SUNSTONE PicoDC User manual

Direct Current Resistance Welder Users Guide
20210615 • PART #1230
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Users Guide
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ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 08/2021 Original Content
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PERMITTED UNDER APPLICABLE LAW.

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Contents
Chapter 1: Overview ....................................................1
Welding Tips and Recommendations ................3
Common Electrode Types......................................4
How to Maintain Repeatable Welds ....................5
Chapter 2: Setup and Installation ............................7
Safety Precautions ...................................................7
Voltage and Power Requirements .......................7
Exploring the Welder’s Front Panel.....................8
Exploring the Welder’s Back Panel .....................9
Exploring the Side Panel...................................... 10
How to Set Up Your Welder................................. 10
Chapter 3: How to Use the Software Interface . 12
Run Screen Operation .......................................... 13
Selecting Weld Schedules........................... 13
Trigger Weld ..................................................... 13
Comparator Monitoring................................ 14
Displacement Monitoring ............................ 14
Weld Head Position........................................ 14
Force ................................................................... 14
Weld Head Control Screen Operation ............ 15
Mode Select...................................................... 15
Force ................................................................... 16
Position .............................................................. 17
Timing ................................................................. 18
Speed.................................................................. 19
Displacement ................................................... 20
Weld Setting Screen Operation ........................ 21
Waveform Graph ............................................. 21
Turn Pulses On or O .................................... 21
Set Voltage........................................................ 21
Set Pulse Duration.......................................... 22
Set Delay Between Pulses........................... 22
Save/Load Screen Operation............................. 23
Communications Screen Operation................ 24
PLC ....................................................................... 24
Alarms................................................................. 26
Importing/Exporting Weld Settings......... 28
Systems Screen Operation................................. 29
Interface Panel................................................. 29
Lock Panel ......................................................... 29
System Panel.................................................... 31
How to Update the Pico’s Software ................. 32
Appendix A: Pinout Details ..................................... 34
 ............................................ 36

Users Guide
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Chapter 1: Overview
The Sunstone Pico is a closed-loop feedback, direct-current, resistance welder engineered for thermocom-
pression and other ne welds. With built-in force and displacement monitoring, the Pico provides unmatched
precision, energy control, and monitoring using a color touchscreen interface.
The Pico provides you with many advantageous benets, including built-in weld monitoring, SPC tools, PLC
communication, closed-loop feedback, and more—all controlled with a 100% digital interface. The touchscreen
provides easy access to all weld parameters in addition to a visual representation of the weld waveform graph,
weld histograms, alarms, and warnings.
For automated production settings, the welder has basic PLC protocols. A cloning feature provides a simplied
method to set up multiple identical welders. Cloning copies all parameters and settings from one welder and
quickly exports them to other welders.
DC resistance welders, like the Pico, can provide consistent and repeatable energy discharges with accurate
controls and ne adjustments. DC resistance welders are ideal for thermocompression applications and small
wires due to the lower peak currents and maintainable energy discharge.
The Pico provides the following features and benets:
• Small heat-aected zone during the weld
• Ability to monitor Force and Displacement during the weld (coupled with the Micro E weld head)
• Versatility to weld very small, thin, and delicate metal parts
• Single or Dual Pulse operation
• Low maintenance required
• Touchscreen Interface
• Weld Monitoring
• Weld Head Controls
• Remote Schedule Select
• Weld Counter
• Histogram of weld results

