Sunstone Weld Head User Manual WH2
Contents
1. 25 Page 5 With the foot pedal 1 that lowers the electrodes STILL DEPRESSED use PEDAL 2 to ACTUATE THE WELD by now pressing the foot pedal that is plugged into the back of the welder Fuse 5A Pedal 2 Weld Actuation foot pedal Voltage Booster 110 240 VAC 16VDC MAX Select On Side Process explanation The first foot pedal is pressed to lower the weld head amp is held down so that the electrodes continue to apply pressure to the work piece to be welded The second foot pedal is pressed after the first pedal is depressed amp held down amp thus sends a signal to ACTUATE THE WELD The advantages with this dual pedal method are 1 The user has more control to ensure that the setup is correct prior to actuating the weld 2 The user also has the ability to decide exactly when the weld is actuated 3 For troubleshooting to verify that the signal to actuate the weld is sent properly 26 Page Thank you for choosing Sunstone Engineering Please feel free to contact us with any questions you may have at 801 658 0015 Sunstone Weld Head User Manual Parallel WH2 Models Copyright Sunstone Engineering 2008 27 Page2. 5 Page 2 Connect the Weld Head to the Foot Pedal Note This section walks through how to set up the weld head to use a single foot pedal There is also a Dual Pedal setup option See page 24 of the manual A Pneumatic Weld Head Versions Connect the Weld Head to AC POWER 110 V AC standard 220 V AC upgrade or Transformer available upon request I Connect the Weld Head Solenoid Valve 110 Volt line to the Foot Switch and then to the Wall Outlet as shown Note a 220 Volt solenoid version is also available Figure 2 110 Volt Weld Head Plug connected to the Foot Pedal amp then to the Wall Outlet from Weld Head to Wall Outlet 6 Page B Manual Foot Pedal Versions Locate amp drill mounting amp chain holes then connect the Weld Head to the Manual Foot Pedal I Locate two holes as shown referenced from the edge of the vertical TSLOT shaft 3 width Drill the 315 hole BEHIND the weld head 1 25 from the back edge of the vertical TSLOT extrusion Drill a through hole for the chain 5 8 recommended approximately 1 625 from the FRONT edge of the vertical TSLOT extrusion We recommend that you mark the hole locations and remove the Weld Head for drilling Figure 4 Drill locations for the weld head chain amp Foot Pedal Lever Holder Note There is also a mounting template available 7 Page Il Mount the Manual Foot Pedal to the underside of the table then to the weld head amp then
3. Typical setting Example 1 4 electrode distance from the work piece should dictate about a 1 2 gap on the Stop Nut Quick Start Step 10 5 Verify that both switches are actuated when the weld head foot pedal is depressed Quick Start Step 11 6 Adjust the Weld Head Pressure Knobs to the desired EQUAL pressure for most applications Quick Start Step 12 B Turn the Welder ON 1 Turn the Power Switch ON 2 Turn the Pulse Switch ON 3 Adjust to the desired Pulse Level 4 Adjust to the desired Power Level For battery packs Typical Settings are Pulse 1 2 0 Pulse 2 5 0 Power 130 250 Watt Seconds depending on application Air Pressure 40PSI See Welder Operation Manuals for more information on how to determine appropriate settings C Press the Foot Pedal amp make a weld 1 Press the Foot Pedal when the switches on the weld head are actuated a weld will be made Use the viewport to view the switches amp simultaneously adjust the Stop Nut as needed 2 Adjust the Welder amp Weld Head parameters as needed to ensure a proper weld 18 Page Weld Head Maintenance Bearing Maintenance Sunstone Weld Heads are equipped with 3 types of bearings proper care amp maintenance will be described in detail below 1 Anti rotation Slot amp Slider requires Teflon WHITE LITHIUM Grease NLGI 2 made by DU PONT Part No DGW614101 2 THOMSON adjustable super pillow block bearings SPB6ADJ requires Teflon SILIC
4. Adjust the flow control valves on the weld head air cylinder These valves will determine how quickly the weld head will go up and down The outside knob adjusts the flow the inside knob locks the setting in place 10 Page 4 Connect the Weld Head to the Welder A Attach the 1 AWG Weld Cable Bolt the angled side of the Weld Cables to the Electrode Holder Boots with the provided M6x1 bolts Il Bolt the non angled side of the Weld Cables to the Welder Terminal Hookups with the provided 1 4 20 nuts amp bolts Figure 13 Attach the Weld Cable A Ge B The weld head connection cable is located on the back of the weld head It is connected to a terminal block Connect this cable to the appropriate socket on the Sunstone Welder Sunstone Weld Heads are compatible with all of our capacitive discharge amp AC welders Figure 14 Attach the 3 pin weld head cable to the welder 11 Page 5 Set up your electrodes as suited for your application A Use 1 8 electrodes B Use 8 32x1 2 screws with a 9 64 Allen Wrench Adjust your electrode to the appropriate position amp height Il IMPORTANT Sand your electrode to remove burrs amp ensure precise level tips Figure 15 Position the electrodes 12 Page 6 Adjust the Weld Head to the appropriate height Note sunstone Weld Heads are equipped with a 1 internal stroke Typically set your electrodes within or less than of the weld piece The ne
