Sunstone Welders Linear DC User Manual

Transcription

1 Sunstone Welders Linear DC User Manual

2 Table of Contents Chapter 1: Introduction Quick Look Chapter 2: Getting Started Set-up Linear DC Connecting Welding Attachments Precautions Chapter 8: Data Specifications Chapter 9: Safety Chapter 3: Interface Operational Controls Settings 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 Overview Chapter 6: Resistance Welding Basics Overview 34 Chapter 7: Technical Assistanc 2

3 Sunstone Welders Linear DC User Manual 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 complete owner satisfaction. If you require assistance after reading this manual please contact us with the information provided below. Sunstone Engineering R&D Corp American Way Suite #5 Payson, UT sales@sunstonewelders.com Voice: Fax: NOTE: The information contained in this manual is subject to change as improvements are made to our products. Visit for the latest version of this document. 3

4 Quick Look TOUCH SCREEN INTERFACE Set all weld parameters here. USB PORT Upload software updates. POWER BUTTON Press to power up. WELDER INFO Welder information is found here. COOLING FANS Keeps system cool. Do not block. (-) (+) TERMINALS Connect weld head or welding attachments cables here. FUSE 20A Fuse. DIN CONNECTION PORTS Connect welding attachment DIN Connections here. AC POWER Attach AC power here. EMERGENCY STOP Press to shut off system. 4

5 Chapter 2: Getting Started Set-up Linear DC WHAT IS IN THE BOX Carefully open the welder package. Remove and place the contents on a clear and clean workbench. Inside the box: Linear DC Welding Unit Power Cable Safety Manual Quick Start Guide SPACE REQUIREMENTS The Linear DC has a 15.2 x11.4 footprint. Be sure to provide enough space to connect a weld head or welding hand attachment and roughly a 2-4 space on the backside of the unit to connect power and weld attachment cables. 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 ¼ -20 screw. Caution: Terminal and/or cable can become HOT during welding. Negative (-) Terminal Connect the other cable from weld head or welding hand attachment to the negative terminal with the included ¼ -20 screw. Caution: Terminal and/or cable can become HOT during welding. AC Inlet This unit can accept a 50-60Hz AC signal from 90VAC to 250VAC. Use the supplied cable to connect to the power inlet. Plug the female end of the provided power cable into the back of the unit. Then plug the male end of the power cable into AC power. 5

6 Fuse 20A fuse included. Replacement fuse: Schurter Inc. Manufacturer # Fans Airflow will come out of the unit from these locations and could be warm. The fans will not normally be spinning, but will turn on if the unit is hot. They may turn on even if welder is not being used, but is turned on. *Do not block fans. USB Port USB flash drive can be inserted for updating the unit software *Use a 4GB stick of memory or less. *See Linear DC product page at for update or contact a Sunstone representative. Connecting Welding Attachments CONNECT WELDING ATTACHMENTS Sunstone Weld Head - automatic weld triggering 1. Connect weld head cables to 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 instructions on weld head foot pedal setup. *Weld head foot pedal will control weld head up and down movement and weld triggering. Sunstone Weld Head - dual foot pedal triggering 1. Connect weld head cables to negative and positive terminals on the back of the Linear DC. 2. Connect included Linear DC foot pedal into Weld Discharge Trigger DIN connection port on the back of the welder. *With this option users will not connect the weld head actuation cable to any of the DIN ports. 3. See weld head manual for instructions on weld head foot pedal setup. *Weld head foot pedal will control weld head up and down movement and Linear DC foot pedal will control weld triggering. 6

7 Sunstone Micro Weld Head - dual foot pedal triggering 1. Connect weld head cables to negative and positive terminals on the back of the Linear DC. 2. Connect included Linear DC foot pedal into Weld Discharge Trigger DIN connection port on the back of the welder. *With this option users will not connect the weld head actuation cable to any of the DIN ports. 3. See micro weld head manual for instructions on micro weld head foot pedal setup. *Micro weld head foot pedal will control weld head up and down movement and Linear DC foot pedal will control weld triggering. Sunstone Hand Attachment 1. Connect hand attachment cables to negative and positive terminals on the back of the Linear DC. 2. Connect hand attachment 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 when handling welded pieces. ELECTRODE CARE For best results sand (shape) and clean the electrodes prior to performing welds and after electrode tip wear; smoother electrodes will provide better results. EMERGENCY STOP SWITCH The Linear DC is able to be equipped with an Emergency Stop Switch, the Emergency Stop Switch will attach to the back of the unit into the Emergency Stop Switch port. The Linear DC comes equipped with an Emergency Stop Switch Key. This key connects to the Emergency Stop Switch port on the back on the unit to bypass the need to have an Emergency Stop Switch. To purchase an Emergency Stop Switch, call in to Sunstone. When using the Emergency Stop Switch, please be aware of the following: 7