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• Weld Comparator
• Full welder parameter cloning
• Lock-Out Mode
• PLC communication ready
• Software Updates
• Multiple Languages available
• Alarms and warnings
What is Direct Current Resistance Welding?
The Sunstone Pico welder converts the AC power coming from the wall to DC power and utilizes an internal
control system to regulate and maintain the weld discharge for accurate, repeatable welds. The control system
allows for ne tuning and manipulation of the weld energy to adjust for various welding applications. DC power
can be ideal for very ne wires and thin components that need the precision other welding power supplies do
not provide. The peak current of DC welders is lower than that of CD welders, but more sustainable throughout
the weld process. The sustained peak currents are ideal for using thermocompression electrodes because the
constant current provides a more even heat during the length of the weld.
DC RESISTANCE WELD FORMATION
Resistive spot welding relies on metal resistivity to heat and fuse metal. Current is generated by the DC power
supply and is passed through the workpiece metal. Energy is dissipated in the form of heat due to the metal’s
resistance to the current. This resultant heat melts the weld materials, fusing them together. There are two
phases to the melting process and the welder must overcome both the “Contact Resistance” and the “Bulk
Resistance” of the material.
Contact Resistance
On the micro scale, surfaces of materials are rough and uneven, resembling peaks and valleys, as shown in Fig-
ure 2.1. When two surfaces are pressed together, contact is only made in a limited number of locations (where
the peaks meet the peaks), instead of across the entire surface. These contact points act as resistive bridges
for the current to ow across and create contact resistance. During the rst few milliseconds of weld formation
these bridges melt, allowing other bridges to come into contact to continue the melting process.
Figure 2.1. Surface roughness limits surface-to-
surface contact. More contact points result in a
lower contact resistance.

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Bulk Resistance
Once all the bridges have fused, the contact resistance nears zero. At this point the second phase of the
melting process begins and the bulk resistance of the materials plays the nal role in weld formation. The “Bulk
Resistance” is the inherent resistive nature of the material and varies depending on the type of material. As
conductivity increases, resistivity decreases. Conductive metals such as copper require much larger amounts
of energy to form a weld compared to more resistive materials such as steel.
What is Thermocompression Welding?
Thermocompression welds utilize the resistive nature of the electrode material to generate the heat for fusion
instead of relying on the resistive nature of the materials being welded. Thermocompression electrodes (gener-
ally made of tungsten) are specially designed to be fused at the very tip. As current is passed through the resis-
tive tip of the electrode, heat is generated. Constant contact between the electrode and material being welded
must be maintained with the correct amount of compressive force to create fusion with the substrate material.
Welding Tips and Recommendations
Remember that every weld application is dierent. Several factors must work together and be balanced to
achieve successful welds. Sometimes experimentation and tweaking is required to get just the right weld. As
previously discussed, the resistivity of the materials and contact resistance play a major role. Other important
factors include the force being applied, the weld discharge energy, the weld discharge length, and the elec-
trodes being used.
WELD FORCE
Since contact resistance plays such an important role in the weld process, the weld force being applied by the
electrodes is critical. The larger the contact resistance, the hotter the resultant weld.
As more force is applied, the contact resistance is reduced due to an increased number of contact points be-
tween the two surfaces at the weld spot (more contact points result in lower contact resistance). More contact
points results in a cooler weld.
Conversely, too little force can lead to arcing between the two surfaces, which causes undesirable weld results.
Too much force can lead to weaker welds and part deformation.
Note: Weld force, as specically described above, applies to resistance welding only. Thermocompression
welds are not aected by contact resistance and therefore lighter forces do not lead to increased weld heat.
In fact, higher forces are sometimes necessary to create good contact fusion (hence the term “compression”
used in the name).
WELD ENERGY
The weld energy is adjusted using the welding power supply. Sunstone recommends that you rst try a weld at
a low energy setting and then increase energy until the desired hold strength is achieved. This tactic helps pre-
vent destroying the workpiece by having too much energy to start out. With thermocompression welds, when
set too high, energy settings can even lead to electrode tip degradation/failure.

