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
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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-
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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.

Questions? Call or Text [phone] • 7
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 elec-
trode). Sunstone recommends cleaning or changing
the electrode when it sticks to the workpiece. A clean,
sharp electrode will give the best results when welding
permanent jewelry.
WHEN TO SHARPEN THE ELECTRODE
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 recom-
mended 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


• Power on the rotary tool then hold it with the
opposite hand.
• Place the electrode tip on the diamond disc so
the grit of the disk is moving parallel with the
electrode shaft and moving towards the tip.
Figure 7.2. A sharp electrode tip improves arc
initiation and results in a better overall weld.
R
O
T
A
T
I
O
N
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
Figure 7.1.
Stylus Hull
Electrode Care & Shield Gas Set Up
15°
15°
Figure 7.3. Use a rotary tool to sharpen the
electrode.
Trade your old rotary tool for the Pilot, the electrode
sharpener that cleans and sharpens your electrode in
seconds! Visit www.sunstonewelders.com or call or text
[phone] to learn more.

8• Questions? Call or Text [phone]
Zapp™User Manual
• See Figure 7.3. Sharpening the electrode in a

quality of the weld.
• Set the electrode on the diamond disk at a
15-degree angle and begin to spin the elec-
Tip:
A helpful way to get a sharp electrode is to
push down on the electrode with your index


• 
the rotary tool and insert the electrode back
into the stylus as explained above.
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 oc-

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

PRESSURIZED GAS SAFETY
There are several important rules that should be fol-
lowed when using a compressed shielding gas such as
argon:

Need argon gas? Sunstone will
ship a right-sized tank to your
doorstep. No more adventurous
trips to the gas store! Call
Sunstone for immediate
delivery: [phone] or
scan the QR code above.
For Pop-Ups and other
remot locations, try the new
Argon Mini! Call Sunstone for
immediate delivery: +1 801-
658-0015 or scan the QR code
above.
Purchase premium argon gas from Sunstone.
Call [phone]
visit www.sunstonewelders.com/gas.
• Delivered directly to your door!
• 
• Premium argon gas for your Zapp Plus!



Questions? Call or Text [phone] • 9
Scan this QR Code to see a
tutorial of how to set up your
Argon Tank.
location (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


doors and windows in the room.
SHIELDING GAS TANK AND REGULATOR SETUP
The following instructions are specic for a Sunstone argon regulator. Other regulators may operate dierently.
Consult instructions that may have come with other regulators.
• Ensure that your shielding gas tank is securely fastened to a stationary point near the
welding area.
• Turn the argon regulator dial (not to be confused with the main argon tank valve) COUN-
TERCLOCKWISE (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

• 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 valve is opened. The primary dial measures and shows pressure inside
the tank; the secondary dial, 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 secondary dial on the left shows gas
pressure between 7-10 liters per second.

Zapp Plus User Manual
How to Connect the Basic Cables
With Auto Darkening Lens
The Zapp Plus cable connections vary. If you pur-
chased the darkening lens or the microscope, ca-
bling needs change slightly. The darkening lens or
microscope will automatically darken when the weld
takes place, which allows the operator to have a view

during the welding process. Reference Figure 10.1 and
follow these instructions for easy setup:
• Remove the welder and Darkening Lens System
-
space.
• Plug the female end of the power cable into
the AC Power port (C) on the back of the power
supply. Then connect the male end into an AC
power supply. The Zapp Plus has an internal
switching power supply that can accept both
120 and 240VAC.
• 
(A) on the back of the welder. It may wiggle
when connected, but should not come out if
pulled on.
• Insert the RJ45 Darkening Lens cable (from the
back of the Darkening Lens System or “ADL”)
into the Shutter port (E) on the front of the
welder. If using a microscope, see page 5 for
instructions.
• Note: Basic ADL is hard wired into the
auto-darkening lens. Upgraded ADL requires 2
connections: 1) Shutter Port on the welder, and
2) RJ45 Port on back of ADL.
Figure 10.1. The back panel of the Zapp Plus. Argon
Gas Port (A). Stylus Port (B). Power Port (C).
Figure 10.3. Upgraded Auto Darkening Lens (Left) and
Regular Auto Darkening Lens (Right).
Appendix A
Figure 10.2. The back panel of the Zapp Plus.
Grounding Port (D). Shutter Port (E).
DE
10 • Questions? Call or Text [phone]
B
A
C

