SUNSTONE Scout User manual

SCOUT
SP PORTABLE WELDER
Users Guide
Version 20200708 • Part #1143
e Micro Welder Experts

ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 06/2020 20200604 Production release.
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OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU.
THE LIMITATIONS OF LIABILITY SET FORTH ABOVE SHALL APPLY TO THE MAXIMUM EXTENT PERMITTED
UNDER APPLICABLE LAW.

Table of Contents
Chapter 1: Product Overview 1
About the Sunstone Scout 1
Common Applications 1
Features 1
Unpacking the Scout 2
What’s in the Box 2
Chapter 2: Resistance Welding Overview 3
What is Capacitive Discharge Resistance
Welding? 3
How a Spot Weld is Formed 4
Factors Contributing to a Successful
Resistance Weld 4
Weld Pressure 4
Electrode Congurations 4
Choosing the Right Electrode Material,
Shape, and Diameter 5
Weld Energy 5
Chapter 3: Set-up 6
Attach a Hand piece/Weld Head 6
Trigger Cable 6
Attaching the Weld Cables 7
Chapter 4: Operation 8
Controls Overview 8
Adjusting the Hand piece (if applicable) 10
Adjusting the Settings 10
Making a Weld (using a hand piece) 11
Thermal Protection 11
Chapter 5: Maintenance 12
Charging the Batteries 12
Replacing the Batteries 12
Chapter 6: Troubleshooting 14

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Chapter 1: Product Overview
About the Sunstone Scout
The Scout SP Portable Welder has been designed and manufactured for welding in the most remote or hard-to-
get-to spots. The Scout does not require an AC power source during operation. With built-in storage space for
a hand piece and cables, and when properly maintained and charged, the Scout will be ready for any out-of-the-
way expedition that requires a ne spot weld. Whether you’re at the top of a cell tower, wind turbine, or hanging
below a highway bridge, the Scout will be your go-to welder.
COMMON APPLICATIONS
The Scout is ideal for making ne spot welds anywhere AC power is not readily available. Common applications
include the following:
• Strain gauges on bridges, wind turbines, or communication towers
• Attaching small wires in remote locations
• Attaching thin sheet metal at jobsites without AC power
• Nickel battery tabs in remote locations
• Cross wires or thermocouples at jobsites without AC power
• Electronic components of machinery located in remote areas
• Research and development applications at remote sites without AC power
FEATURES
Sunstone’s micro welders are simple to use with an intuitive and user-friendly interface. A digital screen displays
total weld energy, an LED battery indicator the displays the remaining charge, and easy-to-use toggles/knobs
allow you to quickly and easily adjust the settings to ne tune for countless spot-welding applications. Chanc-
es are you’ll be wearing gloves when using the Scout, so the knobs and switches are built for easy operation.
Additionally, as a CD welder, the Scout can perform strong and repeatable welds for high levels of consistency
and quality control.

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The Sunstone Scout Single Pulse CD welder provides the following features:
• 100 watt seconds (Ws) Available Energy Discharge
• Single Pulse Operation
• Microprocessor Controlled
• Thermal Protection Circuit – Internal Monitoring
• Up to 2000 Welds on a Single Charge
• Audible ‘Ready’ Notication
• LED Battery Charge Indicator
• Cable Storage Compartment
• Rigid, centrally positioned, built-in Handle for Transport
• Enclosed Controls for Safety
• Adjustable Pulse Width
• Capacitive Energy Storage Adjustable from 0.1% to 100%
• 110/220 VAC to DC Charging Power Block
• Simple, User-Friendly Interface
• Quick Energy Release for Welding Highly Conductive Metals
• Small Heat Aected Zone (HAZ)
• Repeatable Energy Release Independent of Line Voltage Fluctuations
• Capable of Extremely Fine Energy Adjustments
Unpacking the Scout
• Remove the top layer of foam from the box.
• Carefully lift the unit up and out of the foam by pulling up on the unit’s center, orange handle.
• Remove the small, white cardboard box from its foam pocket and open to reveal important contents.
WHAT’S IN THE BOX
(1) Scout Capacitive Discharge Spot Welding Unit
(1) AC to DC Battery Charging Power Supply with Cords
(1) Foot Pedal