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WELD LENGTH
Some applications require longer weld times than others to achieve good welds. Keep in mind that the longer
the weld lasts, the larger the heat aected zone will become. Weld length plays an important role in Thermo-
compression welding because the electrode tip must remain heated long enough for the coating and wire to
melt.
Common Electrode Types
Thermocompression
Thermocompression electrodes are typically used to weld magnet wires or other coated wires. Thermocom-
pression electrodes typically have an 1/8” diameter shaft body; dierent tip sizes/shapes can be available to
cater to various applications. Larger tips require more energy to heat suciently while smaller tips can be more
fragile and require less force.
Parallel Adjustable Gap
Parallel adjustable gap electrodes can be used to weld thin foils and strips and oer exibility in gap distance,
also allowing for a step conguration if required. They are available with a variety of tip sizes and come in Glid-
cop® or molybdenum.
Fixed Gap
Fixed gap electrodes can be used for similar welding applications to the adjustable gap but have the advantage
of easily maintaining the exact same gap for every weld with no need to adjust the gap. They have a smaller gap
that can often be achieved by the adjustable gap electrodes (but cannot be used for step weld congurations).
They are available in molybdenum.
Opposed
The opposed conguration is ideal for cross-wire welds and welds that oer access to both top and bottom of
the material. Electrodes come in Glidcop, Molybdenum, and Tungsten, with a variety of tip shapes.
Electrode Tip Ratings
Dierent electrode tip sizes can handle dierent amounts of force. Use the following as a guide:
• .01” x .01” – 40-1000 grams
• .015” x .025” – 125-1500 grams
• Anything larger – 400-2000 grams

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
Direct weld (Opposed)
Current passes from one electrode through both
workpieces and out the opposing electrode. Typically
the easiest conguration to achieve good weld nuggets
and strength. See Figure 5.1.
Step (Adjustable Gap)
The electrode is placed on both materials, but from the
same side. A step or adjustable gap electrode congu-
ration can be challenging when maintain proper pres-
sure at each electrode due to possibly uneven surface.
See Figure 5.2.
Series (Adjustable Gap/Fixed Gap)
The electrodes are placed on the surface material only.
Because the current is split between both materials,
sometimes this conguration requires more weld ener-
gy than a direct weld would. See Figure 5.3.
Thermocompression
In a thermocompression conguration, the current
does not pass through the materials being welded, but
rather the current passes through the electrode tip. A
thermocompression conguration is most useful for
coated surfaces like magnet wire. See Figure 5.4.
How to Maintain Repeatable Welds
Consistent weld results require a consistent and
repeatable process. A few suggestions for ensuring
repeatable welds include:
• Keep a weld logbook documenting the process
once a successful weld has been achieved. Try
to keep track of the following:
• Force applied
• Electrodes (tip size/shape, electrode
material, etc.)
Figure 5.1. Direct
(opposed) electrode
conguration.
Figure 5.2. Step
(adjustable gap) electrode
conguration.
Figure 5.3. Series
(adjustable gap/xed gap)
electrode conguration.
Figure 5.4. Thermocom-
pression electrode cong-
uration.

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• Measured gap distances (between electrodes, between the tips and workpiece, etc)
• Electrode placement in electrode holders (ush with top, extending “X” amount, etc.)
• Welding Power Supply settings (energy, length, etc.)
• Make sure there are no impediments to shaft movement.
• Make sure all the screws and connectors are tight.
• Make sure the weld head is placed on a stable, level surface that does not wobble.
• Try to make sure the materials being welded are clean and free of contaminants like dirt and oil.
• Whenever possible, xture the parts being welded to ensure repeatable positioning and stability during
the weld.
• Keep electrodes clean (create a process of maintaining the electrodes after a predetermined number of
welds.

