SUNSTONE CD200DP-A User manual

Sunstone Welders
User Manual : CDDP-A
Sunstone Welders
Advanced Capacitive Discharge Dual Pulse Welder
User Manual for Models: CD200DP-A, CD400DP-A, CD600DP-A

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Sunstone Welders User Manual: CDDP-A
Table of Contents
FORWARD - P.3
CHAPTER 1: WELDER OVERVIEW - P.4
Features - P. 4
Applications - P. 4
CHAPTER 2: RESISTANCE WELDING - P.5
What is Capacitive Discharge Resistance Welding? - P. 5
Weld Formation - P. 6
Tips - P. 6
Weld Pressure - P.6
Electrode Congurations - P.6
Weld Energy - P.7
CHAPTER 3: SET UP - P.7
Pre-Setup Information - P.7
Voltage and Power Requirements - P.7
Weld Actuation - P.7
Thermal Protection - P.8
Front Panel Connections - P.8
Power Button - P.8
Weld On/Off - P.8
Screen - P.8
Side Panel Connections - P.8
USB - P.8
Back Panel Connections - P.9
Ethernet - P.9
Accessory - P.9
PLC - P.9
E-STOP - P.10
WH Control - P.10
Primary Trigger - P.10
Secondary Trigger - P.10
Negative Weld Terminal - P.11
Positive Weld Terminal - P.11
Fuse - P.11
Power Inlet - P.11
Welder to Weld Head Setup - P.11
Conguration 1 - P.11
Conguration 2 - P.11
Conguration 3 - P.12
Welder to Hand Held Attachment Setup - P.12
Roll Spot Setup - P.13
CHAPTER 4: OPERATING INSTRUCTIONS - P.14
Pulse Control - P.14
Dual Pulse Welding - P.14
Using The Dual Pulse Weld Function - P.14
Setting Pulse 1 and 2 - P.14
Energy Adjustment - P.14
Timing Diagrams - P.15
Automation - P.17
Maintenance - P.18
Safety - P.18
CHAPTER 5: USER INTERFACE - P.19
Home Screen/Pulse Settings - P.19
Comparator - P.20
2nd Comparator - P.21
Control - P.22
Basic PLC I/O - P.23
Remote Schedule Select - P.24
Alarms - P.24
Import/Export - P.25
Media Screens - P.26
Save/Load Screen - P.28
Lock Screen - P.30
Settings Screen - P.31
Settings Screen Pop Ups - P.32
Warnings and Alarm Pop Ups - P.34
DATA TABLES - P.38
Additional Safety - See included Safety and Basics User Manual
Warranty - See included Safety and Basics User Manual

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Copyright 2018
Sunstone Engineering
R&D Corporation
Foreword:
Thank you for choosing Sunstone Engineering and congratulations on your purchase!
You are now the proud owner of a Sunstone Capacitive Discharge (CD) Dual Pulse (DP) Welder.
This manual was designed to have you welding safely within minutes of unpacking your new welder.
Please read and follow all safety precautions before proceeding with the welding process.
At Sunstone Engineering we are committed to producing quality products and ensuring complete
owner satisfaction. If you require assistance after reading this manual, do not hesitate to contact us
at:
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Payson, UT 84651
Email: [email protected]
Voice: 801-658-0015
Fax: [phone]
NOTE: The information contained in this manual is subject to change as improvements are made to
our products. Visit your product’s respective web page on www.SunstoneWelders.com for the latest
version of this document.

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Sunstone Welders User Manual: CDDP-A
Chapter 1: Welder Overview
Features
Each of the Dual Pulse CD welders can be adjusted and ne-tuned to match the requirements of
countless applications. When combined with Sunstone’s line of weld heads or hand attachments, CD
welders perform strong and repeatable welds for high levels of consistency and quality control.
• Dual Pulse operation removes surface inconsistencies and contaminants
• Available with 200, 400, & 600ws of energy
• Single or Dual Pulse weld congurations
• Microprocessor controlled
• Internal thermal protection circuit
• Adjustable pulse width
• Energy storage adjustable from less than 1% to 100% capacity
• Up to 650 welds/min (using CD200DP-A)
• 110 or 220VAC input
• Simple, user-friendly interface
• Quick energy release for welding highly conductive metals
• Small heat effected weld zones
• Repeatable energy release independent of line voltage uctuations
• Extremely ne energy adjustment (0.01ws increments)
Applications
Sunstone Capacitive Discharge Welders are used all across the globe for a variety of different welds.
Some of the most common uses of our CD Welders include:
• Battery pack manufacturing and repair
• Honeycomb applications
• Aerospace applications
• Automotive welding
• Cross wire welding
• Thermocouples
• Electronic components
• Thin sheet and wire welds of:
• Copper
• Aluminum
• Brass
• Steel

