SUNSTONE AEON HF-2500 User Manual
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SUNSTONE AEON HF-2500 User Manual

High frequency inverter welder
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High Frequency Inverter Welder for Model 2500 Users Guide
20230609 • PART #1453

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Summary of Contents for SUNSTONE AEON HF-2500

  • Page 1 High Frequency Inverter Welder for Model 2500 Users Guide 20230609 • PART #1453...
  • Page 2 LOSS OF VALUE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEER- ING LLC PRODUCT, OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT, EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

  • Page 3: Table Of Contents

    e Micro Welder Experts Contents Chapter 1: Overview Welding Tips and Recommendations Common Electrode Types How to Maintain Repeatable Welds Chapter 2: Setup and Installation Safety Precautions Voltage and Power Requirements Exploring the Welder’s Front Panel Exploring the Welder’s Back Panel Exploring the Side Panel How to Set Up Your Welder Chapter 3: How to Navigate the Āeon HF Software...
  • Page 4 Users Guide...

  • Page 5: Chapter 1: Overview

    Chapter 1: Overview Features Sunstone’s advanced dual pulse HF welders offer many capabilities including weld monitoring, SPC tools, closed loop feedback, and a large capacitive touch-screen interface. The touch-screen interface provides easy access to all weld parameters. In addition, you get a visual of the weld waveform graph, weld histograms, alarms, warnings, and PLC features.
  • Page 6 The slow release of energy is critical to less conductive material. Formation of the weld nugget occurs during the first few milliseconds of the welding process. Sunstone’s proprietary technology allows the energy to be discharged with high precision and accuracy, as seen in Figure 3.1 to produce the best weld nuggets.

  • Page 7: Welding Tips And Recommendations

    TIME first few milliseconds of weld formation, the high-re- sistance metal bridges melt, allowing other bridges to Figure 3.1. With Sunstone’s proprietary HF welding technology allows the energy to be discharged come into contact to continue the melting process. with high precision and accuracy.

  • Page 8: Common Electrode Types

    The waveform of Pulse 1 and Pulse 2 can be changed independent of each other. Sunstone recommends that you first try a weld at a low energy setting and then increase energy until the de- sired hold strength is achieved. This tactic helps prevent destroying the workpiece by having too much energy to start out.
  • Page 9 e Micro Welder Experts FOR STANDARD WELD HEADS Opposed The opposed configuration is ideal for cross-wire welds and welds that offer access to both top and bottom of the material. Electrodes come in Glidcop, Molybdenum, and Tungsten, with a variety of tip shapes. Series/Parallel These electrodes typically have a smaller, non-concen- tric tip protruding from the shank of the electrode that...

  • Page 10: How To Maintain Repeatable Welds

    Users Guide How to Maintain Repeatable Welds Consistent weld results require a consistent and repeatable process. A few suggestions for ensuring repeatable welds include: Keep a weld logbook documenting the process once a successful weld has been achieved. Try to keep track of the following: •...

  • Page 11: Chapter 2: Setup And Installation

    VOLTAGE AND POWER REQUIREMENTS The Sunstone HF Āeon HF welders can accept the following 3 Phase input voltages: 208Y, 400Y, or 480Y. The standard voltage is 400Y, so selection of 208Y and 480Y requires the use of an additional transformer box.

  • Page 12: Exploring The Welder's Front Panel

    Users Guide Voltage requirements must be specified at time of pur- chase, so Sunstone can send the correct configuration for your power input needs. What’s in the Box The Āeon HF is typically shipped in three different boxes: Box 1: Power Supply •...

  • Page 13: Exploring The Welder's Back Panel

    Rotate counterclockwise to the “OFF” position to turn the welder off. WH-E Port (B) is used to interface with Sunstone E-Series Weld Heads. Ethernet Port (A) is used to control the welder with a PLC through an Ethernet connection. Additional informa- tion can be found in Chapter 11.

  • Page 14: Exploring The Side Panel

    Weld Head Feedback (O) is used for weld head feed- back signals such as external voltage sensing and force sensing. WH-X Port (F) can be used to interface with Sunstone X-series and the valves of Pneumatic weld heads. Primary Trigger (Q) is used to connect a foot pedal, or other switch, to initiate the weld process.

