SUNSTONE WH1 User Manual
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SUNSTONE WH1 User Manual

Opposed weld head
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WH1 Opposed Weld Head
For Models WH1125A, WH1125M, WH1250A, WH1250M, WH1187A HF
Users Guide
Version 20201010 • Part #1170

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Summary of Contents for SUNSTONE WH1

  • Page 1 WH1 Opposed Weld Head For Models WH1125A, WH1125M, WH1250A, WH1250M, WH1187A HF Users Guide Version 20201010 • Part #1170...
  • Page 2 INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES, OF ANY NATURE WHAT- SOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGINEERING LLC PROD- UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-...

  • Page 3: Table Of Contents

    e Micro Welder Experts Table of Contents Chapter 1: A Quick Look Chapter 5: Welding with the Weld Head What is in the Box Basic Welding Steps Precautions Chapter 6: Electrode Care Chapter 2: Pneumatic Weld Head Setup Electrode Tip Shapes and Positioning Bolt the Weld Head to the Table Electrode Material Choice Set up Weld Head Trigger Hub...
  • Page 4 WH1 WELD HEAD USERS GUIDE iv • Questions? Call or Text +1 801-658-0015...

  • Page 5: Chapter 1: A Quick Look

    If you need assistance for any reason, please call or text +1 801-658-0015. Before you begin to set up and use your Sunstone WH1 Weld Head you should become familiar with its various components and controls.
  • Page 6 WH1 WELD HEAD USERS GUIDE Pressure Knob. Use this knob to adjust electrode pressure. Turn counter-clockwise to decrease; turn clockwise to increase. Height Adjustment. Loosen these knobs to move the weld head up and down when positioning the electrodes above the work piece.

  • Page 7: Chapter 2: Pneumatic Weld Head Setup

    e Micro Welder Experts Chapter 2: Pneumatic Weld Head Setup NOTE: For Manual weld head setup (WH1125M and WH1250M) see Chapter 3. Bolt the Weld Head to the Table This step is optional. The weld head will stand upright on its own. However, we recommend bolting it to your work table for better support and added stability.

  • Page 8: Set Up Weld Head Trigger Hub

    WH1 WELD HEAD USERS GUIDE • Mark and drill the locations through your table. We recommend positioning the bolts about 1” from the edges of the triple T-SLOT extrusion. • Tighten by tightening the bolt on the underside of the table.

  • Page 9: Set Up Mac Valve Air Hoses And Pressure

    e Micro Welder Experts Figure 5.1. Under the MAC Valve are two air ports, which are connected to valves located under the weld head. The connections between the ports and valves are completed on the factor floor. Verify they are installed correctly.
  • Page 10 WH1 WELD HEAD USERS GUIDE Figure 6.1. Connect the included 1/4” air hose to the air hose port (A) located on the left side of the MAC Valve. Next, connect the provided silver fitting (B) to the other end of the air hose. Then connect the hose to a supply of compressed air using a brass connector (C) (not included).
  • Page 11 e Micro Welder Experts Right valve adjusts the DOWN speed. Left valve adjusts Figure 7.1. The left air valve controls the UP the UP speed. speed. The right valve controls the DOWN speed. To adjust the up or down speed, first loosen the lock nut (C or D);...

  • Page 12: Chapter 3: Manual Weld Head Setup

    If you have a pneumatic model, skip to Chapter 4 on page 11 to complete setup. Bolt the Weld Head to the Table Your Sunstone manual weld head must be bolted to a table. Refer to Figure 8.1 and follow these instructions to secure your weld head to a working table: •...

  • Page 13: Manual Foot Pedal Installation And Setup

    e Micro Welder Experts Manual Foot Pedal Installation and Setup Attaching the Manual Foot Pedal The manual foot pedal system will connect to the bolts run- ning from the weld head base through the table. To attach the manual foot pedal to the weld head, follow these instructions while referencing the figures at left: •...

  • Page 14: Setting Up The Manual Foot Pedal

    You can adjust the angle and pressure of the manual foot pedal by changing the pin locations in (A) and (B). Continue to Chapter 4 to complete the setup of your Sunstone weld head. Figure 10.1. With the foot pedal system...

  • Page 15: Chapter 4: Completing Weld Head Setup

    e Micro Welder Experts Chapter 4: Completing Weld Head Setup Connect Weld Head Cables to the Welder The 1AWG weld head cables will come attached to the electrode blocks (B) on the weld head, but you’ll need to connect the weld head cables to the welder (A). Refer to Figure 11.1. Bolt the 1AWG weld head cables to the positive and negative terminals on the welder (A) with the provided nuts and bolts.

  • Page 16: Set Up Weld Head Triggering

    Figure 12.1. For automatic triggering, connect the Weld Head Actuating Cable (A) to the Trigger Port (B) on the back of the welder. Refer to your Sunstone welder users guide for the proper port to use on the back of the welder.

  • Page 17: Foot Pedal Triggering

    With foot pedal triggering the weld head will be triggered by using a second foot pedal that was shipped with your Sunstone welder. Note: Don’t confuse the foot pedal that came with your Sunstone welder with the weld head foot pedal, or manual foot pedal, that lowers the weld head during operation.

  • Page 18: Standard Electrode Setup, Adjustment

    • Verify electrodes are in the correct location on the work piece. • Now press the trigger foot pedal connected to the Sunstone welder. • Once the weld has triggered, release both foot pedals. NOTE: The trigger foot pedal does not need to be held down, a single press will suffice to trigger a weld.