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There are many other applications for Sunstone’s line of Capacitive Discharge Welders. Let us know
if you nd a unique use for our welding equipment.
Chapter 2: Resistance Welding
What is Capacitive Discharge Resistance Welding?
Capacitive discharge resistance welders, also called capacitive discharge or CD welders, utilize
internal capacitors to store energy. These capacitors are able to discharge large amounts of energy
very rapidly. The rapid discharge of energy is critical to forming the weld nugget. Formation of the
weld nugget occurs during the rst few milliseconds of the welding process. Sunstone’s proprietary
technology allows the energy to be discharged with very high peak currents, as seen in FIGURE 1
below, to produce the best weld nuggets.
This technology is not only designed to increase the energy delivered for weld formation but to
also minimize the heat that is spread to the surrounding material. This ‘heat-affected zone’ around
the weld can suffer from rapid heating and cooling from the weld. But with Sunstone’s proprietary
technology, this zone can be localized to just a small spot around the weld.
FIGURE 1: Sample capacitor discharge curve with high peak current.

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Sunstone Welders User Manual: CDDP-A
WELD FORMATION
Spot welding relies on metal resistivity (resistance) to heat and fuse metal. A large current is passed
through the workpiece metal. Energy is dissipated due to metal resistance in the form of heat which
melts and fuses the weld materials. The welder must overcome both the contact resistance and the
bulk resistance of the material in order to begin the melting process.
FIGURE 2 below shows an example of a micro-scale surface prole. On the micro-scale, material
surfaces are rough and only contact in a limited number of locations. In the rst few milliseconds of
weld formation, the high-resistance metal bridges melt, allowing other bridges to come into contact
to continue the melting process. When all of the bridges have fused, the contact resistance is zero.
The bulk resistance of the metal then plays the nal role in the weld formation.
FIGURE 2: On the micro-scale, surface
roughness limits surface-to-surface contact.
More contact points result in a lower contact
resistance.
Tips
WELD PRESSURE
Several other factors play a part in the contact resistance. The larger the contact resistance the
hotter the resultant weld. On the micro-scale, contact resistance is reduced when more metal bridges
or contact points are formed (see FIGURE 2). Using more electrode pressure creates more metal
bridges. This results in a lower contact resistance and a cooler weld. Conversely, light electrode
pressure results in less metal contact, higher resistance, and a hotter weld. An appropriate amount of
pressure should be used to ensure good weld strength.
ELECTRODE CONFIGURATIONS
FIGURE 3 shows several electrode congurations used in resistance welding. FIGURE 3a is called
an opposed conguration. Current is passed from one electrode through both workpieces and out
an opposing electrode. FIGURE 3b shows a step electrode conguration. This conguration is
used when there is access to only one side of the workpiece and an electrode can be placed on
both materials. FIGURE 3c is a series or parallel conguration. Electrodes can only be placed on
one metal surface from one side. Current is divided between the two parts. This weld conguration
requires more weld energy.

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FIGURE 3: Resistance Welding Electrode Congurations:
WELD ENERGY
Sunstone capacitive dual pulse welders allow adjustment of the stored
energy via the touch screen user interface, shown in FIGURE 4. The
energy is then displayed in watt seconds (Joules) as a waveform
graph on the user interface LCD display. The Total Stored Energy
will change how much energy is stored in the internal capacitors and
directly corresponds to the peak current available. The energy of Pulse
1 and Pulse 2 can be changed independent of each other, but the Total
Stored Energy of Pulse 1 and Pulse 2 added together must be lower
than the Total Stored Energy. More information can be found on p.14 of
this manual.
FIGURE 4: Touch Screen Interface
Chapter 3: Setup
Pre Setup Information
VOLTAGE AND POWER REQUIREMENTS
Sunstone Advanced Capacitive Discharge Dual Pulse (CDDP-A) welders are equipped with universal
power supplies and can be used with either 110 or 220VAC. No voltage selection is required prior to
connecting and powering on the welder. The welder will detect the voltage, and make the appropriate
adjustments automatically.
WELD ACTUATION
The CDDP-A welders are actuated by means of an external trigger port located on the back of
the welder (see FIGURE 5). The trigger uses a 3 DIN (p.12) connector and requires shielded wire.
FIGURE 5 shows the proper pin placement for custom external trigger cables. The standard external
trigger cable connector is an SD-30LP made by CUI Inc.
a. Opposed b. Step c. Series / Parallel