  • Page 15: How To Set Up Your Welder

    e Micro Welder Experts How to Set Up Your Welder Refer to Figure 9.1 and follow these initial setup steps when setting up the welder for the first time: • Unbox the welder. Place on a secure horizonatally level work space. •...
  • Page 16 Users Guide • Attach Foot Pedal and Weld Head Cables. The Āeon HF has several possible control schemes and can interface with several types of weld heads/attachments. The control configuration and weld head selected for your application will dictate which connections are used on the Āeon HF Back Panel. The table below indicates what should be plugged into the back panel connections for the various weld heads and control schemes (for more information regarding weld head control schemes, see “Weld Head Control Operation”...
  • Page 17 If you wish to use a trigger method that is different from the included Sunstone foot pedals, Figure 13.1 illustrates the proper pin placement for custom external trigger cables. The standard external trigger cable connector is an SD- 30LP made by CUI, Inc.

  • Page 18: Chapter 3: How To Navigate The Āeon Hf Software

    Users Guide Chapter 3: How to Navigate the Āeon HF Software This chapter provides a brief overview of the different screens, parameters, and elements found on the touch- screen interface of the welder. More detailed information is found in the following chapters. Navigation Bar The Navigation Bar is always found at the top of the interface screen, as shown in Figure 14.1.
  • Page 19 e Micro Welder Experts Comparator Screen Touch the Comparator Screen Icon (D) to access monitoring information of the weld output. See val- ues such as peak current, voltage, and energy and track weld results graphically. See Page 35. Envelope Screen Touch the Envelope Screen Icon (E) in the Navigation Bar to set the envelope of weld limits.

  • Page 20: Chapter 4: How To Use The Āeon Hf Software

    Users Guide Chapter 4: How to Use the Āeon HF Software Run Screen Operation The Run Screen, seen in Figure 16.1, displays current settings related to the weld discharge and weld head. Additionally, the achieved results from the previous weld are displayed here. The Run Screen is equivalent to a “home”...

  • Page 21: Trigger Weld

    WELD HEAD INFORMATION (K) If a Sunstone E-Series weld head is properly connected to the Back Panel, the lower right-hand side of the Run Screen will display information pertinent to the weld head: the current position of the weld head, weld point, and manual movement buttons.

  • Page 22: Weld Head Control Screen Operation

    Auto with Trigger (C). Select the desired mode by pressing the button and entering the required values. Fully Manual Control Manual Control can be used in conjunction with Sunstone X-Series Heads, Pneumatic heads, or Handpieces. In this scenario, the application of force (via weld head or handpiece) is controlled manually by the operator. Once the force is applied, the operator uses the Secondary Trigger (i.e., foot pedal press, button press, etc.) to initiate...
  • Page 23 Plug a 3DIN Foot Pedal (or the 3DIN from the Hand Piece if applicable) into the “Secondary Trigger” port on the Back Panel. This will be used to trigger the weld energy discharge. Sunstone Pneumatic Head with actuation controlled by the Āeon HF: •...
  • Page 24 To begin, enter a value for Squeeze Time (D) and Hold Time (E) as shown in Figure 18.1. How to Set Up the Āeon HF for Auto with Timing Control of a Weldhead Sunstone Pneumatic Head: • Plug a 3DIN Foot Pedal into the “Primary Trigger” port on Back Panel. This foot pedal will be used to initiate the weld sequence.
  • Page 25 Seondary Trigger (i.e., weld head limit switch) to initiate the weld discharge portion of the sequence. Enter a value for Hold Time (Squeeze time is greyed out). SETUP Sunstone Pneumatic Head: • Plug a 3DIN Foot Pedal into the “Primary Trigger” port on Back Panel. This foot pedal will be used to initiate the weld sequence.
  • Page 26 Users Guide • Weld Energy Discharge (these values are set in the PULSE SETTINGS screen) • Upslope 1: the time it takes to ramp up to Pulse 1. • Pulse 1: The duration of the first weld pulse. • Downslope 1: the time it takes to ramp down from Pulse 1. •...

  • Page 27: Mode Select

    E-Series heads can be controlled using one of two modes: Direct Control or Automatic Control. Direct Control Direct Control can only be used in conjunction with Sunstone E-Series heads and allows operators to control the position of the weld head directly by using an analog foot pedal (plugged into the PRIMARY TRIGGER port on the Āeon HF Back Panel).

