SUNSTONE CDSP User manual

CDSP
User Manual
Capacitive Discharge Single Pulse Welder
For Models 100Ws, 200Ws
Version 20210502 • Part #1226

Sunstone CDSP Users Guide
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 05/2021 20210517 Production release.
LIMITATION OF LIABILITY
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING LLC, ITS DISTRIBUTORS,
OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY
OR PUNITIVE DAMAGES, OF ANY NATURE WHATSOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGI-
NEERING LLC PRODUCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGINEER-
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OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH
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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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Contents
Chapter 1: Meet the Sunstone CDSP ................................................................. 1
Key Features ........................................................................................................... 1
Typical CD Welding Applications..................................................................... 2
Weld Formation ...................................................................................................... 2
CD Welding Tips..................................................................................................... 3
Chapter 2: How to Set Up the CDSP ................................................................... 4
How to Set Up Your Welder................................................................................ 4
How to Set Up Your Weld Head ........................................................................ 5
How to Set Up Your Attachment ...................................................................... 6
Chapter 3: How to Operate the CDSP ................................................................ 7
LCD Displayed Messages................................................................................... 8
Managing Pulse Control Using Pulse Width and Weld Energy ............. 8
How to Adjust Pulse Width................................................................................. 8
How to Adjust Weld Energy................................................................................ 9
Chapter 4: Technical Data......................................................................................10

Sunstone CDSP Users Guide

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Chapter 1: Meet the Sunstone CDSP
The Sunstone CDSP is a single-pulse, capacitive discharge ne-spot welder, available in a 100 or 200 Ws mod-
el. Capacitive discharge (or CD) welders, like the CDSP, perform strong and repeatable welds for high levels of
consistency and quality control. Sunstone ne-spot welders are simple to use with an intuitive and user-friendly
interface. The Sunstone CDSP can be adjusted and ne-tuned to match the requirements of countless applica-
tions. A digital screen accurately displays weld energy settings for absolute weld control.
KEY FEATURES INCLUDE THE FOLLOWING:
• Available with 100 or 200 Ws of energy
• Single pulse operation
• Microprocessor controlled
• Thermal protection circuit for internal monitoring
• Audible ‘Ready’ notication
• Adjustable pulse width
• Energy storage adjustable from 0.1% to 100% capacity
• Up to 120 welds/min
• 110/220VAC automated switching power supply
• Simple, user-friendly interface
• Quick energy release for welding highly conductive
metals
• Small heat eected weld zones
• Repeatable energy release independent of line voltage
uctuations
• Capable of extremely ne energy adjustment
• Innitely adjustable pulse width
• Applications
The Sunstone CDSP: A single-pulse,
capacitive discharge, ne-spot welder.
Available in 100 or 200 Ws models.

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Sunstone CDSP Users Guide
TYPICAL CD WELDING APPLICATIONS
• Cross wires
• Thermocouples
• Strain gauges
• Electronic components
• Thin copper, aluminum, brass, and steel wires and sheets
• Miscellaneous resistive welding applications
• Research and development
After you’ve carefully reviewed the users guide and had a chance to use the welder, you’ll nd that Sunstone
welders are the best ne-spot welders available.
What is Capacitive Discharge Resistance Welding?
Whether you’re a novice hobbyist or experienced industrial welder, you should review the science behind CD
welding. Capacitive discharge resistance welding uses capacitors to store energy for quick release. CD welders,
have many advantages over other welder types:
• Quick energy release for welding highly conductive metals such as copper
• Small heat aected weld zones
• Repeatable energy release independent of line voltage uctuations
• Capable of extremely ne energy adjustment
Weld nugget formation takes place during the rst few milliseconds of the welding process. A CD welder allows
extremely fast energy release with large peak currents; more of the energy goes into weld formation and less
into heating surrounding material. The heat-aected zone, where rapid heating and cooling have changed the
properties of the metal, is localized to a small area around the weld spot. The quick discharge rate of CD weld-
ers also allows electrically and thermally conductive materials, such as copper or aluminum, to be welded. Ca-
pacitive discharge welders deliver repeatable welds even during line voltage uctuations because weld energy
is stored before use.
Weld Formation
Spot welding relies on metal resistivity 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 release of energy can be graphed, as shown in Figure 3.1.
There are two phases to the melting process. The welder must overcome both the material contact resistance
and the bulk resistance of the material. As show in Figure 3.2, on a 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
bridges have fused, the contact resistance is zero. The bulk resistance of the metal then plays the nal role in
the weld formation.

