SUNSTONE CDDP-A User manual

CDDP-A
User Manual
Advanced Capacitive Discharge Dual Pulse Welder
For Models 200Ws, 400Ws, 600Ws, 1200Ws
Version 20210101 • Part #1176

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SUNSTONE CDDP-A USERS GUIDE
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
ISSUE DATE APPROVAL NOTES
0 2/10/2020 DH
GENERAL FORMATTING AND ORGANIZATION CHANGES;
INCLUSION OF PLC AND ETHERNET INFORMATION
1
2
3
4
5
6
Limitation of Liability
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING
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Table of Contents
Chapter 1: Overview ...............................................1
Features.........................................................................1
What is CD Welding?.................................................2
Weld Formation...........................................................3
Tips..................................................................................3
Weld Pressure .............................................................3
Electrode Congurations........................................4
Weld Energy .................................................................4
Chapter 2: Setup and Installation .....................5
Safety .............................................................................5
Workspace Considerations ...................................5
Voltage and Power Requirements........................5
Weld Actuation............................................................6
What’s in the Box........................................................6
Exploring the Front and Back Panel ....................6
Exploring the Side Panel..........................................8
How to Set Up Your Welder ....................................8
Chapter 3: User Interface Overview.............10
Navigation Bar.......................................................... 10
Home Screen............................................................10
Communications.....................................................10
Media ...........................................................................11
Save/Load..................................................................11
Lock Screen..............................................................12
Settings Screen....................................................... 12
Chapter 4: Home Screen Operation..............13
Waveform Display...................................................13
Pulse Settings .......................................................... 14
Comparator...............................................................16
How to Turn On the Comparator .......................16
Control ........................................................................18
Weld Head Controls ...............................................18
Timing Diagrams .....................................................19
Chapter 5: PLC Automation Features...........22
PLC Tab.......................................................................22
Basic PLC I/O ............................................................22
Remote Schedule Select......................................23
Alarms Tab .................................................................24
Import/Export Tab .................................................. 25
Chapter 6: How to Use Media Features.......26
Chapter 7: How to Save and Load Weld
Schedules .................................................................28
Chapter 8: Lock Screen...................................... 30
Chapter 9: How to Make System Changes 32
Chapter 10: How to Update the Welder’s
Software....................................................................33

Connection...............................................................35
Setup and Conguration......................................35
Using the Modbus Server Tester.......................36
Setup the Computer/PLC..................................... 36
Retrieving information from the CDDP-A.......37
Sending Information to the CDDP-A................38
Reading the Output Wwindow............................ 39
Reading the Input Register..................................39
How to Read/Write to a Holding Register.......40
Retrieving General Information from the
CDDP-A.......................................................................42

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Using Modbus Poll.................................................. 43
Setup a Connection ...............................................43
Reading Coils............................................................43
Reading Holding Registers..................................44
Write Single Coil ......................................................44
Write Single Register .............................................45
Receiving general packet.....................................45
Using Simply Modbus TCP Client .....................46
Setup a Connection ...............................................46
Reading a Coil...........................................................46
Reading a Holding Register................................. 47
Writing to a Single Coil..........................................49
Writing to a Single Register.................................50
Receiving a general packet .................................51
Chapter 12: Back Panel Connector Details53
Appendix A: Pin-Out Diagrams ....................... 54
Appendix B: Warnings and Alarms ................57
Appendix C: Modbus Data Tables ..................60
Supported Function Codes.................................60
Data Structures........................................................61
Coils .............................................................................61
Discrete Inputs.........................................................62
Holding Registers....................................................63
Remote Schedule Select Modes ...............64
Weld Head Control Types.............................65
PLC Output Pin Assignments......................65
PLC INput Pin Assignments.........................65
Input Registers......................................................... 66
Comparator Results...............................................68
File Records...............................................................68
Raw Data (Example) ..........................................68
Read File Record (20 / 0x14).......................... 69
Response to “Read File Record” ..................69
Read First 4 Time Values.................................69
Response to “First 4 Time Values” .............. 70
Read First 4 Time Values and First 4 voltage
Values.....................................................................70
Response to “First 4 Time Values and First 4
Voltage Values”...................................................71
Custom Functions ..................................................72
Schedule Weld Data (8 x 16 bit Registers)72
Schedule Extra Weld Data (6 x 16 bit
Registers)..............................................................72
Comparator (28 x 16 bit Registers)............. 73
Alarm Settings (12 x 16 bit Registers)........74
Basic PLC Settings (3 x 16 bit Registers).75
Comparator Failure and Weld Count (4 x 16
bit Registers) .......................................................75
RSS Mode (1 x bit coil) .................................... 75
General Info (16 x 16 bit Registers).............75
Weld Task States ........................................76
Charge Task States ...................................77
Lock States...................................................77
Previous Weld Results (17 x 16 bit
Registers) ......................................................77
General Info: Alarm States (5 x 16 bit
Registers)..............................................................78
Waveform Report General (11 x 16 bit
Registers) ...................................................................79
Emergency Stop States (7 x 8 bit Registers) 79
Basic PLC States (3 x 16 bit Registers) ...........79
RSS States (1 x 8 bit Coil).....................................79
Network Info (20 x 16 bit Registers).................80
Modbus Exception Codes ...................................81
 ...............83

