SUNSTONE CD200DP User manual
CDDP
Users Guide
Capacitive Discharge Dual Pulse Welder
For Models 200Ws, 400Ws, 600Ws, 1000Ws, 1100Ws
Version 20210312 • Part #1175
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CDDP WELDER USERS GUIDE
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
ISSUE DATE APPROVAL NOTES
1 DW FORMATTING AND ORGANIZATIONAL CHANGES
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 WHAT-
SOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGINEERING LLC PROD-
UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-
NEERING 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 LIMI-
TATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT OR GENERAL DAMAGES IN CONTRACT,
TORT (INCLUDING NEGLIGENCE) OR OTHERWISE), THE ENTIRE AGGREGATE LIABILITY OF SUNSTONE EN-
GINEERING 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.
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Table of Contents
Chapter 1: Overview ...................................................................................................1
Features ..............................................................................................................................1
Applications.......................................................................................................................
What is Capacitive Discharge Resistance Welding ............................................
Tips .......................................................................................................................................3
Chapter 2: Setup............................................................................................................5
Pre Setup Information....................................................................................................5
Welder Setup.....................................................................................................................6
Weld Head Setup .............................................................................................................7
Hand Held Attachment Setup.....................................................................................7
Roll Spot Setup.................................................................................................................8
Chapter 3: How to Operate the Sunstone CDDP .........................................10
How to Use Pulse Controls........................................................................................11
How to Adjust Energy..................................................................................................
LCD Screen Messages ...............................................................................................
Welder Specications ..............................................................................................13
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CDDP WELDER USERS GUIDE
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Chapter 1: Overview
Features
Sunstone spot welders are simple to use with an intuitive and user-friendly interface. Each of the dual pulse,
-
tions. When combined with Sunstone’s line of weld heads or hand attachments, dual pulse, capacitive discharge
welders, such as the Sunstone CDDP, perform strong and repeatable welds for high levels of consistency and
• Removes surface inconsistencies and contaminants
•
• Single or dual pulse operation
• Microprocessor controlled.
• Thermal protection circuit for internal monitoring
•
• Adjustable pulse width
• Energy storage adjustable from 9% to 100% capacity
• Up to 600 welds per minute
•
• Simple, user-friendly interface
• Quick energy release for highly conductive metals
•
•
•
•
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Applications
Capacitive Discharge (CD) resistance welders have many advantages over other welder types. Operators
into a small area, which means more delicate projects, such as welding a battery, will maintain the integrity of
the cell’s chemistry when using Sunstone’s dual pulse CD spot welding technology.
• Battery pack welding
• Honeycomb welding
• Aerospace welding
• Automotive welding
• Cross wire welding
• Thermocouple welding
• Electronic component welding
• Copper, aluminum, brass, and steel thin sheet and wire welding
• Miscellaneous resistive welding applications
Whether you are manufacturing battery packs or microscopic assemblies, Sunstone CDDP spot welders are
What is Capacitive Discharge Resistance Welding?
-
• Quick energy release for welding highly conductive metals
•
•
•
A CD welder provides for an extremely fast energy release with large peak currents. More of the energy goes
use.
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With energy in a stored state, your Sunstone CDDP welder pro-
vides control over how the energy is released. The typical ca-
curve. But with adjustments to your welder’s controls, you will
be able to control how much energy is released in two pulses.
See Chapter 3 on page 10 for more information.
Weld Formation
Spot welding relies on metal resistivity (resistance) to heat and
fuse metal. A large current is passed through the work piece
metal. Energy is dissipated due to metal resistance in the form
of heat which melts and fuses the weld materials. There are two
phases to the melting process. The welder must overcome both
the material contact resistance and the bulk resistance of the
material.
On the micro-scale, material surfaces are rough and only con-
metal bridges melt, allowing other bridges to come into contact
to continue the melting process. When all of the bridges have
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
-
ing more electrode pressure creates more metal bridges. This
results in a lower contact resistance and a cooler weld. Con-
versely, light electrode pressure results in less metal contact,
higher resistance, and a hotter weld. An appropriate amount of
pressure should be used to insure good weld strength.