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CD Welding Tips
Weld Pressure
Several other factors play a part in the contact resis-
tance. 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 pres-
sure 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 Congurations
Several electrode congurations can be used in resis-
tance welding, as shown in Figure 3.3. In a Direct weld
(A), current is passed from one electrode through both
workpieces and out an opposing electrode. A Series
electrode conguration (B) is used when there is access
to only one side of the work-piece and an electrode
can be placed on both materials. With a Step congu-
ration (C), 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
The Sunstone CDSP allows you to adjust the amount of
stored energy to be released via an energy adjustment
dial. The energy is then displayed in watt seconds on
the front panel of the CDSP.
POWER
TIME
Figure 3.2: Surface contact point example.
Figure 3.1: Sample Capacitor Discharge Curve
Figure 3.3: Examples of
resistance welding electrode
congurations: A. Direct; B.
Series; C. Step.
A
B
C

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Sunstone CDSP Users Guide
Chapter 2: How to Set Up the CDSP
Warning: Before you begin the setup process, make sure you review and understand the following:
Voltage and Power Requirements
The Sunstone CDSP is equipped with a universal power supply and can be used with both 110V and 220V AC
wall power.
Weld Actuation
The Sunstone CDSP is actuated by means of an external trigger port located on the back of the welder (see (B)
in Figure 5.1). The trigger uses a DIN 3 connector and requires shielded wire. Figure 4.1 shows the proper pin
placement for custom external trigger cables. The standard external trigger cable connector is an SD-30LP
made by CUI Inc.
Audible Welder Beeps
The Sunstone CDSP can sound an audible alarm or beep. When enabled, the welder will beep when the unit has
charged to its targeted weld energy. This signies that the unit is ready to weld. You can turn Welder Beeps on
or o with a switch located on the back of the welder.
Thermal Protection
The Sunstone CDSP is equipped with a temperature sensor. If the unit is close to overheating, 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.
Note: Temperature sensor warning beeps will still occur even if the “Welder Beeps” option is turned o.
Figure 4.1. External trigger wiring diagram.
N.O. means “Normally Open.”
N.O. Circuit
N.O. Circuit
Shield

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To ensure proper cooling, the welder air ow paths, located on the side and rear of the welder, should be unob-
structed. Please maintain a clear space of at least six inches around the welder vents.
How to Set Up Your Welder
Remove the welder from the box and place it on a secure work surface. Refer to Figure 5.1.
• Turn audible beep (A) on or o according to your preference.
• Attach the trigger cable, such as from a foot pedal, to the Trigger port (B).
• Attach weld head or hand attachment cables to negative and positive terminals (C). See additional
instructions below for weld head and hand attachment use with the CDSP.
• Attach the power cable to the power port (D) on the back of the welder and into an AC power outlet.
• Turn the welder on by ipping the power switch (E).
How to Set Up Your Weld Head
Sunstone manufactures a variety of weld heads to accommodate a diverse range of welding applications. Sun-
stone’s parallel and opposed weld heads provide a great amount of control and precision. Reference Figure 5.1
and follow these instructions to set up your Sunstone weld head:
• Remove the weld head from the box and place it on a secure work surface.
• Attach weld head cables to negative and positive terminals (C).
• Select the type of weld head in use:
• Manual Models: See weld head user manual for setup.
• Pneumatic Models:
A
B
C
D
E
Figure 5.1: To get started, select the beep mode (A); Attach the trigger cable (B); Attach weld
head or hand attachment cables (C); Connect the power cord (D); Turn on the welder (E).