  • Page 28: Force

    Users Guide Position, ready for the operator to initiate the next weld. User configured parameters of the Direct Control weld sequence include Force, Timing, and Displacement. You must release the foot pedal to make another weld. Auto Control If Auto Control mode is selected, the weld sequence is initiated by pressing the digital foot pedal switch or by pressing the Trigger Weld button on the Run screen.
  • Page 29 e Micro Welder Experts FORCE CALIBRATION The weld head force needs to be calibrated every time a new desired force is set. Ensure the parts to be welded are in place before performing this step. In Direct Control, calibration occurs immediately after setting the desired force. The analog foot pedal is used to move the electrode to the part to be welded.

  • Page 30: Position

    Users Guide Figure 26.1. Calibrate the force using the Hover Point and Weld Point (C) or Auto Set Position (A). POSITION Setting the position is the third step in the set-up process. In Automatic Control, there are two configurable positions: Weld Point and Hover Point. Weld Point The Weld Point is the position in which the weld head has contacted the part and has reached desired force.
  • Page 31 e Micro Welder Experts Auto Set Position To Set the Weld Point: • Verify that a Desired Force has been entered before continuing. • Slide the “Weld ON/OFF” toggle to the WELD OFF position. • Situate the parts to be welded in weld position below the electrode/s. •...

  • Page 32: Timing

    Users Guide Figure 28.1. Set the Squeeze Time and Hold Time. TIMING The fourth step in setting up the weld head is to set the desired Squeeze Time and Hold Time. These optional delay times can set up to 2000ms. Squeeze Time Once the weld head reaches the weld point, it will wait the allotted time before initiating the weld discharge.

  • Page 33: Speed

    e Micro Welder Experts To set the Hold Time: • Press the Hold Time box. • A pop-up window will appear. • Enter the desired time in milliseconds by using the slider bar or by entering the number using the number pad.

  • Page 34: Displacement

    Users Guide Once the desired speeds have been entered, choose the right arrow button at the bottom of the screen to con- tinue. To end the setup process, press the Close Button. To return to a previous screen, press the back arrow button on the left side of the screen.

  • Page 35: Waveform Graph

    e Micro Welder Experts Figure 30.1. Set a minimum and maximum value for weld displacement. PULSE SETTINGS Screen Operation The Pulse Settings Screen is used to set the desired parameters of the weld discharge. The Āeon HF can be configured to release two independently set pulses of weld energy with customizable pre-weld delay and delay between pulses.
  • Page 36 Users Guide head can travel down fully and exert full force prior to attempting to discharge the weld energy into the parts. Enter a value between 0ms and 10,000ms. UP SLOPE 1 This is the time it will take the Āeon HF to ramp up the energy level to the desired Pulse 1 value. Enter a value between 10ms and 500ms.
  • Page 37 e Micro Welder Experts PULSE SETTINGS The Pulse Settings can be found below the Timing Buttons. These buttons allow operators to select the mode of each pulse and set the values for the weld energy discharge. The adjustable values will vary depending on which weld mode is selected for each pulse (non-adjustable values will be greyed out).
  • Page 38 Users Guide Weld Modes The Āeon HF Inverter is capable of outputting and monitoring the weld discharge using the following modes: Constant Current In this mode, the Current of the Pulse discharge is monitored, ensuring the value entered for current is maintained throughout the duration of the discharge, even as the resistance changes.
  • Page 39 e Micro Welder Experts Weld Ready Indicator The Weld Ready Indicator is shown at the bottom right of the screen. This indicator displays one of three colors: • Green indicates that the welder is ready to weld. • Black indicates that the welder is not ready to weld, or the Weld On/Off button is off. •...
  • Page 40 Users Guide • Peak Power • Resistance • Displacement Pressing the button will change the available limit settings for Pulse 1 and Pulse 2 and show the most recent weld results. Enable Monitoring of Selected Parameter To enable monitoring of the selected Weld Parameter for Pulse 1, Slide the Pulse 1 toggle to “ON”. Slide the toggle to the left to turn it OFF.
  • Page 41 e Micro Welder Experts Figure 37.1. Envelope Screen. ENVELOPE Screen Operation The Envelope Screen can be used to monitor selected intervals of the weld discharge and set limits for a select- ed weld parameter during that interval. Unlike the Comparator screen, only one weld parameter can be select- ed to monitor for the interval selected.
  • Page 42 Users Guide Interval and Offset Buttons The Interval buttons are used to select the start point and end point of the section of weld you wish to monitor. Enter a value in each box (always in milliseconds). This is the only portion of the weld that will be monitored. The Offset Buttons are used to set the desired upper and lower limits for the weld parameter selected.

