SUNSTONE AC1050 User manual

AC1050
User Manual
Copyright 2008 Sunstone Engineering R&D Inc.

2
Contents
The AC1050 AC Spot Welder........................................ 4
Features............................................................................. 4
Product Data Sheet.............................................................. 5
Sa ety Procedures and Precautions ........................................ 5
Chapter 1: Installation and Setup................................6
Positioning Guidelines...........................................................6
Foot Switch Setup................................................................6
Power Cord, Power Source, Fuse, Breaker................................7
Cabling Guidelines............................................................... 7
Heat Considerations............................................................. 7
The User Inter ace............................................................... 8
Jobs and Schedules..............................................................9
Chapter 2: Spot Weld Function.................................... 10
Theory o Operation............................................................. 10
Weld Parameter De initions................................................... 11
Example Walkthrough...........................................................12
Chapter 3: olling Spot Weld Function........................ 13
Theory o Operation............................................................. 13
Weld Parameter De initions................................................... 14
Example Walkthrough...........................................................15
Chapter 4: Seam Weld Function...................................16
Theory o Operation............................................................. 16
Weld Parameter De initions................................................... 16
Example Walkthrough...........................................................17
Chapter 5: Pulsating Spot Weld Function.....................18
Theory o Operation............................................................. 18
Weld Parameter De initions................................................... 19
Example Walkthrough...........................................................20
Chapter 6: Main Menu Functions..................................21
Beep Toggle........................................................................ 21
Add a Schedule................................................................... 21
Lock a Schedule.................................................................. 21
Copy a Schedule..................................................................21
Restart the Schedule Counter................................................ 22
Restart Current Job.............................................................. 22
AC1050 User Manual

3
Chapter 6: Main Menu Functions (Cont.)
Tempering Function..............................................................22
View the Internal Temperature...............................................22
View the Li etime Weld Counter..............................................23
View Welder In ormation.......................................................23
Chapter 7: Job Menu Functions and Chaining.............. 23
Chain and Unchain Schedules................................................ 23
Link a Schedule to the Chain................................................. 23
Remove Last Link rom the Chain........................................... 24
Change the Number o Welds or a Link.................................. 24
Chapter 8: Other Welder Functions..............................24
Resetting to Factory De aults.................................................24
Appendix A: Cable esistance Chart............................ 25
Appendix B: Menu Flowcharts..................................... 26
Main Menu.......................................................................... 26
Job Menu............................................................................27
Appendix C: Glossary...................................................28
Appendix D: Warranty and Contact Information.......... 29
Sample Job Documentation Layout..............................30
NOTE: The in ormation contained in this manual is subject to change as improvements are made
to our products. Visit www.SunstoneEngineering.com or the latest version o this document.
AC1050 User Manual

The AC1050 AC Spot Welder 4
The AC1050 AC Spot Welder
Features
●Embedded digital microprocessor with internal memory space or 100
user programmable welding schedules.
●Ability to link multiple schedules together into a job chain.
●Five welding types:
•Single Pulse Spot Weld
•Dual Pulse Spot Weld
•Auto-Repeating Roll Spot Weld
•Seam Weld
•Multi-Pulse Spot Weld
●Internal 5 kVA welding trans ormer means no costly external
equipment.
●Automatic internal thermal protection with audible alarm.
●Simple digital user inter ace with short learning curve.
●Tempering unction to slowly cool completed welds.
●On-screen weld counter keeps track o how many welds have been
completed and can automatically switch schedules a ter the
programmed number o welds.
●Automatic li etime weld counter will help keep track o daily, monthly,
or yearly weld output.
●Included oot switch or weld iring control.
●Accidental schedule overwrite protection through lock-out eature.
●Small enclosure ootprint means more mobility and less table-top
space required.
AC1050 User Manual