5. set screw Do not adjust this set screw Contact Sunstone Engineering for factory bearing adjustment Electrode Care Always be sure to clean and sand your electrodes prior to performing welds and after electrode tip wear More information is provided at www sunstoneengineering com Please see the instructional videos 23 Page Optional Dual Pedal Actuation Instructions The weld head can also be actuated by bypassing the switches on the weld head using the 2 foot pedal method described below 1 Unplug the 3 pin cable Unplug 3 pin cable 2 Plug in the 3 pin foot pedal to the same location that the weld head 3 pin cable was unplugged The cable is the same as the 3 pin cable that you just disconnected from the weld head except that it is connected to a foot pedal instead of to the weld head a Fuse 5A Pedal 2 Weld Actuation foot pedal Voltage Booster 110 2 S 40 VAC 16VDC MAX i elect On Side 24 Page 3 Adjust the stop nut amp the pressure setting knobs to an appropriate stroke length amp pressure setting for your application 4 Press amp hold the foot pedal 1 that lowers the weld head electrodes With the pedal depressed you should see the electrodes lower onto the work piece to be welded PNEUMATIC FOOT PEDAL 1 Lowers the weld head MANUAL FOOT PEDAL 1 Lowers the weld head anual Versions is foot pedal lowers the weld head electrodes DP P IN 4 u AHF neal m
6. ONE Lubricant made by DuPont Part No DS0614101 3 Iglide J Housing Bearings WJUM 01 10 maintenance amp lubrication free 1 Anti rotation Slot amp Slider This slot provides anti rotation for the electrode holders Slot lube cycle not to exceed 1 year or 500 000 cycles whichever comes first but more frequent application may be required based on duty cycle usage environment and level of contamination EVERY 1 year or 500 000 cycles OR in dirty environments sooner as needed the slots need to be dry wiped clean amp re lubricated Re lubricate with Teflon WHITE LITHIUM Grease NLGI 2 made by DU PONT Part No DGW614101 www teflon com www PerformanceLubricant DUPONT com OR from MCMASTER CARR www mcmaster com part number 8708T13 Do not remove the precisely positioned anti rotation slider to clean out the slot It can easily be cleaned amp re lubricated without removing the slider as explained in the following steps Figure 24 Slot requiring lubrication 19 Page Steps to Re lubricate the anti rotation slots a Figure 25 Thoroughly wipe clean the old lubrication with a dry rag or paper towel Do not remove the precisely positioned anti rotation slider i N b Figure 26 Liberally Apply Teflon White Lithium Grease NLGI 2 to the upper portion of the slot Do not remove the precisely positioned anti rotation slider Mie c Figure 27 Liberally Apply Teflon White Lithium Grease NLGI 2 to the lower porti
7. Sunstone Weld Head User Manual WH2 Parallel Models ew Copyright Sunstone Engineering 2008 Sunstone Weld Head User Manual Weld Head 12 Quick Start StepS iccieiesseactesccsinesacesacscuasteauscseetedatangedusvetioanateuadesseacwecnishatasapaedveitececena Page 3 Opposed Weld Head Datasheet esesesesesesesrresrsserererersrsesrerertrssseurererssesrereerenresessssesesesserreeeseses Page 4 Weld Head Set Up and Operation 9 step guide 1 2 3 4 5 6 7 8 9 B lt the Weld Head to the table sissrersawuiesnoriisirniinii s Page 5 Connect the Weld Head to the Foot Pedal sssessesssesesssererrssssesrereresssreserresrsresesrerereeses Page 6 Connect the Air Pneumatic Versions essssssssssssssssseseressesssrereresssssseereresssesrrerereserereenns Page 10 Connect the Weld Head to the Welder eesssesesssssessesseserresssessererersssesrererersssrsereeesseeses Page 11 SOT 1 VOUT CISC OS ureri error EE E E N E E Page 12 Adjust the Weld Head Height eseessesesseseesseserressesurererersesesrerereeseseurerenesesrensseurerereeseseseee Page 13 Adjust the Stop Nut for stroke length and switch actuation es sssssssrsesrererssrrss Page 14 Adjust the Weld Head Electrode Pressure Knob c ccccccescsssssseceeseecesessessseeeeeenees Page 16 A Uee WE a e E E AEE E A A Page 18 Weld Head Maintenance 1 Proper Maintenance of the Bearings a dessessvaszcesserdsaccnstucxerandessdesdeatawevastoaanesadensucsiantdartss Page 19 2 F