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Sunstone Welders User Manual: CDDP-A
FIGURE 5: External Trigger Wiring Diagram - N.O. stands for
Normally Open.
THERMAL PROTECTION
Sunstone’s capacitive discharge welders are equipped with temperature sensors. If the unit is hot it
will warn the user with a pop up. After the unit is cool enough to operate, the welder will go back to
normal operation. Please maintain a clear space of 6+ inches around the welder fans. FIGURE 6,
below, shows the location of the fans on the back of the welder.
FIGURE 6: For proper cooling, ensure all fan locations are
unobstructed.
Front Panel Connections
POWER BUTTON: A latching push button that turns the unit on when depressed.
If unpressed the unit will turn off. Warning: DO NOT turn the welder off during
boot up. Allow enough time for unit to completely boot up before turning unit
off.
WELD ON/OFF: A latching push button that enables welding when depressed.
An LED will light up when the push button is depressed completely. This
indicates that the weld is enabled. We always recommend to turn OFF the
Weld On/Off switch whenever making changes to electrodes or other welding
equipment connected to the welder.
SCREEN: 8” capacitive touch screen with a WXGA LCD. This makes it
convenient for navigating the interface and setting up the machine.
FIGURE 7: Front Panel
Side Panel Connections
USB: A USB ash drive (thumb drive) can be used to update the machine. A USB ash drive can
also be inserted when data collection in desired from the weld process. You can also connect a
compatible USB wired mouse to navigate the interface.

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Back Panel Connections
All DIN connections are displayed as viewed from the
back panel.
ETHERNET: Plug an Ethernet cable into this port if you
desire to control the CDDP-A with a PLC.
ACCESSORY: Used to connect external accessories
(Coming Soon).
FIGURES 9 through 13 show the DIN connectors
pin-out, looking at the back panel.
FIGURE 8: Back Panel
PLC: MATES TO SD80LP
1: GND/Shield
2: +12V Current Limited
3: PLC Input 1. Short this pin with Pin1 (GND) to trigger an action.
4: PLC Input 2. Short this pin with Pin1 (GND) to trigger an action.
5: Weld Ready. Pull this pin up to +12V by connecting it with Pin 2 (+12V). Signal will go low 0V,
when weld is ready.
6: Alarm. Pull this pin up to +12V by connecting it with Pin 2 (+12V).
Signal will go low 0V, when alarm has occurred.
7: PLC Output 1. Pull this pin up to +12V by connecting it with Pin 2
(+12V). Signal will go low 0V, when this output has been enabled.
8: PLC Output 2. Pull this pin up to +12V by connecting it with Pin 2
(+12V). Signal will go low 0V, when this output has been enabled.
*If you choose to use the software E-STOP alarm as one of the PLC
outputs on the 8 DIN PLC connector, realize that this signal will only be
a pulse that will last a minimum of 50 milliseconds.
FIGURE 9: PLC Connector (SD-80LS)
200 400 600

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Sunstone Welders User Manual: CDDP-A
ESTOP: MATES TO SD60LP
Pin 1: GND/Shield
Pin 2 & 3: Normally open, ESTOP enabled. Close circuit to disable ESTOP
FIGURE 10: E-STOP Connector (SD-60LS)
WH CONTROL: MATES TO SD40LP
Pin 1: GND/Shield
Pin 2: Weld Head Actuation 2. +12VDC(0.5A Max) is sent when weld head
needs to actuate.
Pin 3: Weld Head Actuation 1. +12VDC(0.5A Max) is sent when weld head
needs to actuate.
Pin 4: GND/Shield
FIGURE 11: WH Control Connector (SD-40LS)
PRIMARY TRIGGER: MATES TO SD50LP
Pin 1: Variable Foot Pedal. Connect this to Pin5 (+12VDC) with a 10Kohm
potentiometer.
Pin 2: Primary Trigger. Connect this to pin3 (GND) when trigger is desired.
Pin 3: GND/Shield
Pin 4: Secondary Trigger. Connect this to pin3 (GND) when trigger is desired.
Pin 5: +12VDC limited.
FIGURE 12: Primary Trigger Connector (SD-50LS)
SECONDARY TRIGGER: MATES TO SD30LP
Pin 1: Not Connected
Pin 2: +12V
Pin 3: Secondary Trigger. Connect this to pin 2(+12VDC) when trigger is desired.
FIGURE 13: Secondary Trigger (SD-30LS)

