SUNSTONE OMEGA PA 250i User manual

Users Guide
Version 20220405 • Part #1142
250
i
Ω MEGA

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User Manual
250i
Ω MEGA
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DAT E VERSION NO. DESCRIPTION OF CHANGES
1 06/2020 20200521 Production release.
2 10/2020 20201022 Correction: liters/second changed to liters/minute
304/2022 20220405 Revised Valve Images and Misc Copy Ajustments
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OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY
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PERMITTED UNDER APPLICABLE LAW.

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Contents
Chapter 1: Welder Setup & Assembly 4
What is in the Box 4
Microscope Arm Setup 4
Attach Touchscreen to Microscope Arm 7
Microscope Setup 7
Welding Stylus 8
Electrode Setup 9
Adjusting The Microscope Focus 10
Power Supply Setup 10
Power Supply Setup - Back Panel 10
Power Supply Setup - Front Panel 11
Electrode Care 11
When to Sharpen the Electrode 12
Shield Gas Setup 13
Microscope LCD Shutter System 14
Omega PAWH Weld Head Setup 15
Chapter 2: User Interface Overview 17
Home Screen 17
Waveform Graphic Area 18
Parameter Selection Area 18
Communication Screen 26
Media Screen 31
Save/Load Screen 32
Settings Screen 33
Chapter 3: Make a Weld 40
Weld State Button 40
Finding the Right Settings 42
“Aiming” the Electrode 43
Reading the Waveform Graph 43
Declaration of Conformity 46

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Chapter 1: Welder Setup & Assembly
What is in the Box
BOX 1 CONTENTS:
(2) Alligator Grounding Clips (1) Sunstone PA250i Series Power Supply
(1) Foot Pedal (1) Shielding Gas Hose
(2) Power Supply Mounting Brackets (1) Sunstone Touchscreen
(1) Electrode Vial (10x 1.0mm Electrodes and 1 Diamond Sharpening Disk)
BOX 2 CONTENTS
(1) Fiberglass Brush (1) Sunstone Microscope Arm Assembly
(1) Cross Lock Tweezers (1) Sunstone Safety Guide
(1) System Cover (1) Flat Peaked Pier
ACCESSORIES BOX (Located in Box 2)
(1) Microscope Arm Mounting Hardware (1) Pair Microscope Eye Piece Shields
(1) Welder Power Cord (1) Loop Closing Pliers
(1) Welding Stylus Hand Piece (1) Set Allen Wrenches
(1) Communications Cable (Display Port Ends) (1) Shutter Cable (RJ45 ends)
Microscope Arm Assembly Setup
• Remove the Microscope Arm Assembly from the box and place it on your table.
• There are three available options for mounting the Arm assembly to your table. Select one of the
following methods and use the required mounting hardware from the accessories box as outlined.

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MOUNTING OPTIONS
Mounting Option 1 - Clamp to Table
This option is best for tables with accessible edges and
for mounting without drilling holes in the table.
Note: If your table is thicker than 3-1/2” (9cm), follow
the instructions for mounting options 2 or 3 on the next
page.
Hardware required from Box 2:
(1) Angled Bracket C
(1) Sunstone Microscope Arm Assembly A
(1) Clamp Mechanism D
(5) Flat Head Hex Screws G
• Lay the arm assembly down on the tabletop.
• As shown in Figure 5.1, attach the angled
bracket (C) to the bottom of the arm using three
(3) of the included at head hex screws (G)
using a 4mm (5/16”) Allen wrench (L).
• Attach the clamp mechanism (D) to the angled
bracket using two (2) of the included at head
hex screws. See Figure 5.2. For thicker tables,
attach the clamp mechanism D to the two lower
holes in the angled bracket C.
• Adjust the knob on the clamp mechanism (C)
until the gap is sucient for the thickness of
your tabletop.
• Lock the arm into place by turning the knob
on the clamp mechanism until the clamp is
pressing rmly against the bottom of the table.
• Lift the arm assembly up and slide the arm onto
the table as shown in Figure 5.3.
• A plastic cable guide cover (E) can be clipped
on over the angled bracket if desired. See
Figure 5.4
Figure 5.1. Attach angled
bracket C to A
Figure 5.2. Attach clamp
mechanism D to angled
bracket C.
Figure 5.3. Attach clamp
mechanism D to angled
bracket C.
Figure 5.4. Cover the clamp
mechanism D with the plastic
cable guide cover E.

