SUNSTONE Linear DC Manuel utilisateur

Sunstone Welders

Linear DC User Manual

Table of Contents

Chapter 1: Introduction

Quick Look

Chapter 2: Getting Started

Set-up Linear DC

Connecting Welding Attachments

Precautions

Chapter 3: Interface

Operational Controls

Settings Button

Save Button

Load Button

Video Tab

Schedules Tab

Operational States Button - (Weld

On/Weld Oﬀ Button)

Chapter 4: Start Welding

Example Project Setup

Perform a Weld

Chapter 5: Automated Welding

Overview

Chapter 6: Resistance Welding Basics

Overview

Chapter 7: Technical Assistanc

Chapter 8: Data Speciﬁcations

Chapter 9: Safety

Chapter 1: Introduction:

ank you for choosing Sunstone Welders and congratulations on your purchase!

You are now the proud owner of a Sunstone Linear DC Welder. is manual was designed to

have you welding safely within minutes of unpacking your new welder. Please read and follow

all safety precautions before proceeding with the welding process.

At Sunstone Engineering we are committed to producing quality products and ensuring com-

plete owner satisfaction. If you require assistance after reading this manual please contact us

with the information provided below.

Sunstone Engineering R&D Corp.

1693 American Way Suite #5

Payson, UT 84651

Email: sales@SunstoneWelders.com

Voice: 801-658-0015

Fax: 866-701-1209

NOTE: e information contained in this manual is subject to change as improvements are

made to our products. Visit www.SunstoneWelders.com for the latest version of this docu-

ment.

Sunstone Welders

Linear DC User Manual

Quick Look

EMERGENCY STOP

Press to shut oﬀ system.

AC POWER

Attach AC power here.

COOLING FANS

Keeps system cool. Do

not block.

WELDER INFO

Welder information is

found here.

 + TERMINALS

Connect weld head or

welding attachments cables

here.

FUSE

20A Fuse.

DIN CONNECTION PORTS

Connect welding

attachment DIN

Connections here.

TOUCH SCREEN INTERFACE

Set all weld parameters here.

POWER BUTTON

Press to power up.

USB PORT

Upload software

updates.

Chapter 2: Getting Started

Set-up Linear DC

WHAT IS IN THE BOX

Carefully open the welder package. Remove and place the contents on a clear and clean

workbench.

Inside the box:

• Linear DC Welding Unit

• Power Cable

• Safety Manual

• Quick Start Guide

SPACE REQUIREMENTS

e Linear DC has a 15.2”x11.4” footprint. Be sure to provide enough space to connect a weld head

or welding hand attachment and roughly a 2-4” space on the backside of the unit to connect

power and weld attachment cables.

SETUP BACK PANEL CONNECTIONS

Positive (+) Terminal

Connect one of the cables from weld head or welding hand attachment to the positive terminal

with the included ¼”-20 screw.

Caution: Terminal and/or cable can become HOT during welding.

Negative (-) Terminal

Connect the other cable from weld head or welding hand attachment to the negative terminal with

the included ¼”-20 screw.

Caution: Terminal and/or cable can become HOT during welding.

AC Inlet

is unit can accept a 50-60Hz AC signal from 90VAC to 250VAC. Use the supplied cable to

connect to the power inlet. Plug the female end of the provided power cable into the back of the

unit. en plug the male end of the power cable into AC power.

Fuse

20A fuse included.

Replacement fuse: Schurter Inc. Manufacturer #0034.3130.

Fans

Airﬂow will come out of the unit from these locations and could be warm. e fans will not normally

be spinning, but will turn on if the unit is hot. ey may turn on even if welder is not being used, but

is turned on. *Do not block fans.

USB Port

USB ﬂash drive can be inserted for updating the unit software *Use a 4GB stick of memory or less.

*See Linear DC product page at www.sunstonewelders.com for update or contact a Sunstone

representative.

Connecting Welding Attachments

CONNECT WELDING ATTACHMENTS

Sunstone Weld Head - automatic weld triggering

1. Connect weld head cables to negative and positive terminals on the back of the Linear DC.

2. Connect weld head actuation cable to “Weld Head Actuation” DIN connection port on the

back of the welder.

3. See weld head manual for instructions on weld head foot pedal setup. *Weld head foot

pedal will control weld head up and down movement and weld triggering.