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Chapter 2: Resistance Welding Overview
What is Capacitive Discharge Resistance Welding?
You are most likely an experienced welder who understands and respects capacitive discharge resistance
welding. If that is the case, you may feel the urge to skip Chapter 2. However, even an experienced welder can
appreciate the need to occasionally review the science behind the weld. For that reason, Sunstone recom-
mends that every operator reads Chapter 2.
Capacitive discharge resistance welding uses capacitors to store DC energy for quick release. Also known as
CD welders, capacitive resistance spot welders have some advantages over other types of welders:
• CD welders allow for extremely fast energy release with large peak currents; weld nugget formation
takes place during the rst few milliseconds of the weld process. This means that more of the energy
goes into weld formation and less into heating the surrounding material (see Figure 3.1 below).
• The heat aected zone, wherein rapid heating and cooling can change the properties of the metal, is
localized to a small area around the weld spot.
• The quick discharge rate of CD welders also allows electrically and thermally conductive materials to be
welded.
• With the energy stored it can also be controlled, resulting in precision energy release adjustments.
Figure 3.1. Sample Capacitor Discharge Curve. During a
discharge of energy, the amount of energy released is at peak
level at the beginning of the discharge and then dissipates to
near zero by the time the discharge is complete.

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SCOUT SP Portable Welder Users Guide
How a Spot Weld is Formed
Spot welding relies on metal resistivity to heat and fuse metal. A large current is passed through the workpiece
metal. When energy passes through a material, the resistance it meets creates heat, which melts and then fuses
the weld materials together.
There are two phases to the melting process. The welder must overcome both the material contact resistance
(the resistance at those points where the two materials meet) and the bulk resistance (the cumulative resis-
tance of the two materials being welded together) of the material.
Figure 4.1 shows an example of a micro-scale surface prole. On the micro-scale, material surfaces are rough
and only contact each other in a limited number of locations. In the rst few milliseconds of weld formation,
the high resistance metal bridges melt, allowing other bridges to come into contact to continue the melting
process. When all the bridges have fused, the contact resistance is zero. The bulk resistance of the metal then
plays the nal role in the weld formation.
Factors Contributing to a Successful Resistance Weld
WELD PRESSURE
The amount of electrode pressure at the weld spot plays a part in the contact resistance. The more contact
resistance the energy encounters, the hotter the resultant weld. On the micro-scale, contact resistance is
reduced when more metal bridges or contact points are formed (see Figure 4.1). Using more electrode pressure
creates more metal bridges, resulting in lower contact resistance and therefore less resistive heat in the weld
spot.
Conversely, light electrode pressure results in less metal contact, higher resistance, and a hotter weld. In fact,
too little pressure can lead to arcing between the contact points and cause unwanted sparking or blow out.
An appropriate amount of pressure in conjunction with the appropriate amount of energy discharge should be
determined to ensure good weld strength and strong weld nugget formation.
ELECTRODE CONFIGURATIONS
The placement of electrodes in relation to each other can aect weld results as well. Figure 5.1 shows the typi-
cal electrode congurations used in resistance welding.
• Direct or Opposed Conguration: Current is passed from one electrode through both workpieces
and out through an opposing electrode. This is the typical desired conguration if access is available to
both top and bottom materials.
Figure 4.1. On the micro scale, surface roughness limits
surface-to-surface contact. More contact points result in
lower contact resistance.

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• Step Conguration: This conguration is used when there is access to only one side of the workpiece.
An electrode is placed on the top side of both materials as shown.
• Series or Parallel Conguration: Used when there is only access to the top material. Both electrodes
are placed on the top material. The current is divided between the two parts. This conguration requires
more weld energy to obtain results similar to the prior two examples.
Choosing the Right Electrode Material, Shape, and Diameter
The shape of the electrode tip can make a big dierence in weld results. The type of electrode you use may
depend on the application at hand. A small tip will focus the energy for deeper penetration and create a small
weld spot. A larger tip will spread the energy evenly and create a larger weld spot with less penetration using the
same amount of energy (but may help reduce sticking and increase time between electrode maintenance).
Typical applications will use an electrode that is 1/8” diameter with a conical shaped tip. A grinder, belt sander
or similar instrument can be used create the desired tip shape. You should also clean and maintain the shape of
the electrode regularly.
WELD ENERGY
The amount of energy discharged has the most inuence on weld strength and quality. The Scout can store up
to 100 Ws of energy. Operators can adjust the amount of energy stored (weld energy), and ne tune the weld
results further by adjusting the amount of stored energy that will be discharged (which is called the weld pulse
length) from 0.1% of the stored energy to 100% of the stored energy.
Figure 5.1. Examples of resistance welding electrode
congurations: a)Direct; b)Step; and c)Series.
a b c