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Chapter 1: Overview
Features
Sunstone’s advanced dual pulse CD welders oer many capabilities including weld monitoring, SPC tools,
and a large capacitive touch-screen interface. The touch-screen interface provides easy access to all weld
parameters. In addition, you get a visual of the weld waveform graph, weld histograms, alarms, warnings, and
even on-screen documents and videos. For automated production settings, the welder has multiple PLC
protocols. You can also set up multiple machines in a simplied way thanks to the clone feature. Cloning allows
you to copy all your parameters/settings and easily export/import them to other machines.
Capacitive Discharge (CD) resistance welders have many advantages over other welder types. Since CD
welders use capacitors to store and release weld energy, your weld energy will be highly repeatable and will not
be aected by line voltage uctuations. You can also achieve quick energy release for welding highly conductive
metals such as copper. This quick energy release is concentrated into a small area, generating a small heat
signature or heat aected zone.
Sunstone’s CDDP-A welders provide the following benets:
• A very small heat-aected zone during the weld
• Ability to easily position welds exactly where you need them
• The versatility of welding on very small, thin, and delicate metal parts
• A wide range of metals that can be welded
• Dual Pulse operation removes surface inconsistencies and contaminants
• Single or Dual Pulse operation
• Consistency and repeatability
• Very low maintenance on the machine
• Small compact size designed to t on and around any work area

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The key features of the Sunstone CDDP-A are as follows:
• Touch-screen interface
• Microprocessor controlled operation
• Dual pulse
• Weld monitoring of peak currents
• Monitor limits with logic (inhibit second pulse)
• Weld head controls
• Remote schedule select
• Weld counter
• Set current or voltage
• Visual graph of weld waveform
• Statistical process controls
• Histogram
• Comparator
• Alarms and warnings
• Timestamp data feedback
• Full welder cloning
• Emergency Stop
• Roll-Spot Welding
• High-Precision Energy Adjustment
• Lock-Out Mode
• PLC Ready
• Import/Export weld data
• Software updates
• Multiple languages
• Save settings
• Wi-Fi connectivity
• On-screen PDFs and videos
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

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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 3.1 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-aected zone’
around the weld can suer 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.
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. The welder
must overcome both the contact resistance and the bulk resis-
tance of the material in order to begin the melting process.
Figure 3.2 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.
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
3.2). Using more electrode pressure creates more metal
bridges, resulting in 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 ensures good weld strength.
Figure 3.2. On the micro scale, surface roughness
limits surface-to-surface contact. More contact
points result in lower resistance.
Figure 3.1. Sample capacitor discharge curve with
high peak current.

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ELECTRODE CONFIGURATIONS
As shown in Figure 4.1, several electrode congurations can be
used in resistance welding:
•  Current is passed from
one electrode through both work pieces and out an
opposing electrode.
•  This conguration is
used when there is access to only one side of the work
piece and an electrode can be placed on both mate-
rials.
•  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.
WELD ENERGY
Sunstone capacitive discharge dual pulse welders allow adjust-
ment of the stored energy via the touch screen user interface,
shown in FIGURE 4. The energy is then displayed in watt sec-
onds (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
less than or equal to the Total Stored Energy. More information
can be found on page 14 of this manual.
Figure 4.1. Resistance welding electrodes can
appear in three dierent congurations: a)
Opposed; b)Step; and c)Series or Parallel.