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Mounting Option 2 - Bolt through Table
Mounting Option 2 is best for tables without accessible edg-
es. Hardware required from Box 2:
(1) Flat Mounting Plate H
(3) Flat Head Hex Screws G
(1) Long Carriage Bolt F
(1) Flat Pressure Plate I
(1) Adjustment Knob J
• As shown in Figure 6.1, using a 4mm (5/32”) Allen
wrench, unscrew the at head hex screws (G)
holding the mounting plate (H) to the arm.
• Run the included 8mm (5/16”) carriage bolt (F)
through the included mounting plate (H).
• Attach mounting plate (H) to the bottom of the arm
using (3) at head hex screws (G).
• Drill a 3/8” (9.5mm) hole through the tabletop.
• Lower the arm so the bolt goes through the hole in
the tabletop. See Figure 6.2.
• Slide the at pressure plate (I) onto the bolt. Turn the
adjustment knob (J) clockwise to tighten the plate to
the underside of the table. See Figure 6.3.
Mounting Option 3 - Screw to Table (vertical surface)
Required hardware from Box 2:
(1) Angled Mount Bracket
(3) Flat Head Screws
(2) Wood Screws (not included)
• Attach the angled bracket (A) to the bottom of the
arm assembly using three (3) of the included at
head hex screws (G) as shown in Figure 5.1.
• Lift and position the arm assembly onto the table in
the desired location.
• Run wood screws through the bracket (A) and into
vertical surface of the table, as shown in Figure 6.4.
Figure 6.1. Remove the plate from the arm,
run the carriage bolt through the plate, then
re-attach the plate to the arm.
Figure 6.2. Lower the arm so the
bolt goes through the hole in the
table.
Figure 6.3. Turn the twist knob
clockwise to tighten the plate to
the table.
Figure 6.4. Use wood screws (not
included) to attach the angled
bracket (A) to the table.

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Attach Touchscreen to Microscope Arm
Assembly
Once the Microscope Arm Assembly has been rmly se-
cured, the Touchscreen can be attached.
• Remove the Touchscreen from the foam in box 1.
• Line up the mount bracket on the back of the Touch-
screen with the slot in the clip mechanism on top of
the arm and lower it into the slot until the clip clicks
into place. It can be helpful to pull the clip back while
sliding down. See Figure 7.1.
• Remove the screen protector lm from the front of
the Touchscreen.
Arm Tension Adjustment
The spring tension is factory pre-set, but should changes be
desired, the tension can be adjusted by turning a hex screw
located on the arm joint, as shown in Figure 7.2. Use the
included 6mm Allen wrench to make adjustments.
• Turn the hex screw counterclockwise (in the direc-
tion of the “+” symbol on the arm) if the arm does
not hold the microscope up.
• Turn the hex screw clockwise (in the direction of the
“-“ symbol) if the arm does not allow the microscope
to be lowered easily.
Microscope Setup
• Install the rubber eyepiece covers onto the micro-
scope lenses.
• Plug the included Shutter Cable into the RJ45 port
on the microscope (the bottom of the microscope
head). See Figure 7.3.
• Plug the other end of the Shutter Cable into the
shutter port on the back of the Touchscreen.
Note: Connecting other RJ45 compatible devices to the
Sunstone shutter RJ45 port may damage the welder and/or
the other devices.
Figure 7.1. Attach the Touchscreen to the Microscope
Arm Assembly. Remove the screen protector lm.
Figure 7.2. Adjust the tension of the Arm Assembly for
more loose or more tight movement.
Figure 7.3 After installing the rubber eyepiece covers,
use the Shutter Cable to connect the Touchscreen to
the bottom of the microscope head.

