SUNSTONE WH1 User manual
WH1 Opposed Weld Head
For Models WH1125A, WH1125M, WH1250A, WH1250M, WH1187A HF
Users Guide
Version 20201010 • Part #1170
ii • Questions? Call or Text +1 801-658-0015
WH1 WELD HEAD USERS GUIDE
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
ISSUE DATE APPROVAL NOTES
1 DH
FORMATTING CHANGES, WELD HEAD TRIGGER HUB
ADDITION, HIGH FORCE MODEL ADDITIONS, IMAGE
UPGRADES
Limitation of Liability
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LLC, ITS DISTRIBUTORS, OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT,
INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES, OF ANY NATURE WHAT-
SOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGINEERING LLC PROD-
UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-
NEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE
ENGINEERING LLC PRODUCT, OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY
THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT,
EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
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Table of Contents
Chapter 1: A Quick Look 1
What is in the Box
Precautions
Chapter 2: Pneumatic Weld Head Setup 3
Bolt the Weld Head to the Table 3
Set up Weld Head Trigger Hub 4
Set up MAC Valve Air Hoses and Pressure 5
Chapter 3: Manual Weld Head Setup 8
Bolt the Weld Head to the Table 8
Manual Foot Pedal Installation and Setup 9
Setting Up the Manual Foot Pedal 10
Chapter 4: Completing Weld Head Setup 11
Connect Weld Head Cables to the Welder11
Foot Pedal Triggering 13
Standard Electrode Setup, Adjustment 14
High Force Electrode Setup, Adjustment 15
Adjust Electrode Gap 15
Weld Head Height Adjustment 16
Electrode Spring Pressure Setup 17
Standard Spring Pressure Values 19
Chapter 5: Welding with the Weld Head 21
Basic Welding Steps
Chapter 6: Electrode Care 22
Chapter 7: Resistance Welding Basics 24
Technical Assistance 26
Data Specications 27
Opposed Weld Head Mounting Template 29
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WH1 WELD HEAD USERS GUIDE
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Chapter 1: A Quick Look
Thank you for choosing Sunstone to help you reach your vision and goals. Every member of the Sunstone team
is working to make sure you love our products and rave about our customer service. If you need assistance for
any reason, please call or text +1 801-658-0015.
Before you begin to set up and use your Sunstone WH1 Weld Head you should become familiar with its various
components and controls.
Carefully review the illustrations on page 2.
What is in the Box
Carefully open the weld head package. Remove and place the contents on a clear and clean workbench. You’ll
•
• Weld Head Unit
•
• Weld Head Trigger Hub
•
Note: The weld head footprint of 10.25”x4.5”. Verify there is enough work space for the weld head and welding
unit.
Precautions
• Pieces that have been welded can be HOT. Always use caution when handling welded pieces.
•
wear; smoother electrodes will provide better results.
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Pressure Regulator. The amount
of air pressure coming in to the
weld head from the air compressor
is regulated by this valve. Sunstone
recommends a pressure between
60 to 80 PSI.
Flow Control Valves. The Flow
Control Valves adjust the air ow
that is raising and lowering the weld
head after stepping on the weld
head foot pedal. The valves control
how quickly or slowly the weld
heard raises or lowers.
Moveable Electrode Gap Scale.
Refer to this scale when conguring
the electrode gap (the distance
between the heads of the two
electrodes). Follow the directions
as noted in the Electrode Spring
Pressure Setup section on page 17.
Electrode Holders. Place the
electrodes in these holders and
tighten.
Pressure Knob. Use this knob to
adjust electrode pressure. Turn
counter-clockwise to decrease; turn
clockwise to increase.
Weld Cable Connectors. Cables
coming from the welder are
attached to the weld head here.
Note that the cable connected
to the positive (+) terminal on the
welder will put a little bit more heat
to the positive electrode on the weld
head. If you are welding a coated
or thick to thin piece, congure the
welding process with the positive (+)
electrode contacting the coated or
thicker part rst.
80/20 Base. The base of the
weld head is designed suciently
to safely support the weld head
during operation; however, it is
recommended that you bolt the
weld head to a table when possible.