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Chapter 2: Setup and Installation
Safety Precautions
• Carefully read the Sunstone Safety and Basics booklet that accompanied this welder prior to operation.
As the operator of this welder, you assume full responsibility for your safety and those around you.
• Carefully read the users guide that accompanied your weld head or hand piece.
• Before depressing the foot pedtal and triggering a weld, make sure nothing is obstructing the elec-
trodes other than the workpiece being welded.
• If maintenance or setup is required, put the welder in the “Weld O” state or turn the unit o before
making adjustments to the weld head or other connected devices.
Workspace Considerations
• Ensure the workspace around the power supply is adequate for welding operations.
• Ensure there is sucient clearance around the sides and rear of the power supply for cables to run
freely.
• Good ventilation is important to keep the power supply from overheating. Be sure to have proper air
ow in and around the power supply.
• Be sure to keep the work surface stable, level, free of vibration, and strong enough to support the power
supply.
• Ensure the power supply is suciently distant from the weld head and incoming power.
• Avoid placing the power supply near sources of high frequency electromagnetic radiation.
• Keep the work area clear of excessive dust, ammable materials, acids, corrosive gases, salt, and any
moisture. Keep a clean work space!
Voltage and Power Requirements
The Sunstone Pico DC welder can be used with either 110VAC or 220VAC input voltage. The voltage is auto-
matically detected by the welder so no voltage selection is required prior to connecting and powering up.

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What’s in the Box
• Pico DC Welder
• 90-250VAC Power Cord
• Foot Pedal
• Users Guide
• Safety Guide
Exploring the Welder’s Front Panel
The front of the welder (see gure 8.1) consists of three
components: the digital Touchscreen (A), the Power
Button (B), and the Weld On/O Button (C).
Touchscreen
The digital touchscreen (A) displays the graphical user
interface and allows the operator to make changes to
the welding parameters. Every interaction with the weld
settings will happen via the touchscreen.
Power Button
The Power Button (B) will turn the welder on and o.
When turned on, the button will latch and stay de-
pressed. To turn the welder o, press the button again
to unlatch it and start the power down sequence.
Warning: Do NOT turn the welder o during boot up.
Allow the welder to complete the boot process before
turning the welder o.

The Weld On/O Button (C) can be used any time the
welder is powered on. When pressed, the button will
illuminate and stay depressed, allowing the welder to
make welds. When o, the touchscreen remains fully
functional, but no welds can be triggered (no energy
can be released). The weld on/o button allows oper-
ators to safely make changes to welding electrodes,
weld heads, and hand attachments. Operators can also
perform ‘dry runs’ to test timing, delays, and automa-
tions without releasing any weld energy.
A
B
C
Figure 8.1. The front panel of the Pico
includes the Touchscreen (A), the Power
Button (B), and the Weld On/O Button (C).

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R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N
Figure 9.1. On the Pico’s back panel you’ll
nd all the ports, plugs, and connections
necessary to connect the Pico to a weld
head, foot pedal, power cables, and more.
Exploring the Welder’s Back Panel
On the back panel of the Pico you’ll nd identifying
details such as model and serial numbers as well as
certication marks. The following components can also
be found on the back panel, as shown in Figure 9.1 (see
also Appendix A, page 34 about connector pinouts):
Ethernet Port
The Ethernet Port (A) allows you to connect the Pico
to a computer network via an Ethernet connection, a
feature to be available in the future.
Accessory Port
The Accessory Port (B) is used to communicate with
external accessories such as the Micro E weld head.
PLC Port
The PLC Port (C) includes logic inputs and outputs that
can be used to communicate with a PLC.
E-Stop
The E-Stop Bypass Plug must be plugged into the unit
if you’re not using an E-Stop button. The E-Stop (D)
circuit is normally open and engaged. To disengage it is
necessary to close the circuit (in other words, if nothing
is plugged into this port, the E-Stop is engaged). If the
Power Button and Weld On/O Button are not illumi-
nated, but the display is on, the E-Stop is activated and
must be disengaged before the Pico will operate. Pinout
information can be found in Appendix A on page 34.
Weld Head Control
At time of press, the Pico does not use the Weld Head
Control Port (E). Rather the weld held is connected
using the Accessory Port (B).
Primary Trigger
Use the Primary Trigger Port (F) to connect an analog
foot pedal, or other switch, to the Pico to initiate a weld.
A
B
C
D
E
F
G