The AC1050 AC Spot Welder 5
Product Data Sheet
Safety Procedures and Precautions
●Care should be taken not to short across the positive and negative
terminals. At ull power, the weld current is many thousands o amps
and is dangerous i the terminals are accidentally bridged.
●Do not wear metal jewelry when welding. The terminals are sa e to
touch without ear o arcing as long as no metal is on your hands.
●Wear sa ety glasses at all times while using the welder.
●Welding cables can become extremely hot. A ter extended use, be
cautious when removing the weld cables.
●When altering any part o the welding path (such as swapping electrodes
or cables), turn the unit o or enter the menu to ensure no accidental
triggering o a weld.
●The AC1050 was designed or indoor use only.
AC1050 User Manual
AC1050
Internal Trans ormer Rating
Welding Duty Cycle 50%
Total Number o Savable Schedules 100
Total Number o Jobs 10
Maximum Internal Operating Temperature
Fuse Rating 20A
Power Supply Requirements 220-240VAC 50-60Hz
Weight
Case Dimensions (L X W X H without terminals, with eet) (33.6 cm X 25.4 cm X 13.9 cm)
Power Cord Length
Minimum Pulse Length 16.67 ms
Maximum Pulse Length 1.65 sec
Example Welds Welds/Minute
Single Pulse lasting 10 cycles 180
6 Pulses o 7 cycles with 2 cycle spacing 67
Dual pulse o 25 cycles each with 12 cycle spacing 29
5.0 kVA
75 °C
32 lbs (14.5 kg)
13¼” X 10” X 5½”
5½' (168 cm)

Chapter 1: Installation and Setup 6
Chapter 1: Installation and Setup
Positioning Guidelines
The goal when deciding the location o the unit is to minimize welding
cable length. Place the unit on a tabletop or workbench directly
behind your workspace with the welding terminals acing your
workspace. Keep the unit away rom edges to avoid the risk o the
welder alling to the loor. Be sure there is at least 6” o space on all
sides and on top o the welder to ensure adequate cooling throughout
the case. The diagram below shows the air low direction inside the
unit.
Foot Switch Setup
The included oot switch can be plugged into the rear panel o the
welder into the Ext. Trigger port. To attach the coupling, push it into
the port and then secure it by twisting the ring clockwise until tight.
Do not orce the coupling as it can only be inserted in one orientation.
When using the oot switch to trigger a weld, keep in mind that some
o the welding unctions require the switch to be simply depressed
and released, while others require a prolonged depression
corresponding with desired weld time. See the chapters on each
speci ic weld unction or more in ormation (Chapters 2-5).
AC1050 User Manual
Front RearAir low
Intake
Exhaust

Chapter 1: Installation and Setup 7
Power Cord, Power Source, Fuse, Breaker
The power cord on the AC1050 can only be connected to 220-240VAC,
50-60Hz electricity. NEVER use a power strip or extension cords with
the AC1050. The welder is protected with a 250VAC, 20A time-lag
use. Replace the use with a compatible device only. The rear o the
unit also has a 250VAC circuit breaker as added user protection.
Make sure it is switched into the up position be ore using.
Cabling Guidelines
For maximum power output, the cabling between the terminals and
the work piece should be as short as possible. The optimal resistance
or the complete weld path is .3mΩ - .5mΩ. The internal resistance
rom the secondary trans ormer winding to the terminals is .02mΩ. A
recommended cable con iguration that has been thoroughly tested
with a weld head is to use 1.5' 1AWG cable lengths on both terminals.
A chart o cable resistances and gages can be ound in Appendix A.
Heat Considerations
A ter extended use, the welding cable and terminals will become
extremely hot. While the unit monitors the internal trans ormer and
relay temperature it cannot monitor the external cables. Be sure to
use cables with a suitable temperature rating or your application to
avoid cable ailure.
In the event o internal overheating, the unit will beep three times
and display a status message with the internal temperatures. During
this time, none o the welder's unctions will operate. Once the heat
levels have allen to acceptable levels, the unit will beep twice and
resume normal operation. I the heat alarm occurred during a weld,
the remainder o the weld will be canceled.
AC1050 User Manual

