SUNSTONE AC1050 Bedienungsanleitung
AC1050
User Manual
Copyright 2008 Sunstone Engineering R&D Inc.
2
Contents
The AC1050 AC Spot Welder........................................ 4
Features............................................................................. 4
Product Data Sheet.............................................................. 5
Sa ety Procedures and Precautions ........................................ 5
Chapter 1: Installation and Setup................................6
Positioning Guidelines...........................................................6
Foot Switch Setup................................................................6
Power Cord, Power Source, Fuse, Breaker................................7
Cabling Guidelines............................................................... 7
Heat Considerations............................................................. 7
The User Inter ace............................................................... 8
Jobs and Schedules..............................................................9
Chapter 2: Spot Weld Function.................................... 10
Theory o Operation............................................................. 10
Weld Parameter De initions................................................... 11
Example Walkthrough...........................................................12
Chapter 3: olling Spot Weld Function........................ 13
Theory o Operation............................................................. 13
Weld Parameter De initions................................................... 14
Example Walkthrough...........................................................15
Chapter 4: Seam Weld Function...................................16
Theory o Operation............................................................. 16
Weld Parameter De initions................................................... 16
Example Walkthrough...........................................................17
Chapter 5: Pulsating Spot Weld Function.....................18
Theory o Operation............................................................. 18
Weld Parameter De initions................................................... 19
Example Walkthrough...........................................................20
Chapter 6: Main Menu Functions..................................21
Beep Toggle........................................................................ 21
Add a Schedule................................................................... 21
Lock a Schedule.................................................................. 21
Copy a Schedule..................................................................21
Restart the Schedule Counter................................................ 22
Restart Current Job.............................................................. 22
AC1050 User Manual
3
Chapter 6: Main Menu Functions (Cont.)
Tempering Function..............................................................22
View the Internal Temperature...............................................22
View the Li etime Weld Counter..............................................23
View Welder In ormation.......................................................23
Chapter 7: Job Menu Functions and Chaining.............. 23
Chain and Unchain Schedules................................................ 23
Link a Schedule to the Chain................................................. 23
Remove Last Link rom the Chain........................................... 24
Change the Number o Welds or a Link.................................. 24
Chapter 8: Other Welder Functions..............................24
Resetting to Factory De aults.................................................24
Appendix A: Cable esistance Chart............................ 25
Appendix B: Menu Flowcharts..................................... 26
Main Menu.......................................................................... 26
Job Menu............................................................................27
Appendix C: Glossary...................................................28
Appendix D: Warranty and Contact Information.......... 29
Sample Job Documentation Layout..............................30
NOTE: The in ormation contained in this manual is subject to change as improvements are made
to our products. Visit www.SunstoneEngineering.com or the latest version o this document.
AC1050 User Manual
The AC1050 AC Spot Welder 4
The AC1050 AC Spot Welder
Features
●Embedded digital microprocessor with internal memory space or 100
user programmable welding schedules.
●Ability to link multiple schedules together into a job chain.
●Five welding types:
•Single Pulse Spot Weld
•Dual Pulse Spot Weld
•Auto-Repeating Roll Spot Weld
•Seam Weld
•Multi-Pulse Spot Weld
●Internal 5 kVA welding trans ormer means no costly external
equipment.
●Automatic internal thermal protection with audible alarm.
●Simple digital user inter ace with short learning curve.
●Tempering unction to slowly cool completed welds.
●On-screen weld counter keeps track o how many welds have been
completed and can automatically switch schedules a ter the
programmed number o welds.
●Automatic li etime weld counter will help keep track o daily, monthly,
or yearly weld output.
●Included oot switch or weld iring control.
●Accidental schedule overwrite protection through lock-out eature.
●Small enclosure ootprint means more mobility and less table-top
space required.
AC1050 User Manual
The AC1050 AC Spot Welder 5
Product Data Sheet
Safety Procedures and Precautions
●Care should be taken not to short across the positive and negative
terminals. At ull power, the weld current is many thousands o amps
and is dangerous i the terminals are accidentally bridged.
●Do not wear metal jewelry when welding. The terminals are sa e to
touch without ear o arcing as long as no metal is on your hands.
●Wear sa ety glasses at all times while using the welder.
●Welding cables can become extremely hot. A ter extended use, be
cautious when removing the weld cables.
●When altering any part o the welding path (such as swapping electrodes
or cables), turn the unit o or enter the menu to ensure no accidental
triggering o a weld.
●The AC1050 was designed or indoor use only.
AC1050 User Manual
AC1050
Internal Trans ormer Rating
Welding Duty Cycle 50%
Total Number o Savable Schedules 100
Total Number o Jobs 10
Maximum Internal Operating Temperature
Fuse Rating 20A
Power Supply Requirements 220-240VAC 50-60Hz
Weight
Case Dimensions (L X W X H without terminals, with eet) (33.6 cm X 25.4 cm X 13.9 cm)
Power Cord Length
Minimum Pulse Length 16.67 ms
Maximum Pulse Length 1.65 sec
Example Welds Welds/Minute
Single Pulse lasting 10 cycles 180
6 Pulses o 7 cycles with 2 cycle spacing 67
Dual pulse o 25 cycles each with 12 cycle spacing 29
5.0 kVA
75 °C
32 lbs (14.5 kg)
13¼” X 10” X 5½”
5½' (168 cm)
Chapter 1: Installation and Setup 6
Chapter 1: Installation and Setup
Positioning Guidelines
The goal when deciding the location o the unit is to minimize welding
cable length. Place the unit on a tabletop or workbench directly
behind your workspace with the welding terminals acing your
workspace. Keep the unit away rom edges to avoid the risk o the
welder alling to the loor. Be sure there is at least 6” o space on all
sides and on top o the welder to ensure adequate cooling throughout
the case. The diagram below shows the air low direction inside the
unit.
