SUNSTONE CD200DP-A, CD400DP-A, CD600DP-A User Manual
Sunstone Welders
Sunstone Welders
Advanced Capacitive Discharge Dual Pulse Welder
User Manual for Models: CD200DP-A, CD400DP-A, CD600DP-A
User Manual : CDDP-A
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 Congurations - 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
Conguration 1 - P.11
Conguration 2 - P.11
Conguration 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
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
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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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: sales@SunstoneWelders.com
Voice: 801-658-0015
Fax: 866-701-1209
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.
Copyright 2018
Sunstone Engineering
R&D Corporation
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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 congurations
• 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 prole. 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 congurations used in resistance welding. FIGURE 3a is called
an opposed conguration. Current is passed from one electrode through both workpieces and out
an opposing electrode. FIGURE 3b shows a step electrode conguration. This conguration 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 conguration. Electrodes can only be placed on
one metal surface from one side. Current is divided between the two parts. This weld conguration
requires more weld energy.
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FIGURE 3: Resistance Welding Electrode Congurations:
a. Opposed b. Step c. Series / Parallel
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.
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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.
200 400 600
FIGURE 8: Back Panel
PLC: MATES TO SD80LP
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)
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Sunstone Welders User Manual: CDDP-A
ESTOP: MATES TO SD60LP
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 SD40LP
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 SD50LP
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 SD30LP
Pin 1: Not Connected
Pin 2: +12V
Pin 3: Secondary Trigger. Connect this to pin 2(+12VDC) when trigger is desired.
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FIGURE 13: Secondary Trigger (SD-30LS)
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 congurations 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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