Height Adjustment. Loosen these
knobs to move the weld head up
and down when positioning the
electrodes above the work piece.
Sunstone suggests you start with a
gap of 1/8” (0.125 inches) above the
work piece.
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Chapter 2: Pneumatic Weld Head Setup
NOTE: For Manual weld head setup (WH1125M and WH1250M) see Chapter 3.
Bolt the Weld Head to the Table
This step is optional. The weld head will stand upright on its own. However, we recommend bolting it to your
work table for better support and added stability.
Bolting Instructions (Option 1 - Use the Mounting Template)
•
instructed to drill a hole, simply drill through the illustrated holes on the mounting template.
•
• Ensure that the bolts will go through your table. (If not, you may need to drill a counter-bore on the
• Slide the provided 5/16-18 T-SLOT Bolts into the channels on the underside of the weld head. See
Figure 3.1.
• Align the bolts with the drilled out holes then lower the
bolts into the holes.
• Next, secure the weld head by tightening the provided
5/16-18 nuts to the bolts on the under-side of the table.
Bolting Instructions (Option 2 - No Mounting Template)
•
nuts. Ensure the bolts will go through your table. (If not,
you may need to drill a counter-bore on the underside of
•
Figure 3.1. The heads of the included T-SLOT
5/16-18x1.5” bolts will slide into the channels
found on the 80/20 aluminum base of the weld
head. Use the bolts to secure the weld head to the
table, with or without using the template found on
page 29.
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WH1 WELD HEAD USERS GUIDE
•
edges of the triple T-SLOT extrusion.
• Tighten by tightening the bolt on the underside of the table.
Set up Weld Head Trigger Hub
Connect Foot Pedal to Weld Head Trigger Hub
Connect the Foot Pedal cable to the 3-pin connector port on the left side of the Weld Head Trigger Hub, as
shown in Figure 4.1.
Connect MAC Valve Control Cable to Weld Head Trigger Hub
Connect the MAC Valve Control Cable to the 4-pin connector port on the right side of the Weld Head Trigger
Hub, as shown in Figure 4.1.
Connect Weld Head Trigger Hub Power
Plug the Weld Head Trigger Hub power cable into a reliable power source.
Safely Position Weld Head Trigger Hub
Place the Weld Head Trigger Hub in a spot that secures all cables from impeding operation or contacting ex-
tremely hot surfaces.
Foot Pedal Connection. Connect
the cable from the Foot Pedal to
the Weld Head Trigger Hub here.
Power Cable Connection. Using
the power cable that came with the
Weld Head Trigger Head, connect
the power here.
MAC Valve Control Cable. The
MAC Valve Control Cable coming
from the MAC Valve on the weld
head is connected to the Weld
Head Trigger Hub here.
Figure 4.1. Weld Head Trigger Hub
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Setup MAC Valve Air Hoses, Pressure (WH1125A, WH1250A, WH1187A HF)
Verify MAC Valve Air Hoses
• Verify that your air hoses are securely fastened.
• Verify that your air hoses are in the correct ports. See Figure 5.1. The air hose leading from the top port
Figure 5.1. Under the MAC Valve are
two air ports, which are connected to
valves located under the weld head.
The connections between the ports
and valves are completed on the
factor oor. Verify they are installed
correctly.
A
C
B
D
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Connect Compressed Air
•
•
•
• Set the air compressor pressure between 80 and 100 PSI.
Figure 6.1. Connect the included 1/4” air hose to the air
hose port (A) located on the left side of the MAC Valve.
Next, connect the provided silver tting (B) to the other
end of the air hose. Then connect the hose to a supply of
compressed air using a brass connector (C) (not included).
A
B
Figure 6.2. Pull down and turn the regular
adjustment knob (A) to increase or
decrease air pressure to the weld head.
A
C
Set the MAC Valve air pressure
•
• Turn the knob to the clockwise to increase the amount of air pres-
sure coming into the weld head from the air compressor or coun-
terclockwise to decrease the air pressure coming into the weld
head.