  • Page 43: Save/Load Screen Operation

    e Micro Welder Experts Save/Load Screen Operation The Save/Load screen allows you to save and load weld schedules. See Figure 38.1. A weld schedule is the collection of all settings for a particular weld, such as energy levels, delays, number of pulses, weld head settings, etc.

  • Page 44: Communications Screen Operation

    Users Guide Figure 40.1. Communications Screen Operation. Communications Screen Operation Select the Communications Screen icon in the Navigation Bar to access the Āeon HF’s automation features, alarms, and import/export features. The Communications Screen has three sub sections: The PLC tab, the Alarms tab, and the Import/Export tab, as shown in Figure 40.1.
  • Page 45 e Micro Welder Experts Pin Functions Input Pins Hard Coded Pins Pins 1.9, 1.10, 2.9, 2.10 are inputs that can be config- ured to one of the following options by selecting the • Pin 1.1 is hard coded as a +24V. desired function from the drop-down box: •...
  • Page 46 Users Guide Figure 42.1. Remote schedule select pins. REMOTE SCHEDULE SELECT PINS Pins 2.2 through 2.8 are used for remote schedule select and are configured in the remote schedule select tab. These pins are in an “Active Low” configuration meaning a low value (0v) is used for selecting the pin. These seven pins are bit-mapped into a number between 0 and 127.
  • Page 47 e Micro Welder Experts Toggle the Remote Schedule Select Enabled Switch (B) to the On position. Enabling the Remote Schedule Se- lect feature will enable the RSS pins on the Basic PLC I/O tab to use the remote schedule select. If the Remote Schedule Select button is later disabled, the pins will return to an unassigned state.

  • Page 48: Alarms

    Users Guide Figure 44.1. Alarms control panel within the Communications Screen. ALARMS To access the Āeon HF alarms control panel, press the Alarms Button (A) in the Communications Screen, as shown in Figure 44.1. The Alarms control panel will display certain power supply statuses, active warnings, ac- tive alarms, and other alarm-related settings.
  • Page 49 e Micro Welder Experts To set and activate a warning or alarm: • Find the setting for which you wish to set a warning or alarm. • Press the round switch (D) or warning or alarm next to the setting. The switch will be gray if the warning or alarm is already off;...
  • Page 50 Users Guide PART CHECK Each power supply is equipped with a part check feature that will verify a part is in place prior to releasing energy. This is an important feature in automated environments where an operator is not visually ensuring each part is properly placed.

  • Page 51: Interface Panel

    e Micro Welder Experts Import Clone Settings (E) The Import Clone Settings feature uploads the exported welder settings and schedules from a USB drive. Export Saved Welds (F) The Export Saved Welds feature copies all the saved weld schedules to a USB drive. Unlike cloning, the Export Welds feature does not copy system settings from one welder to another, only weld schedules.

  • Page 52: Lock Panel

    Users Guide To adjust the screen brightness: • Press and move the Slider Bar (J) to the right to increase the brightness and to the left to decrease the brightness. To Set the Date and Time: • Press the Set Button (K) under the current displayed system date and time. •...

  • Page 53: System Panel

    Operators can dismiss the message or navigate directly to the lock screen where the PIN can be input to unlock the welder. If a PIN is forgotten, call Sunstone Customer Service at +1 801-658-0015 for assistance. Figure 48.1. System Settings System Panel Screen, SYSTEM PANEL Tap the System Button (D) to access the following tools (as shown in Figure 49.1):...
  • Page 54 How to Update the Āeon HF’s Software The Sunstone Āeon HF software will be updated from time to time as needed. The software can be updated directly from the welder via Wi-Fi or the update can be downloaded to a USB storage device and plugged into the welder for updating.
  • Page 55 Follow the on-screen prompts. • Once the update is complete, the welder will display an error message, which can be ignored—don’t call Sunstone Customer Service. Continue to the next bullet point. • Turn the welder off and wait 10 seconds.

