SUNSTONE Zapp Plus User manual

Users Guide
Version 20231107 • Part #1620
Zapp Plus™

ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 11/2023 20231107 First Edition
LIMITATION OF LIABILITY
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING 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 WHATSOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGI-
NEERING LLC PRODUCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGINEER-
ING 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
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HAS NO LIABILITY FOR ANY DAMAGE OR DESTRUCTION TO ANY PROPERTY. NOTWITHSTANDING ANY DAMAGES THAT YOU MIGHT
INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMITATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT
OR GENERAL DAMAGES IN CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE), THE ENTIRE AGGREGATE LIABILITY OF
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PAID BY YOU FOR THE SUNSTONE ENGINEERING LLC PRODUCT GIVING RISE TO LIABILITY. SOME STATES AND/OR JURISDICTIONS
DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL 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.

Contents
Welder Setup & Assembly ....................................................................................................... 1
Electrode Setup .................................................................................................................. 2
How to Use the Dial.............................................................................................................. 3
How to Make a Weld ............................................................................................................ 4
Recommended Weld Settings ............................................................................................... 6
Electrode Care & Shield Gas Setup...................................................................................... 7
Microscope Tips .................................................................................................................10
Appendix A ..................................................................................................................................11
How to Connect the Basic Cables With Auto Darkening Lens..........................11
How to Place the Welding Stylus .................................................................................12
Appendix B ..................................................................................................................................13
Microscope Arm Mounting Options ...........................................................................13
How to Adjust Microscope Focus ................................................................................15
How to Place the Welding Stylus .................................................................................16
 .............................................................................................................15

Permanent Jewelry Training Video
Watch this video for permanent jewelry training, setup
recommendations, time-saving tips and tricks, and more!
Pulse Arc Welding Workbook and Safety Guide
Download this document to access advanced welding
techniques and safety information.

Questions? Call or Text [phone] • 1

The Zapp Plus does not require the use of any lens or microscope. Always wear proper eye protection when you

• 
• Plug the male end of the power cable into the AC Power port (C) on the back of the power supply. Then
connect the female end into an AC power supply. The Zapp Plus Plus has an internal switching power
supply that can accept both 120 and 240VAC.
• 
connected, but should not come out if pulled on.
• Connect the alligator clip to the grounding port (D) on the front panel.
• Connect the stylus to the back of the welder (B).
Electrode Setup
The Zapp Plus comes standard with a 1.0mm electrode collet and three (3) 1.0mm electrodes. The 1.0mm elec-

0.5mm electrodes.
Figure 1.1. The back panel of the Zapp Plus. Argon Gas
Port (A). Stylus Port (B). Power Port (C).
Figure 1.2. The back panel of the Zapp Plus. Grounding
Port (D). Shutter Port (E).
D
E
What is in the Box
(1) Zapp Plus Welder/Power Supply and Stylus Hand Piece
(1) Zapp Plus Welder Power Cord (2 pieces)
(1) Alligator Clip
(1) Precision Grounding Clip
(1) Shielding Gas Hose
(1) Electrode Vial (three 1.0 mm Electrodes)
(1) Metal sample card
(1) Pair of shaded welding glasses
How to Connect the Basic Cables
Welder Setup & Assembly
B
A
C

2• Questions? Call or Text [phone]
Zapp™User Manual
Figure 2.1. To install the electrode, rst remove the Stylus
Shaft (A) from the Stylus Hull (E) by pulling them apart.
Figure 2.2. Use the guide on the side of the Stylus Hull (E) for
proper Electrode (D) positioning.
Install the Tungsten Electrode Onto the
Welding Stylus
Refer to the Stylus Components Chart (Figure 2.4) to install
the tungsten electrode (D).
• Remove the Stylus Hull (E) by pulling it away from
the Stylus Shaft (A). See Figure 2.1.
• 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 elec-
trode collet installed.
• Insert a 1.0mm electrode (D) into the Collet (B).
Helpful Tip: There is a machined groove 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 (C), then make sure the Electrode (D)
extends as indicated. See Figure 2.2.
• 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 Shaft once the Stylus
Hull (E) is placed back on the Stylus Shaft.
• Lock the Electrode (D) into place by hand tightening
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. The Electrode (D)
should protrude from the Stylus Hull (E) by 1/8 –
1/4 inch (3.175 – 6.35mm) after the Stylus Hull is
snapped back into place. See Figure 2.3.
Figure 2.3. Electrodes should protrude past the stylus
hull 1/8 to 1/4 inch (3.175 to 6.35mm).
Stylus Shaft A Collet B Collet Cap C Electrode D Stylus Hull E
Stylus Components
Figure 2.4.

