Sunstone Zapp User Guide

Version 20250805 • Part #1604

Safety Information

⚠️ ATTENTION: Read the Safety Guide before operating this welder! Operator assumes all liability.

The document includes various safety warning symbols, such as those for explosion hazards (?), electrical hazards (⚡), hot surfaces (?), eye protection (?), general hazards (⚠️), magnetic fields (?), radioactive materials (☢️), and flammable materials (?).

Limitation of Liability: Sunstone Engineering LLC, its distributors, or suppliers are not liable for any indirect, incidental, consequential, special, exemplary, or punitive damages arising from the use or inability to use the Zapp product. This includes property damage, loss of value, or loss of use. Sunstone Engineering LLC's aggregate liability is limited to the amount actually paid by the customer for the product. Some jurisdictions may not allow these limitations.

Revision History

REVISION	DATE	VERSION NO.	DESCRIPTION OF CHANGES
1	08/2023	20230818	First Edition
2	11/2023	20231115	Update images
3	08/2025	20250805	Design Update

Getting Started

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 (WITHOUT LENS/MICROSCOPE)

The Zapp does not require a lens or microscope. Always wear proper eye protection.

Remove welder and accessories from the box and place on a flat workspace.
Plug the male end of the power cable into the AC Power port (C) on the back of the power supply. Connect the female end into an AC power supply. The Zapp has an internal switching power supply compatible with 120 and 240VAC.
Insert the 1/4" gas tube firmly into the Gas port (A) on the back of the welder.
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. These are suitable for most welding applications. 0.5mm electrodes are available separately.

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).
Loosen the Collet Cap (C) by twisting it counterclockwise.
The welder accommodates 0.5mm and 1.0mm electrodes. The 1.0mm electrode collet is installed by default.
Insert a 1.0mm electrode (D) into the Collet (B). Ensure 0.6 - 0.7 inch (1.5 – 2cm) of the electrode protrudes from the Stylus Shaft (A).
Lock the Electrode (D) into place by hand-tightening the Collet Cap (C) clockwise.
Replace the Stylus Hull (E) by twisting until tight. 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 tightened.

Stylus Components (Figure 2.4): Stylus Shaft (A), Collet (B), Collet Cap (C), Electrode (D), Stylus Hull (E).

Operation

How to Use the Dial

The Zapp dial controls all welding parameters with an easy-to-use interface.

Weld Energy Level: The Zapp offers a weld energy range of 3 to 10 Joules (or Ws), adjustable in one-joule increments. Higher numbers provide more energy and a larger weld spot.
Weld On/Off: When powered on, a small green light near the knob indicates the Zapp is ready to weld. Power off the unit when not in use.
The Dial: Turning the dial clockwise increases the Weld Energy Level by 1 Joule per number (e.g., 3 = 3 Joules). Aligning the arrow directly with a number provides the most accurate reading.
Light Blink: A blinking LED indicates the Zapp is changing energy levels or weld settings.

For new users, practice on the provided welding plate before performing actual welds.

How To Make a Weld

Turn the welder on. Energy is released when the electrode touches the welding plate AND the alligator clip is attached to the plate (or workpiece).
Ensure eyes are protected with the darkening lens or microscope. Never operate without eye protection.
If using an Auto Darkening Lens (ADL) or microscope, refer to Appendix A or B respectively. If not, use #5 shaded welding glasses.
Attach the alligator clip to the Stainless Steel Weld Plate.
Rest arms on the table, holding the plate with both hands. Ensure a clear view of the plate.
The Stainless Steel Weld Plate has rows labeled 'None', 'Sloped', 'Sustained', and 'Negative'. For Zapp, focus on the 'None' row. Create lower-powered welds on the left and higher-powered welds towards the right (up to 10J).
When the electrode touches the workpiece, do not retract it until the weld is complete. The Zapp automatically retracts the electrode slightly after the weld.
Practice by adjusting the Weld Energy Level from 3 to 4J, then 4 to 5J, and so on, touching the electrode to the plate in the second minimum column for each setting. Observe the difference in spot size and weld depth. Continue until welds are placed in every box, reaching the maximum power of 10J.

Tip: When the electrode touches the workpiece, wait for the weld to complete before moving. The Zapp's automatic retraction helps form a better weld spot.