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Secondary Trigger
Use the Secondary Trigger Port (G) to connect a foot
pedal, or other switch, to initiate a weld.
Positive and Negative Weld Terminals
Use the Positive and Negative Weld Terminals (H) to
connect the weld cables from a weld head or hand at-
tachment to the Pico to deliver weld energy. See Figure
10.1. Make sure weld cable resistance is greater than or
equal to 1 milliohm (1mΩ) of resistance.
Cooling Fans
The Pico’s cooling fans (I) are internally powered and
controlled. Make sure the fans are free from obstruction
and have at least two inches of free space behind the
welder for optimum airow.
Fuse
For safety, the Pico uses a 5mm x 20mm 15amp fuse (J)
rated for up to 250VAC.
Power Inlet
The Pico Power Inlet (K) requires an IEC 320 C13 power
cord and can accept 90-250VAC, 50-60Hz.
Exploring the Side Panel
The welder features a USB port on the left side, near
the front. See (L) in Figure. 10.2. The USB port can be
used for three purposes:
1. Update the rmware and software of the welder
(see Chapter 3 for software update instruc-
tions).
2. Export and import saved schedules, welder
settings, and historical weld data (see the
section on Import/Export tab on page 28).
3. Connect a USB mouse and use the mouse to
navigate the interface.
Figure 10.1. Additional plugs and connections
on the Pico’s back panel.
H
J
K
I
Figure 10.2. Use the USB port (L) on the left side
of the Pico to update rmware/software, export/
import saved welding data, or to connect a
mouse to navigate the interface.
L

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How to Set Up Your Welder
• Unbox the welder and place on a stable surface.
• Connect the E-Stop Bypass Plug or an E-Stop
switch into the E-Stop Port on the back of the
welder. See (C) in Figure 11.1.
• Connect the female end of the power cord into
the Pico’s Power Inlet and connect the male
end into an AC power outlet (90-220VAC). See
(E) in Figure. 11.1.
• Connect the weld cables (B) from the weld head
or hand attachment to the positive and nega-
tive weld terminals.
• Use the included ¼-20 socket cap
screw with lock washer and hex nut.
• Attach the ends of the weld cables
coming from the weld head or hand
piece rmly to the copper terminals on
the back panel of the welder. One cable
should be attached to the negative, one
cable should be attached to the posi-
tive.
• Connect the Weld Head Control cable (if using
the Sunstone Micro E weld head) to the Weld
Head Control Port (D).
• Attach one end of the cable to the Accessory
Port (A) on the back of the welder. Connect the
other end of the cable to the Comm Port on the
weld head.
• Determine which weld trigger conguration is
best for your setup and connect accordingly.
Options include:
• Direct Control using an Analog foot
pedal
• Auto Mode
The system is now properly connected and ready to
weld.
Figure 11.1. Unbox the Pico and make sure
these basic connections are completed: Power
(E), weld cables (B), E-Stop (C), and Accessory
Port (A).
B
E
C
A
D

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Chapter 3: How to Use the Pico Software Interface
The Pico’s secret sauce is its digital interface. The Pico lets you set energy, force, displacement, timing, and oth-
er weld parameters to an exact number, something you can’t do with other welders. In this chapter you’ll learn
how the software is organized and how to use each feature.
Navigation Bar
The Navigation Bar at the top of the screen allows you to quickly access other parts of the welder’s systems
by touching each icon with your nger (see Figure 12.1). The Navigation Bar includes six icons representing the
welder’s main systems: Run, Servo Control, Weld Settings, Communications, Save/Load, and System Settings.
Run Screen (A)
Touch the Run Screen icon (A) in the Navigation Bar to display the current settings of the weld dis-
charge and servo weld head. See page 13 to learn how to use the Run Screen.
Weld Head Control Screen (B)
Touch the Weld Head Control Screen icon (B) to be guided through the set-up of a weld head. On page
15 you’ll learn how to use the Weld Head Control Screen. The Weld Head Control Screen icon only
appears when the weld head is connected and powered on.
Weld Settings Screen (C)
Touch the Weld Settings Screen icon (F) to set the parameters of the weld discharge. See page 21 for
additional details regarding pulse settings and weld control.
Figure 12.1. The Navigation Bar allows you to access the Pico’s six main operational screens: (A) Run Screen; (B) Weld Head Control
Screen; (C) Weld Settings Screen; (D) Save/Load Screen; (E) Communications Screen for PLC features; and (F) Systems Setting Screen.
A B C D E F