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NEGATIVE : Negative weld terminal. Connect weld cable
using ¼-20 x ¾” bolt and nut. Make sure your total weld cable
resistance is greater or equal to 1 milliohm of resistance.
POSITIVE +: Positive weld terminal. Connect weld cable using
¼-20 x ¾” bolt and nut. Make sure your weld cable resistance is
greater or equal to 1 milliohm of resistance.
FUSE: 10A fuse rated for up to 250VAC
90-250 VAC, 60Hz
POWER INLET: Plug wall power into this port. Can accept voltage
from 90-250VAC at a frequency of 50/60Hz.
FIGURE 14: Back Panel
Welder to Weld Head Setup
There are 3 possible congurations when using a weld head or hand attachment.
CONFIGURATION 1: Using manual weld head and driven separately from the CDDP-A welder.
1. Remove the welder from the box and place it on a secure work surface.
2. Connect the female end of the power cord into the back of the welder and the male end into an AC
power outlet.
3. Attach weld head or hand attachment cables to negative and positive terminals.
4. Ensure either E-STOP bypass plug in plugged in or an E-STOP switch is plugged into the 6 DIN
E-STOP connector labeled “E-STOP”on back panel.
5. Attach a foot pedal to secondary trigger on back panel.
6. Turn the welder on by pressing in Power button on front panel.
7. On main screen adjust you Total Stored Energy, Pulse 1 energy, and Pulse 2 energy.
8. On the control screen adjust your weld head control scheme to “Fully Manual”.
9. Enable welder, by pressing in Weld On button on front panel.
10. Trigger a weld with foot pedal.
CONFIGURATION 2: Using with weld head actuated manually and driven with the CDDP-A welder.
1. Remove the welder from the box and place it on a secure work surface.
2. Connect the female end of the power cord into the back of the welder and the male end into an AC

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Sunstone Welders User Manual: CDDP-A
power outlet.
3. Attach weld head to negative and positive terminals.
4. Ensure either E-STOP bypass plug in plugged in or an E-STOP switch is plugged into the 6 DIN
E-STOP connector labeled “E-STOP”on back panel.
5. Attach a foot pedal to secondary trigger on back panel.
6. Attach the weld head 4 DIN actuation cable to the 4 DIN connector labeled “WH Control” on back
panel.
7. Turn the welder on by pressing in Power button on front panel.
8. On the main screen adjust your Total Stored Energy, Pulse 1 energy, and Pulse 2 energy.
9. On the control screen adjust your weld head control scheme to “Fully Manual”.
10. Enable welder, by pressing in Weld On button on front panel.
11. Trigger a weld with foot pedal.
CONFIGURATION 3: Using air actuated weld head and driven with the CDDP-A welder.
1. Remove the welder from the box and place it on a secure work surface.
2. Connect the female end of the power cord into the back of the welder and the male end into an AC
power outlet.
3. Attach weld head to negative and positive terminals.
4. Ensure either E-STOP bypass plug in plugged in or an E-STOP switch is plugged into the 6 DIN
E-STOP connector labeled “E-STOP”on back panel.
5. Attach a foot pedal to primary trigger on back panel.
6. Attach the weld head 3 DIN trigger cable to the secondary trigger on back panel.
6. Attach the weld head 4 DIN actuation cable to the 4 DIN connector labeled “WH Control” on back
panel.
7. Turn the welder on by pressing in Power button on front panel.
8. On the main screen adjust your Total Stored Energy, Pulse 1 energy, and Pulse 2 energy.
9. On the control screen adjust your weld head control scheme to “Auto with Timing” or “Auto with
Trigger”.
10. Enable welder, by pressing in Weld On button on front panel.
11. Trigger a weld with foot pedal.
Welder to Hand Held Attachment Setup
QUICK START SET UP OF HAND HELD ATTACHMENTS TO CDDP-A WELDERS
Sunstone Engineering manufactures a variety of welding hand pieces to accommodate a diverse
range of welding applications. Hand piece welding attachments allow ease of use and versatility.
1a. Turn off welder and unplug AC power cord for safety.
1b. Remove hand held attachment from its package.