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Sunstone CDSP Users Guide
• Connect the foot pedal to the Weld Head Trigger Hub
• Connect the MAC valve control cable to the Weld Head Trigger Hub
• Plug the Weld Head Trigger Hub into a reliable power source
• Place the Weld Head Trigger Hub in a spot that secures all cables from impeding operation or
contacting extremely hot surfaces.
• Connect the Weld Head Trigger cable from the weld head to the Trigger Port on the back of the
welder.
• Turn the welder on using the power switch (E) on the front of the welder as shown in Figure 5.1.
• Set the desired pulse width (C) and weld energy (D) as shown in Figure 7.1.
• Actuate the weld head.
Note: See the Sunstone weld head users guide for more precise setup information.
How to Set Up a Hand Attachment
Sunstone 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. Reference Figure 5.1 and follow these
instructions to connect a hand-held attachment to the Sunstone CDSP:
• Remove the attachment from its package.
• For Single Probe, Dual Probe, and Tweezer Handheld Attachments:
• Connect the attachment cables to the negative and positive terminals (C) on the front of the
welder.
• Connect the 3-pin actuation foot pedal cable to the Trigger port (B).
• For Pressure Actuated Hand Attachments:
• Connect the attachment cable to either of the terminals (C) on the front of the welder and the
grounding clip cable to the other terminal.
• Attach the hand attachment’s trigger cable to the Trigger port (B) on the back of the welder.
• Attach the power to the power port (D) on the back of the welder and into an AC power outlet.
• Turn the welder on by ipping the power switch (E).

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Chapter 3: How to Operate the Sunstone CDSP
If you’ve completed the process of setting up the CDSP, connecting either a weld head or hand-held attach-
ment, and have plugged the welder power cable into an AC power outlet, then you’re ready to get to work. Make
sure you have reviewed all safety items found on the front, inside cover of this users guide.
Turn on the welder by pushing the power switch to the On position. The power switch is located in the bottom,
right-hand corner on the front of the welder. See (A) in Figure 7.1. The LCD screen on the front of the welder (B)
will display “POWER ON”, and after a brief pause, the LCD will display the current power setting.
Set the pulse width. Turn the pulse width dial (C) left or right to set the desired amount of pulse width. See Table
1 or 2 on page 10 and 11 to determine the desired setting. You’ll nd more information about pulse width further
in this chapter.
Set the weld energy. Turn the weld energy dial (D) left or right to set the desired amount of energy. As you turn
the dial the LCD screen on the left will display the energy setting.
Position the workpiece. If you’re using a handheld attachment, place the electrode where you wish to place the
weld and depress the trigger. If you’re using a weld head, place the workpiece in the desired location and then
actuate the weld head. When the welder has recharged and is ready for the next weld you will hear an audible
beep, unless you’ve turned o the audible beep using the switch on the back of the welder.
Important Note: Turn the welder o when not in use.
A
Figure 7.1: To get operate the Sunstone CDSP welder, turn the
welder on (A); Set the pulse width (C); Set the weld energy (D);
position the workpiece and then trigger the weld.
B C D