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Welding Stylus
• Remove the Welding Stylus from the accessories
box.
• Insert the Welding Stylus into the holder at the
bottom of the arm assembly as shown in Figure 8.1.
• The tubing can be routed up and through the remov-
able cable guide portion of the arm if desired. See
Figure 8.2.
• For now, position the Welding Stylus such that only
the smaller diameter portion protrudes from the
holder. Then, tighten the thumb screw on the bottom
of the stylus holder to hold it in place.
• Rotate the stylus holder to approximately a
45-degree angle as shown in Figure 8.1 (the stylus
should be angled down).
• Fine tune the position of the Welding Stylus while
looking through the microscope: Loosen the thumb
screw on the bottom side of the stylus holder and
slide the Welding Stylus forward and backward until
the tip of the Welding Stylus is in the center of your
focus. See the example in Figure 8.3.
• Now securely tighten the Welding Stylus in place
by tightening the thumb screw on the bottom of the
stylus holder, which you can see in Figure 8.1.
Stylus Shaft A Collet B Collet Cap C Electrode D Stylus Hull E
Figure 8.2. Tubing and other cables can be routed up and
through the removable cable guide portion of the arm.
Figure 8.1. Mount the Welding Stylus to the holder below
the microscope.
Figure 8.3. When
looking through the
microscope, the stylus
should appear in the
center of your focus,
as shown here.
Stylus Components
Figure 8.4

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Electrode Setup
The PA250i comes standard with a 1.0mm electrode
collet and ten (10) 1.0mm electrodes. The 1.0mm elec-
trodes are a good multipurpose electrode for most weld-
ing applications. Available separately, Sunstone oers
0.5mm electrodes, which are more suited for very small
applications (less than 5 Ws of energy).
INSTALL THE TUNGSTEN ELECTRODE ONTO
THE WELDING STYLUS
See the Stylus Components Chart (Figure 8.4) on previ-
ous page to install the tungsten electrode (D).
• Remove the stylus hull (E) by pulling it away from
the stylus shaft (A). See Figure 9.2.
• Loosen the collet cap (C) by twisting it counter-
clockwise.
• The welder accommodates 0.5mm and 1.0mm
electrodes. The electrode stylus will be shipped
with the 1.0mm electrode collet (B) installed.
• Insert a 1.0mm electrode (D) into the collet.
Helpful Tip: There is a engraved guide on the
side of the stylus hull (E) that helps measure
the electrode length. Place the end of the
stylus hull (E) against the collet cap, then make
sure the electrode extends as indicated. See
Figure 9.3.
• There should be between 0.6 - 0.7 inch (1.5 –
2cm) of the electrode (D) protruding from the
stylus shaft (A). This will allow the electrode
enough room to stick out from the stylus once
the stylus hull (E) is placed back on the stylus.
• Lock the electrode (D) into place by hand tight-
ening the collet cap (C) in a clockwise direction.
• Replace the stylus hull (E) by pushing it in until
you feel it snap back into place. Tthe electrode
(D) should stick out between 1/8 – 1/4 inch
(3.175 – 6.35mm after the stylus hull is snapped
back into place). See Figure 9.4.
Figure 9.1. The PA250i is shipped with a 1mm collet and
ten (10) electrodes. Also available from Sunstone are
0.5mm electrodes and applicable collet.
Figure 9.2. To install the electrode, rst remove the
stylus shaft from the stylus hull by pulling them apart.
Figure 9.3. Use the guide engraved on the side of the
stylus hull E for proper electrode D positioning.
Figure 9.4. The electrode should protrude past the
stylus hull 1/8 to 1/4 inch (3.175 to 6.35mm).

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Adjusting The Microscope Focus
• Twist the knob on the microscope forward and
backward to lower and raise the head. This will allow
you to focus the microscope on the welding stylus.
See Figure 10.1.
• Place your nger under the welding electrode to
help judge the correct focus location. Focus the
microscope until the texture on the skin of your
nger is clearly visible.
Power Supply Setup
POWER SUPPLY SUPPORT MOUNT BRACKETS
The PA250i Power Supply can either be mounted to a at
vertical surface (such as a wall or the side of a desk) us-
ing mounting brackets, or rest on a at horizontal surface.
Keep in mind that the Power Supply will need to be mount-
ed in proximity to the Microscope Arm Assembly.
Mounting Brackets
If you wish to mount the Power Supply to a vertical wall,
attach the mounting brackets only to a structurally sound
vertical support. One mounting bracket should attach to
the top of the Power Supply and one to the bottom.
Attach the lower mounting bracket to the wall rst (using
wood screws or other appropriate hardware, not included)
and attach the Power Supply to the lower mounting brack-
et using the two provided screws. Next, attach the upper
mounting bracket to the Power Supply, then attach the
upper mounting bracket to the wall. See Figure 10.2.
Power Supply Setup - Back Panel
All required cables are found in the accessories box.
• Plug the female end of the included power cable
into the 90-250 VAC Power Port.
• Connect the male end of the power cable into AC
power (wall outlet). The PA250i can accept voltages
ranging from 90VAC to 250VAC. (When plugged in
for the rst time the Power Button LED will blink a
couple of times and then turn o.)
Figure 10.2. Use the two mounting brackets to attach
the Power Supply to wall or other vertical surface.
Figure 10.3. Power Supply back panel.
Figure 10.1. Turn
this knob to adjust
microscope focus.
You’ll nd one knob
on each side of the
microscope arm.