8. eumatic Series Feature Unit of Measure Model Manual Pneumatic Actuation Manual Pedal Air Weld Force Standard Ibs 1 0 8 0 1 0 8 0 Weld Force Heavy Duty Ibs 3 0 21 0 3 0 21 0 Max Rating Watt Sec 600 600 Max Electrode Stroke Inches 1 1 Electrode Diameter Inches 1 8 or 1 4 1 8 or 1 4 Electrode Tip Min 06 06 Electrode Configuration Parallel Parallel Electrode Holder Type Offset Offset Electrode Min Max Gap Inches 05 1 5 05 1 5 Max Throat Size HxD Inches 8x5 8x5 Weld Cable Size Length AWG Inch 2 24 2 24 Foot Pedal Type Manual Chain AC 3 prong Air Solenoid Voltage VAC 110 or 220 110 or 220 Air Pressure for Max Force PSI 60 60 Air Cylinder Inside Diam Bore Inches 1 1 16 1 1 16 Cycle Rate Full Stroke Sec 1 1 Max Dimensions including Height x Depthx 21x10 5x5 5 19x 10 5x9 5 Width Inches Ibs 18 18 4 Page Weld Head Set Up amp Operation 1 Bolt the Weld Head to the table A Use the 5 16 18 x1 5 bolts and the 5 16 18 nuts provided Use a 1 4 allen wrench to tighten the bolts Ensure that the Bolts will go through both the Weld Head Base Plate and your table If not you may need to acquire longer bolts or drill amp tap the 5 16 18 threads into your table Reference Figure 1 Bottom Mounting Plate with the hole locations for bolting to the table 4 000 3 000 3689 Note There is also a mounting template available
9. ineering that have been rated amp modified for your weld head Light duty standard springs These come standard with the 1 8 lb range per EACH electrode They attach with one end on the nub and the other end that is curled in is oriented down Figure 23 Interchanging springs 9 Heavy duty springs Can be ordered separately amp will allow a 3 21 Ib range per electrode Both ends of the heavy duty springs are curled inward as such they attach by simply dropping either end of the spring into the shaft hole amp putting the knob on The chart below represents approximate pressure settings with these springs Heavy Duty Spring Force Settings Pressure Setting lbs ONE electrode 17 Page 9 Actuate the Weld A Ensure that all previous parameters are set without turning on the Welder yet Refer to the Weld Head 12 Quick Start Steps at the beginning of this manual After the Weld Head is set up follow these steps prior to performing a new weld 1 Pneumatic Versions Adjust the PSI Set air pressure 30 60 PSI standard Quick Start Step 5 2 Adjust the Electrode position to desired location See section 5 of this manual Quick Start Step 8 3 Adjust the Weld Head Height so the electrodes are close to the work piece generally within 1 16 to 1 4 Quick Start Step 9 4 Set the Stop Nut stroke length it needs to exceed the travel distance of the electrodes to the top of the work piece
10. lectrode Cire serre A NAT RAR Page 23 3 Optional Dual Foot Pedal Actuation ccccccscscccssssssccesessssessecesseesessescesseseesesssseeseees Page 24 2 Page Parallel Weld Head 12 Quick Start Steps Pneumatic Versions Steps 3 4 amp 5 5 Regulator 7 Adjust gauge to 30 60 PSI 10 Adjustable aq stop Nut wes Adjust for stroke Ly length amp switch pa actuation i ie 4 i ad A i f f UY N Anti Rotation A E Slot Lubricate 3 Air Inlet f preemia Attach to Air f ee EE o i every 500 000 Compressor I cycles 4 110VAC a Bea ee Cat ri in Power Cord ee des s j i every 2 milion cycles Plug in to 3 prong Foot Pedal amp then AS to the wall f _11 Switch Viewport pe View switch actuation as f set by height amp stop nut 12 Pressure Adjust Knobs 9 Height Adjust Adjust to desired electrode pressure Lever Setthe Weld Head Sis height close to the pari in Le a work plece 8 Electrodes IK x7 Ss Adjust position to SIS la 7 Switch Cable desired location gt UD i Cy Attach the 3 pin a connector to the back of the welder 1 Base Plate Bolt to the table 6 Weld Cable Hookup Attach to Welder Terminals ey 2 Manual Versions Note Follow Set up Steps in Order Drill Holes for chain amp Foot Pedal Bolt lever behind Weld Head Attach chain Series Parallel Weld Heads Datasheet 1 Manual Series 2 Pn
11. on of the slot lift up the anti rotation slider with your hands you may want to retract the spring loaded knobs past the zero mark Do not remove the precisely positioned anti rotation slider 20 Page d Figure 28 A newly re lubricated slot will look like this and will allow a smooth sliding motion 21 Page 2 Adjustable super pillow block bearings Bearing lube cycle not to exceed 1 year or 2 million cycles whichever comes first but more frequent application may be required based on duty cycle usage environment and level of contamination Re lubricate with Teflon SILICONE Lubricant made by DuPont Part No DS0614101 www PerformanceLubricant DUPONT com OR from MCMASTER CARR www mcmaster compart number 8708T13 You can also use LinearLube lubricant that utilizes suspended Teflon in a specially formulated compound provided by Danaher Motion Figure 28 Re lube the ball bearings Lubrication points at shaft entrance OR at Lube port hole 22 Page 3 Iglide Bearings These plastic bearings are maintenance free They do not require any lubrication For maximum efficiency and wear qualities keep the Weld Head in a clean environment Also do not provide any exterior forces or moments on the Weld Head In optimal conditions and use they are rated for a lifetime of 50 million cycles Figure 29 Iglide plastic bearings do not require lubrication Note Some newer models are equipped with an adjustment