ELECTRODE CONFIGURATIONS
resistance welding. Figure 3.3a is called a direct weld. Current
is passed from one electrode through both work pieces and
POWER
TIME
Figure 3.1. Sample capacitor discharge curve.
Figure 3.3. Examples of resistance welding
electrode congurations. A: Direct. B: Step. C:
Series.
Figure 3.2. Surface roughness limits surface-to-
surface contact. More contact points result in a
lower contact resistance.
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there is access to only one side of the work piece and an electrode can be placed on both materials. Figure 3.3c
WELD ENERGY
Sunstone capacitive dual pulse welders allow adjustment of the stored energy via an energy adjustment dial.
Figure 4.1. The amount of energy to be released by
the welder is displayed here in Ws (or Joules).
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Chapter 2: Setup
Pre Setup Information
VOLTAGE AND POWER REQUIREMENTS
detect the voltage, and make the appropriate adjustments automatically.
WELD ACTUATION
The CDDP welder is actuated by means of an external trigger port located on the back of the welder (see page
shows the proper pin placement for custom external trigger cables. The standard external trigger cable con-
nector is an SD-30LP made by CUI Inc.
WELDER BEEPS
-
able or disable the alarm using a switch located on the back of the welder.
THERMAL PROTECTION
-
ing, the operator will hear six successive beeps and will not be able to weld during this time. When the unit has
cooled, the operator will hear three successive beeps, signifying that the unit is again ready to weld.
Figure 5.1. External trigger wiring diagram.
N.O. means “Normally Open.”
N.O. Circuit
N.O. Circuit
Shield
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Note: The audible alarm (beeps) for overheating will still occur even if the “Welder Beeps” option is turned o.
To ensure proper cooling, please maintain a clear space of six or more inches around the welder vents.
Welder Setup
• Remove the welder from the box and place it on a secure work surface. Make sure the work space is
-
tion.
•
welder’s back panel. See Figure 6.1.
• Connect the external trigger (the component that will trigger the weld, usually a foot pedal) into the Ext.
Trigger port (B) found on the back of the welder.
• You can connect hand attachments or a weld head to the CDDP. Attach the cables to the negative
and positive terminals (C) found on the front of the welder. If you plan to use a weld head, see the next
section, “Weld Head Setup,” for additional information. If you plan to use a hand attachment, see “Hand-
held Attachment Setup” on page 7. If you plan to use a roll spot, see “Roll Spot Setup” on page 8.
• Connect the power cord into the back of the welder and into an AC power outlet (D).
•
Figure 6.1. Back and Front panels of the Sunstone CDDP welder.
A B
D C E
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Weld Head Setup
Sunstone manufactures a variety of weld heads to accom-
modate a diverse range of welding applications, as shown in
Figure 7.1. Both the parallel and opposed Sunstone weld head
provides a great amount of control and precision. Follow these
abbreviated instructions to connect a weld head to the CDDP.
• Remove the weld head from the box and place it on a
secure work surface.
• Attach the weld head cables to the negative and posi-
tive terminals (see (C) in Figure 6.1).
• For operating the weld head manually, see the weld
head users guide for setup.
• For operating the weld head pneumatically, see the
weld head users guide for setup.
• Turn the welder on, assure the weld head is actuating,
then set the desired energy setting. See Chapter 3 on
how to select desired energy settings.
Note: See weld head user manual for more precise setup infor-
mation.
Hand Held Attachment Setup
Sunstone Engineering manufactures a variety of welding hand
pieces to accommodate a diverse range of welding applica-
tions. Hand piece welding attachments allow ease of use and
versatility. Follow these instructions to connect a hand held
• Remove the hand held attachment from its package.
•
-
ment cables to the negative and positive terminals (see
(C) in Figure 6.1) on the front of the welder, then connect
the 3 pin actuation foot pedal cable to the Ext. Trigger
port (see B in Figure 6.1) on the back of the welder.
• For Pressure Actuated hand attachments (see Figure
7.3), connect the attachment cable to either of the
terminals on the front of the welder and the grounding Figure 7.3. Pressure Actuated hand held
attachment sample.