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Chapter 2: Setup and Installation
Safety
• Carefully read the Sunstone Safety and Basics booklet that accompanied this welder prior to operation.
As the operator of this welder, you assume responsibility for your safety and those around you.
• Carefully read the user guide that accompanied your weld head or hand piece.
• Before pressing the foot pedal and triggering a weld, make sure nothing is obstructing the electrodes,
other than the work piece being welded.
• If maintenance or setup is required, put the welder in a “Weld O” state, or turn unit o before adjusting
weld head.
WORKSPACE CONSIDERATIONS
• Ensure workspace around the power supply is adequate for welding operation.
• Ensure enough clearance on both sides and back of power supply for cables to run.
• Good ventilation is important to keep the power supply from overheating. Be sure to have proper air
ow in and around the power supply.
• Be sure to keep the work surface stable, level, free of vibration, and strong enough to support the power
supply.
• Ensure the power supply is mounted the proper distance from the weld head, and incoming power.
• Avoid placing the power supply near sources of high frequency radiation.
• Keep the working area clear of excessive dust, acids, corrosive gases, salt, and any moisture.
VOLTAGE AND POWER REQUIREMENTS
The Sunstone CDDP-A welder is equipped with universal power supplies and can be used with either 110VAC
or 220VAC. No voltage selection is required prior to connecting and powering on the welder. The welder will
automatically detect the voltage and make the appropriate adjustments automatically.

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WELD ACTUATION
The CDDP-A welder is actuated by means of an external trigger
port located on the back of the welder (see Figure 7.1). The trig-
ger uses a 3 DIN connector and requires shielded wire. Figure
6.1 shows the proper pin placement for custom external trigger
cables. The standard external trigger cable connector is an SD-
30LP made by CUI, Inc.
What’s in the Box
• Welder
• Power cord
• Foot pedal
• User manual
• Safety Guide
Exploring the Welder’s Front Panel
The front of the welder (see Figure 6.2) consists of three
components; the digital touchscreen, the power button, and the
weld on/o button.
The digital touchscreen displays the graphic user interface
and allows the operator to make changes to the welding
parameters. Every interaction with the weld settings will happen
via the touch screen.
The power button will turn the welder on and o. When turned
on, the button will latch and stay depressed. To turn the welder
o, press the button again to unlatch it and turn o the welder.
Warning: DO NOT turn the welder o during boot up. Allow the
welder to completely boot up before turning it o.
The weld on/o button can be used anytime the welder is
turned on. When turned on, the button will illuminate and stay
depressed and the welder will make welds. When o, the
welder will perform all weld functions, but no weld energy will
be released, and no welds will be made. The weld on/o button
allows operators to safely make changes to welding electrodes,
weld heads, and hand attachments. Operators can also per-
form ‘dry runs’ to test timing, delays, and automations, without
Figure 6.1.External trigger wiring diagram. N.O. is
short for “Normally Open.”.
N.O. Circuit
N.O. Circuit
Shield
Figure 6.2.The CDDP-A’s front panel consists of
three main components:
Power Button
Digital Touchscreen
Weld On/O Button

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releasing any weld energy.
Exploring the Welder’s Back Panel
The back panel of the welder has a dozen dierent components including: Ethernet port, accessory port, PLC,
E-Stop, WH Control, Primary Trigger, Secondary Trigger, Positive and Negative weld Terminals, Fuse, AC line in,
and cooling fans. The back panel also show identifying details such as model number, serial number, and certi-
cation marks.
The Ethernet Port is used to control the welder with a PLC through an Ethernet connection. Additional
information can be found in Chapter 11.
The Accessory Port can be used to connect to and communicate with external accessories.
The PLC Port includes logic inputs and outputs that can be used to communicate with a PLC.
The E-Stop can be used as an emergency stop. The E-stop is normally open and engaged. It must be closed to
disengage the E-Stop. Pin out information can be found in Appendix A, page 54.
Figure 7.1. On the back of the
CDDP-A is where you’ll nd all
connections to power, weld heads,
triggers, and more.
Ethernet Port
Accessory Port
PLC Port
E-stop
Weld Head Control
Primary Trigger
Secondary Trigger
Negative Weld Terminal
Postivie Weld Terminal
Fuse
Power