8 Ensure Emergency Stop Switch is working WARNING: THIS MUST BE DONE PRIOR TO OPERATING WELDER In order to verify that the emergency stop switch is working properly, plug in the included emergency stop push button into the 3DIN connector on the back panel. Plug the welder into AC power. Turn the unit on by pressing the power LED button on front panel. Once the unit has come to the interface users will see WELD OFF on a tab at the top left of the screen. Press that button to place the unit into a welding state. The button should now indicate WELD 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 this happens, then the emergency stop is working properly and users can begin welding with the unit. If this doesn t happen please contact customer support. DRAINING STORED ENERGY (Opening Unit, 3 hours to 0.1V) WARNING: ONLY QUALIFIED TECHNICAL PERSONNEL SHOULD OPEN UNIT. A large amount of stored energy in this unit can cause great harm and even potential death if not handled correctly. If unit needs to be opened for any reason, the unit needs to be turned off and unplugged for eight hours, to give enough time for the stored energy to be drained. 8

9 Chapter 3: Interface Operational Controls NUMERIC KEYPAD AND SLIDER BAR The Linear DC touch screen display features a numeric keypad with a build in slider bar for easy setting of weld parameters. Users simply touch the weld setting boxes on the display and then 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 the users finger. If the user moves their finger quickly across the slider bar, the numeric value will increase or decrease rapidly. Conversely, if the user moves their finger along the slider bar slowly, the numeric value will increase or decrease in fine increments. 9

10 Settings Button UPDATE WELDER As software updates become available, user can download them from the resource page on the Sunstone website. Once the update is downloaded and place 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 for troubleshooting for authorized representatives. RESET WELD VALUES This will reset all welder settings back to their factory default settings. This will not affect saved settings. 10

11 Save Button Touch the Save Button to create a custom weld parameter. This feature will save all the current weld parameter settings. 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 any notes that would be useful to remember when returning to this custom setting. 3. Save as new or Save Over Selected Schedule. 11

12 Load Button 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 load button. 12

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

14 Schedules Tab PRECHECK SCREEN The Linear DC is equipped with an optional Precheck feature that enables the welder to test the resistance of the weld path before a weld is performed. This allows the weld controller to notify the user if the chosen weld parameters 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. *This is useful in high volume production or automated systems. Enable - To enable this feature, select the Precheck button and then ensure that the box next to Enabled has a check mark in it. Time - This displays how long the voltage will be applied during the precheck. 14

15 Voltage - This displays how much voltage will be applied during the precheck. Generally these values should be low to avoid discharging significant amounts of energy into the weld path. Min Current/Max Current - To ensure that too much or too little energy is not discharged into the weld path during the Precheck, the user can define a maximum and a minimum allowable current. Monitored Current - The monitored current values is the measured current of the previous Precheck. If a Precheck has not occurred since the welding unit has been powered on, this value will be blank. *If using a weld head during the 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 - Resistance shows the measured resistance value in mω. Calibrate - Select this button to calibrate the resistance of the system. In calibrate the weld head or hand attachment will actuate and send the full voltage of the welder and will calibrate the resistance of that weld head or hand attachment. *Warning: During this process the full energy of the machine is discharged which could potentially melt smaller electrodes. Be sure to use 1/8 in or larger electrodes when using this feature. Also be sure the electrodes are lined up correctly and have good contact when using this feature in order to prevent sparking. 15

16 PULSE SETTINGS SCREEN Unit Selector - The welder can control the pulse in terms of Current, Voltage, or Power. Before making any setting, select the desired unit of power. Single and Dual Pulse Description - Single pulse welds are typically used where the work pieces are fairly clean. Single pulse welds are often beneficial when welding small parts such as fine wires where very 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 weld accurately and consistently. Pulse 1 and Pulse 2 Buttons - When the Pulse 1 button is selected the weld parameters displayed on the screen are specific for Pulse 1. Select Pulse 1 parameters (Weld Power, Agitation, Frequency, upslope, weld, downslope, and rest) by touching the box next to each parameter, and then use the numeric keypad to enter the desired values. Users can also 16

