SUNSTONE Linear DC User manual

Sunstone Welders
Linear DC User Manual

Table of Contents
2
Chapter 1: Introduction
Quick Look
Chapter 2: Getting Started
Set-up Linear DC
Connecting Welding Attachments
Precautions
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
Chapter 7: Technical Assistanc
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4
5
5
6
7
9
9
10
11
12
13
14
23
26
26
28
30
30
32
32
34
Chapter 8: Data Specifications
Chapter 9: Safety
35
36

Chapter 1: Introduction:
ank you for choosing Sunstone Welders and congratulations on your purchase!
You are now the proud owner of a Sunstone Linear DC Welder. is 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: [e-mail]
Voice: 801-658-0015
Fax: [phone]
NOTE: e 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

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Quick Look
EMERGENCY STOP
Press to shut off system.
AC POWER
Attach AC power here.
COOLING FANS
Keeps system cool. Do
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.
TOUCH SCREEN INTERFACE
Set all weld parameters here.
POWER BUTTON
Press to power up.
USB PORT
Upload software
updates.

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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
e 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
is 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. en plug the male end of the power cable into AC power.

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Fuse
20A fuse included.
Replacement fuse: Schurter Inc. Manufacturer #0034.3130.
Fans
Airflow will come out of the unit from these locations and could be warm. e fans will not normally
be spinning, but will turn on if the unit is hot. ey 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 www.sunstonewelders.com 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.

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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
e 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.
e Linear DC comes equipped with an “Emergency Stop Switch Key”. is 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:

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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. e 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. e 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.

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Chapter 3: Interface
Operational Controls
NUMERIC KEYPAD AND SLIDER BAR
e 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.
e 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.

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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
is is used for troubleshooting for authorized representatives.
RESET WELD VALUES
is will reset all welder settings back to their factory default settings. is will not affect saved
settings.

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Save Button
Touch the Save Button to create a custom weld parameter. is 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.

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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. en
touch the load button.

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

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Schedules Tab
PRECHECK SCREEN
e 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. is allows the weld controller to notify
the user if the chosen weld parameters are attainable with the connected weld path resistance.
e user has the option to have the welder stop operation when the “Precheck” fails or to continue
welding with a warning message or signal. *is 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.

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• 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.

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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

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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.

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COMPARATOR SCREEN
is 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:

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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.

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WELD HEAD SCREEN
ere 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