SUNSTONE CD200DP-A - Chapter 4: Operating Instructions; Pulse Control; Dual Pulse Welding; Using the Dual Pulse Weld Function

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Sunstone Welders User Manual: CDDP-A
Chapter 4: Operating Instructions
Pulse Control
DUAL PULSE WELDING
Sunstone dual pulse welders have two pulse width energy controls. Each pulse can be adjusted
separately or turned off 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 all 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.
USING THE DUAL PULSE WELD FUNCTION
Using multiple pulses increases weld quality. In dual pulse mode Sunstone welders will re twice
from a single actuation. The rst pulse is used to remove surface inconsistencies and contaminants
which helps to displace oils, break through oxide layers, and seat the welding electrodes.
FIGURE 15: This shows what the welder discharge curve would
look like when using the dual pulse setting as outlined above.
SETTING Pulse 1 AND 2
The Pulse 1 energy setting should be chosen such that the parts adhere weakly. To determine Pulse
1, turn off 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 stick together to achieve maximum heat. Pulse 1
energy is typically below 10%. Pulse 2 energy is typically between 50% and 70%. 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
and leaving the weld nuggets on the battery terminal. Thicker materials should be pulled with a
specic pull force requirement in mind.
ENERGY ADJUSTMENT
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 Table 2 on page
37 for additional details on weld repetition rates. The weld energy text entry box can be used to set