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2a. Single probe, dual probe, and tweezer hand held attachments - Connect
the hand held attachment cables to the negative and positive terminals on
the back of the welder, then connect the 3 pin actuation foot pedal cable to
the back of the welder.
2b. Pressure actuated hand attachments - Connect the hand held
attachment cable to either of the terminals on the back of the welder and the
grounding clip cable to the other terminal. Then attach the trigger cable to the
back of the welder.
3. Plug the welder power cable into an AC power outlet.
4. Turn the welder on and set the desired energy settings.
Roll Spot Setup
QUICK START SET UP OF CDDP-A ROLL SPOT HAND ATTACHMENT
Roll Spot is a function that allows users to perform a continuous string of welds for any prolonged
time period – for as long as the trigger signal is actuated. The Roll Spot function requires an
attachment that is specically designed for roll spot welding.
1a. Turn off welder and unplug AC power cord for safety.
1b. Remove the roll spot attachment from its package.
2. Connect the roll spot cable to the terminals on the back of the welder and the grounding clip cable
to the other terminal. Then attach the trigger cable to the back of the welder.
3. Plug the welder power cable into an AC power outlet.
4. Turn the welder on and set the desired energy settings.
5. Roll Spot mode can be turned on or off in the “Control” tab within the home screen.
a. In Roll Spot mode, the system has an adjustable “Welds per second” text entry box that
affects the frequency or rate of welding while a trigger signal is maintained.
b. In Roll Spot mode, both pulses can be used, but the comparator is disabled.
c. In Roll Spot mode, the device will continuously weld at an adjustable rate for as long as
the trigger signal is maintained. If using a foot pedal, the welder will continue to weld for as
long as the foot pedal is depressed. If using a pressure actuated hand piece, the welder will
continue to weld for as long as the pressure actuated switch is engaged.
d. In Roll Spot mode, two variables will affect the time between each weld. The rst is an
adjustable “welds per second” text entry box that can be set by the operator. The second factor
is the recharge time between welds. This is determined based on the energy setting. The
higher the weld energy, the longer the delay between welds will be.
e. When in Roll Spot mode, the operator can choose to use single or dual pulse. When dual
pulses are chosen, operator can change the “Delay Between Pulses” text entry box to adjust
the this delay to match the delay between welds.

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Sunstone Welders User Manual: CDDP-A
Chapter 4: Operating Instructions
Pulse Control
DUAL PULSE WELDING
Sunstone dual pulse welders have two pulse width energy controls. Each pulse can be adjusted
separately or turned off if desired. Pulse 1 is adjustable between 0.1WS and 30% of Total Stored
Energy. Pulse 2 is adjustable between 0.1WS and 100% of Total Stored Energy. In order for Pulse
2 to use all of the Total Stored Energy, Pulse 1 must be disabled. When Pulse 1 is enabled, Pulse 2
can only use the remaining Total Stored Energy.
USING THE DUAL PULSE WELD FUNCTION
Using multiple pulses increases weld quality. In dual pulse mode Sunstone welders will re twice
from a single actuation. The rst pulse is used to remove surface inconsistencies and contaminants
which helps to displace oils, break through oxide layers, and seat the welding electrodes.
FIGURE 15: This shows what the welder discharge curve would
look like when using the dual pulse setting as outlined above.
SETTING Pulse 1 AND 2
The Pulse 1 energy setting should be chosen such that the parts adhere weakly. To determine Pulse
1, turn off Pulse 2 and do a series of test welds starting at a low pulse energy setting. Increase the
pulse energy about 3% every test until the parts stick together to achieve maximum heat. Pulse 1
energy is typically below 10%. Pulse 2 energy is typically between 50% and 70%. A test weld should
be performed and pulled apart to determine weld strength. A nickel strip to nickel plated steel weld,
typically seen in battery pack manufacturing, should pull apart leaving holes in the thin nickel metal
and leaving the weld nuggets on the battery terminal. Thicker materials should be pulled with a
specic pull force requirement in mind.
ENERGY ADJUSTMENT
Each Sunstone welder is fully adjustable between its minimum and maximum energy. Sunstone
capacitive dual pulse welders have weld repetition rates of up to 650 welds/min. See Table 2 on page
37 for additional details on weld repetition rates. The weld energy text entry box can be used to set