Chapter 1: Installation and Setup 8
The User Interface
1. LCD: This displays all welding parameters and inter ace items.
2. Adjust Wheel: Turn this to move the on-screen cursor and to
change welding parameters when a ield has been selected.
3. Select Button: Press this to select welding parameters to change
or to con irm menu selections.
4. Menu Button: Press this to access the main menu rom the run
screen. In all other instances press this to cancel or exit menus.
5. Welding Terminals: Connect welding cable to these terminals
using the included asteners.
6. Main Power Switch: This switch powers the unit.
*For more detailed in ormation on the run screen, see the chapter
corresponding to the weld unction you wish to use (Chapters 2-5).
For more in ormation on the menus, see Chapters 6-7.
AC1050 User Manual
-------AC1025-------
Sunstone Engineering
Resistance Welding
---Copyright 2008---
Adjust Menu Select
1
24 3
ower
Off
On
5 6
-------AC1050-------
Sunstone Engineering
Resistance Welding
---Copyright 2008---

Chapter 1: Installation and Setup 9
Jobs and Schedules
When the welder arrives rom the actory, it is con igured with 10 jobs
numbered 0-9. Each job has schedule 0 activated. Schedule 0 is the
“scratch-pad” schedule that you can use to develop weld
con igurations that work with your applications. Each job can have up
to 9 additional schedules added to it or a total o 100 schedules. You
must use the menu unction Add a Schedule to add schedules to the
current job. The current job and current schedule are displayed in the
upper le t portion o the run screen. Any changes made to a
schedule's parameters are immediately saved to memory. A visual
representation o a sample job/schedule architecture is given below.
AC1050 User Manual
Job 1 Job 2 Job 3 . . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .

Chapter 2: Dual Pulse Spot Weld Function 10
Chapter 2: Dual Pulse Spot Weld
Function
Theory of Operation
The Dual Pulse Spot Weld Function is the de ault unction or newly
added schedules and provides the most lexible welding option. Two
pulses are desirable in many applications because a pre-welding pulse
can reduce splash as well as remove any sur ace impurities that might
hamper the main welding pulse. On the AC1050, the two pulses can
be programmed to whatever power level and length is desired and
can even be shut o or single pulse operation.
The initial pulse's power is controlled by the Pow1 parameter and is
displayed as a percentage o maximum power. Its length is governed
by the Cyc1 parameter and is given in units o AC cycles where:
1AC cycle=1
60Hz
=16.67ms
The time between pulses is represented by the Pspace parameter and
is also given in units o AC cycles. The second pulse operates
similarly to the irst and its power and length are controlled by the
Pow2 and Cyc2 parameters respectively.
Either pulse can be any percentage o maximum power you choose
and at most, 99 AC cycles long. Additionally, the spacing between
pulses can be any length you choose up to 99 AC cycles. To
deactivate a pulse, set either its power or cycle length to 0 and that
pulse will be ignored.
To initiate the weld, be sure the run screen is displayed and not any o
the menu screens. Depress the oot switch and then release it to
make the weld. As part o the unit's heat management protocols, a
waiting period equal to the total welding time begins immediately
a ter each weld during which another weld cannot be initiated. For
example:
8cyc for pulse135 cyc for pulse2=43 cyctotal wait time
I audible beeps are activated, a short chirp will signal that the unit is
ready to weld again.
AC1050 User Manual