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The Weld Head Control is used to send a trigger signal to a weld head.
The Primary Trigger is used to connect a foot pedal, or other switch, to initiate a weld.
The Secondary Trigger is used to connect a foot pedal, or other switch, to initiate a weld.
The Positive and Negative Terminals are used to connect a weld head or hand attachment to deliver the weld
energy. Make sure the weld cable resistance is greater than or equal to 1 milliohm (1mΩ) of resistance.
The Fuse houses a 10A fuse rated for up to 250VAC.
The Power Inlet accepts an IEC 320 C13 power cord and can accept 90-250 VAC, 50-60 Hz.
The cooling fans must be free from obstruction and have at least two inches of free space behind the welder.
Additional information and specic pin-out diagrams can be found in Appendix A.
NOTE: The signals and relays are congured for LOW= Ground=TRUE INPUTS. Applicable to: E-STOP, wh con-
trol, pri trigger, sec trigger. See Appendix A for additional details.
Exploring the Side Panel
The welder features a USB port on the LEFT side, near the FRONT. This USB port can be used for three purpos-
es. First, operators can plug in a USB ash drive to update the rmware and software of the welder (see Chapter
10 for software update instructions). Second, operators can export and import saved schedules, welder set-
tings, and historical weld data (see page 25 for import/export instructions). Third, operators can plug in a com-
patible USB mouse and use the mouse to navigate the interface.
How to Set Up Your Welder
Follow these initial setup steps when setting up the welder for the rst time.
• Unbox the welder and place it on a secure workspace.
• Connect the E-Stop bypass plug, or an E-Stop switch into the E-Stop port on the back of the welder.
• Connect the female end of the power cord into the back of the welder and connect the male end into an
AC power outlet.
• Connect the weld head or hand attachment to the welder.
• Connect one end of one weld cable to the positive terminal on the back of the welder using a ¼” bolt
and nut.
• Connect one end of the other weld cable to the negative terminal on the back of the welder using a ¼”
bolt and nut.
• If the other ends of the weld cables are not connected to the weld head or hand attachment, refer to
that product’s user manual for instruction on how to connect the weld cable.

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• Determine which weld trigger conguration is best for your setup. Options include:
• Pneumatic weld head controlled by the CDDP-A welder.
• Fully manual operation
• Auto with Timing option
• Fully Automatic option
• Manual weld head actuated
• Two foot pedal operation: one to control weld head, one to trigger weld energy.
See Control Tab for additional weld head setup options on page 18.
The system is now properly connected and ready to weld.

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Chapter 3: User Interface Overview
This chapter will provide a brief overview of the dierent screens, parameters, and elements found on the
touchscreen interface of the welder.
NAVIGATION BAR
The Navigation Bar (A), as shown in Figure 11.1, runs across the top of the screen and allows operators to switch
between the following screens: Home, Communications, Media, Save/Load, Lock, Settings
HOME SCREEN
The Home Screen, as shown in Figure 11.1, includes all aspects relating to the weld energy, waveform, and tim-
ing delays. See Chapter 4 for specic details about elements of the Home Screen.
Waveform. The Waveform (B) display shows a graphical representation of the weld settings and parameters.
Pulse Settings Tab. When you click on the Pulse Settings tab, three additional energy settings tab will appear
below: Total Energy, Pulse 1 Energy, and Pulse 2 Energy. Pre-weld Delay and Delay Between Pulses settings will
also appear.
Comparator Tab. The Comparator tab allows operators to set acceptable values for Peak Voltage, Peak Cur-
rent, and Peak Power for each weld.
Control Tab. The Control tab allows operators to make changes to the weld head conguration and timing
options, as well as roll spot parameters.
COMMUNICATIONS
The Communications Screen, as shown in Figure 11.2, provides PLC controls for automation, settings for
Alarms, and features for Importing/Exporting pre-set welds. See Chapter 5 for specic details about elements
of the Communications Screen.
PLC. A Sunstone CDDP-A PLC’s capabilities were designed to be used with a Probotix or Janome robotic table.
Use this screen to enter the necessary instructions to control the table. See Chapter 5 for PLC instructions.

