The provided document is a user manual for the Zapp Plus™ pulse arc welder, manufactured by Sunstone, "The Micro Welder Experts." This manual outlines the setup, operation, maintenance, and specifications of the Zapp Plus, along with information on compatible accessories and other Sunstone welding products.
Function Description:
The Zapp Plus is a pulse arc welder designed for various welding applications, particularly for permanent jewelry. It utilizes pulse arc welding technology where a high-temperature plasma quickly melts metal into a molten pool. A small amount of shielding gas (argon) is released through the weld stylus to prevent oxygen from entering the molten pool, which would otherwise result in brittle, porous, and burnt-looking metal oxide. The device is user-friendly, offering precise control over welding parameters through a single dial. It can be used with or without a microscope or auto-darkening lens, though proper eye protection is always required.
Important Technical Specifications:
- Weld Modes: 1
- Peak Power (J): 30 J
- Energy (J): 1-30 J (adjustable in one-joule increments)
- Energy Settings: 8 (This likely refers to internal settings or presets, though the dial allows for 1-30J selection)
- Welds/Second: 1
- Weld Spot Diameter: 0.5-2.0mm
- Input Power: 100/230 VAC (Auto Detect) – The Zapp Plus has an internal switching power supply that can accept both 120 and 240VAC.
- Footprint (LxWxH): 14.60 x 17 x 9.44 cm
- Weight: 1.9 lbs (0.86kg)
- Eye Protection: Auto Darkening Lens, Microscope, or Glasses (provided shaded welding glasses are #5 shade).
- Electrode Compatibility: 0.5mm and 1.0mm electrodes (shipped with 1.0mm collet and three 1.0mm electrodes).
- Shielding Gas: 99.996% pure argon (Argon 4.6) is recommended.
Usage Features:
- Simple Dial Control: The Zapp Plus features a single dial for adjusting the weld energy level from 1 to 30 Joules. Turning the dial to the right increases energy. A small green light indicates when the unit is ready to weld. A blinking LED light signifies a change in weld setting as the knob is adjusted.
- Weld Activation: Energy is released only when the electrode touches the workpiece AND the alligator clip is attached to the workpiece.
- Electrode Retraction: The Zapp Plus automatically retracts the electrode a few millimeters from the workpiece after a weld, which helps form a more desirable weld spot.
- Eye Protection: Users must always wear proper eye protection. Options include the provided #5 shaded welding glasses, an Auto Darkening Lens (ADL), or a microscope with a shutter system.
- Practice Welding: A metal sample card (welding plate) is included for practicing welds and familiarizing oneself with the welder's operation. The manual recommends starting with lower energy settings (1-2J) and gradually increasing them up to 30J.
- Stylus Connection: The stylus hand piece connects to the Stylus Port (B) on the back of the welder.
- Grounding: The alligator clip connects to the grounding port (D) on the front panel.
- Shielding Gas Connection: A 1/4" gas tube is inserted into the Gas port (A) on the back of the welder.
- Microscope Integration (Optional): The Zapp Plus can be integrated with Sunstone's Auto Darkening Lens (ADL), swing arm microscope, or PJ Scope. These accessories automatically darken during a weld to protect the operator's eyes while providing a clear view of the workpiece. Specific instructions are provided for connecting these accessories, including the RJ45 Darkening Lens cable to the Shutter port (E) on the welder.
- Stylus Placement: Instructions are provided for placing the welding stylus in its holder, adjusting its angle (approximately 45 degrees down), and fine-tuning its position for optimal focus when using a microscope.
- Microscope Focus Adjustment: A knob on the microscope allows for adjusting the head's height to focus on the welding stylus. Users are advised to use their finger under the electrode to help judge the correct focus location.
- Microscope Arm Mounting Options: The manual details three mounting options for the microscope arm: Clamp to Table, Bolt through Table, and Screw to Table (vertical surface), providing hardware requirements and step-by-step instructions for each.
- Microscope Arm Tension Adjustment: The spring tension of the microscope arm can be adjusted using a hex screw and a 6mm Allen wrench.
Maintenance Features:
- Electrode Sharpening: A clean, sharp electrode tip is crucial for best welding results. Electrodes should be sharpened when they appear dark or covered with material from previous welds. The manual provides a step-by-step guide for sharpening electrodes using a diamond disk attached to a rotary tool, emphasizing the correct angle (15 degrees) and movement. Sunstone also offers the "Pilot" electrode sharpener as an upgrade.
- Electrode Replacement: The Zapp Plus accommodates 0.5mm and 1.0mm electrodes. Instructions are provided for installing and locking electrodes into the collet, including a machined groove on the stylus hull for measuring proper electrode length (0.6-0.7 inches protruding from the stylus shaft, or 1/8-1/4 inch from the stylus hull).
- Shielding Gas Management: Proper setup of the argon gas tank and regulator is detailed, including ensuring the tank is securely fastened, slowly opening the main valve, and setting the regulator dial to achieve 7-10 liters per second gas pressure. It is crucial to turn off the shielding gas at the main valve when finished to prevent leaks and ensure safety.
- Knob Reattachment: Instructions are given for reattaching the dial knob if it comes off, ensuring it is pushed onto the potentiometer with the indicator pointing at the left marking on the sticker after spinning the potentiometer counterclockwise.
The manual also includes a "Limitation of Liability" statement, emphasizing that the operator assumes all liability and must read the Safety Guide before operation. It provides contact information for Sunstone for questions, support, and purchasing additional accessories like argon gas and chains.
Need help?
General
To Next Page