What To Do If The Knob Comes Off

Spin the potentiometer counterclockwise as far as it will go. Push the knob onto the potentiometer with the marking indicator pointing at the left marking on the sticker.

Weld Settings for Chain

Below are energy settings for Sunstone's chains:

Aria: Yellow Gold Filled (3J), Sterling Silver (3J)
Aspen: Rose Gold Filled (3J), Yellow Gold Filled (5J), Sterling Silver (5J)
Brittany: Rose Gold Filled (6J), Yellow Gold Filled (6J), Sterling Silver (5J)
Bryce: Rose Gold Filled (6J), Yellow Gold Filled (3J), Sterling Silver (3J)
Charlie: Yellow Gold Filled (4J), 14k Yellow Gold (4J), Sterling Silver (4J)
Chloe: Rose Gold Filled (4J), Yellow Gold Filled (4J), 14k White Gold (4J), 14k Yellow Gold (4J), Sterling Silver (4J)
Ella: Rose Gold Filled (5J), Yellow Gold Filled (5J), Sterling Silver (5J)
Paisley: Yellow Gold Filled (4J), Sterling Silver (3J)
Robyn: Rose Gold Filled (4J), Yellow Gold Filled (4J), 14k Yellow Gold (4J)
Sarah: Yellow Gold Filled (4J), 14k Yellow Gold (4J), Sterling Silver (4J)
Shaylee: Rose Gold Filled (7J), Yellow Gold Filled (7J), Sterling Silver (6J)

For more chain options, scan the QR code to visit Sunstone Chains.

Maintenance & Setup

Electrode Care & Shield Gas Set Up

Electrode Care

Workpiece Electrode Pressure: Use very light pressure when touching the workpiece to the electrode. Excessive pressure can cause the workpiece to stick and contaminate the electrode. Clean or change the electrode when it sticks. A clean, sharp electrode yields the best results.
When to Sharpen the Electrode: A sharp tip improves arc initiation and focus. If an electrode appears dark or covered with material from previous welds, it can lead to inconsistent welding. Sharpen the electrode using the included diamond disk, which can be attached to a rotary tool.

Steps for Sharpening:

Completely remove the electrode from the stylus.
Pinch the electrode between the thumb and index/middle finger, with the shaft perpendicular to the fingers.
Power on the rotary tool and hold it with the opposite hand.
Place the electrode tip on the diamond disk, ensuring the grit moves parallel with the electrode shaft and towards the tip.
Turn the hex screw counterclockwise (towards the '+' symbol) to loosen the arm tension if it does not hold the microscope up. Turn clockwise (towards the '-' symbol) if the arm is too stiff to lower.
For cable management, tubes and cables can be routed through a removable guide.

PILOT Electrode Sharpener: Trade your old rotary tool for the Pilot, an electrode sharpener that cleans and sharpens electrodes in seconds. Visit www.sunstonewelders.com or call/text +1-801-658-0015.

Shield Gas Setup

During pulse arc welding, shielding gas prevents oxygen from entering the molten pool, which can cause brittle, porous, and burnt-looking metal. 99.996% pure argon (Argon 4.6) is recommended.

Pressurized Gas Safety: Always secure gas tanks to a fixed location. If a cylinder tips and is damaged, it can become a projectile.
Argon Gas Purchase: Premium argon gas is available from Sunstone. Call +1-801-658-0015 or visit www.sunstonewelders.com/gas for delivery.

Shielding Gas Tank and Regulator Setup

These instructions are specific to a Sunstone argon regulator. Consult other regulator instructions if necessary.

Ensure the shielding gas tank is securely fastened near the welding area.
Turn the argon regulator dial counterclockwise (closed) until it is fully backed out and loose.
Screw the gas regulator onto the shielding gas tank and tighten with a wrench.
Insert one end of the 1/4" OD gas tubing into the gas port on the back of the power supply. Tug gently to ensure a tight fit.
Connect the other end of the gas tubing to the gas regulator.
Open the gas tank main valve slowly. The regulator dials should respond. The primary dial shows tank pressure; the secondary dial shows hose pressure (should be zero when the regulator dial is fully backed out).
Slowly turn the regulator dial clockwise until the secondary dial shows gas pressure between 7-10 liters per second.