Figure 7.2. Dual Probe hand held attachment
example.
Figure 7.1. Weld head connected to the CDDP
welder.
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clip cable to the other terminal. Then connect the
trigger cable to the Ext. Trigger port (see (B) in Figure
6.1) on the back of the welder.
• Turn the welder on and set the desired energy settings.
See Chapter 3 on how to select desired energy
settings.
Roll Spot Setup
The Sunstone CDDP can be upgraded to accept a roll spot
attachment (see Figure 8.1). With a roll spot, the operator can
perform a continuous string of welds for any prolonged time
period, for as long as the trigger signal is held. The roll spot
-
cally for roll spot welding. Follow these instructions to connect
• Remove the roll spot attachment from its package.
• Connect the roll spot cable to either of the terminals
on the front of the welder (see C in Figure 6.1) and the
grounding clip cable to the other terminal. Then attach
the trigger cable to the Ext. Trigger port on the back of
the welder (see B in Figure 6.1).
• Plug the welder power cable into an AC power outlet.
• Turn the welder on and set the desired energy settings.
See Chapter 3 on how to select desired energy
settings.
•
-
rations of the welder. See details below.
•
front of the welder, which normally would turn
switch between Single Fire (SF) and Roll Spot
(RS) modes; thus, the welds cannot ever be
Thus,
when the Pulse Switch is o, the welder is in
single re mode; when the Pulse Switch is on
the welder is ready for roll spot functionality.
Figure 8.1. Roll Spot hand held attachment
example. This conguration requires an upgrade.
Figure 8.2. When using a Roll Spot hand held
attachment, be sure the Pulse setting is on.
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• Important:
welder is active and will weld if a trigger signal is sent to the welder.
• In SF mode, the unit will weld once per trigger signal.
•
the same as on the standard, non-upgraded, base model welder.
• In RS mode, however, 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.
•
rate of welding while a trigger signal is maintained.
•
minimum weld delay that can be set by the operator. This is accomplished by turning the “Pulse
1” dial on the front of the welder. 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.
•
takes place during the RS welding process.
•
time, or pulse width, of every weld. The Weld Energy knob controls peak weld energy. Note:
Higher energy will require longer recharge times between wels.
• The distance between welds is based on the welding rate and the electrode travel speed
moving across the work piece. To place welds closer together, decrease the weld time or
slow the elctrode travel time. To increase the space between welds, increase the weld time or
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Chapter 3: How to Operate the Sunstone CDDP
Assuming you have read all safety notices, have a clear work area, and have already connected a weld head
or hand held attachment to the CDDP, refer to Figure 10.1 and follow these instructions to release energy and
A
• Power on the CDDP using the Power Switch (A) in the
bottom right-hand corner of the welder’s front panel.
The LCD screen on the front of the welder will illuminate
and display the message POWER ON.
• Make sure the Pulse Switch (E) is turned to the ON
position if you wish to actuate a weld. If you are using a
Roll Spot hand held attachment, see Roll Spot Setup on
page 8.
• Select the desired weld energy by turning the Weld
Energy adjustment knob (D). The LCD screen will
display the energy level as you turn the knob. Sunstone
The maximum energy level you can select depends
upon the model you are using.
• The CDDP has two pulse width energy controls. The
LCD screen displays each pulses’ total stored energy
as a percentage of the total stored energy in Joules (J).
desired, using the Pulse Switch (B). Both pulses can be
weld attachment setup or electrode maintenance. Pulse
1 is adjustable between 1% and approximately 30%
DCB
Figure 10.1. To operate the Sunstone CDDP:
1. Turn on the welder using the Power Switch (A).
2. Make sure the Pulses Switch (E) is on.
3. Set the weld energy by turning the Weld Energy
knob (D).
4. Next, set the turn the Pulse 1 adjustment knob
(B) to set power for Pulse 1 and then the Pulse 2
adjustment knob (C) for Pulse 2.
5. Actuate the trigger to send energy to the
electrode(s).
E
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1% and 99% of the total weld energy. Please note that
when used in dual pulse mode, the Pulse 2 energy
level represents the percent of remaining power. For
example if Pulse 1 was set to 25%, the Pulse 2 setting
would actually be taken from the remaining 75% of
the total weld energy. -
tion on energy adjustments.