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SCOUT SP Portable Welder Users Guide
Chapter 3: Set-up
Attach a Hand piece/Weld Head
The Sunstone Scout is a versatile spot welder and can be used with several dierent attachments including
weld heads, tweezer hand pieces, pressure actuated hand pieces, and dual probe hand pieces. Refer to the
attachment’s documentation for more detailed set-up information; this guide stays focused on the Scout.
Sunstone sells a wide variety of hand pieces for any type of application. Visit www.sunstonewelders.com or
call or text [phone].
TRIGGER CABLE
You can congure the Scout to actuate (or release energy and initiate a weld) using any one of the following
congurations:
• Foot Pedal Actuation. For dual probe hand pieces or other attachments that do not have trigger
cables, you’ll actuate the weld using a foot pedal. Plug the connector from the included foot pedal into
the Trigger Port located in the storage compartment side of the Scout (found below the two copper
terminals). Twist the housing until it threads into place and tightens to prevent unplugging.
• Hand piece Actuation. If your hand piece is pressure actuated or has a push button trigger, plug the
connector from the hand piece into the Trigger Port located in the storage compartment side of the
Scout (found below the two copper terminals). Twist the housing until it threads into place and tightens
to prevent unplugging.
• Weld Head Actuation. Sunstone weld heads are equipped with a mechanism to trigger the weld at the
correct time. Connect the weld head trigger cable to the Trigger Port located in the storage compart-
ment side of the Scout (found below the two copper terminals). Twist the housing until it threads into
place and tightens to prevent unplugging.
For custom trigger cables the following information is helpful:
• The Trigger Port is a DIN 3 connector and requires shielded wire.
• The standard external trigger cable connector is an SD-30LP made by CUI Inc.
• Figure 7.1 shows the wiring diagram for the SD-30LP connector (see next page).

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Note: Sunstone oers an external switch connection cable that includes the cable and connector mentioned
here.
ATTACHING THE WELD CABLES
Every Sunstone welding attachment comes with weld cables. Refer to each attachment’s users guide for more
detailed weld cable set up. Generally speaking, follow these steps to attach the weld cables to the Scout.
• Attach one cable to the copper terminal labeled “-“ (located in the storage compartment). See Figure
7.2 below. Use the included ¼-20 x ½” socket cap screw with a split lock washer and ¼-20 hex nut.
• Attach the other weld cable (coming from the hand piece) to the copper terminal labeled “+” (located in
the storage compartment). Use the included ¼-20 x ½” socket cap screw with a split lock washer and
¼-20 hex nut.
• Route the cables through the notch in the side panel during use.
• When in use, make sure the cables are clear of debris that may cause damage.
• When not in use or during transportation, coil the cables and place them in the storage compartment
along with the hand piece.
Figure 7.1. External trigger wiring diagram, looking at back of
welder, for the welder’s rear connector. “N.O.” is an acronym
for “Normally Open.”
Figure 7.2
Cable Notch. Route the welding attachment cables through this
notch at the rear, left-side of the Scout.
Copper Terminals. Welding attachment cables are connected to
the Scout to these copper terminals located under the right-side
panel.
Storage. Place the weld attachment and cables in this storage
compartment when not in use.