Chapter 2: Dual Pulse Spot Weld Function 11
Weld Parameter Definitions
1. Current Job: Displays the current job number.
2. Cursor: The cursor indicates the current changeable parameter.
3. Current Schedule: Displays the current schedule number.
4. Weld Function: Displays the current weld unction.
5. Select Toggle Indicator: 'S' indicates that turning the Adjust
Wheel will adjust the currently selected parameter. A blank space
indicates that turning the Adjust Wheel will move the cursor.
6. Pulse One Power: Percentage o maximum power or pulse one.
7. Pulse One Length: Length in AC cycles or pulse one.
8. Pulse Spacing: Space in AC cycles between pulses one and two.
9. Current Weld Count: Displays the number o welds that have
been made with the current job. Can be reset to zero by selecting the
Reset Schedule Counter option rom the main menu.
10. Pulse Two Power: Percentage o maximum power or pulse two.
11. Pulse Two Length: Length in AC cycles or pulse two.
AC1050 User Manual
J:1 ►S:4 F:Spot S
ow1: 40% Cyc1: 3
Space: 2 Count: 54
ow2:100% Cyc2:5
12 3
7
8
5
4
6
9
10 11
0 1 2 3 4 5 6 7 8 9 10 11 12
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Dual Pulse Spot Weld
AC Cycles
AC Pow er
'
7
8
11
'
10
6

Chapter 2: Dual Pulse Spot Weld Function 12
Example Walkthrough
This walkthrough will provide a step-by-step guide or making a dual pulse spot
weld with some common weld parameters.
●Press the Menu Button to access the main menu
●Move the cursor down to Add Schedule and press Select
●Press the Menu Button to exit the main menu
●Move the cursor to Pow1 and press Select
●Adjust Pow1 to 50% and then press Select
●Move the cursor to Cyc1 and press Select
●Adjust Cyc1 to 5 cycles and press Select
●Move the cursor to PSpace and press Select
●Adjust PSpace to 2 cycles and press Select
●Move the cursor to Pow2 and press Select
●Adjust Pow2 to 100% and press Select
●Move the cursor to Cyc2 and press Select
●Adjust Cyc2 to 15 cycles and press Select
●When the workpiece is in position, and the LCD appears as shown, depress
the oot switch to make the weld.
AC1050 User Manual
Menu
Menu
Select
Select
Adjust
Adjust
Select
Adjust
Select
J:0 S:1 F:Spot
ow1: 50% Cyc1: 5
space: 2 Count: 0
ow2:100% ►Cyc2:15
Adjust
Adjust
Adjust
Adjust
Adjust
Adjust
Adjust
Adjust
Select
Select
Select
Select
Select
Select
Select

Chapter 3: Rolling Spot Weld Function 13
Chapter 3: olling Spot Weld Function
Theory of Operation
The Rolling Spot Weld Function provides a way to repeat single pulses
o welding current or as long as the user depresses the oot switch,
subject only to internal temperature limits. This unction would
typically be used in conjunction with specialized rolling weld heads.
The pulse power is controlled by the Pow parameter and is given as a
percentage o maximum power. The pulse length is controlled by the
Cycles On parameter and is given in units o AC cycles where:
1AC cycle=1
60Hz
=16.67ms
The time between successive pulses is governed by the Cycles O
parameter and is also given in units o AC cycles.
The power o the repeated pulse can be any percentage o maximum
power and up to 99 AC cycles long. The time between cycles can be
between 1 and 99 AC cycles.
To initiate the weld, be sure the run screen is displayed and not sny o
the menu screens. Depress the oot switch or as long as you want
the pulses to continue. Release the oot switch to end the welding
pulses. As part o the unit's heat management protocols, the welding
pulses may end unexpectedly i the internal temperature exceeds the
prede ined limits. In such an event, an audible alarm will sound. To
resume welding, release the oot switch and wait until the internal
temperature alls into a normal range. I audible beeps are activated,
a short chirp will signal that the unit is ready to weld again.
AC1050 User Manual