• Set the power for Pulse 1. Turn the Pulse 1 adjust-
ment knob (B) to select the desired energy setting as
percentage of the total stored energy. The LCD screen
will display the percentage.
• -
ment knob (C) to select the desired energy setting as a
percentage of the total stored energy. The LCD screen
will display the percentage.
• Make sure the work piece is ready for welding and the
workspace is clear.
• Place the hand held attachment’s electrode(s) where
you wish to place the weld and depress or activate the
trigger. The welder will release energy accordingly. If
using a weld head, see the weld head users guide for
how to actuate the weld.
How to Adjust Energy
Each Sunstone welder is fully adjustable between its minimum
and maximum energy. Sunstone capacitive dual pulse welders
have weld repetition rates of up to 600 welds/min. See table on
The Weld Energy knob (D) is used to set the total welder en-
ergy storage and is also used to set the peak weld current. The
pulse widths are then adjusted to provide the appropriate weld
energy released during each weld.
How to Use Pulse Controls
Sunstone dual pulse welders have two pulse width energy
to remove surface inconsistencies and contaminants which Figure 11.1 Graphical representation of a weld with
dual pulses of energy.
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helps to displace oils, break through oxide layers, and seat the welding electrodes. As mentioned earlier, Pulse 1
and 99% of the stored energy.
Note: When used in dual pulse mode the Pulse 2 energy level represents the percent of remaining power. For
example, if Pulse 1 was set to 25%, the Pulse 2 setting would actually be taken from the remaining 75% of the
set-point energy. The energy of Pulse 1 and 2 combined cannot be greater than the total weld energy.
SETTING PULSE 1 AND 2
every test until the parts stick together to achieve maximum heat. Pulse 1 energy is typically below 10%. Pulse
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
LCD Screen Messages
Messages are shown on the LCD display to indicated that a change is being made to the welder. Here is a list of
POWER ON. This message is displayed when the welder has been turned on.
READY. This message is displayed after you weld and the unit is ready to weld again.
BEEP ON/OFF.Displays when you toggle the “Beep Enabled” switch. You will hear audible beeps when on.
WELD ON/OFF.
P1 ON/OFF.
P2 ON/OFF.
NO PULSE.
NEW P1/P2.
Cooling/Enabled. Should the CDDP overheat, it will display “COOLING” until it has reached an operable tem-
perature. Then the welder will display “ENABLED” to let you know that it is done cooling.
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CDDP Welder Data
CD200DP CD400DP CD600DP CD1000DP CD1100DP
Footprint
(HXWXD)
Weight 39 lbs./18kg 39 lbs./18kg
Input Voltage
Frequency Range
Power Factor (typ.)
AC Current (typ.)
Min/Max Output 5 Ws - 600 Ws 5 Ws - 1000 Ws 5 Ws - 1100 Ws
Pulse Width
Rise Time (to Max
Voltage)
Min Pulse Height
Max Pulse Height
Peak Current for
1 AWG 4’ 7905 9130 11180 10750
Peak Current for
4 AWG 6’ 6081 8600 7885
Peak Current for
8 AWG 6’
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CDDP Welder Speeds with PG2 Copper Wheel or Weld Head (1 AWG @ 1.8 mW)
WS CD200DP CD400DP CD1000DP CD1100DP
10 185 167
20 150 135
40 118 105 96 96
100 73 68 68
200 51 51
400 - 38 36 36
600 - -
CDDP Welder Speeds with DPHP-MP (4 AWG @ 4.2 mW)
WS CD200DP CD400DP CD1000DP CD1100DP
10 188
20 158
40 111
100 88 76 71 71
200 66 56 51 51
400 - 39 36 36
600 - - 30 30
CDDP Welder Speeds with DPHP-LP (8 AWG @ 8.8 mW)
WS CD200DP CD400DP CD1000DP CD1100DP
10 196 177 177
20 177 170
40 117 117
100 93 81 76 76
200 69 60 56 56
400 - 30 39 39
600 - - 30 30
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3
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