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Chapter 4: Operation
Controls Overview
Refer to Figure 9.1 (see next page) when learning about the Scout’s Control Panel.
Mode Toggle Switch
• Charge. When not in use and you wish to keep the Scout ready for anytime use, ip the toggle to this
mode while the unit is connected to a power source. The Scout will recharge only when the Mode
Toggle Switch is in the Charge position.
• O. Use this mode when the unit is not in use and you don’t intend to recharge the batteries. Use this
mode when transporting the Scout.
• Weld. When you’re ready to weld, ip the toggle to this mode to power the unit.
Charge Port
Plug the included Charging Power Supply into the Charge Port on the Scout and to a power source to charge
the unit. Make sure you also ip the Mode Toggle Switch to Charge if you wish to recharge the batteries. An LED
will illuminate on the Charging Power Supply to indicate charging is taking place.
Energy Display
When the unit is powered on, the Energy Display will show the current energy setting in watt seconds (Ws).
Battery Charge Indicator
When the unit is powered on, the Battery Charge Indicator will display the charge state of the batteries. As the
charge in the batteries diminishes the number of illuminated LED bars will decrease accordingly. When the last
bar disappears, it is time to charge the unit.
Pulse Width Adjustment Knob
The Pulse Width Adjustment Knob adjusts the width of the weld pulse discharge. At lower settings, the amount

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of energy being discharged is “cut o.” At the highest setting (recommended) the full amount of energy will be
discharged. See “Pulse Width” on page 10 for a detailed explanation of how pulse width aects the weld.
Weld Energy Adjustment Knob
To adjust the amount of energy released during a weld, use the Weld Energy Adjustment Knob. A higher amount
of energy increases the amount of heat present during the weld. Conversely, decreasing the amount of energy
released during the weld decreases the amount of heat present during the weld.
Weld Beep Toggle
This switch will enable or disable an audible beep to conrm a weld has taken place.
Figure 9.1 Scout Control Panel
Mode Toggle Swich. Flip
the switch to Charge when
charging the battery. Flip the
switch to Weld when in use.
Flip the switch to O when
the welder is not being used
or charged.
Charge Port. Use the
included Charging Power
Supply to charge the
Scout’s batteries.
Battery. Indicates the
charge strength of the
batteries.
Energy Display. The
current energy setting is
displayed here.
Welder Beep. Enables or
disables an audible beep to
conrm a weld has occured.
Weld Energy. Adjusts the
amount of energy released
during a weld
Pluse Width. Adjusts the
width of the weld pulse
discharge.

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SCOUT SP Portable Welder Users Guide
Adjusting the Hand piece (if applicable)
If the hand piece is equipped with adjustable force triggering, an adjustment screw will allow you to change the
spring tension (and thus the force being applied by the electrode). Tighten the screw to increase force. Loosen
the screw to decrease force.
Keep in mind that with all hand pieces, operator consistency is important. Pressing too hard or not enough can
aect weld quality and consistency.
ADJUSTING THE SETTINGS
Finding the proper weld settings can depend on several factors, such as material type, material thickness, mate-
rial coating, force being applied by the electrode, electrode shape, and electrode material. For this reason, trial
and error is sometimes necessary in nding just the right settings. Be sure to maintain consistent force on the
electrode during each trial.
Pulse Width
Unless you have experience with a particular type of weld, you’ll most likely start a weld by setting the pulse
width to 100%. Turn the Pulse Width dial to the right as far as it will go, which will allow the unit to discharge the
full amount of available energy. Pulse width can be used to ne tune the amount of energy being discharged to
nd a satisfactory welding result.
Several factors should be considered when selecting the correct pulse width setting. For example, when weld-
ing conductive materials, it is ideal to set the weld energy at its maximum and have a lower pulse width to create
a high peak current for a short amount of time. Less conductive materials have better weld results with a higher
pulse width (knob turned all the way up).
Weld Energy
Use the Weld Energy knob to set the amount of stored energy that will be released when you initiate a weld.
Determining the weld energy level also sets the peak current for the weld.
Tip: It can be helpful to start at a lower energy level and incrementally increase the energy until desired weld
results are achieved. Thicker materials and conductive materials require more energy than thin materials and
resistive materials.
The Scout’s ability to control energy storage and pulse width
allows you to manage both the energy released during the
welding process and the peak electrical current experienced
by the weld material. These parameters are important when
welding materials that have diverse thermal and electrical
properties. Figure 10.1 shows how voltage, peak current, and
energy relate over time during a typical capacitive discharge
weld. It should be noted that the energy stored can also be
thought of as capacitor voltage in this diagram.
Figure 10.1 Typical capacitive discharge weldform graph.