17 use the slider adjustment bar under the numeric key pad to enter desired values. The image displayed on the screen above the Pulse 1 parameters shows a representation of what the pulse 1 waveform looks like. After setting the Pulse 1 parameters select the Pulse 2 button and select the Pulse 2 desired settings. Weld Power - Sets the Voltage/Current/Power for the selected pulse (This is the top flat part of the pulse as seen in the graph above the weld settings). Agitation Voltage - Sets the agitation voltage for the selected pulse. Agitation provides additional power for deeper penetration (remember: this does add heat and energy into the piece). Frequency - This controls the frequency of the agitation micro pulses. Only applies to a pulse that is using agitation. Higher frequency relates to more micro pulses and lower 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. Downslope - The length in milliseconds for the weld amount to decrease back to zero in the welding process. Rest - The Rest Time box represents the amount of time the welder will maintain a zero value after a pulse has finished and before the second pulse begins. This value is represented in milliseconds. Monitor Enabled - Check this box to enable weld monitoring. *Be aware that users will need to calibrate the system in order to have actual monitoring. Users only need to calibrate the system once unless a different weld head or hand piece is going to be used. Monitor max and Monitor min - The adjusted max and min values that are actually applied to the work piece through the electrodes. These numbers are found through the calibration process and take into account the resistivity of the weld head or hand attachment. 17

18 COMPARATOR SCREEN This screen is used when monitoring is enabled on the Pulse Settings Screen. However users have the capability to turn the function on or off. Desired (voltage, current, or power) - This displays the desired (voltage, current, or power) that has been selected on the Pulse Settings screen. 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. Maximum and Minimum (voltage, current, or power) - The user can select the max and min (voltage, current, or power) that is allowable through the weld. If out of range - If weld (voltage, current, or power) goes outside the range set in the min and max, there are 3 options for the user to decide what happens next: 18

19 1. Do nothing - The welder will continue operation as normal even when the previous (voltage, current, or power) were out of the min max range. 2. Flag and stop weld - The welder will 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 that the (voltage, current, or power) went out of the min max range that was set. Previous Weld - This box tells the user if the previous weld was within the set max and min values. 19

20 WELD HEAD SCREEN There are three weld head control options. One must be selected before entering welding parameters. 1. Disabled - Select this when using a hand piece. 2. Manual - Select this when controlling 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 Discharge Options: Squeeze - The Weld will be initiated after the time value in the Squeeze Time box has been reached Weld Head - The Weld will be initiated by the micro switch within the Weld Head once 20

21 it has reached the set force. Pre-Weld Delay - The time the weld head will wait to begin moving after receiving a weld signal from the foot pedal or PLC Squeeze Time - The time the weld head will wait to start the actual weld after 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 time the weld head will continue to apply pressure after the weld has completed before starting to move up again. Post Weld Delay - After the entire weld is completed, this is the amount of time before the next weld can be initiated. 21

22 CONTROL SCREEN There 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 (Programmable Logic Controller). 22

23 Operational States Button The operational states tab is next to the schedules tab and displays the welders current status. Below is a description of each status. Remember that some of these flash by so quickly that they may not be seen, but we will give a description of each. The main purpose and functionality of this button is to change from weld on to weld off and vice versa. STARTUP After the power button has been pressed to turn the welder on, the welder will be in this state while the user interface starts up and previous settings are being loaded. The welder automatically transitions from this state when all startup operations have finished, no user intervention is needed or accepted during this state. INITIALIZING This state indicates that the welder has started up and is building up stored energy for welding. The welder automatically transitions to this state 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 no welds will be allowed to occur. CHARGING These states are very short, usually right after a weld has occurred. NO WELD This state is an idle state where the no welds can occur. The welder transitions to this state after the STARTUP and CHARGING states have occurred or if the user touches the WELD button on the user interface. Welder and user interface settings may be adjusted in this state. In order for the welder to transition from this state the user must touch the NO WELD button. WELD This is an idle state when the welder has sufficient stored energy to weld, the weld settings have been or are being set correctly and the user has pressed the NO WELD button. Welder and interface settings may be adjusted in this state, however, it is recommended that all settings be adjust and the welder be idle before a weld trigger signal is sent to the welder. The welder will leave 23