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Sunstone CDSP Users Guide
Managing Pulse Control Using Pulse
Width and Weld Energy
Controlling energy storage and pulse width allows you
to manage both the energy released during the welding
process and the peak electrical current experienced
by the weld material. These parameters are important
when welding materials that have diverse thermal and
electrical properties. The Sunstone CDSP has one
pulse width energy control dial and one weld energy
control dial. The blue back-lit LCD displays the total
stored energy in watt seconds (ws).
How to Adjust Pulse Width
Sunstone single pulse welders allow a large degree of
control over the entire welding process. The energy
stored and released with each weld discharge can be
adjusted down to very ne increments for welding very
small parts.
The pulse width dial allows ne control over the du-
ration of the weld pulse and the energy released with
each pulse. See Figure 8.1 (A). The pulse is adjustable
between 0.1% and 100% of the total stored energy.
The pulse width dial can be set to point to dierent tick
marks around the dial. If you turn the dial all the way to
the left until it stops, you’ve selected no pulse width. If
you turn the dial all the way to the right you’ve selected
the maximum amount of pulse width. Tables 1 and 2 on
page 10 explain the values for each tick mark.
Several factors should be considered when selecting
the correct pulse width setting. For example, when
welding highly conductive materials such as copper, the
peak weld current must be higher when welding higher
resistive materials (e.g. steel).
Thus, welding a thin copper part may require high weld
energy displayed on the screen (high peak current) but
a small pulse width (to produce a small total energy re-
leased). Conversely a thin steel part may require a lower
displayed weld energy (peak current) and longer pulse
width (to provide enough energy).
Figure 9.1 shows how voltage, peak current and energy
A
Figure 8.1. Turn the Pulse Width dial (A) to adjust pulse width
between 0.1% and 100% of the total stored energy.
B

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relate. It should be noted that the energy stored can
also be thought of as capacitor voltage in this diagram.
How to Adjust Weld Energy
The weld energy dial controls the total welder energy
storage and sets the peak weld current. See Figure 8.1
(B). The weld energy dial is used to set the total weld
energy 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.
See Tables 1and 2 on page 10 for additional details
including weld repetition rates.
Typical values of peak current with weld energy and
load are given in Tables 1 and 2 on page 10. You’ll also
nd the amount of energy released for each pulse in
Table 1, as well as a function of the welding load (resis-
tance).
Each Sunstone welder is fully adjustable between its
minimum and maximum energy. The Sunstone CDSP
has a repetition rate of up to 120 welds/min. See Table
4 on page 11 for additional details on weld repetition
rates.
R
O
T
A
T
I
O
N
Figure 9.1. Graph showing the relationship between voltage,
peak current and energy.

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Chapter 4: Technical Data
TABLE 1: CD100SP ENERGY RELEASE AS A FUNCTION OF WELD LOAD & PULSE WIDTH
Pulse Width Dial
Marker
Pulse Time in ms 1.0mΩ Load % of
energy
1.5mΩ Load % of
energy
4.0mΩ Load % of
energy
1 0.26 ms 27% 20% 12%
1.5 0.28 ms 29% 22% 12%
2 0.45 ms 42% 33% 19%
2.5 0.59 ms 51% 40% 24%
3 0.75 ms 60% 48% 29%
3.5 0.90 ms 67% 55% 35%
4 1.06 ms 72% 60% 39%
4.5 1.43 ms 82% 71% 49%
5 2.23 ms 93% 86% 65%
5.5 3.54 ms 99% 95% 81%
6 4.80 ms 100% 98% 89%
6.5 5.51 ms 100% 99% 92%
7 5.54 ms 100% 99% 93%
TABLE 2: CD200SP ENERGY RELEASE AS A FUNCTION OF WELD LOAD & PULSE WIDTH
Pulse Width Dial
Marker
Pulse Time in ms 1.0mΩ Load % of
energy
1.5mΩ Load % of
energy
4.0mΩ Load % of
energy
1 0.47 ms 25% 19% 10%
1.5 0.50 ms 26% 20% 11%
2 0.81 ms 39% 30% 17%
2.5 1.07 ms 48% 37% 22%
3 1.34 ms 56% 44% 27%
20 1.63 ms 63% 51% 32%
4 1.90 ms 69% 56% 36%
4.5 2.57 ms 79% 67% 45%
5 4.02 ms 91% 83% 61%