Questions? Call or Text [phone] • 3
The Zapp Plus dial is very user friendly. Users have access to every welding parameter with one easy-to-use
dial.
Weld Energy Level
The Zapp Plus has weld energy range of 1 to 30 Joules (or Ws), which is selected in one joule increments. The
larger the number the more energy released through the electrode and, generally speaking, the larger the weld
spot.

When the Zapp Plus is initially powered on it is ready to weld. A small green light in the upper left corner, near
the knob, will illuminate when the Zapp Plus is ready to weld. 
The Dial
As you twist the dial to the right, the Weld Energy Level will increase 1 Joule. 3 = 3 Joule, 4 = 4 Joules, etc.
Pointing the arrow on the dial directly at the number will give the most accurate power reading.
Light Blink
When the small LED light blinks, the Zapp Plus is changing energy. As the knob is turned up or down this blink
indicates a change in weld setting.

welding plate. After careful setup and familiarization of how the welder operates, follow these instructions using
the welding plate.
Figure 3.1. The dial and it’s settings.
How To Use the Dial

4• Questions? Call or Text [phone]
Zapp™User Manual
• Turn the welder on. With the welder on, energy
will only be released when the electrode
touches the welding plate AND the alligator
clip is attached to the welding plate (or any
workpiece). Don’t worry about the alligator clip
yet.
• Make sure your eyes are protected by properly
using the darkening lens or microscope. Never
operate the welder without eye protection.
• If you are using an Auto Darkening
Lens (ADL) with the Zapp Plus, refer to
Appendix A before proceeding.
• If you are using a swing arm micro-
scope or the PJ Scope, refer to
Appendix B before proceeding.
• If you don’t have an Auto Darkening
Lens (ADL), microscope, or PJ Scope,
ensure that you are using #5 shaded
welding glasses.
• Attach the alligator clip to the Stainless Steel
Weld Plate as shown in Figure 4.2.
• Rest your arms on the table or workbench,
holding the metal plate with both hands.
• Make sure you have a clear view of the metal
plate.
• The Stainless Steel Weld Plate is organized into
rows. For this exercise, lightly touch the welding

minimum column. When the electrode makes
contact with the welding plate, the welder will
release energy and a weld will occur.
Note: Sloped, Sustained, and Negative Rows are not
Figure 4.1 Set the Weld Energy Level to 3 J energy.
Figure 4.2 Attach the alligator clip to the welding plate. With
proper eye protection, hold the welding plate with both hands
and lightly touch the electrode to the welding plate. When the
electrode contacts the welding plate, the welder will release
energy and create a weld.
How To Make a Weld

Questions? Call or Text [phone] • 5
applicable to the Zapp Plus, so ignore the labels and focus on the row labeled “None”. Create lower-powered
practice welds on the left and higher powered welds as you move right (maximizing at 30J).
Tip: When the electrode touches the workpiece, don’t back away from the electrode until after the weld is
completed. The Zapp Plus will automatically retract the electrode away from the workpiece by a few millimeters
when the weld occurs. This retraction assists in forming a more desirable weld spot. If you move the workpiece
away from the electrode just before or during the weld, the weld will not occur.
• Adjust the Weld Energy Level from 1 to 2J using the dial. Then touch the electrode to the second
minimum column.
• Next, adjust the Weld Energy Level from 3 to 4J using the knob. Then touch the electrode to the second

larger and the weld will be deeper.
• Repeat the process of increasing the energy level and then touching the plate in the next box. And then
repeat again until you’ve placed a weld in every box. Eventually, you should reach the maximum amount
of power (30J).

Spin the potentiometer as far as it can counterclockwise. Push the knob onto the potentiometer with the mark-
ing indicator pointing at the left marking on the sticker.

6• Questions? Call or Text [phone]
Zapp™User Manual
Weld Settings for Chain
Below are energy settings for Sunstone’s chains.