24 this state when a weld trigger signal is received or when the user touches the WELD button. The welder enters this state when the user touches the NO WELD button or after a welding and/or charging sequence has occurred. WELDING Transition to this state happens from the WELD state when a trigger signal is received. This is where all weld head operations, PLC signaling, and welding processes take place. Welder and user interface settings may not be adjusted in this state. Transition from this state occurs automatically when all current welding-related processes have finished. COOLING-WELD Many of the components inside the welding unit generate significant amounts of heat under various operational conditions that, if not dissipated quickly, could damage critical components of the welder. The welder is equipped with sensors that detect excess heat conditions and activate heat dissipating fans to remove it. The welder is moved to this state when the heat sensors detect excess heat to ensure that component damage is avoided. All functionality 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 not dissipated quickly, could damage critical components of the welder. The welder is equipped with sensors that detect excess heat conditions and activate heat dissipating fans to remove it. The welder is moved to this state when the heat sensors detect critical amounts of heat. Welding processes are suspended to ensure that component damage is avoided. All functionality of the NO WELD state may be performed in this state. ALARM/NOTIFICATION-WELD This state is used when certain functions of the welder are enabled to notify the user of specified conditions. When a fault or error condition is detected, a warning message is displayed until the message is suspended. Welding processes continue normally unless the user intervenes. ALARM/NOTIFICATION-NO WELD This state is used when certain functions of the welder are enabled to notify the user of specified conditions. When a fault or error condition is detected, all welding procedures are aborted and a warning message is displayed until the message is suspended. Welding processes will not 24

25 continue normally until the user clears the error. EMERGENCY STOP For safety reasons this state is used to suspend all charging and welding functions 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 specific conditions. The welder will stay in this state until the emergency stop signal is removed and the welder does not detect unsafe conditions. 25

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 26

27 COMPARATOR WELD HEAD 27

28 CONTROL Perform a Weld BASIC WELDING STEPS 1. Ensure that the weld head or welding attachment cables are connected correctly and tightly to the (-) and (+) terminals. 2. Power on the welder and set weld parameters accordingly (weld pulses, voltage, length, agitation, etc.). If this is the first time welding the part, start with the voltage at 1 volts and weld length around 10ms. These settings will likely not produce a quality weld; but they will serve as a good place to start. 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 Welding Attachments section and the weld head or weld attachment user manual for setup instruction) 5. Actuate the weld head with the part in place and verify that the desired stroke is possible and that pinching of the part actually takes place. 6. Set the spring force on the weld head if equipped (half of max force is often a good starting point). 7. Press the Weld: On button to activate the welder. 8. Initiate the weld (lower the weld head or hand attachment electrodes). 28

29 9. If using a separate foot pedal to trigger the weld, press the foot pedal to trigger a weld output from the welder. 10. Inspect the weld and adjust weld parameters accordingly. 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 weld time is useful for fine tuning weld results. 11. Once acceptable weld settings have been established, a pull test can be performed to establish a statistical tracking value. 29

30 Chapter 5: Automated Welding Overview The Linear DC Basic welding unit has been designed to be able to be integrated into automated welding systems. To aid in this integration the welder has the ability to output a series of sensing inputs, control output signals, and notification signals. OUTPUTS Logic: Weld Good Signal State Weld No Good Signal State Weld was good Closed (Grounded) Open Weld was not good Open Closed (Grounded) Welder Welding/No weld has happened Open Open Error Closed (Grounded) Closed (Grounded) Weld Good: If this signal (Open Collector) is closed (grounded) it indicates that the previous weld was considered within the tolerances set by the user. If this signal and Weld No Good signal are both open at the same time then the welder is either welding or hasn t made a weld since being turned on. Recommend at least a 1K Ohm resistor pulled 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. If this signal and Weld No Good signal are both open at the same time then the welder is either welding or hasn t made a weld since being turned on. Recommend at least a 1K Ohm resistor pulled to Limited +12VDC for a 12VDC Logic signal (active low). Welder Ready: If this signal (Open Collector) is closed (grounded) it indicates that the welder is ready to weld. If this signal is open it indicates that the welder is not ready to weld. This can be because the unit has not been put in a weld ready state. To do this press the button on the top left of the Retina touch display labeled No Weld. This signal can also be open indicating that a weld is occurring. Recommend at least a 1K Ohm resistor pulled to Limited +12VDC for a 12VDC Logic signal (active low). SENSORS AND INPUTS Voltage Feedback: The Linear DC welding unit is capable of measuring output voltage in 30