Sunstone Weld Head - dual foot pedal triggering

1. Connect weld head cables to negative and positive terminals on the back of the Linear DC.

2. Connect included Linear DC foot pedal into “Weld Discharge Trigger” DIN connection port

on the back of the welder. *With this option users will not connect the weld head actuation

cable to any of the DIN ports.

3. See weld head manual for instructions on weld head foot pedal setup. *Weld head foot

pedal will control weld head up and down movement and Linear DC foot pedal will control

weld triggering.

Sunstone Micro Weld Head - dual foot pedal triggering

1. Connect weld head cables to negative and positive terminals on the back of the Linear DC.

2. Connect included Linear DC foot pedal into “Weld Discharge Trigger” DIN connection port

on the back of the welder. *With this option users will not connect the weld head actuation

cable to any of the DIN ports.

3. See micro weld head manual for instructions on micro weld head foot pedal setup. *Micro

weld head foot pedal will control weld head up and down movement and Linear DC foot

pedal will control weld triggering.

Sunstone Hand Attachment

1. Connect hand attachment cables to negative and positive terminals on the back of the

Linear DC.

2. Connect hand attachment actuation cable to “Weld Head Actuation” DIN connection port on

the back of the welder.

Precautions

HANDLING PARTS BEING WELDED

Caution: Pieces that have been welded can be HOT. Always use caution when handling welded

pieces.

ELECTRODE CARE

For best results sand (shape) and clean the electrodes prior to performing welds and after

electrode tip wear; smoother electrodes will provide better results.

EMERGENCY STOP SWITCH

e Linear DC is able to be equipped with an Emergency Stop Switch, the Emergency Stop Switch

will attach to the back of the unit into the “Emergency Stop Switch” port.

e Linear DC comes equipped with an “Emergency Stop Switch Key”. is key connects to the

Emergency Stop Switch port on the back on the unit to bypass the need to have an Emergency

Stop Switch. To purchase an Emergency Stop Switch, call in to Sunstone.

When using the Emergency Stop Switch, please be aware of the following:

Ensure Emergency Stop Switch is working

WARNING: THIS MUST BE DONE PRIOR TO OPERATING WELDER

In order to verify that the emergency stop switch is working properly, plug in the included

emergency stop push button into the 3DIN connector on the back panel. Plug the welder into AC

power. Turn the unit on by pressing the power LED button on front panel. Once the unit has come

to the interface users will see “WELD OFF” on a tab at the top left of the screen. Press that button

to place the unit into a welding state. e button should now indicate “WELD ON”. At this point

engage the emergency stop button. After this the welder should automatically go into a “WELD

OFF” state. e button on the top left of the screen will change from “WELD ON” to “WELD OFF”. If

this happens, then the emergency stop is working properly and users can begin welding with the

unit. If this doesn’t happen please contact customer support.

DRAINING STORED ENERGY

(Opening Unit, 3 hours to 0.1V)

WARNING: ONLY QUALIFIED TECHNICAL PERSONNEL SHOULD OPEN UNIT.

A large amount of stored energy in this unit can cause great harm and even potential death if not

handled correctly. If unit needs to be opened for any reason, the unit needs to be turned oﬀ and

unplugged for eight hours, to give enough time for the stored energy to be drained.

Chapter 3: Interface

Operational Controls

NUMERIC KEYPAD AND SLIDER BAR

e Linear DC touch screen display features a numeric keypad with a build in slider bar for easy

setting of weld parameters. Users simply touch the weld setting boxes on the display and then

either type in their desired parameter in the numeric keypad or slide their ﬁnger on the slider bar

to move the weld parameter value up or down.

e slider bar was designed to react to the speed of the users ﬁnger. If the user moves their ﬁnger

quickly across the slider bar, the numeric value will increase or decrease rapidly. Conversely, if the

user moves their ﬁnger along the slider bar slowly, the numeric value will increase or decrease in

ﬁne increments.

Settings Button

UPDATE WELDER

As software updates become available, user can download them from the resource page on the

Sunstone website. Once the update is downloaded and place in th root directory of the USB thumb

drive follow the steps below.

1. Insert the USB stick into the USB slot on the side of the welder.

2. Touch the update welder button.

ENTER TEST SUITE

is is used for troubleshooting for authorized representatives.

RESET WELD VALUES

is will reset all welder settings back to their factory default settings. is will not aﬀect saved

settings.

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