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• Insert the included 1/4” gas tube rmly into the Shield Gas Port. The tube may feel loose when
connected but should not come out if pulled.
• Plug the foot pedal cable into the Foot Pedal Port.
• Insert the stylus connector into the Weld Stylus Port on the back panel of the Power Supply. Ensure that
the white circular indicator on the stylus is lined up with the white indicator on the Weld Stylus Port. The
connector will snap into place.
• When making welds using the stylus, an alligator clip cable can be connected to the Pulse Arc (+) Port
on the back of the Power Supply for grounding the workpiece during the weld.
• When tack welding, plug one alligator clip cable into the Tack (+) Port and one into the Tack (-) Port. Be
sure to attach each alligator clip to each workpiece before tack welding them together.
• Plug the included communications cable (long display port cable) into the Comm. Port.
• Plug the other end of the communications cable into the Comm. Port on the back of the Touchscreen
(the cable can be routed through the removable cable guides on the Microscope Assembly Arm).
• If using the unit with the Omega PAWH weld head (whether manual or CNC head), follow these steps:
• Connect the red spade connector to the Pulse Arc (+) Port, and the black spade connector to
the Tack (-) Port.
• Plug the standard RJ12 connector to the Acc. Port, with the oset RJ12 connector plugged into
the Omega PAWH head.
• Take the CNC/Sunstone PA250i adapter cable, and plug the green connector into the PLC I/O
Port on the PA250i, and the 25 pin parallel connector to the I/O-1 Port (for Janome robotic
systems) on the back of the CNC. (The Omega uses a Term Block Plug 20POS STR 3.5mm Part
#170182 available from Phoenix Contact.) If you’re using a robotic system from a dierent
manufacturer, call Sunstone for assistance.
• For more information on setting up the Omega PAWH weld head, go to page 15.
Note: Connecting other display port compatible devices to the PA250i’s Comm. Port may damage the welder
and/or the other devices.
Power Supply Setup - Front Panel
• Push the Power Button to initiate the power up sequence. The Power Button will illuminate. The Touch-
screen and the microscope light will begin to power on.
Electrode Care
WORKPIECE ELECTRODE PRESSURE
Touch the workpiece to the electrode with very light pressure. Too much pressure will cause the workpiece to
stick to the electrode and cause the electrode to become contaminated (workpiece material on the electrode).
Sunstone recommends cleaning or changing the electrode when it sticks to the workpiece.

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When to Sharpen the Electrode
Refer to Chapter 3 for more information on electrodes.
The majority of applications are best accomplished using a
sharp electrode tip. A sharp tip improves arc initiation and
helps focus the arc properly. It is recommended that you
pay close attention to the electrode condition. An electrode
that appears to be dark colored or covered with material
from previous welds can lead to inconsistent welding and
poor ignition of the weld arc. When this occurs, simply
sharpen the electrode with the included diamond disk. The
diamond disk can be attached to a rotary tool. Follow these
steps for sharpening the electrode:
• Completely remove the electrode from the stylus.
• Pinch the electrode between the thumb and index
and/or middle nger with the shaft going perpen-
dicular to the ngers. See Figure 12.1.
• Power on the rotary tool then hold it with the oppo-
site hand.
• Place the electrode tip on the diamond disc so the
grit of the disk is moving parallel with the elec-
trode shaft and moving towards the tip. See Figure
12.2. Sharpening the electrode in a way other than
explained here will aect the quality of the weld.
• Set the electrode on the diamond disk at a
10-degree angle and begin to spin the electrode
with the thumb and middle nger. Tip: A helpful
way to get a sharp electrode is to push down

twisting the electrode with the thumb and middle

• Once the electrode is sharp and clean, turn o the
rotary tool and insert the electrode back into the
stylus as explained above.
Note: As a rule of thumb, Sunstone recommends a sharp-
ened electrode anytime a new workpiece is being welded.