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Alarms. You are able to instruct the Sunstone CDDP-A to alert you to temperature uctuations, comparator
failures, electrode sticks, and more.
Import/Export. You are able to import or export weld settings from one CDDP-A welder to another.
MEDIA
The Media Screen, as shown in Figure 11.3, provides the operator with a library of instructional application
videos, user guides, and training materials. See Chapter 6 for specic details about elements of the Media
Screen.
Applications. Click on Applications to view a list of available application videos.
PDF. Click on PDF to view a list of applicable manuals and other documents.
Training. Click on Training to view a list of available training material.

The Save/Load Screen allows you to save or load weld settings. See Chapter 7 for specic details about
elements of the Save/Load Screen.
Figure 11.1. Homescreen with Pulse Settings
Tab selected. See Chapter 4 for specic
details about the Home Screen.
A
B
Figure 11.2. Commuications Screen with the
PLC tab selected. See Chapter 5 for specic
details about the Communications Screen.
Figure 11.3. Access the Media Screen to
view instructional material. See Chapter 6 for
specic details about the Media Screen.

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LOCK SCREEN
The Sunstone CDDP-A allows the operator to lock the welder, preventing others from using the welder or pre-
venting others from changing the welder’s settings. See Chapter 8 for specic details about elements of the
Lock Screen.
SETTINGS SCREEN
Use the Settings Screen to modify the welder’s basic settings, such as language, date and time, speaker vol-
ume, screen brightness, and more. See Chapter 9 for specic details about elements of the Settings Screen.
Figure 12.1.Use the Lock Screen to create/
enter a password to lock the CDDP-A’s weld
settings. See Chapter 8 for more information.
Figure 12.2. Settings Screen. See Chapter 9
for more information.

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Chapter 4: Home Screen Operation
The Home Screen is where the operator controls all aspects relating to the weld energy, waveform, and timing
delays. During operation, the Home Screen will be accessed more than any other screen.
Waveform Display
The Waveform displays a graphical representation of the settings determined for each weld parameters. See
Figure 13.1. Weld Voltage is displayed on the y-axis, and pulse width (time) is displayed on the x-axis. The total
energy per pulse, as displayed in the blue Info Box within the Waveform, is calculated based on the voltage and
time, and is displayed next to the waveform peaks. Total energy is measured in watt-seconds (Ws).
The blue Info Box in the upper right corner of the waveform display shows the saved name of the Active Sched-
ule (if the settings were previously saved to the welder. Also, the Info Box shows the comparator results from
the previous weld (if the comparator is enabled. See page 16 for additional detail about the comparator).
If the Comparator Tab is selected, green lines will appear in the Waveform to indicate the lower limit of the com-
parator values. Red lines will indicate the upper limit of the comparator values. See page 16 to learn more about
the Comparator.
Note: the waveform background color is orange when the Weld On/O button is turned on and gray when the
Weld On/O button is turned o.
Figure 13.1.The Waveform displays a
graphical representation of the weld
settings. Voltage is displayed on the
y-axis. Time is displayed on the x-axis.

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Pulse Settings
Click on the Pulse Settings Tab to set energy release values per
pulse. The Pulse Settings Tab is the default selection.
Total Stored Energy
The Total Stored Energy value (A), as shown in Figure 14.1,
determines the initial peak value of the weld energy. The total
stored energy will determine the maximum amount of energy
that could be delivered in one weld. However, operators may
choose to not use 100% of the maximum stored energy. The
total energy can be set to 100% of the welders total available
energy, yet the pulse 1 and pulse 2 energies do not need to
equal the total stored energy value.
For example, Total energy can be set to 100Ws, Pulse 1 can be
set to 5Ws, and Pulse 2 can be set to 20Ws. The actual weld
energy delivered is only 25Ws (5+20), even though the total
stored energy is set to 100Ws.
Higher Total Stored Energy amounts will lead to welds with
more ‘punch’ because of the higher peak voltages. The example
scenario mentioned above (Total Stored Energy of 100Ws,
Pulse 1: 5Ws, Pulse 2: 20Ws) will have more initial ‘punch’ than
a weld with Total Stored Energy of 25Ws, Pulse 1 of 5Ws, and
Pulse 2 of 20Ws.
Pulse 1 and Pulse 2
Sunstone dual pulse welders have two pulse width energy
controls. Each pulse can be adjusted separately or turned o 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 100% 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 (Pulse 2 Maximum Energy equals Total Stored Energy
minus Pulse 1 Energy).
Using multiple pulses can increase weld quality. In dual pulse
mode, Sunstone CDDP-A welders will discharge two separate
times with each weld trigger/initiation. The rst pulse is de-
Figure 14.1. The Home Screen with the Pulse
Settings Tab selected, which display energy values
for the current weld.
A
POWER
TIME
PULSE 1 PULSE 2
Figure 14.2. Example of dual pulse energy
discharge curve.