Scan the QR code for an Argon Gas Tutorial.

Appendix A: How to Connect the Basic Cables With Auto Darkening Lens

If you purchased a darkening lens or microscope, cabling needs vary slightly. The darkening lens or microscope will automatically darken during welding, allowing a view of the workpiece while protecting the operator.

Remove the welder and Darkening Lens System from the box and place on a flat workspace.
Plug the female end of the power cable into the AC Power port (C) on the back of the power supply. Connect the male end into an AC power supply. The Zapp has an internal switching power supply for 120 and 240VAC.
Insert the 1/4" gas tube firmly into the Gas port (A) on the back of the welder.
Insert the RJ45 Darkening Lens cable into the Shutter port (E) on the front of the welder. If using a microscope, see page 5 for instructions.
Note: Basic ADL is hard-wired. Upgraded ADL requires 2 connections: 1) Shutter Port on the welder, and 2) RJ45 Port on back of ADL.
Connect the alligator clip to the grounding port (D) on the front panel.
Connect the stylus to the back of the welder (B).

How to Place the Welding Stylus (with Auto Darkening Lens)

The basic Auto Darkening Lens darkness can be adjusted by turning the shade dial clockwise for lighter shade and counter-clockwise for darker shade.
Insert the Welding Stylus into the holder located behind the screen.
Adjust the stylus holder to approximately a 45-degree angle, angled down.
Connect the Stylus Cord to the back of the Zapp to the stylus port.

Appendix B: Microscope Arm Mounting Options

Mounting Option 1 - Clamp to Table

This option is best for tables with accessible edges and requires no drilling.

Hardware required: (1) Angled Bracket (C), (1) Sunstone Microscope Arm Assembly (A), (1) Clamp Mechanism (D), (5) Flat Head Hex Screws (G).
Lay the arm assembly down on a flat surface.
Attach the Angled Bracket (C) to the bottom of the Microscope Arm Assembly (A) using three (3) flat head hex screws (G) and a 4mm (5/16") Allen wrench.
Attach the Clamp Mechanism (D) to the Angled Bracket (C) using two (2) flat head hex screws. For thicker tables, use the two lower holes in the Angled Bracket.
Adjust the knob on the Clamp Mechanism (D) to ensure sufficient gap for the tabletop thickness.
Slide the arm onto the table.
Lock the arm into place by turning the knob on the Clamp Mechanism (D) until the clamp presses firmly against the underside of the table.
A plastic cable guide cover (E) can be clipped onto the angled bracket.

Mounting Option 2 - Bolt through Table

This option is best for tables without accessible edges.

Hardware required: (1) Flat Mounting Plate (H), (3) Flat Head Hex Screws (G), (1) Long Carriage Bolt (F), (1) Flat Pressure Plate (I), (1) Adjustment Knob (J).
Using a 4mm (5/32") Allen wrench, unscrew the flat head hex screws (G) holding the Flat Mounting Plate (H) to the arm.
Run the 8mm (5/16") Long Carriage Bolt (F) through the Flat Mounting Plate (H).
Attach the Flat Mounting Plate (H) to the bottom of the arm using (3) flat head hex screws (G).
Drill a 3/8" (9.5mm) hole through the tabletop.
Lower the arm so the Long Carriage Bolt (F) goes through the hole in the tabletop.
Slide the Flat Pressure Plate (I) onto the bolt.
Turn the Adjustment knob (J) clockwise to tighten the plate to the underside of the table.

Mounting Option 3 - Screw to Table (vertical surface)

Hardware required: (1) Angled Mount Bracket (C), (3) Flat Head Screws (G), (2) Wood Screws (not included).
Attach the Angled Bracket (C) to the bottom of the Microscope Arm Assembly (A) using three (3) flat head hex screws (G).
Run wood screws through the Mounting Bracket (C) and into a vertical surface of the table.

ARM TENSION ADJUSTMENT

Spring tension is factory pre-set. Adjustments can be made by turning a hex screw on the arm joint using the included 6mm Allen wrench.

Turn the hex screw counterclockwise (towards the '+' symbol) if the arm does not hold the microscope up.
Turn the hex screw clockwise (towards the '-' symbol) if the arm does not allow the microscope to be lowered easily.
For cable management, tubes and cables can be routed through a removable guide.