• When working with silver, copper, and other highly
conductive metals in energy levels above 20 Ws,
Figure 12.1. A sharp electrode tip improves arc initiation
and results in a better overall weld.
Figure 12.2. Use a rotary tool to sharpen the electrode.
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N
Figure 12.3.

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it is recommended to blunt the electrode instead of sharpening it, as shown in Figure 12.3. A at or
blunted electrode is ideal when using the Omega PAWH weld head.
• Follow the “When to Sharpen the Electrode” instructions on the previous page.
• Once the electrode is sharp and clean, turn the electrode to a 90-degree angle and push it against the
diamond disk in order to place a at/blunt tip on the electrode. Cleaning the edge of a blunt tip elec-
trode assists in preventing the electrode from sticking to the weld surface, especially when using the
PAWH weld head.
• Once the electrode has a at/blunt tip, turn o the rotary tool and insert the electrode back into the
stylus as explained earlier.
Shield Gas Setup
During the pulse-arc welding process high temperature plasma quickly melts metal into a molten pool. As the
weld is performed, a small amount of shielding gas is released through the weld stylus to prevent oxygen from
entering the molten pool. After the weld has occurred the protective gas turns o.
If oxygen from the air enters this molten pool, the result is a metal oxide that is brittle, porous, and burnt-looking.
Protective shielding gas is used, such as 99.996% pure argon (Argon 4.6), to prevent these eects.
PRESSURIZED GAS SAFETY
There are several important rules that should be followed when using a compressed shielding
gas such as argon:
(such as a sturdy table leg). If
the pressurized gas cylinder were to tip and become damaged there is possibility that the
tank could become a projectile, expelling the high-pressure shielding gas as propellant.
This will help your shielding gas supply
last longer in case there is a small leak in the tubing. This is also a good safety practice. If the tube becomes
dislodged shielding gas could ll the room and displace oxygen, which can lead to suocation. Argon is heavier
than air and will ll the room from the bottom upward. If you experience a large shielding gas leak, open all of the
doors and windows in the room.
SHIELDING GAS TANK AND REGULATOR SETUP
• Ensure that your shielding gas tank is securely fastened to a stationary point near the welding area.
• Turn the regulator dial COUNTERCLOCKWISE (closed) until it is fully backed out, meaning the dial
becomes loose, to prevent over-pressurization of the line.
• Screw the gas regulator onto the shielding gas tank and tighten fully using a wrench.
• If not already done, insert one end of the included ¼” OD gas tubing into the gas port on the back of the
power supply. Tug gently on the tube to verify a tight t.
• Connect the other end of the gas tubing to the gas regulator.
• Open the gas tank at the main valve slowly. The dials attached to the regulator should respond as the

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Ω MEGA
valve is opened. The right dial should measure and show pressure inside the tank; the dial on the left,
which measures pressure in the hose, should remain at zero (when the regulator dial is fully backed out).
• Slowly turn the regulator dial CLOCKWISE until the dial on the left shows gas pressure between 7-10
liters per second.
Microscope LCD Filter Shutter System
The Microscope LCD Filter Shutter System provides an unobstructed working view before welding and com-
pletely protects your eyes during the welding process. The PA250i’s internal computer veries the Microscope
LCD Filter Shutter System has been closed before allowing the weld to take place. Should the shutter not close,
the microscope lens is equipped with >UV 16 and >IR 16 for maximum eye protection.
BECOME FAMILIAR WITH THE MICROSCOPE
The Sunstone microscope has been designed to provide maximum visual clarity, eye protection, and ease of
use. One challenge using the microscope is getting used to bringing the workpiece to the welding electrode
while looking through the microscope. This is an easy challenge to overcome. To begin, follow the suggested
practices below while the welder is in Weld O Mode. While the welder is in Weld O Mode, it will not be able to
make a weld when the workpiece touches the electrode.
• Rest your hands on the table and position the workpiece close to the welding electrode before looking
into the microscope.
• Make sure your focus is at the tip of the electrode.
• Use slow, controlled movements.
• It is helpful to have your hands resting on the table and
to only use your ngers to move the workpiece up to
the electrode. See Figure 14.1.
• Place the workpiece surface perpendicular to the point
of the electrode. As discussed in later chapters, the
angle of the electrode tip relative to the workpiece
surface is very important and will take practice.
• Now practice making soft contact with the workpiece
to the electrode.
• Once you feel comfortable, attach the alligator clip to
the workpiece and enable welds (switching the unit to
Weld On Mode) to begin welding. Be mindful of your
energy setting: Too much power may damage the
workpiece.
Figure 14.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., then
look through the microscope.