Foot Switch Setup
The included oot switch can be plugged into the rear panel o the
welder into the Ext. Trigger port. To attach the coupling, push it into
the port and then secure it by twisting the ring clockwise until tight.
Do not orce the coupling as it can only be inserted in one orientation.
When using the oot switch to trigger a weld, keep in mind that some
o the welding unctions require the switch to be simply depressed
and released, while others require a prolonged depression
corresponding with desired weld time. See the chapters on each
speci ic weld unction or more in ormation (Chapters 2-5).
AC1050 User Manual
Front RearAir low
Intake
Exhaust
Chapter 1: Installation and Setup 7
Power Cord, Power Source, Fuse, Breaker
The power cord on the AC1050 can only be connected to 220-240VAC,
50-60Hz electricity. NEVER use a power strip or extension cords with
the AC1050. The welder is protected with a 250VAC, 20A time-lag
use. Replace the use with a compatible device only. The rear o the
unit also has a 250VAC circuit breaker as added user protection.
Make sure it is switched into the up position be ore using.
Cabling Guidelines
For maximum power output, the cabling between the terminals and
the work piece should be as short as possible. The optimal resistance
or the complete weld path is .3mΩ - .5mΩ. The internal resistance
rom the secondary trans ormer winding to the terminals is .02mΩ. A
recommended cable con iguration that has been thoroughly tested
with a weld head is to use 1.5' 1AWG cable lengths on both terminals.
A chart o cable resistances and gages can be ound in Appendix A.
Heat Considerations
A ter extended use, the welding cable and terminals will become
extremely hot. While the unit monitors the internal trans ormer and
relay temperature it cannot monitor the external cables. Be sure to
use cables with a suitable temperature rating or your application to
avoid cable ailure.
In the event o internal overheating, the unit will beep three times
and display a status message with the internal temperatures. During
this time, none o the welder's unctions will operate. Once the heat
levels have allen to acceptable levels, the unit will beep twice and
resume normal operation. I the heat alarm occurred during a weld,
the remainder o the weld will be canceled.
AC1050 User Manual
Chapter 1: Installation and Setup 8
The User Interface
1. LCD: This displays all welding parameters and inter ace items.
2. Adjust Wheel: Turn this to move the on-screen cursor and to
change welding parameters when a ield has been selected.
3. Select Button: Press this to select welding parameters to change
or to con irm menu selections.
4. Menu Button: Press this to access the main menu rom the run
screen. In all other instances press this to cancel or exit menus.
5. Welding Terminals: Connect welding cable to these terminals
using the included asteners.
6. Main Power Switch: This switch powers the unit.
*For more detailed in ormation on the run screen, see the chapter
corresponding to the weld unction you wish to use (Chapters 2-5).
For more in ormation on the menus, see Chapters 6-7.
AC1050 User Manual
-------AC1025-------
Sunstone Engineering
Resistance Welding
---Copyright 2008---
Adjust Menu
Select
1
24
3
ower
Off
On
5 6
-------AC1050-------
Sunstone Engineering
Resistance Welding
---Copyright 2008---
Chapter 1: Installation and Setup 9
Jobs and Schedules
When the welder arrives rom the actory, it is con igured with 10 jobs
numbered 0-9. Each job has schedule 0 activated. Schedule 0 is the
“scratch-pad” schedule that you can use to develop weld
con igurations that work with your applications. Each job can have up
to 9 additional schedules added to it or a total o 100 schedules. You
must use the menu unction Add a Schedule to add schedules to the
current job. The current job and current schedule are displayed in the
upper le t portion o the run screen. Any changes made to a
schedule's parameters are immediately saved to memory. A visual
representation o a sample job/schedule architecture is given below.
AC1050 User Manual
Job 1 Job 2 Job 3 . . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .
Sch 1
Sch 2
Sch 3
Sch 4
. . .
Chapter 2: Dual Pulse Spot Weld Function 10
Chapter 2: Dual Pulse Spot Weld
Function
Theory of Operation
The Dual Pulse Spot Weld Function is the de ault unction or newly
added schedules and provides the most lexible welding option. Two
pulses are desirable in many applications because a pre-welding pulse
can reduce splash as well as remove any sur ace impurities that might
hamper the main welding pulse. On the AC1050, the two pulses can
be programmed to whatever power level and length is desired and
can even be shut o or single pulse operation.
The initial pulse's power is controlled by the Pow1 parameter and is
displayed as a percentage o maximum power. Its length is governed
by the Cyc1 parameter and is given in units o AC cycles where:
1AC cycle=1
60Hz
=16.67ms
The time between pulses is represented by the Pspace parameter and
is also given in units o AC cycles. The second pulse operates
similarly to the irst and its power and length are controlled by the
Pow2 and Cyc2 parameters respectively.
Either pulse can be any percentage o maximum power you choose
and at most, 99 AC cycles long. Additionally, the spacing between
pulses can be any length you choose up to 99 AC cycles. To
deactivate a pulse, set either its power or cycle length to 0 and that
pulse will be ignored.
To initiate the weld, be sure the run screen is displayed and not any o
the menu screens. Depress the oot switch and then release it to
make the weld. As part o the unit's heat management protocols, a
waiting period equal to the total welding time begins immediately
a ter each weld during which another weld cannot be initiated. For
example:
8cyc for pulse135 cyc for pulse2=43 cyctotal wait time
I audible beeps are activated, a short chirp will signal that the unit is
ready to weld again.
AC1050 User Manual
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