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5.5 6.37 ms 98% 94% 78%
6 8.68 ms 99% 98% 87%
6.5 9.92 ms 100% 99% 90%
7 9.98 ms 100% 99% 90%
TABLE 3: PEAK WELD CURRENT AS A FUNCTION OF WELD ENERGY AND EXTERNAL
WELDING LOAD
Energy (Ws)
(CD100 | CD200)
1.0mΩ Load
(Amps)
1.5mΩ Load
(Amps)
4.0mΩ Load
(Amps)
0.1 | 0.2 250 200 100
25 | 50 3953 3162 1581
50 | 100 5590 4472 2236
75 | 150 6847 5477 2739
100 | 200 7906 6325 3162
TABLE 4: WELD REPETITION RATES IN WELDS PER MINUTE
Weld Energy
(% of maximum energy)
Nominal Rep Rate CD100SP
welds/min
Nominal Rep Rate CD200SP
welds/min
100% 40 20
75% 50 25
50% 60 30
25% 85 42
2.5% 120 120
TABLE 5: WELD PULSE CHARACTERISTICS
Model Energy
Min - Max
Pulse Width
Min - Max
Pulse Height
Minimum
CD100SP 0.1ws - 100ws 0.26ms - 5ms 0.2 V
CD200SP 0.1ws - 200ws 0.47ms - 10ms 0.2 V
TABLE 6: WELDER CHARACTERISTICS
CD100SP CD200SP
Inches cm Inches cm
Height 8 20.3 8 20.3
Width 8.5 21.6 8.5 21.6
Depth 11 28 11 28
Weight 17 lbs 8 kg 19 lbs 9 kg

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DECLARATION OF CONFORMITY
Manufacturer Information
Name Sunstone Engineering LLC
Address 1693 American Way Ste 5
Payson UT 84651 USA
Telephone [phone]
Fax [phone]
Product Information
Name CDSP
Description Multi-mode resistance welder
Model Number CDSP
Conformity Information
This product conforms to the following directives:
Directive Document Number Description
Electromagnetic Compatibility
(EMC)
2014/20/EU Council Directive 2014/30/EU (February 26,
2014) on Electromagnetic Compatibility
Low Voltage Directive (LVD) 2014/35/EU Council Directive 2014/35/EU (February 26,
2014) Low Voltage Equipment Safety
This product conforms to the following harmonized standards:
Standard Document Number Description
EMC Immunity Standard EN 61000-6-1-2007 Immunity for residential, commercial, and
light industrial environments
LVD Standard EN 60974-6-2016 Arc Welding Equipment - Safety
Requirements
The Technical File required by both directives above is maintained at the headquarters of Sunstone
Engineering LLC, 1693 American Way Ste 5, Payson Utah 84651 USA. CE Year 2020

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Sunstone CDSP Users Guide

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Another World-Class Micro Welder from Sunstone:
Sunstone™
CDDP-A
Now available in
four models:
• 200 Ws
• 400 Ws
• 600 Ws
• 1200 Ws NEW!
Advanced CD Fine-Spot Resistance Welders
Precise, Repeatable Control Over Every Aspect of Every Weld!
e Micro Welder Experts
The Sunstone hallmark is precision control
over power delivery details. And the Sunstone
CDDP-A line of ne-spot resistance welders is
no exception. A touchscreen interface lets you
adjust power by 1/100th of a Ws! Plus you have
full control over the wavelength. With absolute
energy control you’ll always be able to dial in and
nd the sweet spot for any welding application.
The CDDP-A is PLC-enabled and automation
ready for any production oor. If you need a
solution for honeycomb tacking, continuous roll
spot welding, cross-wire welding, thermocouples,
or other resistive applications, the CDDP-A is the
right welder for you.
Call or Text [phone]
www.sunstonewelders.com

1693 American Way Ste 5 • Payson UT 84651 USA
Tel. [phone]
www.sunstonewelders.com
©2020 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20210502 • PART #1226