31 conjunction with an internal current sensor for monitoring and comparator options available in the user interface. The voltage measurement can be taken internal to the welding unit (no extra connections needed) Basic PLC Trigger Input: This input gives an automated weld delivery system the ability to notify the Linear DC welding unit when to trigger a welding sequence. This signal can be controlled and delivered by other automation system components such as a PLC. 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 start a welding sequence. They are typically delivered by a manual foot pedal switch, however, an automated weld delivery system could provide these signals as well. Options for how the welding unit responds to Foot Trigger signals can be found in the user interface. WH Trigger: This input gives and automated weld delivery system the ability to notify the Linear DC welding unit when to weld. The user interface provides triggering options for when this signal is active. 31

32 Chapter 6: Resistance Welding Basics Overview SINGLE AND DUAL PULSE DESCRIPTION Single pulse welds are typically used where the work pieces are fairly clean. Single pulse welds are often beneficial when welding small parts such as fine wires where very 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 weld accurately and consistently. WELD FORMATION Spot welding relies on metal resistivity (resistance) to heat and fuse metal. A large current is passed through the workpiece metal. Energy is dissipated due to metal resistance in the form of heat which melts and fuses the weld materials. There are two phases to the melting process. The welder must overcome both the material contact resistance and the bulk resistance 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 milliseconds of weld formation, the high-resistance metal bridges melt, allowing other bridges to come into contact to continue the melting process. When all of the bridges have fused, the contact resistance is zero. The bulk resistance of the metal then plays the final role in the weld formation. WELD PRESSURE Several other factors play a part in the contact Surface 1 resistance. The larger the contact resistance the Contact Point Surface 2 hotter the resultant weld. On the micro-scale, contact resistance is reduced when more metal bridges or contact points are formed. Using more electrode pressure creates more metal bridges. This results in a lower contact resistance and a cooler weld. Conversely, light electrode pressure results in less metal contact, higher resistance, and a hotter weld. An appropriate amount of pressure should be used to insure good weld strength. 32

33 WELDING ATTACHMENTS Weld heads or welding hand attachments will be chosen based on electrode access, and the type of application. When both sides (top and bottom) of the work piece can be accessed, an OPPOSED type weld head or welding hand attachment is ideal. When the user only has access to one side of the work piece, either a PARALLEL weld head or a welding hand attachment can be used. Weld heads are typically the best option, as the welding force is consistent 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 is passed from one electrode through both workpieces and out an opposing electrode. Example B A B C shows a step electrode configuration. This configuration is used when there is access to only one side of the workpiece and an electrode can be placed on both materials. Example C is a series configuration. Electrodes can only be placed on one metal surface from one side. Current is divided between the two parts. This weld configuration requires more weld energy. 33

34 Chapter 7: Technical Assistance For technical assistance or part replacement contact: Sunstone 1693 American Way Suite #5 Payson, UT (international) (toll free) SOFTWARE In rare circumstances a warning message may pop-up and warn that the unit is having an issue. 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 resolve the issue. HARDWARE In rare circumstances the unit may become inoperable. If this happens turn the unit off and back on. If the issue continues to happen, please contact support and we will gladly help resolve the issue. If the unit is visibly having issues, please disconnect unit from power and call support immediately. 34

35 Chapter 8: Data Specifications Linear DC Voltage (Single Phase) AC Version Power Source 110 or 220 Single Phase Current A 10 Amp/Step Voltage V at 10mV/Step Power kW at 10W/Step Peak Current 4000A Peak Voltage 10V Peak Power 20kW Weld Period Ranges weld time (each section) Squeeze/hold Periods Ranges (msec) Resolution (steps) 0.1ms 1ms Current Output Accuracy ±10A Voltage Output Accuracy ±0.005V Welder (L x W x H) 15.2 x 11.4 x 15.5 (38.5 x 28.9 x 39.3cm) Weight 46.5 lbs. (21.1kg) 35