  • Page 56: Chapter 5: How To Configure An Ethernet Connection

    Chapter 5: How to Configure an Ethernet Connection The Sunstone Āeon HF Inverter can be connected to and controlled by a computer using an Ethernet con- nection. A Sunstone weld head connected to the welder can also be controlled by this connection. Follow the instructions below to setup and configure the Ethernet connection.
  • Page 57 e Micro Welder Experts 7. The default port for Modbus is 502. You can enter any number; however, port 502 will still be available to use even with an additional port defined. Available port 8. Enter the Priority IP Address One, which is the IP address that will have priority when communicating with the Āeon HF.
  • Page 58 Users Guide • Type in the IP address used in the Welder IP Information screen. In this guide, 10.9.7.244 was used. The other two fields can be left at default: 60 second timeout and Slave Address of “FF”. See Figure 54.1. •...
  • Page 59 e Micro Welder Experts coil is pulled from the Āeon HF when reading from coils 0 through 23. If you choose “0000” as the starting address and “0001” as the quan- tity of outputs, then you will see a reply from the Āeon HF of the Pulse 1 Power Comparator Enable boolean.
  • Page 60 Users Guide SENDING INFORMATION TO THE ĀEON HF • Press the “Send Frame” icon • Keep the default settings of “1” Times with “100” ms of Delay. Click on “05 Write Single Output”. The Request Data window will appear. Enter a function code, output address, and output value, as shown in Figure 56.1.
  • Page 61 e Micro Welder Experts READING THE OUTPUT WINDOW: REQUESTS AND RESPONSES Each time you send a request the first two columns of data in the Frame section will increment (A), as high- lighted in Figure 57.2. The third through seventh columns in the Frame section is part of the header that is sent/received (B) as shown in Figure 57.2.
  • Page 62 Users Guide READING THE INPUT REGISTER Follow these steps to read from the Input Register Function Code. • Send a new frame by clicking on the Send Frame icon in the upper toolbar. • In the Send New Frame window, select 04 Read Input Registers.
  • Page 63 e Micro Welder Experts Address to “000F” for “Energy Total mWs”. This register happens to be one of only three registers that are 32 bit, which sends two 16 bit numbers by utilizing two registers. Change the quantity of registers to “0002”. Byte count will be 4.
  • Page 64 Users Guide RETRIEVING GENERAL INFORMATION FROM THE HF Āeon HF The Modbus Server Tester software is able to read general information from the Āeon HF welder. Follow these instructions to access information stored on the Āeon HF: • Send a new frame by clicking on the Send Frame icon in the upper toolbar.
  • Page 65 e Micro Welder Experts Using Modbus Poll The second piece of software that can be used to control the Āeon HF is Modbus Poll, a good example of a program that continues to poll information from/to the Āeon HF. Paid and trial versions of the Modbus Poll are available at https://www.mod-bustools.com/download.
  • Page 66 Users Guide In the Modbus Poll main window (see Figure 61.2), coil 0x0000 is on the top left and has a value of 0, so Pulse 1 Power Comparator Enable is Off “0x00”. Further down that column you will see data for coils 0 through 9. Coil 10 starts on the next column and Coil 20 on the third column.
  • Page 67 e Micro Welder Experts WRITE SINGLE COIL To write a single coil, follow these instructions: • Click on the Setup menu and choose Read/Write Definition. The Read/Write Definition window will appear. • As shown in Figure 63.1, Click on 05 Write Single Coil in the Function drop down menu box.
  • Page 68 Users Guide • Click on the Setup menu and choose Read/Write Once (or press F6), which then sends to the Āeon HF a 1 to turn on the Remote Schedule Select Mode, which is Basic. If you place a 0 in the cell and Read/Write Once (F6) again, the Remote Schedule Select Mode will be turned off.
  • Page 69 e Micro Welder Experts READING A COIL To read from a coil, and with the Āeon HF connect- ed, refer to Figure 65.1 and follow these instruc- tions: • Verify the Slave ID is 1. • Verify the value of the First Coil address is 40000.
  • Page 70 Users Guide READING A HOLDING REGISTER To read from a holding register, and with the Āeon HF connected, refer to Figure 66.1 and follow these instruction: • Change the No. of Reg to 36. • Change Function Code” to 3. •...
  • Page 71 e Micro Welder Experts WRITING TO A SINGLE COIL To write to a single coil, follow these instructions: • On the main screen click the Write button (A) near the bottom of the window as shown in Figure 67.1. • A new window will appear.
  • Page 72 Users Guide WRITING TO A SINGLE REGISTER To write to a single register, follow these instructions: • On the main screen click the Write button (A) near the bottom of the window as shown in Figure 68.1. • A new window will appear. See Figure 68.2. In this new window, make sure Mode is set to TCP.
  • Page 73 e Micro Welder Experts RECEIVING A GENERAL PACKET To receive a general packet, follow these instructions: • On the main screen click the Write button (A) near the bottom of the window as shown in Figure 69.1. • A new window will appear. In this new window, make sure Mode is set to TCP. •...

