SUNSTONE Zapp Manuale utente

Users Guide

Version 20230818 • Part #1604

Zapp™

ATTENTION: Read the Safety Guide before operating this welder!

Operator assumes all liability.

REVISION DATE VERSION NO. DESCRIPTION OF CHANGES

1 08/2023 20230818 First Edition

LIMITATION OF LIABILITY

IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING LLC, ITS DISTRIBUTORS,

OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY

OR PUNITIVE DAMAGES, OF ANY NATURE WHATSOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGI-

NEERING LLC PRODUCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGINEER-

ING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING 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. WITHOUT LIMITING THE FOREGOING, YOU UNDERSTAND AND AGREE THAT SUNSTONE ENGINEERING LLC

HAS NO LIABILITY FOR ANY DAMAGE OR DESTRUCTION TO ANY PROPERTY. NOTWITHSTANDING ANY DAMAGES THAT YOU MIGHT

INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMITATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT

OR GENERAL DAMAGES IN CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE), THE ENTIRE AGGREGATE LIABILITY OF

SUNSTONE ENGINEERING LLC AND ANY OF ITS DISTRIBUTORS AND/OR SUPPLIERS SHALL BE LIMITED TO THE AMOUNT ACTUALLY

PAID BY YOU FOR THE SUNSTONE ENGINEERING LLC PRODUCT GIVING RISE TO LIABILITY. SOME STATES AND/OR JURISDICTIONS

DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR

EXCLUSIONS MAY NOT APPLY TO YOU. THE LIMITATIONS OF LIABILITY SET FORTH ABOVE SHALL APPLY TO THE MAXIMUM EXTENT

PERMITTED UNDER APPLICABLE LAW.

Contents

Welder Setup & Assembly ....................................................................................................... 1

Electrode Setup .................................................................................................................. 2

How to Use the Dial.............................................................................................................. 3

How to Make a Weld ............................................................................................................ 4

Recommended Weld Settings ............................................................................................... 6

Electrode Care & Shield Gas Setup...................................................................................... 7

Microscope Tips .................................................................................................................10

Appendix A ..................................................................................................................................11

How to Connect the Basic Cables With Auto Darkening Lens..........................11

How to Place the Welding Stylus .................................................................................12

Appendix B ..................................................................................................................................13

Microscope Arm Mounting Options ...........................................................................13

How to Adjust Microscope Focus ................................................................................15

How to Place the Welding Stylus .................................................................................16

 .............................................................................................................15

Permanent Jewelry Training Video

Watch this video for permanent jewelry training, setup

recommendations, time-saving tips and tricks, and more!

Pulse Arc Welding Workbook and Safety Guide

Download this document to access advanced welding

techniques and safety information.

Questions? Call or Text +1-801-658-0015 • 1



The Zapp does not require the use of any lens or microscope. Always wear proper eye protection when you are



• 

• Plug the male end of the power cable into the AC Power port (C) on the back of the power supply. Then

connect the female end into an AC power supply. The Zapp has an internal switching power supply

that can accept both 120 and 240VAC.

• 

connected, but should not come out if pulled on.

• Connect the alligator clip to the grounding port (D) on the front panel.

• Connect the stylus to the back of the welder (B).

Electrode Setup

The Zapp comes standard with a 1.0mm electrode collet and three (3) 1.0mm electrodes. The 1.0mm elec-



0.5mm electrodes.

Figure 1.1. The back panel of the Zapp. Argon Gas Port

(A). Stylus Port (B). Power Port (C).

Figure 1.2. The back panel of the Zapp. Grounding Port

(D). Shutter Port (E).

What is in the Box

(1) Zapp Welder/Power Supply and Stylus Hand Piece

(1) Zapp Welder Power Cord (2 pieces)

(1) Alligator Clip

(1) Shielding Gas Hose

(1) Electrode Vial (three 1.0 mm Electrodes)

(1) Metal sample card

(1) Pair of shaded welding glasses

How to Connect the Basic Cables

Welder Setup & Assembly

2• Questions? Call or Text +1-801-658-0015

Zapp™User Manual

Figure 2.1. To install the electrode, rst remove the Stylus

Shaft (A) from the Stylus Hull (E) by pulling them apart.

Figure 2.2. Use the guide on the side of the Stylus Hull (E) for

proper Electrode (D) positioning.

Install the Tungsten Electrode Onto the

Welding Stylus

Refer to the Stylus Components Chart (Figure 2.4) to install

the tungsten electrode (D).

• Remove the Stylus Hull (E) by pulling it away from

the Stylus Shaft (A). See Figure 2.1.

• Loosen the Collet Cap (C) by twisting it counter-

clockwise.

The welder accommodates 0.5mm and 1.0mm electrodes.

The electrode stylus will be shipped with the 1.0mm elec-

trode collet installed.

• Insert a 1.0mm electrode (D) into the Collet (B).