36 Chapter 9: Safety Read Before Welding ONLY PERSONNEL TRAINED AND CERTIFIED BY THE MANUFACTURER SHOULD SERVICE THE UNIT. Use only genuine replacement parts from the manufacturer. **Contact Sunstone Engineering before opening the unit for any reason** SAFETY PRECAUTIONS The below safety advice is generalized advice for the welding industry. These safety precautions are not all inclusive. All users should exercise caution while using this device. The following groups of symbols are warning symbols: SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION There is a possibility that flying sparks, hot work pieces, and/or hot equipment can cause fires and burns. Ensure that 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 install or operate unit near flammables. Do not weld where flying sparks can strike flammable material. Remove all flammable materials from the welding area. If this is not possible, tightly cover them with approved covers. Protect yourself and others from flying sparks and hot metal. Do not weld where the atmosphere may contain flammable dust, gas, or vapors. Remove any combustibles, such as butane lighters or matches, from your person before doing any welding. Watch for fire and keep a fire extinguisher nearby. Do not overload your building s electrical wiring be sure the power distribution system is properly sized, rated, and protected to handle this unit. 36

37 Do not exceed the equipment s rated capacity. Use only correct fuses or circuit breakers. Do not oversize or bypass them. SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK Touching live electrical parts can cause fatal shocks or severe burns. Incorrectly installed or improperly grounded equipment is a hazard. Do not operate weld head in a wet/damp environment. Care should be taken not to short across the positive and negative terminals. At full power, the weld current carries thousands of amps and is dangerous if the terminals are accidentally bridged. All welds are performed at low voltage for increased safety of operation. Do not wear metal jewelry when welding. The terminals are safe to touch without fear of arcing as long as no metal is on your hands. When altering or maintaining any part 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 this equipment. (Refer to the grounding codes and specifications of the area you live in) Do not weld with wet hands or wet clothing. Always verify the supply ground check and be sure that the input power cord ground wire is properly connected to a ground terminal in the disconnect box or that the input power cord plug is connected to a properly grounded receptacle outlet. Do not remove or bypass the ground prong. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect the input power cord and ground conductor for damage or bare wiring replace immediately if damaged bare wiring can kill. Check ground conductor for continuity. Turn off all equipment when not in use. Use only well-maintained equipment and repair or replace damaged parts at once. 37

38 PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND ARC RAYS It is essential for every person in the immediate work area to wear/utilize proper personal protection equipment. There is a possibility that sparks can fly off from the weld joint area; therefore, take the necessary precautions to avoid trapping a spark within your own clothing. Wear protective garments such as oil-free, flame-resistant leather gloves, heavy shirt, cuff-less trousers, high shoes, and a cap. Avoid synthetic fibers as they melt easily. Use an approved face shield or safety goggles with side shields when welding or when observing others performing welds. SAFETY PRECAUTIONS FOR HOT METAL AND CABLES Welding material that has a high thermal conductivity will cause metal to 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 weld areas barehanded. Allow sufficient cooling time before handling welded pieces. Welding cables can become extremely hot. After extended use, be cautious when handling the weld cables. SAFETY PRECAUTIONS FOR FUMES AND GASES Welding can produce fumes and gases. Breathing these fumes and gases can be hazardous to your health. Sunstone weld heads produce minimal fumes and gases when compared to largescale weld heads. Though not required, some form of ventilation is recommended. Keep fumes away from face. Do not breathe the fumes. Ventilate the area and/or use local forced ventilation at the weld spot to remove welding fumes. If ventilation is poor, wear an approved air-supplied respirator. Read and understand the Material Safety Data Sheets (MSDS) and the manufacturer s 38

39 instructions for metals, consumables, coatings, cleaners, and degreasers. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the weld can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium-plated steel, unless the coating is removed from the weld area, the work area is well ventilated, and the operator is wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. SAFETY PRECAUTIONS FOR FALLING EQUIPMENT Use a working surface of adequate physical strength to support the welding unit during 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 devices should keep away. Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. OVERUSE CAN CAUSE OVERHEATING Allow a cooling period between strenuous welding schedules; follow rated duty cycle. If overheating occurs often, reduce duty cycle before starting to weld again. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: , website: OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal 39

40 Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box , Pittsburgh, PA (phone: ) (there are 10 Regional Offices phone for Region 5, Chicago, is , website: National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA (phone: , website: and org). Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian Standards Association, Standards Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (phone: or in Toronto , website: Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY (phone: , website: 40

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42 SUNSTONE ENGINEERING R&D CORPORATION 1693 American Way Suite #5 Payson, UT (toll free) (international) SunstoneWelders.com