Chapter 3: Rolling Spot Weld Function 14
Weld Parameter Definitions
1. Current Job: Displays the current job number.
2. Cursor: The cursor indicates the current changeable parameter.
3. Current Schedule: Displays the current schedule number.
4. Weld Function: Displays the current weld unction.
5. Select Toggle Indicator: 'S' indicates that turning the Adjust
Wheel will adjust the currently selected parameter. A blank space
indicates that turning the Adjust Wheel will move the cursor.
6. Pulse Power: Percentage o maximum power or each pulse.
7. Current Weld Count: Displays the number o welds that have
been made with the current job. Can be reset to zero by selecting the
Reset Schedule Counter option rom the main menu.
8. Pulse Length: Length in AC cycles or each pulse.
9. Pulse Spacing: Space in AC cycles between subsequent pulses.
AC1050 User Manual
J:1 ►S:4 F:Roll S
ow: 50% Count: 3
Cycles On: 3
Cycles Off: 2
12 3
7
8
5
4
6
9
0 1 2 3 4 5 6 7 8 9 10 11 12
0%
10%
20%
30%
40%
50%
60%
70%
Rolling Spot Weld
AC Cycles
AC Pow er
8 9 8 9
'
'
6 6 6 6

Chapter 3: Rolling Spot Weld Function 15
Example Walkthrough
This walkthrough will provide a step-by-step guide or making a rolling spot weld
with some common weld parameters.
●Press the Menu Button to access the main menu
●Move the cursor down to Add Schedule and press Select
●Press the Menu Button to exit the main menu
●Move the cursor to Pow and press Select
●Adjust Pow to 75% and then press Select
●Move the cursor to Cycles On and press Select
●Adjust Cycles On to 15 cycles and press Select
●Move the cursor to Cycles O and press Select
●Adjust Cycles O to 30 cycles and press Select
●When the workpiece is in position, and the LCD appears as shown, depress
the oot switch or as long as is desired, then release to end the weld.
AC1050 User Manual
Menu
Menu
Select
Select
Adjust
Adjust
Select
Adjust
Select
Adjust
Adjust
Adjust
AdjustAdjustAdjust
Select
Select
SelectSelectSelect
J:0 S:1 F:Roll
ow: 75% Count: 0
Cycles On: 15
►Cycles Off: 30

Chapter 4: Seam Weld Function 16
Chapter 4: Seam Weld Function
Theory of Operation
The Seam Weld Function provides a non-stop pulse o welding current
or as long as the user depresses the oot switch. Like the Rolling
Spot Function, the length o the pulse is subject only to internal
temperature controls and is typically used with specialized rolling weld
heads. The purpose o the Seam Weld Function is to create a linear
shaped weld nugget on the aying sur aces.
The pulse power is controlled by the Pow parameter and is given as a
percentage o maximum power. The pulse length is controlled
entirely by the depression o the oot switch and will end only when
the switch is released or i the internal temperature protocols engage.
The weld can only be initiated rom the run screen and not in a menu.
I audible beeps are activated, a short chirp will signal that the unit is
ready to weld again.
Weld Parameter Definitions
1. Current Job: Displays the current job number.
2. Cursor: The cursor indicates the current changeable parameter.
3. Current Schedule: Displays the current schedule number.
4. Weld Function: Displays the current weld unction.
5. Select Toggle Indicator: 'S' indicates that turning the Adjust
Wheel will adjust the currently selected parameter. Nothing indicates
that turning the Adjust Wheel will move the cursor.
6. Pulse Power: Percentage o maximum power or pulse.
AC1050 User Manual
0 1 2 3 4 5 6 7 8 9 10 11 12
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Seam Weld
AC Cycles
AC Power
'
6
J:1 ►S:4 F:Seam S
ow: 80% Count: 3
12 3
7
5
4
6

Chapter 4: Seam Weld Function 17
7. Current Weld Count: Displays the number o welds that have
been made with the current job. Can be reset to zero by selecting the
Reset Schedule Counter option rom the main menu.
Example Walkthrough
This walkthrough will provide a step-by-step guide or making a seam weld with
some common weld parameters.
●Press the Menu Button to access the main menu
●Move the cursor down to Add Schedule and press Select
●Press the Menu Button again to exit the main menu
●Move the cursor to Pow and press Select
●Adjust Pow to 85% and then press Select
●When the workpiece is in position, and the LCD appears as shown, depress
the oot switch or as long as is desired, then release to end the weld.
AC1050 User Manual
Menu
Menu
Select
Select
Adjust
Adjust
Select
Adjust
J:0 S:1 F:Seam
► ow: 85% Count: 0