Helpful Tip: There is a machined groove on the side of

the Stylus Hull (E) that helps measure the electrode

length. Place the end of the Stylus Hull (E) against

the Collet Cap (C), then make sure the Electrode (D)

extends as indicated. See Figure 2.2.

• There should be between 0.6 - 0.7 inch (1.5 – 2cm)

of the Electrode (D) protruding from the Stylus

Shaft (A). This will allow the Electrode enough room

to stick out from the Stylus Shaft once the Stylus

Hull (E) is placed back on the Stylus Shaft.

• Lock the Electrode (D) into place by hand tightening

the Collet Cap (C) in a clockwise direction.

• Replace the Stylus Hull (E) by pushing it in until

you feel it snap back into place. The Electrode (D)

should protrude from the Stylus Hull (E) by 1/8 –

1/4 inch (3.175 – 6.35mm) after the Stylus Hull is

snapped back into place. See Figure 2.3.

Figure 2.3. Electrodes should protrude past the stylus

hull 1/8 to 1/4 inch (3.175 to 6.35mm).

Stylus Shaft A Collet B Collet Cap C Electrode D Stylus Hull E

Stylus Components

Figure 2.4.

Questions? Call or Text +1-801-658-0015 • 3

The Zapp dial is very user friendly. Users have access to every welding parameter with one easy-to-use dial.

Weld Energy Level

The Zapp has weld energy range of 3 to 10 Joules (or Ws), which is selected in one joule increments. The larger

the number the more energy released through the electrode and, generally speaking, the larger the weld spot.



When the Zapp is initially powered on it is ready to weld. A small green light in the upper left corner, near the

knob, will illuminate when the Zapp is ready to weld.



The Dial

As you twist the dial to the right, the Weld Energy Level will increase 1 Joule. 3 = 3 Joule, 4 = 4 Joules, etc.

Pointing the arrow on the dial directly at the number will give the most accurate power reading.

Light Blink

When the small LED light blinks, the Zapp is changing energy. As the knob is turned up or down this blink indi-

cates a change in weld setting.

-

ing plate. After careful setup and familiarization of how the welder operates, follow these instructions using the

welding plate.

Figure 3.1. The dial and it’s settings.

How To Use the Dial

4• Questions? Call or Text +1-801-658-0015

Zapp™User Manual

• Turn the welder on. With the welder on, energy

will only be released when the electrode

touches the welding plate AND the alligator

clip is attached to the welding plate (or any

workpiece). Don’t worry about the alligator clip

yet.

• Make sure your eyes are protected by properly

using the darkening lens or microscope. Never

operate the welder without eye protection.

• If you are using an Auto Darkening Lens

(ADL) with the Zapp, refer to Appendix

A before proceeding.

• If you are using a swing arm micro-

scope or the PJ Scope, refer to

Appendix B before proceeding.

• If you don’t have an Auto Darkening

Lens (ADL), microscope, or PJ Scope,

ensure that you are using #5 shaded

welding glasses.

• Attach the alligator clip to the Stainless Steel

Weld Plate as shown in Figure 4.2.

• Rest your arms on the table or workbench,

holding the metal plate with both hands.

• Make sure you have a clear view of the metal

plate.

• The Stainless Steel Weld Plate is organized into

rows. For this exercise, lightly touch the welding



minimum column. When the electrode makes

contact with the welding plate, the welder will

release energy and a weld will occur.

Note: Sloped, Sustained, and Negative Rows are not

applicable to the Zapp, so ignore the labels and focus

Figure 4.1 Set the Weld Energy Level to 3 J energy.

Figure 4.2 Attach the alligator clip to the welding plate. With

proper eye protection, hold the welding plate with both hands

and lightly touch the electrode to the welding plate. When the

electrode contacts the welding plate, the welder will release

energy and create a weld.

How To Make a Weld

Questions? Call or Text +1-801-658-0015 • 5

on the row labeled “None”. Create lower-powered practice welds on the left and higher powered welds as you

move right (maximizing at 10J).

Tip: When the electrode touches the workpiece, don’t back away from the electrode until after the weld is com-

pleted. The Zapp will automatically retract the electrode away from the workpiece by a few millimeters when the

weld occurs. This retraction assists in forming a more desirable weld spot. If you move the workpiece away from

the electrode just before or during the weld, the weld will not occur.

• Adjust the Weld Energy Level from 3 to 4J using the dial. Then touch the electrode to the second

minimum column.

• Next, adjust the Weld Energy Level from 4 to 5J using the knob. Then touch the electrode to the second



larger and the weld will be deeper.

• Repeat the process of increasing the energy level and then touching the plate in the next box. And then

repeat again until you’ve placed a weld in every box. Eventually, you should reach the maximum amount

of power (10J).

6• Questions? Call or Text +1-801-658-0015

Zapp™User Manual

Weld Settings for Chain

Below are energy settings for Sunstone’s chains.

Indice

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