to remove surface inconsistencies and contami nants which helps to displace oils break through oxide layers and seat the wel...

Page 26: ...lue using the arrow buttons Setting the length of the weld discharge can help fine tune weld results especially when using thermocompres sion electrodes It is recommended to start with shorter lengths...

Page 27: ...settings of the previously saved schedule will be dis played as a waveform The center of the screen displays any previously saved schedules B You can scroll through the list by swiping left or right...

Page 28: ...een Operation Select the Communications Screen icon in the Naviga tion Bar to access the Pico s automation features The Communications Screen has three sub sections The PLC tab the Alarms tab and the...

Page 29: ...igger Reset Weld Count Lockout Remote Schedule Select Note If remote schedule select is chosen both Pin 3 and Pin 4 will be used Pin 5 is hard coded as the Weld Ready Signal Pin 6 is hard coded as the...

Page 30: ...ved schedule as seen in Figure 261 To select pre saved schedules Click on the drop down menus and select the desired saved schedule You can choose four different schedules that are selectable through...

Page 31: ...ult Part Check Failed Trigger in No Weld State Wrong Trigger Detected The bottom portion of the screen will show a list of active alarms and warnings F If there are more active alarms and warning than...

Page 32: ...re a USB drive is attached to the USB port found on the Pico s left panel Clear Weld History C Press the Clear Weld History Button C to clear the past weld results history Export Clone Settings D The...

Page 33: ...choose the desired lan guage speaker volume and system date and time To change the language Touch the Language box I A list of available languages will appear Press the desired language The Pico s sof...

Page 34: ...ggle Lock Mode Button B See Figure 30 1 A popup message will appear and will show the different lock options Tap on the desired option and follow the screen prompts The options include Limited Lockout...

Page 35: ...w Update Welder Over Wi Fi H To update the Pico s software over a Wi Fi connection press the Update Welder Over Wi Fi Button H and follow the instructions that appear on the screen See detailed instru...

Page 36: ...vice Continue to the next bullet point Turn the welder off and wait 10 seconds Remove the USB drive Turn the welder on The updated software will now launch which may take a few minutes Once the new so...

Page 37: ...essage which can be ignored don t call Sunstone Customer Service Continue to the next bullet point Turn the welder off and wait 10 seconds Remove the USB drive Turn the welder on The updated software...

Page 38: ...Ready Pull this pin up to 12V by connecting it with Pin 2 12V Signal will go low 0V when weld is ready 6 Alarm Pull this pin up to 12V by connecting it with Pin 2 12V Signal will go low 0V when alarm...

Page 39: ...see Figure 35 2 mates to SD 50LP con nects to analog foot pedal 1 Variable Foot Pedal Connect this to Pin5 12VDC with a 10Kohm potentiometer 2 Primary Trigger Connect this pin3 GND when trigger is de...

Page 40: ...NGLE PHASE 90 264 VAC FREQUENCY RANGE 47 63 Hz POWER FACTOR TYP 0 95 230 VAC 0 98 115 VAC at Full Load OUTPUT VOLTAGE RANGE 0 10 5 00 V 0 01 V Intervals OUTPUT CURRENT RANGE 10 0 250 A OUTPUT POWER RA...

Page 41: ...Questions Call or Text 1 801 658 0015 37 The Micro Welder Experts...

Page 42: ...38 Questions Call or Text 1 801 658 0015 Users Guide Pic...

Page 43: ...Questions Call or Text 1 801 658 0015 39 The Micro Welder Experts...

Page 44: ...eep your production levels up If you re in the circle we ll take care of you Free Replacement Sometimes it makes more sense to replace a broken welder with a current or refurbished model or offer a di...

Page 45: ...the circle your request for customer service gets moved to the front of the line You get extra attention Just another perk when you subscribe today Complimentary Shipping Should your Sunstone welder...

Page 46: ...Ste 5 Payson UT 84651 USA Tel 1 801 658 0015 wwww sunstonewelders com 2021 Sunstone Engineering LLC Safety information subject to change Sunstone and Orion are trademarks of Sunstone Engineering LLC 2...

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