Questions? Call or Text [phone] • 11
Figure 11.1. Stylus mounting for the Auto
Darkenng Lens System.
• Connect the alligator clip to the grounding port (D) on
the front panel.
• Connect the stylus to the back of the welder (B).
• The basic Auto Darkening Lens darkness can be
adjusted by turning the shade dial above the darkening
lens screen. Turn clockwise for a lighter shade and
counter-clockwise for darker shade.
How to Place the Welding Stylus
• Insert the Welding Stylus into the holder located
behind the screen. See Figure 11.1 (Right).
• Adjust the stylus holder to approximately a 45-degree
angle as shown in Figure 11.1 (the stylus should be
angled down).
• Connect the Stylus Cord to the back of the Zapp Plus
to the stylus port as seen in Figure 10.1.
Mounting Zapp Plus Stylus in Upgraded
Darkening Lens:
• Remove gray spacer (See Figure 11.2) from stylus
holder. This is lightly glued into place to not come loose
during operation with the Orion Stylus. The spacer is
not required when using the Zapp Plus stylus. One end

-

stylus holder until the spacer slides out the end of the
holder.
• Connect Included shutter cable into the RJ45 port I
both the welder and the ADL.
• Place Zapp Plus Stylus in stylus holder and secure
using thumb screw.
• Adjust stylus to desire position inside of viewing area
of ADL.

12 • Questions? Call or Text [phone]
Zapp™User Manual
Figure 12.1. Attach Angled
Bracket (C) to Microscope
Arm Assembly (A).
Figure 12.2. Attach Clamp
Mechanism (D) to Angled
Bracket (C).
Figure 12.3.
Figure 12.4. Place the cable
guide cover onto the angled
bracket.
Microscope Arm Mounting Options
If you purchased the Zapp Plus with an arm-mounted
microscope, carefully follow these instructions.
Mounting Option 1 - Clamp to Table
This option is best for tables with accessible edges and
for mounting without drilling holes in the table.
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)
• 
• As shown in Figure 12.1, attach the Angled
Bracket (C) to the bottom of the Microscope
Arm Assembly using three (3) of the included

Allen wrench (L).
• Attach the Clamp Mechanism (D) to the Angled

head hex screws. See Figure 12.2. 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 (D)

your tabletop.
• Lift the Microscope Arm Assembly (A) up, slide
the arm onto the table as shown in Figure 12.3.
• Lock the arm into place by turning the knob
on the Clamp Mechanism (D) until the clamp is

Appendix B

Questions? Call or Text [phone] • 13
• A plastic cable guide cover (E) can be clipped
on over the angled bracket if desired. See
Figure 12.4.
Mounting Option 2 - Bolt through Table
Mounting Option 2 is best for tables without accessible
edges. 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 13.1, using a 4mm (5/32”)

(G) holding the Flat Mounting Plate (H) to the
arm.
• Run the included 8mm (5/16”) Long Carriage
Bolt (F) through the included Flat Mounting
Plate (H).
• Attach Flat Mounting Plate (H) to the bottom of

• Drill a 3/8” (9.5mm) hole through the tabletop.
• Lower the arm so the Long Carriage Bolt (F)
goes through the hole in the tabletop. See
Figure 13.2.
• Slide the Flat Pressure Plate (I) onto the bolt.
Turn the Adjustment knob (J) clockwise to
tighten the plate to the underside of the table.
See Figure 13.3.
Mounting Option 3 - Screw to Table (vertical
surface)
Required hardware from Box 2:
(1) Angled Mount Bracket (C)
(3) Flat Head Screws (G)
(2) Wood Screws (not included)
Figure 13.4. Use wood
screws (not included) to
attach the Angled Mount
Bracket (C) to the table.
Figure 13.1. Remove
the plate from the arm,
run the carriage bolt (F)
through the mounting
plate (H), then re-attach
the mounting plate to
the arm.
Figure 13.2. Lower the
arm so the bolt goes
through the hole in the
table.
Figure 13.3. Turn the
Adjustment knob (J)
clockwise to tighten the
plate to the table.