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Save/Load Screen (D)
Touch the Save/Load Screen icon (D) to save
weld settings or load weld settings from a
previously saved weld. See page 23.
Communications Screen (E)
Touch the Communications Screen icon (C) to
access PLC controls for automation, settings
for alarms, and features for importing/exporting pre-set
welds. See page 24 for PLC instructions.
Systems Settings Screen (F)
Touch the Settings Screen icon (F) to modify
the Pico’s basic settings, such as language,
date and time, speaker volume, screen bright-
ness, and more. See page 29 to learn how to make
system changes.
Run Screen Operation
The Run Screen, seen in Figure 13.1, displays current
settings relating to the weld discharge and weld head.
Additionally, the achieved results from the previous
weld are displayed here as well. The Run Screen is
equivalent to a “home” screen and should be the active
screen when triggering a weld.
Important: The Pico will only release energy and trig-
ger a weld when the Run Screen or Settings Screen is
active. If another screen is displayed, the Pico will not
trigger a weld.

To quickly load an existing weld schedule from the Run
Screen, tap the Select Weld Schedule button (G) in
Figure 13.1 and select the schedule from the pop-up
window. Existing weld schedules can also be loaded in
the Save/Load Screen, further explained on page 23.

You can trigger a weld in Auto mode by pressing the
Trigger Weld button (J). Pressing this button will act as if
you depressed a foot pedal plugged into the Secondary
Trigger Port found on Pico’s rear panel.
Figure 13.1. The Run Screen.
G
H
I
J
K
L
N
P
M
O

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
A graph (K) at the top of the Run Screen in Figure 13.1 displays a visual representation of the last recorded weld
discharge. Weld voltage/current/power (dependent on what is selected in the comparator screen) is displayed
on the Y axis, and weld discharge length (time) is displayed on the X axis.

The results from the comparator are shown directly below the waveform graph of the previous weld. See (L).
A green dot indicates that the previous comparator results were within set bounds. A red dot indicates some-
thing was out of bounds. The comparator can be turned on for either or both weld pulses if the weld pulses are
enabled. In the Weld Settings Screen, go to the comparator section by clicking on the Comparator Button. You
can place an envelope around your weld output waveform and the system will warn you if the weld output goes
out of bounds. See page 21 to learn more comparator features.

The results from the displacement of the previous weld are shown below the Comparator Monitoring resuls. See
(M). A green dot indicates that the previous displacement results were within set bounds. A red dot indicates
something was out of bounds.

In the lower right-hand side of the Run Screen, the weld head’s current position is displayed. See (N). In Auto
Control mode, the weld head can be moved directly using the up and down arrows found to the right of the
current position display. In Direct Control mode, the weld head’s position is controlled only by the analog foot
pedal.

The Weld Point (O) displays the current set weld point position.

The Voltage/Current/Power Feedback section (H) shows Pulse 1 and/or Pulse 2 desired and achieved results
from the previous weld. The displayed results of Voltage/Current/Power are dependent on what is selected in
the Comparator section in the Weld Settings Screen. Pulse 1 and/or Pulse 2 will be grayed out if disabled in the
weld pulse settings screen.

In the Force section (I) you’ll see two numbers. The Desired number represents the amount of force you select-
ed in the Weld Head Settings Screen. The Achieved number is the amount of force that was achieved in the last
weld.