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Omega PAWH Weld Head Setup
These instructions are for the manual version of the Omega
PAWH Weld Head.
CONNECT THE COMPRESSED AIR
• Plug the tube from the compressed air tank into the
Air Valve System (A) on the back of the weld head.
• Two air valve ports are located on the back of the
weld head and two ports at the top of the weld
head. The top port (B1) on the back of the weld
head connects to the top port (B2) at the top of the
weld head. The bottom port (C1) on the back of the
weld head connects to the bottom port (C2) at the
top of the weld head. See Figures 15.1 and 15.2
CONNECT SHIELD GAS
• Using the provided splitter, plug the tubes into the
gas port on the back of the Power Supply and into
the port on the back of the weld head at the bottom
of the Air Valve System (D). See Figure 15.3.
COMPLETE CABLE CONNECTIONS
• Plug the 4 DIN connector on the back of the weld
head into the Valve Control Port on the side of the
weld head.
• Using the wires on the weld head, connect the red
wire to the Pulse Arc (+) Port and the black wire to
the Tack (-) Port on the back of the PA250i.
• Connect the RJ-11 cable to the To Welder Port on
the welder and then to Acc. Port on the back of the
weld head.
• Plug the AC power cable into the side of the weld
head. Then plug the other end into any standard
110-220VAC outlet.

• To mount the weld head to a table top or bench
top, pull the base plate cap o the front of the weld
head base. Drill four holes into your table top. Slide
the screws into the base, then lower the weld head
Figure 15.2.
Figure 15.1.
Figure 15.3.
A
B1
C1
D

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250i
Ω MEGA
into the screw holes, ensuring the weld head will be
secured during welding.
INSTALL THE WELD HEAD BASE PLATE
• Remove the base plate cap.
• Now slide the base plate onto the base of the weld
head and tighten the wheel on the side of the base
plate to secure.
• Replace the base plate cap. See Figure 16.1.
INSTALL ELECTRODE IN THE NOSE CONE
• Remove the nose cone from the weld head, as
shown in Figure 16.2.
• Twist the electrode holder counterclockwise to
open the collet.
• Insert the electrode into the collet. See Figure 16.3.
• Tighten the electrode holder clockwise to secure
the electrode in place. The electrode should
protrude about ½ to 1 inch out of the holder. See
Figure 16.4.
• Replace the nose cone.
Note: You can choose to use a 1mm or 0.5mm electrode
with the Omega PAWH weld head.
POWER THE WELDER AND THE WELD HEAD
• Turn on the PA250i using the button on the front of
the welder, then turn on the PAWH weld head with
the switch found on the side.
Figure 16.1.
Figure 16.2.
Figure 16.3.
Figure 16.4.

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Chapter 2: User Interface Overview
The PA250i interface consists of ve main “screens” that can be accessed at any time using the icons located
along the top of the screen in the header area:
• Home
• Communications
• Media
• Save/Load
• Settings
Home Screen
The Home Screen is comprised of three separate areas: The Waveform Graphic Area, The Parameter Selection
Area, and the Mini-Screen Area. See Figure 17.1.
Figure 17.1. The Home
Screen is organized into three
main areas:
Waveform Graphic Area
Parameter Selection Area
Mini-Screen Area

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Ω MEGA
Waveform Graphic Area
The Waveform Graphic Area (see Figure 18.1) illustrates
how energy is released during a weld and provides a quick
reference for various settings. The waveform displayed
will change based on the control settings you select. (Also
see Reading the Waveform Graph on page 43). With a
gray background, the welder is in safety mode and will not
release energy. With a colored background the welder is
ready to release energy.
• Along the left side of the graph, the vertical axis
represents the total weld energy available. The
horizontal axis represents time (ms). The actual
values are displayed below the graph.
• In the upper right-hand corner, an approximation of
the weld spot size is shown based on the current
settings and represents a full discharge of the total
weld energy available, providing a visual reference
of changes in spot size as settings are adjusted.
• Current settings are displayed along the bottom
of the graph. Energy discharged and weld length
values are shown.
• As length decreases, the amount of energy
discharged will decrease as represented in text
just below the graph. The represented spot size
displayed will not decrease, but the actual weld
spot size will decrease as length is adjusted down.
Parameter Selection Area
The Parameter Selection Area (see Figure 18.2) displays
the buttons and sliders used to control parameters that will
aect the weld.
HEADER BUTTONS
The three buttons at the top of the Parameter Selection
Area display dierent controls. Pressing any will change
the controls that are displayed in the area.
WELD HEAD CONTROL LAYOUT
The Weld Head Control Layout lets you select the type of
metals being welded and the thickness of the two metals,
Figure 18.1. The Waveform Graphic Area
displays a graphical representation of the active
weld. With a gray background, the welder is in
safety mode and will not release energy. With
a colored background the welder is ready to
release energy.
Figure 18.2. The Parameters Selection Area
displays the necessary input to control
parameters that will aect the weld.

