SUNSTONE CD200DP Bedienungsanleitung

CDDP

Users Guide

Capacitive Discharge Dual Pulse Welder

For Models 200Ws, 400Ws, 600Ws, 1000Ws, 1100Ws

Version 20210312 • Part #1175

ii • Questions? Call or Text +1 801-658-0015

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

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UCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGI-

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Questions? Call or Text +1 801-658-0015 • iii

e Micro Welder Experts

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 Specications ..............................................................................................13

iv • Questions? Call or Text +1 801-658-0015

CDDP WELDER USERS GUIDE

Questions? Call or Text +1 801-658-0015 • 1

e Micro Welder Experts

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

• 

• 

• 

• 

2• Questions? Call or Text +1 801-658-0015

CDDP WELDER USERS GUIDE

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.

Questions? Call or Text +1 801-658-0015 • 3

e Micro Welder Experts

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 congurations. 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.

4• Questions? Call or Text +1 801-658-0015

CDDP WELDER USERS GUIDE



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).

Questions? Call or Text +1 801-658-0015 • 5

e Micro Welder Experts

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

Shield

6• Questions? Call or Text +1 801-658-0015

CDDP WELDER USERS GUIDE

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

Dieses Handbuch passt für folgende Modelle

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