• Set the MAC Valve pressure between 60 and 80 PSI.
• Push the regulator adjustment knob back in to lock the air pressure
setting in place.
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Adjust Weld Head Up/Down Speed Using the Air Valves
The air valves shown in Figure 7.1 adjust the up and down speed of the weld head. The air valve on the left
controls the up speed; the air valve on the right controls the down speed. To adjust the up or down speed of the
To Adjust UP Speed
•
•
•
•
To Adjust DOWN Speed
•
•
•
head.
•
Pneumatic Setup Completed. Jump to Chapter 4 on page 11 to complete weld head setup.
Figure 7.1. The left air valve controls the UP
speed. The right valve controls the DOWN
speed. To adjust the up or down speed, rst
loosen the lock nut (C or D); adjust the speed;
then tighten the lock nut (C or D).
C
D
Right valve adjusts
the DOWN speed.
Left valve adjusts
the UP speed.
B
A
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WH1 WELD HEAD USERS GUIDE
Chapter 3: Manual Weld Head Setup
Note: The instructions in this chapter are only for the WH1125M and WH1250M manually actuated weld head
models. If you have a pneumatic model, skip to Chapter 4 on page 11 to complete setup.
Bolt the Weld Head to the Table
Your Sunstone manual weld head must be bolted to a table. Refer
to Figure 8.1 and follow these instructions to secure your weld
•
tape it to the work table’s top side. When instructed to drill a
hole, simply drill through the hole illustrated on the mounting
template.
•
drill bit.
•
•
and 4 will go through your table.
• Slide the provided 5/16-18 T-SLOT Bolts into the channels on
the underside of the weld head as seen in the image.
•
•
• Align the bolts and the rod with the holes that have been drilled
through the mounting template into the table.
• Lower the bolts and rod into the holes.
The manual foot pedal will connect into the bolts on the under
side of the table as described in the next section.
Figure 8.1. When used manually, the weld
head must be bolted to a work surface. Use the
mounting template found on page 29.
B
A
C
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Manual Foot Pedal Installation and Setup
Attaching the Manual Foot Pedal
The manual foot pedal system will connect to the bolts run-
ning from the weld head base through the table. To attach the
manual foot pedal to the weld head, follow these instructions
• Line up the manual foot pedal holes with the bolts going
• Be sure that the spring on the manual foot pedal base is
•
• Secure the manual foot pedal to the table by tightening
running through the table/manual foot pedal base.
• Next, connect the weld head rod to the manual foot
pedal.
•
•
A
B
C
D
E
F
G
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WH1 WELD HEAD USERS GUIDE
Setting Up the Manual Foot Pedal
With the foot pedal system attached to the work table, you can now attach the manual foot pedal leg to the arm
Continue to Chapter 4 to complete the setup of your Sunstone weld head.
A
B
C
Figure 10.1. With the foot pedal system
attached to the work table, attach the foot
pedal leg to the arm of the manual foot
pedal system.
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Chapter 4: Completing Weld Head Setup
Connect Weld Head Cables to the Welder
and bolts. Verify connections on both the welder and the weld head are securely fastened.
Note: The cable connected to the positive (+) terminal on the welder will produce slightly more heat to the
respected electrode on the weld head. If you are welding a coated part or a thick to thin piece, try setting up the
welding process so that the positive (+) electrode contacts the coated part or thicker piece.
Figure 11.1. Weld Head Connections
Connect this end to
the welder’s positive (+)
terminal.
Connect this end to the
weld head’s positive (+)
terminal, determined by
the operator.
Connect this end to the
welder’s negative (-)
terminal.
Connect this end to the weld
head’s negative (-) terminal,
determined by the operator.
Weld Head Cables BA
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WH1 WELD HEAD USERS GUIDE
Set up Weld Head Triggering
AUTOMATIC TRIGGERING USING ONE FOOT PEDAL
With automatic triggering, the weld head will automatically trigger when the force of the electrode on the work
piece reaches a certain pressure point.
lower the weld head by pressing and holding the weld head foot pedal for the pneumatic model, or the manual
foot pedal for manual models. Verify the electrodes are in the correct location on the work piece. The weld head
foot pedal for pneumatic models will be connected to the Weld Head Trigger Hub, as seen on page 4. See the
electrode setup sections on page 14 and 15 for further information on electrode placement.