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MAKING A WELD (USING A HAND PIECE)
To make a weld, follow these instructions:
• Attach the hand piece to the Scout’s terminal. See page 7 for details.
• Attach the grounding cable to the base material or a grounding plane upon which the base material
will rest upon, if you’re using a pistol grip-style hand piece. If you’re using a tweezer-style hand piece,
the ground cable is connected to the hand piece.
• Position the material to be welded. Make sure the parts are in their proper locations and safely
secured.
• Flip the Mode Toggle Switch to Weld.
• Select the desired Pulse Width. Turn the Pulse Width knob to the desired width.
• Select the desired Weld Energy. Turn the Weld Energy knob to the desired amount.
• Position the electrode. Line up the electrode with the desired weld spot location (on the top material).
• Apply force to the electrode. Make sure the hand piece remains perpendicular to the surface being
welded. Press down on the hand piece to apply force to the electrode. Too much force can damage the
parts and will minimize the heat of the weld. Too little force can cause unwanted arcing or “burnouts.”
• Trigger the weld. If the hand piece is equipped with pressure actuated triggering, the weld will initiate
automatically once the pressure reaches the set amount. If the hand piece is equipped with a button
trigger, press the button to initiate the weld. If the hand piece has no trigger cable, use the included foot
pedal to initiate the weld.
Once the signal is sent, the stored capacitive energy will be discharged and create a weld spot. If the Weld Beep
toggle is on, you’ll hear an audible beep to indicate energy has been discharged.
Tip: Flip the Mode Toggle Switch to the OFF position while the unit is not being used to weld. This will help con-
serve battery power.
THERMAL PROTECTION
The Sunstone Scout is equipped with temperature sensors. If the internal temperature nears the preset maxi-
mum (unit is overheating), you’ll hear six successive beeps. You will not be able to weld when the Scout is over-
heated. When the unit has cooled, you’ll hear three successive beeps, signifying the unit is ready to weld again.
Note: these warning beeps will occur even if the Weld Beep toggle switch is set to o.

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SCOUT SP Portable Welder Users Guide
Chapter 5: Maintenance
Charging the Batteries
To charge the batteries, follow these instructions:
• Plug the barrel jack connector from the Charging Power Supply into the Charge Port on the control
panel.
• Plug the AC cord into a 110V outlet.
• Flip the Mode Toggle Switch to Charge. The scout will NOT charge unless this Mode Toggle Switch is
ipped to Charge.
• Verify the LED on the Charging Power Supply is lit, which indicates the Scout’s batteries are being
recharged.
• Allow the Scout to charge for six hours to recharge from no charge to full charge. The Scout can be
used if the batteries are not fully charged, albeit the number of available welds will be less than those
available with a full charge.
Replacing the Batteries
The Sunstone Scout batteries, like all batteries, will degrade in performance over time and use and will need to
be replaced. Contact Sunstone’s customer service team to procure replacement batteries.
To replace the batteries, refer to the diagram on the next page and carefully follow these instructions:
• Remove the storage compartment side panel A. Remove the two pan head screws located in the
upper portion of the storage compartment. Remove the two at head screws on the side panel, then
pull the side panel out away from the center plate.
• Remove the screws on the storage compartment base plate B and set the plate aside.
• Disconnect the battery wires by pulling the quick disconnects o the spades of the batteries (make
note of the locations for each wire).
• Remove the four screws on the battery strap C and set the strap aside.
• Remove the battery spacer D.
• Slide the batteries E out and away from the center plate.

