SUNSTONE AC1050 User Manual
AC1050
User Manual
Copyright 2008 Sunstone Engineering R&D Inc.
Contents
The AC1050 AC Spot Welder........................................ 4
Features............................................................................. 4
Product Data Sheet.............................................................. 5
Safety 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 Interface............................................................... 8
Jobs and Schedules..............................................................9
Chapter 2: Spot Weld Function.................................... 10
Theory of Operation............................................................. 10
Weld Parameter Definitions................................................... 11
Example Walkthrough...........................................................12
Chapter 3: Rolling Spot Weld Function........................ 13
Theory of Operation............................................................. 13
Weld Parameter Definitions................................................... 14
Example Walkthrough...........................................................15
Chapter 4: Seam Weld Function...................................16
Theory of Operation............................................................. 16
Weld Parameter Definitions................................................... 16
Example Walkthrough...........................................................17
Chapter 5: Pulsating Spot Weld Function.....................18
Theory of Operation............................................................. 18
Weld Parameter Definitions................................................... 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
2
AC1050 User Manual
Chapter 6: Main Menu Functions (Cont.)
Tempering Function..............................................................22
View the Internal Temperature...............................................22
View the Lifetime Weld Counter..............................................23
View Welder Information.......................................................23
Chapter 7: Job Menu Functions and Chaining.............. 23
Chain and Unchain Schedules................................................ 23
Link a Schedule to the Chain................................................. 23
Remove Last Link from the Chain........................................... 24
Change the Number of Welds for a Link.................................. 24
Chapter 8: Other Welder Functions..............................24
Resetting to Factory Defaults.................................................24
Appendix A: Cable Resistance 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
3
NOTE: The information contained in this manual is subject to change as improvements are made
to our products. Visit www.SunstoneEngineering.com for the latest version of this document.
AC1050 User Manual
The AC1050 AC Spot Welder 4
The AC1050 AC Spot Welder
Features
● Embedded digital microprocessor with internal memory space for 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 transformer means no costly external
equipment.
● Automatic internal thermal protection with audible alarm.
● Simple digital user interface with short learning curve.
● Tempering function to slowly cool completed welds.
● On-screen weld counter keeps track of how many welds have been
completed and can automatically switch schedules after the
programmed number of welds.
● Automatic lifetime weld counter will help keep track of daily, monthly,
or yearly weld output.
● Included foot switch for weld firing control.
● Accidental schedule overwrite protection through lock-out feature.
● Small enclosure footprint means more mobility and less table-top
space required.
AC1050 User Manual
The AC1050 AC Spot Welder 5
AC1050
Internal Transformer Rating
Welding Duty Cycle 50%
Total Number of Savable Schedules 100
Total Number of 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 feet)
(33.6 cm X 25.4 cm X 13.9 c m)
Power Cord Length
Minimum Pulse Length 16.67 ms
Maximum Pulse Length 1.65 sec
Example Welds Welds/Minute
Single Pulse lasting 10 cyc les 180
6 Pulses of 7 cycles with 2 cycle spacing 67
Dual pulse of 25 cyc les eac h with 12 cyc le spacing 29
5.0 kVA
75 °C
32 lbs (14.5 kg)
13¼” X 10” X 5½”
5½' (168 cm)
Product Data Sheet
Safety Procedures and Precautions
● Care should be taken not to short across the positive and negative
terminals. At full power, the weld current is many thousands of amps
and is dangerous if the terminals are accidentally bridged.
● Do not wear metal jewelry when welding. The terminals are safe to
touch without fear of arcing as long as no metal is on your hands.
● Wear safety glasses at all times while using the welder.
● Welding cables can become extremely hot. After extended use, be
cautious when removing the weld cables.
● When altering any part of the welding path (such as swapping electrodes
or cables), turn the unit off or enter the menu to ensure no accidental
triggering of a weld.
● The AC1050 was designed for indoor use only.
AC1050 User Manual
Chapter 1: Installation and Setup 6
Chapter 1: Installation and Setup
Positioning Guidelines
The goal when deciding the location of the unit is to minimize welding
cable length. Place the unit on a tabletop or workbench directly
behind your workspace with the welding terminals facing your
workspace. Keep the unit away from edges to avoid the risk of the
welder falling to the floor. Be sure there is at least 6” of space on all
sides and on top of the welder to ensure adequate cooling throughout
the case. The diagram below shows the airflow direction inside the
unit.
Exhaust
Front
Foot Switch Setup
The included foot switch can be plugged into the rear panel of 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 force the coupling as it can only be inserted in one orientation.
When using the foot switch to trigger a weld, keep in mind that some
of the welding functions 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
specific weld function for more information (Chapters 2-5).
RearAirflow
Intake
AC1050 User Manual
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
fuse. Replace the fuse with a compatible device only. The rear of the
unit also has a 250VAC circuit breaker as added user protection.
Make sure it is switched into the up position before 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
for the complete weld path is .3mΩ - .5mΩ. The internal resistance
from the secondary transformer winding to the terminals is .02mΩ. A
recommended cable configuration that has been thoroughly tested
with a weld head is to use 1.5' 1AWG cable lengths on both terminals.
A chart of cable resistances and gages can be found in Appendix A.
Heat Considerations
After extended use, the welding cable and terminals will become
extremely hot. While the unit monitors the internal transformer and
relay temperature it cannot monitor the external cables. Be sure to
use cables with a suitable temperature rating for your application to
avoid cable failure.
In the event of internal overheating, the unit will beep three times
and display a status message with the internal temperatures. During
this time, none of the welder's functions will operate. Once the heat
levels have fallen to acceptable levels, the unit will beep twice and
resume normal operation. If the heat alarm occurred during a weld,
the remainder of the weld will be canceled.
AC1050 User Manual
Chapter 1: Installation and Setup 8
The User Interface
1
-------AC1050-------
-------AC1025-------
Sunstone Engineering
Sunstone Engineering
Resistance Welding
Resistance Welding
---Copyright 2008---
---Copyright 2008---
5 6
1. LCD: This displays all welding parameters and interface items.
Adjust
2
Select
On
3
Menu
Power
4
Off
2. Adjust Wheel: Turn this to move the on-screen cursor and to
change welding parameters when a field has been selected.
3. Select Button: Press this to select welding parameters to change
or to confirm menu selections.
4. Menu Button: Press this to access the main menu from 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 fasteners.
6. Main Power Switch: This switch powers the unit.
*For more detailed information on the run screen, see the chapter
corresponding to the weld function you wish to use (Chapters 2-5).
For more information on the menus, see Chapters 6-7.
AC1050 User Manual
Chapter 1: Installation and Setup 9
Jobs and Schedules
When the welder arrives from the factory, it is configured 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
configurations that work with your applications. Each job can have up
to 9 additional schedules added to it for a total of 100 schedules. You
must use the menu function Add a Schedule to add schedules to the
current job. The current job and current schedule are displayed in the
upper left portion of the run screen. Any changes made to a
schedule's parameters are immediately saved to memory. A visual
representation of a sample job/schedule architecture is given below.
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
. . .
AC1050 User Manual
Loading...