Note: The trigger port will dier from welder to welder. Refer to your Sunstone welder users guide.
Figure 12.1. For automatic triggering, connect the Weld Head Actuating Cable (A) to the Trigger Port (B) on the back of
the welder. Refer to your Sunstone welder users guide for the proper port to use on the back of the welder.
A
B
C
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How to Use Automatic Triggering
• Press and hold the weld head foot pedal or manual foot pedal that lowers the weld head.
• As the weld head is lowering it will reach a sensor that will send a signal to the welder through the Weld
Head Actuating Trigger Cable to tell the welder to initiate the weld
• Once the weld has triggered, release the weld head foot pedal.
needed.
For increased precision, if you want to use the foot pedal to trigger the weld instead of using automatic trigger-
ing, you’ll want to use the Foot Pedal Trigger option, as described next.
FOOT PEDAL TRIGGERING
With foot pedal triggering the weld head will be triggered by using a second foot pedal that was shipped with
your Sunstone welder.
Note: Don’t confuse the foot pedal that came with your Sunstone welder with the weld head foot pedal, or
manual foot pedal, that lowers the weld head during operation.
•
•
Figure 13.1. For foot pedal triggering, connect the
foot pedal that came with your Sunstone Welder (B) to
the Ext. Trigger Port (A) on the back of the welder. A
B
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WH1 WELD HEAD USERS GUIDE
How to Use Foot Pedal Triggering
• Press and hold the weld head foot pedal that lowers the weld head.
• Verify electrodes are in the correct location on the work piece.
• Now press the trigger foot pedal connected to the Sunstone welder.
• Once the weld has triggered, release both foot pedals.
NOTE: The trigger foot pedal does not need to be held down, a single press will suce to trigger a weld.
Foot pedal triggering provides the operator with more control by deciding when to trigger the weld.
Standard Electrode Setup and Adjustment
Note: For the WH1187 HF model, jump to the next section, “High Force Electrode Setup and Adjustment.”
Note: Carefully follow the steps below in the same order every time you adjust your electrodes.
Insert electrodes into the electrode holders
•
•
•
Figure 14.1. To insert the electrodes, rst loosen
the bolts on the side of the electrode holders (A),
then insert the electrodes making sure they are in
vertical alignment (B). Then tighten the bolts on the
side of the electrode holders (A).
AB
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High Force Electrode Setup and Adjustment
Note: Carefully follow the steps below in the same order every time you adjust your electrodes.
Insert electrodes into the electrode holders
•
•
•
Adjust Electrode Gap
Move the weld head up or down as described in the next section, Weld Head Height Adjustment. Sunstone rec-
when the work piece is placed on top of the lower electrode. See Figure 16.1.
B
Figure 15.1. To insert the electrodes on a high
force weld head, rst loosen the bolts on the
side of the electrode holders (A), then insert
the electrodes making sure they are in vertical
alignment (B). Then tighten the bolts on the side of
the electrode holders (A).
A
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WH1 WELD HEAD USERS GUIDE
Weld Head Height Adjustment
• Place one hand under the weld head body to support
the weight as the weld head height adjustment knobs
are being loosened.
• Use your other hand to loosen the Weld Head Height
• Now move the weld head up or down.
• Tighten the Weld Head Height Adjustment Knobs once
the desired height is reached.
• We recommend that the weld head be set to a height
work piece.
Figure 16.1. The top electrode
(A) should be positioned 1/8”
above the work piece when the
work piece is placed on the top
of the lower electrode. Make sure
you frequently shape and clean
electrodes prior to use and after
tip wear.
1/8”
Figure 16.2. To adjust the height of the weld head, place
one hand under the weld head for support. With the other
hand, loosen the Weld Head Height Adjustment Knobs
(A). Position as desired, and then tighten the knobs.
A
A
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4
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