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• Slide two new batteries E into place.
• Replace the battery spacer D.
• Replace the battery strap C.
• Replace the battery wires. Push the quick disconnects onto the spades of the batteries.
• Replace the storage compartment base plate B.
• Replace the side panel A.
Note: Dispose of batteries properly and per local regulations.
Lead-acid batteries contain heavy metals (Hg - mercury, Cd - cadmium, or Pb – lead) that negatively impact the
environment and harm your health. Do not discard the batteries in a municipal waste facility or bin.
The spent batteries can be returned to Sunstone for a discount on replacement batteries or disposed at the
nearest recycling/battery collection facility. Contact Sunstone’s customer service team for more information
California Proposition 65 Warning:
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to the
State of California to cause cancer. Wash hands after handling.
Warning: Do not disassemble, heat above 60 degrees Celsius, or incinerate batteries.
A
B
C
DE

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SCOUT SP Portable Welder Users Guide
Chapter 6: Troubleshooting
No Weld Occurs
• Check to make sure the grounding cable is contacting the base material.
• Make sure there is good contact between the materials being welded together.
• Make sure the cables are connected securely to the copper terminals inside the storage compartment.
• Make sure the Mode Toggle Switch is set to “Weld”.
• Make sure the Trigger Cable is securely connected.
Unit is Not Powering ON
• Charge the unit.
• Make sure the Mode Toggle Switch is set to “Weld”
Contact the Sunstone customer service team if the Scout will not power on after verifying the two previous
troubleshooting measures have been tried but unsuccessful in powering on the unit.
Battery Life Diminished Greatly or Won’t Hold a Charge
• Replace the batteries.

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KEY UNIT SPECIFICATIONS
 22.9x22.9x38.1 cm / 9x9x15 inches
 11.4 kg/25 lbs.
 100-240 VAC
 
INPUT AC CURRENT 0.7 A
OUTPUT 
 
 
 
 0.26ms - 5ms
 0.2 V
WELD REPETITION RATES (WELDS/MINUTES AT % OF MAX ENERGY)
    
40 50 60 85 120
ENERGY RELEASE DATA



IN ms






1 0.26 ms   
1.5 0.28 ms   
2 0.45 ms   
2.5 0.59 ms   
3 0.75 ms   
3.5 0.90 ms   
4 1.06 ms   
4.5 1.43 ms   
5 2.23 ms   
5.5 3.54 ms   
6 4.80 ms   
6.5 5.51 ms   
7 5.54 ms   
PEAK WELD CURRENT 
 





 250 200 100
25  3953 3162 1581
50  5590 4472 2236
75  6847 5477 2739
100  7906 6325 3162
SPECIFICATIONS

16 • Questions? Call or Text [phone]
SCOUT SP Portable Welder Users Guide
RECOMMENDED HAND PIECES
Call Sunstone at [phone] to order the hand piece you need or visit
www.sunstonewelders.com/hand-pieces for convenient on-line shopping.
Single Probe PG1
The PG1 is the smallest single side gun you’ll nd in the Sunstone
collection of hand pieces. The PG1 includes a built-in switch and
can be tted with a straight or 90-degree tip. The PG1 comes with
a 3” long 3/8” diameter electrode.
Pistol Grip PG2
The PG2 is a highly ergonomic hand piece that’s perfect for more
hazardous work locations, where being able to keep a secure grip
on every tool is paramount. The PG2 includes a trigger and 3” long
3/8” electrode (and will also accept threaded electrodes).
Tweezer PG5M
The Tweezer PG5M is a pressure-activated hand piece with an
ergonomic design for easy operation. The PG5M provides th nest
pressure range and the highest degree of precision. The design
includes a quick release system for simple electrode changes.

Questions? Call or Text [phone] • 19
e Micro Welder Experts
Other World-Class Micro Welders from Sunstone:
Sunstone™
CDDP-A
Now available in
four models:
• 200 Ws
• 400 Ws
• 600 Ws
• 1200 Ws NEW!
Advanced CD Fine-Spot Resistance Welders
Precise, Repeatable Control Over Every Aspect of Every Weld!
e Micro Welder Experts
The Sunstone hallmark is precision control
over power delivery details. And the Sunstone
CDDP-A line of ne-spot resistance welders is
no exception. A touchscreen interface lets you
adjust power by 1/100th of a Ws! Plus you have
full control over the wavelength. With absolute
energy control you’ll always be able to dial in and
nd the sweet spot for any welding application.
The CDDP-A is PLC-enabled and automation
ready for any production oor. If you need a
solution for honeycomb tacking, continuous roll
spot welding, cross-wire welding, thermocouples,
or other resistive applications, the CDDP-A is the
right welder for you.
Call or Text [phone]
www.sunstonewelders.com