  • Page 74: Chapter 6: Back Panel Connector Details

    Āeon HF to a computer via an Ethernet connection (CAT5 or CAT6). WH-E. Used to connect to Sunstone E Series Weld Heads. Connect an ethernet cable (CAT5 or CAT6) between this port and the COMM port on the weld head to establish communications.

  • Page 75: Appendix A: Connection Pin-Out Diagrams

    e Micro Welder Experts Appendix A: Connection Pin-Out Diagrams WH FeedBack Pin-Out Refer to Figure 71.1. 1. 0V 2. Force Sensor. Note, this connection is currently unused, this feature will come later. 3. 0V 4. Voltage Sense Positive 5. Voltage Sense Negative Figure 71.1.
  • Page 76 Users Guide WH X Pin-Out Refer to Figure 72.1. 1: GND/Shield 2: Weld Head Actuation 2. +12VDC(0.5A Max) is sent when weld head needs to actuate. 3: Weld Head Actuation 1. +12VDC(0.5A Max) is sent when weld head needs to actuate. 4: GND/Shield Figure 72.1.
  • Page 77 e Micro Welder Experts PLC CONNECTION Figure 73.1. PLC Connection. 24V (Supplied by Āeon HF) Remote Schedule Select 0 External Power Remote Schedule Select 1 Output 0 Remote Schedule Select 2 Output 1 Remote Schedule Select 3 Output 2 Remote Schedule Select 4 Output 3 Remote Schedule Select 5 Output 4...

  • Page 78: Appendix B: Warnings And Alarms

    Unsafe states may include the following: Internal communi- cations error, voltage error on terminals, voltage error on capacitors, internal temperature over heating, or capacitors not charging. Call Sunstone’s cus- tomer service team for immediate assistance. Error Corrupt File If the Āeon is unable to read a file, the unit will display this alarm and name the...
  • Page 79 Micro Welder Experts Failed to Connect to Server If the Āeon is unable to connect to the Sunstone server in order to update its soft- ware and firmware, this alarm will appear. Touch the Dismiss button and then check all physical connections, software configuration settings on the Āeon, and verify the...
  • Page 80 If the welder becomes overheated, wait for Āeon to cool and display this message. Touch the Dismiss button, verify you are operating under safe conditions, and then continue. Feel free to contact Sunstone’s customer service team if the Āeon contin- ues to overheat.