PJ Scope Set Up

MICROSCOPE SETUP

Refer to the setup instructions that shipped with the PJ Scope.
Plug the included Shutter Cable into the RJ45 port on the microscope (the bottom of the microscope head).
Plug the other end of the Shutter Cable into the Shutter port on the front of the welder.
Note: Connecting non-Sunstone products to the RJ45 port on the Zapp may damage the welder and/or other devices.

How to Adjust Microscope Focus

Twist the knob on the microscope forward and backward to lower and raise the head, allowing you to focus on the welding stylus.
Place your finger under the welding electrode to help judge the correct focus location. Focus until the texture on your finger is clearly visible.

Mounting Zapp Stylus in Upgraded Darkening Lens

Remove the gray spacer (See Figure 15.2) from the stylus holder. This spacer is not required for the Zapp stylus.
Connect the shutter cable into the RJ45 port on both the welder and the ADL.
Place Zapp Stylus in the stylus holder and secure with the thumb screw.
Adjust the stylus to the desired position within the viewing area of the ADL.

Mounting Zapp Stylus in Microscope & PJ Scope

Install the rubber eyepiece covers onto the microscope lenses.
Plug the included Shutter Cable into the RJ45 port on the microscope (the bottom of the microscope head).
Plug the other end of the Shutter Cable into the Shutter port on the back of the welder.
Connecting other RJ45 compatible devices to the Orion PJ shutter RJ45 port may damage the welder and/or other devices.
Remove the gray spacer (See Figure 15.4) from the stylus holder.

How to Place the Welding Stylus (with Microscope)

If using a microscope, insert the Welding Stylus into the holder at the bottom of the Microscope Arm Assembly.
The tubing can be routed up and through the removable cable guide portion of the Microscope Arm Assembly.
Position the Welding Stylus so only the smaller diameter portion protrudes from the holder. Tighten the thumb screw on the bottom of the stylus holder.
Adjust the stylus holder to approximately a 45-degree angle (angled down).
Fine-tune the position of the Welding Stylus by loosening the thumb screw on the bottom side of the stylus holder and sliding the Welding Stylus forward and backward until the tip is centered in your focus.

Microscope Tips

The Zapp microscope offers visual clarity, eye protection, and ease of use. A common challenge is positioning the workpiece to the welding electrode while looking through the microscope.

While the welder is paused, rest your hands on the table and position the workpiece close to the welding electrode before looking into the microscope.
Ensure your focus is at the tip of the electrode.
Use slow, controlled movements. Move the workpiece with your fingers.
Place the workpiece surface perpendicular to the electrode tip. The angle of the electrode tip relative to the workpiece surface is crucial and requires practice.
Practice making soft contact with the workpiece to the electrode.
Once comfortable, attach the alligator clip to the workpiece and touch the workpiece to the electrode. Hold steady for the weld to occur.

Note: Be mindful of energy settings. Start low (3-4J) and increase gradually to avoid damaging the workpiece.

Microscope LCD Filter Shutter System

The Microscope LCD Filter Shutter System provides an unobstructed view before welding and protects eyes during the process. The Zapp's internal computer verifies the shutter system has activated before allowing a weld. If the shutter does not activate, the microscope lens is equipped with >UV 16 and >IR 16 for maximum eye protection.

Warning: Avoid direct view of the welding area without protective lenses.

Product Specifications


WELD MODES	1
PEAK POWER (J)	10 J
ENERGY (J)	3-10 J
ENERGY SETTINGS	8
WELDS/SECOND	1
WELD SPOT DIAMETER	0.5 - 1.0mm
INPUT POWER	100/230 VAC (Auto Detect)
FOOTPRINT (LXWXH)	14.60 x 17 x 9.44 cm
WEIGHT	1.9 lbs (0.86kg)
EYE PROTECTION	Auto Darkening Lens or Glasses

Download the Safety Guide by scanning the QR code for more detailed information on welding science and techniques.

Contact Information

Sunstone Engineering LLC
The Micro Welder Experts
1693 American Way Ste 5 • Payson UT 84651 USA
Tel. +1-801-658-0015
www.sunstonewelders.com