  • Page 19: High Force Electrode Setup, Adjustment

    Adjust Electrode Gap Move the weld head up or down as described in the next section, Weld Head Height Adjustment. Sunstone rec- ommends that the weld head be set to a height where the top electrode is an 1/8” (0.125”) above the work piece when the work piece is placed on top of the lower electrode.

  • Page 20: Weld Head Height Adjustment

    WH1 WELD HEAD USERS GUIDE 1/8” Figure 16.1. The top electrode (A) should be positioned 1/8” above the work piece when the work piece is placed on the top of the lower electrode. Make sure you frequently shape and clean electrodes prior to use and after tip wear.

  • Page 21: Electrode Spring Pressure Setup

    Adjust the electrode gap and weld head height as described previously on pages 15-16, “Adjust Electrode Gap” and “Weld Head Height Adjustment.” Sunstone recommends an 1/8” (0.125”) gap between the work piece and the top electrode (A) in Figure 16.1.
  • Page 22 The Sunstone weld head comes standard with light duty springs that range between 1-15 lbs of compression force. The eight notches (C) on the Movable Scale (E) (see Figure 18.1) di- vide the compressible distance into quantifiable sections.

  • Page 23: Standard Spring Pressure Values

    e Micro Welder Experts Standard Spring Pressure Values For weld heads with force ranges between 1-15 lbf (WH1125, WH1250) 1/8” (0.125) Electrode Gap Electrode to Electrode to Spring Force lbs / ONE Kg / ONE Work Piece Gap Work Piece Gap Marker electrode electrode...

  • Page 24: High Force Spring Pressure Values

    WH1 WELD HEAD USERS GUIDE High Force Spring Pressure Values For high force weld heads with force ranges between 5-50 lbf (WH1187A HF) 1/8” (0.125) Electrode Gap Electrode to Electrode to Spring Force lbs / ONE Kg / ONE Work Piece Gap...

  • Page 25: Chapter 5: Welding With The Weld Head

    • Verify the Moveable Scale is set correctly (equal to the electrode gap distance between the work piece and the top electrode). Sunstone recommends a 1/8” (.125”) gap. • Set the spring force on the weld head (half of max force is often a good starting point).

  • Page 26: Chapter 6: Electrode Care

    WH1 WELD HEAD USERS GUIDE Chapter 6: Electrode Care Electrode Tip Shapes and Positioning Electrode tip shape can play an important role in achieving desired weld characteristics. Several different sizes and shapes can be used to manipulate weld results in your favor, as show below. Experimentation with size, orientation, and geometry can often lead to increased weld strength and longer times between necessary elec- trode cleaning.

  • Page 27: Electrode Material Choice

    e Micro Welder Experts Electrode Material Choice Spot welding electrodes are typically made of conductive metals such as a copper alloy, or of resistive metals such as tungsten or molybdenum. If the material you want to weld is resistive (stainless steel, nickel, platinum, etc.), the typical electrode used would be copper.

  • Page 28: Chapter 7: Resistance Welding Basics

    WH1 WELD HEAD USERS GUIDE Chapter 7: Resistance Welding Basics Single and Dual Pulse Description Single pulse welds are typically used where the work pieces are fairly clean. Single pulse welds are often ben- eficial when welding small parts, such as fine wires, where very low heat is required. Dual pulse welds are helpful when the piece is dirty, or has oxides/plating on it.

  • Page 29: Welding Attachments

    Examples B and C are for parallel weld heads and not achievable with the WH1, but shown here for clarification. Example B shows a step electrode configuration. This configura- tion is used when there is access to only one side of the work piece and an electrode can be placed on both materials.

  • Page 30: Technical Assistance

    In rare circumstances the unit may become inoperable. If this happens turn the unit off and back on. If the is- sue continues to happen, please contact support and we will gladly help resolve the issue. If the unit is visibly having issues, please disconnect unit from power and contact Sunstone’s customer service team. Call +1 801-658-0015 • eMail support@sunstonewelders.com...

  • Page 31: Data Specifications

    Micro Welder Experts Data Specifications WH1 - Opposed Weld Head Standard Force Model High Force Model Weld Force 1 - 15 lbs 1.7 - 45 lbs Max Electrode Stroke 1 in 1 in Electrode Diameter 1/8 in 3/16 in...
  • Page 32 WH1 WELD HEAD USERS GUIDE 28 • Questions? Call or Text +1 801-658-0015...

  • Page 33: Opposed Weld Head Mounting Template

    e Micro Welder Experts Opposed Weld Head Mounting Template Instructions Tape the template to your work- Cut here and tape to workbench. bench. When ready to drill, simply drill through the circles printed on the paper. For Air/Pneumatic Models • Drill the four holes numbered 1, 2, 3, 4 with a 5/16”...
  • Page 34 WH1 WELD HEAD USERS GUIDE 30 • Questions? Call or Text +1 801-658-0015...
  • Page 35 Other World-Class Micro Welders from Sunstone: e Micro Welder Experts The World’s Most Advanced Micro TIG Welder When you need a tiny little weld in exactly the right spot! +1-801-658-0015 Call or Text www.sunstonewelders.com e Micro Welder Experts Questions? Call or Text +1 801-658-0015 • 31...
  • Page 36 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 wwww.sunstonewelders.com PART #1170 ©2020 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20201010 • 32 • Questions? Call or Text +1 801-658-0015...

This manual is also suitable for:

Wh1125a, wh1125mWh1250aWh1250mWh1187a hf

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