15
the total welder energy storage and is also used to set the peak weld current. The pulse energies are
then adjusted to provide the appropriate weld energy released during each weld.
Timing Diagrams
D1: A delay that occurs from the time primary trigger is triggered and the signal to the weld head is
sent. Typical time for this is between 1 and 50 milliseconds.
D2: A delay that occurs from the time the weld head is engaged and when trigger 2 is triggered.
D3: A delay that occurs from the time the secondary trigger is triggered and the weld occurs. Typical
time for this is between 1 and 50 milliseconds.
Pulse 1: The duration of this delay is dependent on the energy programmed on welder for Pulse 1.
Cool: The duration of delay is dependent on the time programmed on welder for time between pulses.
User can select between 1 and 100 milliseconds. This time will be ignored if either pulse is disabled.
Pulse 2: The duration of this delay is dependent on the energy programmed on welder for Pulse 2.
D4: After this delay, alarms and warnings are sent. Typical time for this is between 1 and 50
milliseconds.
D5: After this delay the Weld Ready signal will return to a high position. This delay will depend on the
time needed to charge to the desired energy, but will typically be between 50 and 5000 milliseconds.

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Sunstone Welders User Manual: CDDP-A
D1: A delay that occurs from the time primary trigger is triggered and the weld ready signal changes
to a low value. Typical time for this is between 1 and 50 milliseconds.
Pre-Weld: A user dened delay that happens before the signal to the weld head is sent. Can be set
between 1 and 10000 milliseconds.
Squeeze Time: A user dened delay that occurs from the time the weld head signal is sent and the
beginning of pulse 1.
Pulse 1: The duration of this delay is dependent on the energy programmed on welder for pulse 1.
Cool: The duration of this delay is dependent on the time programmed on welder for time between
pulses. User can select between 1 and 100 milliseconds. This time will be ignored if either pulse is
disabled.
Pulse 2: The duration of this delay is dependent on the energy programmed on welder for pulse 2.
Hold Time: A user dened delay that occurs from the time pulse 2 ends and the weld head begins to
return to home position.
D2: After this delay the Weld Ready signal will return to a high position. This delay will depend on the
time needed to charge to the desired energy, but will typically be between 50 and 5000 milliseconds
minus the length of the hold time.
D1: A delay that occurs from the time primary trigger is triggered and the weld ready signal changes
to a low value. Typical time for this is between 1 and 50 milliseconds.
Pre-Weld: A user dened delay that happens before the signal to the weld head is sent. Can be set
between 1 and 10000 milliseconds.

17
D2: A delay set to allow time for the weld head to fully extend. Once the weld has fully descended,
the weld discharge will be triggered. This will timeout after 10000 milliseconds.
Pulse 1: The duration of this delay is dependent on the energy programmed on welder for pulse 1.
Cool: The duration of this delay is dependent on the time programmed on welder for time between
pulses. User can select between 1 and 100 milliseconds. This time will be ignored if either pulse is
disabled.
Pulse 2: The duration of this delay is dependent on the energy programmed on welder for pulse 2.
Hold Time: A user dened delay that occurs from the time pulse 2 ends and the weld head begins to
return to home position.
D3: After this delay the Weld Ready signal will return to a high position. This delay will depend on the
time needed to charge to the desired energy, but will typically be between 50 and 5000 milliseconds
minus the length of the hold time.
Automation
The CDDP-A units will come with a basic PLC connection. For more information on pinout and
connections, please refer to the Back Panel Connections section of the user manual on p. 9.
• Through the 8 DIN connector a PLC has access to the following inputs:
▪ Two general inputs. (Choose from the list below)
▪ Clear Alarm
▪ Primary Trigger
▪ Secondary Trigger
▪ Lockout
▪ Remote Schedule Select
• When this option is selected it will use both inputs. While using Remote Schedule
Select the user can choose which saved welds are to be used via the “Remote
Schedule Select” sub tab within the PLC main tab.
• Through the 8 DIN connector a PLC has access to the following outputs:
▪ Two general outputs (Choose from the list below)
▪ Weld Ready
▪ Weld Good
▪ Weld No Good
▪ Any Alarm
▪ Any Warning
▪ Emergency Stop
▪ Alarm: Temperature
▪ Alarm: Comparator Failures in a row