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e Micro Welder Experts
and then to apply the Sunstone recommended settings. The PA250i will then adjust settings automatically for
that application. Settings can be changed if needed.
Note: The top material refers to the material that comes into contact with the electrode. For battery welds, as an
example, the top material is the tab connecting battery cells, and the bottom material is the battery cell (or can).
Select Materials
Under Material, touch the down arrow buttons to select the metal materials from a drop down list. Both top and
bottom materials will need to be selected before the Preset Settings can be applied.
Select Metal Thicknesses
Under Thickness, touch the down arrow buttons to select the thickness of the two metals using the drop down
menus. Dierent materials will have dierent thicknesses available; select the material before selecting the
thicknesses. Both top and bottom metal thicknesses must be selected before Preset Settings can be applied.
Apply Preset/Preset Loaded
Once materials and thicknesses are selected, press the Apply Preset Button to load Sunstone’s recommended
settings. After the preset is loaded the button text will turn orange and display Preset Loaded. The button
will remain in this state until settings are changed, at which point it will revert to the gray Apply Preset text.
Waveform Drop-down
Use the Waveform drop down menu to select which waveform shape you would like to use for welding. For more
information on the strengths of each waveform, see the Waveforms section on page 21.
Agitation Drop-down
Use the Agitation drop down menu to select which agitation option you would like to use for welding. Please
note that in classic mode, Sustained Agitation is disabled above 132 Ws, and Sloped Agitation is disabled above
231 Ws. For more information on the benets of agitation, please see the Agitation section on page 22.
Power/Energy Slider
This slider adjusts the amount of energy that is being applied in the weld to achieve desired results for your
application. If you need more precision, press the Keypad Icon to open the keypad mode. More information
regarding this slider can be found in the Power/ Energy Slider section on page 22.
Length Slider
Use the Length Slider to adjust the length of the weld discharge. See page 23 to learn more about lengths.
Weld Head Control
The Retract and Extend Buttons are used to check that there is an appropriate length of electrode extending
beyond the collet. Once the electrode is in the collet, extending between ½” and 1” beyond the collet, put the

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Ω MEGA
nose cone on and press the Extend Button. Keep your ngers away from the nose cone until the electrode is
done extending, then look at the bottom of the nose cone. The electrode should extend beyond the bottom of
the nose cone, and if it doesn’t, the electrode will need to be adjusted so it extends further from the collet.
Once you are satised with the electrode length, press the Retract Button to return the electrode to its home
position within the nose cone.
Weld State
The Sunstone PA250i has three dierent Weld States: Dry Run, Weld O, and Weld On.
•  In this state, the welder is not ready to make a weld. There is no energy waiting to be
released. In this state, if a weld is triggered a message will appear asking the operator to check the weld
state. This state is useful for initial and daily settings setup and electrode maintenance, as there is no
worry for accidental welds or weld head movement.
• Dry Run State: In Dry Run, the welder accepts weld triggers, and will go through the full weld process
(complete with weld head movement), but disables the energy discharge. This is especially useful for
testing any timing settings, as well as locations programmed if using a CNC table.
• Weld On State: In this state, the welder is fully operational. The energy banks charge to the set energy,
and all weld head movement, as well as energy discharge, are enabled. Use this state once you are
satised with your setup.
ARC CONTROL LAYOUT
The Arc Control Layout (see Figure 20.1) consists of controls for Waveform, Ignition, Agitation, Energy, Length,
and Weld Speed. This allows for adjustments that will allow welding many dierent types of metals/applications.
Figure 20.1. When you touch “ARC”,
the button will turn blue and new
parameter controls will appear for
Waveform, Ignition, Agitation, Energy,
Length, and Weld Speed.