Questions? Call or Text [phone] • 15
e Micro Welder Experts
signed to remove surface inconsistencies and contaminants which helps to displace oils, break through oxide
layers, and seat the welding electrodes. See Figure 14.2 to view this type of weld graphically.
The Pulse 1 energy setting should be chosen such that the parts adhere weakly. To determine Pulse 1, turn o
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 barely stick together. Pulse 1 energy is typically below 10% of the total available weld
energy of the welder. Pulse 2 energy is typically between 50% and 70%.
Pre-Weld Delay
The Pre-Weld Delay controls the amount of time between when the weld is trigger/initiated and when the weld
energy is released.
Delay Between Pulse
This delay controls the amount of time between the end of Pulse 1 and the beginning of Pulse 2. This will be
represented on the waveform display. This option is only available when both pulses are enabled.
Welder Charge State
The welder charge state is a small indicator on the bottom of this screen. The indicator will display one of three
colors:
• Green indicates that the welder is charged and ready to weld.
• Black indicates that the welder is not ready to weld, or the Weld On/O button is o.
• Red indicates that the E-Stop is engaged.
Additional Weld Energy Notes
For new applications, a test weld should be performed, and the resulting weld should be evaluated for strength.
To do so, perform the weld, and then try to pull the pieces apart to determine weld strength.
For example, a nickel strip welded to nickel plated steel, as 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. If the nickel
‘pops’ o without tearing, more energy should be used. Thicker materials should be pulled with a specic pull
force requirement in mind.
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 page 88 for additional details on weld
repetition rates.

16 • Questions? Call or Text [phone]
SUNSTONE CDDP-A USERS GUIDE
Comparator
The Comparator Screen can be used to monitor the peak weld
values of the previous welds. The welder can monitor the peak
voltage, peak current, and peak power simultaneously. Both
Pulse 1 and Pulse 2 can be monitored.
The Comparator Screen has a similar layout to the Home
screen. The Waveform displays the output from the previous
weld. The values of the previous weld will be drawn on the graph
in red. Horizontal blue bars will represent the lower and upper
limits for the peak values. The lower and upper limits can be
programmed on the lower half of this screen. See Figure 16.1.
The three tabs below the “comparator” button will toggle the
input values between Peak Voltage, Peak Current, and Peak
Power. The circle in the upper right of each of these buttons will
display a color based on the previous weld’s monitored values.
A green circle indicates that the previous weld was within the
limits. A red circle indicates that the previous weld was outside
of the limits.
HOW TO TURN ON THE COMPARATOR
• Select the tab of the value you want to monitor (Peak
Voltage, Peak Current, and/or Peak Power)
• Turn the comparator on for Pulse 1, Pulse 2, or both.
• Set the upper limit values for the pulses that will be
monitored.
• Set the lower limit values for the pulses that will be
monitored.
NOTE: If you are unsure of what values to set for the limits,
make a dozen test welds that pass your quality control
standards, and see what values are recorded. That should give
you a small sample set of data to use. Next, take those values
and determine how much tolerance you want to add to those
values, and then set your limits based on those tolerances.
The “Last Peak” displays the monitored peak results from the
last weld. The horizontal bar under the number will be green if
the monitored peak value was between the upper and lower
limits. The horizontal bar under the number will be red if the
monitored peak value was outside of the upper and lower limits.
Figure 16.1. The Home Screen with the
Comparator Tab and Peak Voltage sub-tab
selected.