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Sunstone Welders User Manual: CDDP-A
▪ Alarm: Electrode Stuck
▪ Alarm: Weld Counter Preset Limit
▪ Alarm: Invalid Remote Schedule Selection
▪ Alarm: Wrong trigger detected
▪ Alarm: Trigger in No Weld State
▪ Alarm: Part Check Failed
▪ Warning: Temperature
▪ Warning: Comparator Failures in a Row
▪ Warning: Weld Counter Preset Limit
▪ Weld Ready
▪ Alarm
• An ESTOP is available for safety. It is normally open and engaged. It must be closed to
disengage the E-STOP. Pin out information can be found on p. 9.
• Ethernet (Coming Soon)
▪ This is available for those who would like to control the welder, with a PLC, through Ethernet.
Maintenance
• Internal verications can be performed, but can only be accessed through a technical support
screen.
• This can be performed anytime the welder seems to be creating weak welds.
• User will want to perform this Internal verication at least once a year to ensure that their
welder is performing optimally.
• Certicate of Calibration
• This is a service that Sunstone Engineering can perform. Contact Sunstone Support if
desired.
Safety
Safety Precautions for Mechanical Moving Parts
• Refer to the user manual included with your weld head or hand piece.
• Before pressing foot pedal and triggering weld, make sure nothing is obstructing the
electrodes, other than the workpiece being welded.
• If maintenance or setup is required put the welder in a “Weld Off” state, or turn unit off before
adjusting weld head.

19
Chapter 5: User Interface
Home Screen/Pulse Settings
1. Navigation Bar: Home, Communications,
Media, Save/Load, Lock, Settings
2. Waveform display of current energy settings.
a. Voltage is displayed on the y-axis, time is
displayed on the x-axis
b. The green lines indicate the lower limit of
the comparator values.
c. The red lines indicate the upper limit of the
comparator values.
d. Waveform background color is orange
when “Weld On” button is turned on and
depressed; gray when turned off.
3. Shows Active Schedule (when enabled, also
shows comparator results from previous
weld).
4. Pulse Settings tab within Home screen
5. Total energy stored in welder
a. All or part of this energy can be divided into
Pulse 1 and Pulse 2.
b. In order for Part Check to work as intended
a Total Stored Energy must be set to a
minimum of 25WS for CD600DPA, 20WS
for CD400DPA, or 15WS for CD200DPA.
6. Amount of energy to be discharged during
Pulse 1 weld. Can be turned on or off.
7. Amount of energy to be discharged during Pulse 2 weld. Can be turned on or off.
8. Amount of time that will occur before weld process begins.
a. Only occurs for rst weld. During Roll Spot, Pre-Weld delay is ignored for all subsequent welds.
9. Amount of time that will occur between pulses when both pulses are enabled.
10. Shows the charge state of the welder. Is black when welder is not ready to weld or unit is in
“Weld Off” state. Will turn green when charged and ready. Will turn red when unit is in emergency
stop.
1.
2. 3.
6.
4.
7.
5.
8.
9.
10.

20
Sunstone Welders User Manual: CDDP-A
Comparator
1. The Comparator tab within the Home screen.
2. A generated waveform of the previous weld.
3. The user can choose three different types of
comparators; voltage, current, and/or power.
The green dots will turn red if that type of
comparator fails.
a. User can choose to compare any or all of
the different types.
4. User can choose whether to use the
comparator on the rst or second pulse.
5. Each pulse has an upper limit.
6. Each pulse has a lower limit.
7. The previous weld peak result is displayed
here for Pulse 1 and Pulse 2.
a. The result will be green if passed and red if
failed.
8. User can choose to continue to Pulse 2 if
Pulse 1 fails or to stop the weld.
9. Shows the results of past weld results.
1.
2.
3.
6.
4.
7.
5.
8.
9.