If the Pico displays a green dot in the bottom, right-hand corner of the screen (P), the welder is ready for oper-
ation. If the Pico displays a red dot, the welder is not ready for operation. To achieve a green dot, review all weld

Questions? Call or Text [phone] • 15
e Micro Welder Experts
settings and connections. Verify that the Weld On/O
button is in the on state. If you need assistance, call the
Sunstone Customer Service team at [phone]
or send a message to [e-mail].
Weld Head Control Screen
Operation
The Weld Head Control Screen is used to set all param-
eters required for controlling a connected weld head
during the weld process.
Note: The Weld Head Control Screen icon only appears
when a weld head is connected and powered on.
When you press the Weld Head Control Screen Icon
in the Navigation Bar, the Pico will begin a sequence
of step-by-step, pop-up windows to guide you
through the setup process.
You can choose to follow the step-by-step setup
process or jump to any portion of the setup process
by pressing any of the icons in the Weld Head Control
sub-navigation bar (found under the Navigation Bar
when the Weld Head Control icon is pressed). See Fig-
ure 15.2.
MODE SELECT
The rst step of the set up process is choosing
how you wish to control the weld head. The Mode Se-
lect icon (A) in Figure. 15.2, is identical to the Weld Head
Control Screen icon due to it being an extension of
the weld head controls. The weld head has two modes
available: Direct Control and Automatic Control.
Direct Control
Direct Control allows operators to control the position
of the weld head directly by using an analog foot pedal.
The position of the weld head corresponds to the posi-
tion of the foot pedal. Pressing down on the foot pedal
lowers the weld head; letting up on the pedal raises the
weld head.
In this mode, the operator presses the analog foot
pedal to lower the weld head until contact is made with
Figure 15.1. The Weld Head Control Screen in the Mode
Select step. When you touch the Weld Head Control Screen
icon, the Pico will want to walk you through a step-by-step
process to complete the weld head setup process. When
you’ve selected the desired settings for each step, press the
right arrow button at the bottom of the screen to advance to
the next step. You can press the left arrow button to go back.
Press the Close button to save and end the setup process.
A B C D E F
Figure 15.2. The Weld Head Control Screen sub-navigation
bar contains six areas of weld head control: Mode Select
(A), Force (B), Position (C), Timing (D), Speed (E), and
Displacement (F).

16 • Questions? Call or Text [phone]
Users Guide
Picó
the workpiece. Once the desired force is met, the weld
process is triggered. Upon completion of the sequence,
the weld head will return to the Home Position, ready
for the operator to initiate the next weld. User cong-
ured parameters of the Direct Control weld sequence
include Force, Timing, and Displacement. You must
release the foot pedal in order to make another weld.
Automatic Control
If Automatic Control mode is selected, the weld se-
quence is initiated by pressing the digital foot pedal
switch or by pressing the Trigger Weld button on the
Run screen. User congured parameters of the Auto-
matic Control weld sequence include Force, Position,
Timing, Speed, and Displacement.
Select a mode and the next popup window will appear
accordingly.
FORCE
The second step in the weld head setup pro-
cess is entering the desired weld force (in grams). See
Figure 16.1. Touch the Desired Force box and then en-
ter the desired force using the slider bar or number pad
that will appear in a pop-up window. See Figure 16.2.
The weld head will attempt to achieve this force with
each weld actuation. An upper and lower limit can be
set to trigger an alert if the force lies outside the set
limits for any reason. Allowed forces range from 30g
to 2000g with a 100% duty cycle, and 2001g to 4000g
with a 10% duty cycle.
Force Calibration
The weld head’s force needs to be calibrated every
time a new desired force is set. Ensure the parts to be
welded are in place before performing this step.
In Direct Control, calibration occurs immediately after
setting the desired force. The analog foot pedal is used
to move the electrode to the part to be welded. Once
the desired force is met, the servo is automatically cali-
brated, and setup is resumed.
Figure 16.1. Select the desired amount of force to be
delivered by the weld head in the Force Screen, the second
weld head setup step.
Figure 16.2. When you
touch the Desired Force
box a pop-up window will
appear. You can use the
slider bar or the number
pad to enter the amount
of force you desire,
measured in grams.