14 • Questions? Call or Text [phone]
Zapp™User Manual
Figure 14.1. Adjust the tension of the Microscope Arm
Assembly for more loose or more tight movement.
Figure 14.3. After installing the rubber eyepiece covers, use
the RJ45 Shutter Cable to connect the welder to the back
and bottom of the microscope head. The other end of the
cable connects to the port in the front of the Zapp Plus. (See
Figure 2.1)
• Attach the Angled Bracket (C) to the bottom of
the Microscope Arm Assembly (A) using three

shown in Figure 12.1.
• Lift and position the arm assembly onto the
table in the desired location.
• Run wood screws through the Mounting
Bracket (C) and into a vertical surface of the
table, as shown in Figure 13.4.
ARM TENSION ADJUSTMENT
The spring tension is factory pre-set, but should chang-
es be desired, the tension can be adjusted by turning a
hex screw located on the arm joint, as shown in Figure
14.1. Use the included 6mm Allen wrench to make
adjustments.
• Turn the hex screw counterclockwise (in the
direction 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.
For cable management, tubes and cables can be routed
through a removable guide as shown in Figure 14.2.
PJ Scope Set Up
MICROSCOPE SETUP
• Refer to the setup instructions that shipped
with the PJ Scope.
• Plug the included Shutter Cable into the RJ45
port on the microscope (the bottom of the
microscope head). See Figure 14.3.
• Plug the other end of the Shutter Cable into the
Shutter port on the front of the welder.
Note: Connecting non-Sunstone products to the RJ45
port on the Zapp Plus may damage the welder and/or
the other devices.
Figure 14.2. Tubing and other cables can be routed up
and through the removable cable guide portion of the
arm.
Figure 14.4. PJ Scope.

Questions? Call or Text [phone] • 15
Figure 15.1. Turn this knob to adjust microscope
focus. You’ll nd one knob on each side of the
microscope arm.
How to Adjust 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 15.1.
• 
to help judge the correct focus location. Focus
the microscope until the texture on the skin of

How to Place the Welding Stylus
• If using a microscope with the Zapp Plus,
insert the Welding Stylus into the holder at the
bottom of the Microscope Arm Assembly as
shown in Figure 15.2.
• The tubing can be routed up and through the
removable cable guide portion of the Micro-
scope Arm Assembly if desired.
• For now, position the Welding Stylus such that
only the smaller diameter portion protrudes
from the holder, as shown in Figure 15.2. Then,
tighten the thumb screw on the bottom of the
stylus holder to hold it in place.
• Adjust the stylus holder to approximately a
45-degree angle as shown in Figure 15.2 (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 15.3.
Figure 15.2. Stylus mounting for microscope.
Figure 15.3. Only a small portion of the
electrode should extrude from the holder.

16 • Questions? Call or Text [phone]
Microscope Tips
The Zapp Plus microscope has been designed to pro-
vide 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 paused. While the welder is in paused, it
will not make a weld when the workpiece touches the
electrode.
Rest your hands on the table and position the work-
piece 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.

electrode. See Figure 16.1.
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 touch the workpiece to the electrode.
Hold still and wait for the weld to occur.
Note: Be mindful of your energy setting: Too much power may damage the workpiece. Start low (3-4J) and work
up to higher energies (8-10).
Microscope LCD Filter Shutter System
The Microscope LCD Filter Shutter System provides an unobstructed working view before welding and com-
-
scope LCD Filter Shutter System has been activated before allowing the weld to take place. Should the shutter
not activate, the microscope lens is equipped with >UV 16 and >IR 16 for maximum eye protection.
Warning: Avoid direct view of the welding area without protective lenses.
Mounting Zapp Plus Stylus in Microscope & PJ Scope:
• Install the rubber eyepiece covers onto the microscope lenses.
• Plug the included Shutter Cable into the RJ45 port on the microscope (the bottom of the microscope
head). See Figure 17.1.
Figure 16.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., Then
look through the microscope.
Zapp Plus User Manual