12. oper switch actuation epeat adjustment as necessary Note Newer models are also equipped with an LED on the top of the Weld Head which acts as a actuation indicator 14 Page Figure 20 Weld Head Actuation Foot Pedal Depressed Electrodes are on the work peice the Stop Nut is adjusted to limit the stroke and the switch is just actuated LEAN J iq ia D Figure 21 Now that the Stop Nut stroke and switch actuation are set gently tighten the Stop Nut with the locking bolt this will ensure the position you have set This should be a light duty tightening as further adjustment for other work pieces will be desired 15 Page 8 Adjust the Weld Head Electrode Pressure A These Weld Heads come standard with springs that set the pressure from 3 0 Ibs to 8 0 Ibs on each electrode at the switch actuation point Other springs are available to increase the pressure up to 21 0 lbs per electrode Sunstone Engineering is also developing Weld Head versions with pressure settings below the 1 0 Ib range and above the 21 0 Ib range This chart indicates approximate pressure settings with the standard spring at the switch actuation point Light Duty Standard Spring Force Settings Ibs ONE electrode 16 Page B Springs can be easily interchanged by simply unscrewing the knob assembly pushing on the new spring and re inserting the knob assembly Note make sure to acquire springs from Sunstone Eng
13. to the floor Figure 5 Manual Foot Pedal Mounted to table Use the pre drilled hole behind the weld head and the 5 16 1 5 provided screw to mount the Foot Pedal Lever Holder Figure 6 Attach the Weld Head chain Attach the chain from the Weld Head to the lever arm NOTE extra chain is provided so you may need to determine the appropriate chain link to attach based on the height you desire for your Weld Head Attach the chain such that when the weld head is in the UP position the lever arm angle is about 15 20 degrees from the horizontal 8 Page Figure 7 Adjust the Foot Pedal Adjust the foot pedal chain to the correct height so as to make about a 20 degree angle from the floor Figure 8 Bolt the Foot Pedal to the Floor or to an alternate floor mount OR Bolt the Foot Pedal to an alternate floor mount Bolt Foot Pedal to Floor Figure 9 Manual Foot Pedal Correctly Mounted 9 Page 3 Pneumatic Versions Connect the Pneumatic air Hose from the Weld Head to your Air Compressor A Figure 10 Use a inch quick disconnect set up similar to the figures below B Figure 11 Set the Air Pressure to 30 60 PSI 40 PSI is recommended for most applications Pull up on the Black Regulator Adjust Knob Turn clockwise to increase pressure counterclockwise to decrease pressure Read the gauge Push the Black Regulator Adjust Knob back down to lock the desired air pressure setting in place C Figure 12
14. xt step will show you how to use the Stop Nut to adjust for switch actuation amp stroke length A Use the Weld Head Adjust Handle with your right hand to loosen the weld head position while holding the head with the other hand and raising or lowering it to its desired height B Gently tighten the weld head adjust handle at the desired position Figure 17 Height adjust 13 Page 7 Adjust the Stop Nut for stroke length amp switch actuation Do not turn your Welder on yet Without turning your welder on some adjustments can be made to ensure proper Weld Head stroke and switch actuation A Figure 18 Lower the Stop Nut to reduce the stroke length as desired A gap will correspond to a stroke KA B Figure 19 Use the Sunstone view holes located on both sides of the weld head to view the switch es actuation With your welder OFF press the foot pedal to lower the Weld Head to the now set stroke length Notice the switch es using BOTH viewports The switch will be actuated as the electrodes make contact with the weld piece amp follow through to the stroke set by the stop nut If your weld head has two switches both switches must be actuated in order for a weld to be made Pre Actuation of switch Just Actuated Switch C If the Stop Nut is set correctly the screw that actuates the switch should go just beyond the point of actuation Re adjust the stop nut and press the foot pedal again to ensure pr
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