  • Page 81: Appendix C: Modbus Data Tables

    e Micro Welder Experts Appendix C: Modbus Data Tables Reference these tables when sending/receiving messages to/from the via an ethernet connection us ing AEON Modbus software. SUPPORTED FUNCTION CODES Function Function Name Read/Write Code (dec) Code (hex) 0x01 Read Coils 0x02 Read Discrete Inputs 0x03...
  • Page 82 Users Guide Function Function Name Read/Write Code (dec) Code (hex) 0x67 General Info Read 0x68 Previous Weld Results Read 0x69 Alarm States Read 0x6A Waveform Report General Read 0x6B Emergency Stop State Read 0x6C Basic PLC States Read 0x6D RSS States Read 0x6E Network info...
  • Page 83 e Micro Welder Experts 0x000F Alarm - Trigger Enable 0x0010 Alarm - Wrong Trigger Enable 0x0011 Alarm - Invalid Selection Enable 0x0012 Warning - Temperature Enable 0x0013 Warning - Comparator Enable 0x0014 Warning - Weld Counter Enable 0x0015 Weld Triggered 0x0016 Modbus E-Stop DISCRETE INPUTS...
  • Page 84 Users Guide HOLDING REGISTERS Holding Register Length Minimum Maximum Note See Table See Table Remote Schedule Select Mode 0x0000 Pulse 1 Power Comparator Limit Upper 0x4E20 0x0000 Pulse 1 Power Comparator Limit Lower 0x4E20 Pulse 2 Power Comparator Limit Upper 0x0000 0x4E20 0x0000...
  • Page 85 e Micro Welder Experts 19 & 0x00000064 Energy Pulse 2 0x00030D40 (200000), 0x00061A80 (400000), 0x000927C0 (600000), 0x00124F80 (1200000) Time Between Pulses 0x0001 0x0064 Pre Weld Delay 0x0001 0x2710 Weld Head Control Type See Table See Table Welds Per Second 0x0032 0x03E8 Welds per hecto- second...
  • Page 86 Users Guide HOLDING REGISTERS: WELD HEAD CONTROL TYPES Weld Head Control Type Value Fully Automatic 0x0000 Automatic with Timing 0x0001 Automatic with Trigger 0x0002 HOLDING REGISTERS: PLC OUTPUT PIN ASSIGNMENTS PLC Output Pin Assignment Value Unassigned 0x0000 0x0001 Weld Ready 0x0002 Weld Good 0x0003...
  • Page 87 e Micro Welder Experts INPUT REGISTERS Index Input Register Length Notes PLC Pin 5 - Assignment PLC Output PLC Pin 6 - Assignment PLC Output Foot Pedal Analog Charge Temperature Weld Temperature Bleed Temperature Previous Weld Peak Voltage P1 Previous Weld Peak Voltage P2 Previous Weld Peak Current P1 Previous Weld Peak Current P2 Previous Weld Peak Power P1...
  • Page 88 Users Guide Gateway[3] Alternative Port Network Timeout Whitelist IP 1[0] Whitelist IP 1[1] Whitelist IP 1[2] Whitelist IP 1[3] Whitelist IP 2[0] Whitelist IP 2[1] Whitelist IP 2[2] Whitelist IP 2[3] Whitelist IP 3[0] Whitelist IP 3[1] Whitelist IP 3[2] Whitelist IP 3[3] Whitelist IP 4[0] Whitelist IP 4[1]...
  • Page 89 e Micro Welder Experts Waveform Report Starting Voltage Waveform Report P1 Start Time Waveform Report P1 End Time Waveform Report P2 Start Time Waveform Report P2 End Time Waveform Report Total Duration Waveform Report P1 Duration Waveform Report P2 Duration COMPARATOR RESULTS Comparator Result (hex) Name...
  • Page 90 Users Guide FILE RECORDS: READ FILE RECORD (20 / 0X14) Data Type Data Size Data Input 1 Byte 0xFF Server Address Function Code 1 Byte 0x14 Byte Count 1 Byte 0x07 – 0xF5 Sub Request x: Reference Type 1 Byte 0x06 Sub Request x: File Number 2 Byte...
  • Page 91 e Micro Welder Experts FILE RECORDS: RESPONSE TO “FIRST 4 TIME VALUES” Data Type Data Size Data Output Data Value Server Address 1 Byte 0xFF Function Code 1 Byte 0x14 Response Length 1 Byte 0x0A Request Length 1 Byte 0x09 Reference Type 1 Byte 0x06...
  • Page 92 Users Guide Sub Request 2: File Record 2 - Data [0] 2 Byte 0x0000 Sub Request 2: File Record 2 - Data [1] 2 Byte 0x0614 1,556mV=1.556V Sub Request 2: File Record 2 - Data [2] 2 Byte 0x1AF3 6,899mV=6.899V Sub Request 2: File Record 2 - Data [3] 2 Byte 0x1C45...
  • Page 93 e Micro Welder Experts CUSTOM FUNCTIONS: COMPARATOR (28 X 16 BIT REGISTERS) Byte Compara- Comparator - Pulse 1 - Power - Upper Limit (unit) Comparator - Pulse 1 - Power - Lower Name tor - Pulse Limit (unit)[3:1] 1 - Power - Enabled Type bool...
  • Page 94 Users Guide Byte Compara- Comparator - Pulse 2 - Current - Lower Limit (A) Compara- Comparator - Pulse 2 Name tor - Pulse tor - Pulse - Voltage - Upper Limit 2 - Current 2 - Voltage (mV)[3:2] - Upper - Enabled Limit (A)[0] Type...