Chapter 5: Pulsating Spot Weld Function 18
Chapter 5: Pulsating Spot Weld
Function
Theory of Operation
The Pulsating Spot Weld Function is similar in operation to the Rolling
Spot Function. Unlike the Rolling Spot though, this unction adds the
ability to precisely control the number o weld pulses generated.
Each pulse's power is controlled by the Pow parameter and is
displayed as a percentage o maximum power. Each pulse's length is
governed by the Cyc parameter and is given in units o AC cycles
where:
1AC cycle=1
60Hz
=16.67ms
The time between pulses is represented by the Cycles O parameter
and is also given in units o AC cycles. Lastly, the total number o
pulses is controlled by the Pulses parameter and is unitless.
The pulses can be any percentage o maximum power you choose and
at most, 99 AC cycles long. Additionally, the spacing between pulses
can be any length you choose up to 99 AC cycles. The maximum
number o pulses that can be generated is 99.
To initiate the weld, be sure the run screen is displayed and not any o
the menu screens. Depress the oot switch and then release to make
the weld. I audible beeps are activated, a short chirp will signal that
the unit is ready to weld again.
AC1050 User Manual

Chapter 5: Pulsating Spot Weld Function 19
Weld Parameter Definitions
1. Current Job: Displays the current job number.
2. Cursor: The cursor indicates the current changeable parameter.
3. Current Schedule: Displays the current schedule number.
4. Weld Function: Displays the current weld unction.
5. Select Toggle Indicator: 'S' indicates that turning the Adjust
Wheel will adjust the currently selected parameter. A blank space
indicates that turning the Adjust Wheel will move the cursor.
6. Pulse Power: Percentage o maximum power or each pulse.
7. Pulse Length: Length in AC cycles or each pulse.
8. Number of Pulses: The number o pulses or each weld.
9. Current Weld Count: Displays the number o welds that have
been made with the current job. Can be reset to zero by selecting the
Reset Schedule Counter option rom the main menu.
10. Pulse Spacing: Spacing in AC cycles between each pulse.
AC1050 User Manual
J:1 ►S:4 F: ulse S
ow: 80% Cyc: 3
ulses: 3 Count: 5
Cycles Off: 1
12 3
7
8
5
4
6
10
9
0 1 2 3 4 5 6 7 8 9 10 11 12 13
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Pulsating Spot Weld
AC Cycles
AC Power
7
10 10
7 7
8
'
6

Chapter 5: Pulsating Spot Weld Function 20
Example Walkthrough
This walkthrough will provide a step-by-step guide or making a pulsating spot
weld with some common weld parameters.
●Press the Menu Button to access the main menu
●Move the cursor down to Add Schedule and press Select
●Press the Menu Button to exit the main menu
●Move the cursor to Pow and press Select
●Adjust Pow to 100% and then press Select
●Move the cursor to Cyc and press Select
●Adjust Cyc to 10 cycles and press Select
●Move the cursor to Pulses and press Select
●Adjust Pulses to 8 and press Select
●Move the cursor to Cycles O and press Select
●Adjust Cycles O to 3 cycles and press Select
●When the workpiece is in position, and the LCD appears as shown, depress
the oot switch to make the weld.
AC1050 User Manual
Menu
Menu
Select
Select
Adjust
Adjust
Select
Adjust
Select
Adjust
Adjust
Adjust
Adjust
Adjust
AdjustAdjustAdjust
Select
Select
Select
Select
SelectSelectSelect
J:0 S:1 F: ulse
ow:100% Cyc: 10
ulses: 8 Count: 0
►Cycles Off: 3