  • Page 95 e Micro Welder Experts CUSTOM FUNCTIONS: BASIC PLC SETTINGS (3 X 16 BIT REGISTERS) Byte PLC Pin 3 PLC Pin 4 PLC Pin 5 PLC Pin 6 PLC Pin 7 PLC Pin 8 Name Type PLC Input PLC Input PLC Out- PLC Out- Assign- Assign-...
  • Page 96 Users Guide Byte Capacitor Voltage (mV) Terminal Voltage (mV) Terminal Current (A) [3:2] Name [1:0] Type uint32 uint32 uint32 Byte Name Terminal Current Weld Charge Weld Charge PLC Set to (A) [1:0] Task Task Cur- is Good Lock Input Current rent State State Enough...
  • Page 97 e Micro Welder Experts CUSTOM FUNCTIONS: GENERAL INFO: CHARGE TASK STATES Charge Task State (hex) Name Invalid 0x0000 0x0001 Charged 0x0002 Charging 0x0003 Draining 0x0004 Drained CUSTOM FUNCTIONS: GENERAL INFO: LOCK STATES Charge Task State (hex) Name Unlocked 0x0000 0x0001 Locked 0x0002 Lock Disabled...
  • Page 98 Users Guide Byte Name Pulse 2 Peak Current (A) Pulse 1 Peak Voltage Pulse [2:0] (mV) 2 Peak Volage (mV)[3] Type uint32 uint32 uint32 Byte Pulse 2 Peak Voltage (mV)[2:0] Pulse 1 Peak Power (10s of W) Pulse 2 Name Peak Power (10s of W)[3] Type...
  • Page 99 e Micro Welder Experts WAVEFORM REPORT GENERAL (11 X 16 BIT REGISTERS) Byte Total Samples P1 State P2 State Starting Voltage (mV) Name Index Index Type uint16 uint8 uint8 uint32 Byte Time - Pulse 1 - Start Time - Pulse 1 - Finish Time - Pulse 2 - Start Time - Pulse 2 - Finish Name...
  • Page 100 Users Guide NETWORK INFO (20 X 16 BIT REGISTERS) Byte IP[3] IP[2] IP[1] IP[0] Subnet Subnet Subnet Subnet Name Mask[3] Mask[2] Mask[1] Mask[0] Type uint8 uint8 uint8 uint8 uint8 uint8 uint8 uint8 Byte Gate- Gate- Gate way[1] Gate way[0] Alterna- Priority IP Priority IP Name...
  • Page 101 e Micro Welder Experts MODBUS EXCEPTION CODES Code Name Explanation ILLEGAL FUNCTION The function code received in the query is not an al- 0x01 lowable action for the server. This may be because the function code is only applicable to newer devices and was not implemented in the unit selected.
  • Page 102 Users Guide 0x06 SERVER DEVICE BUSY Specialized use in conjunction with programming com- mands. The server is engaged in processing a long dura tion program command. The client should retransmit the message later when the server is free. 0x08 MEMORY PARITY ERROR Specialized use in conjunction with function codes 20 and 21 and reference type 6, to indicate that the extended file area failed to pass a consistency check.
  • Page 103 e Micro Welder Experts HF AEON DATA SPECIFICATIONS TABLE MODEL NUMBER HF-2500/208 HF-2500/400 HF-2500/480 NOMINAL VOLTAGE RANGE (3 PHASE) 208 VAC 400 VAC 480 VAC LINE VOLTAGE RANGE (VAC) 192 TO 220VAC 360 TO 420 430 TO 504 OUTPUT kW @ MAXIMUM DEMAND 6.25kW OUTPUT TRANSFORMER VOLTAGE @ 2.5V...
  • Page 104 ©2022 Sunstone Engineering LLC. Sunstone and Sunstone Circle are trademarks of Sunstone Engineering LLC. Conditions and restrictions apply. Ask for details or visit www.suntonewelders.com/sunstonecircle for complete terms of service. Sunstone Engineering LLC reserves the right to change, alter, modify, or cancel this program at any time. 100 • Questions? Call or Text +1-801-658-0015...
  • Page 105 Call now to join the circle! 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 To Learn More wwww.sunstonewelders.com www.sunstonewelders.com/sunstonecircle PART #1230 ©2022 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20220322 •...
  • Page 106 ©2022 Sunstone Engineering LLC. Sunstone and Sunstone Circle are trademarks of Sunstone Engineering LLC. Conditions and restrictions apply. Ask for details or visit www.suntonewelders.com/sunstonecircle for complete terms of service. Sunstone Engineering LLC reserves the right to change, alter, modify, or cancel this program at any time.
  • Page 107 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 wwww.sunstonewelders.com PART #1230 ©2022 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20220322 •...

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Aeon hf-2500/208Aeon hf-2500/400Aeon hf-2500/480

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