The Sunstone CDDP (Capacitive Discharge Dual Pulse) Welder is a series of advanced micro welders designed for precise and repeatable spot welding applications. These welders are available in various energy capacities, including 200Ws, 400Ws, 600Ws, 1000Ws, and 1100Ws, catering to a wide range of industrial and specialized welding needs. The core function of the CDDP welder is to deliver strong and consistent welds by utilizing capacitive discharge resistance welding technology, which is particularly effective for highly conductive metals and applications requiring minimal heat-affected zones.
Function Description:
The Sunstone CDDP welders operate on the principle of capacitive discharge resistance welding. This method involves rapidly discharging stored electrical energy through the workpieces, generating a localized burst of heat that melts and fuses the materials at the contact point. The "dual pulse" feature is a significant advantage, allowing for two distinct pulses of energy during a single weld actuation. The first pulse, typically lower in energy, serves to clean the weld surface by displacing oils, breaking through oxide layers, and seating the welding electrodes. This preparatory pulse ensures optimal contact and reduces surface inconsistencies and contaminants. The second pulse delivers the main welding energy, creating a strong and reliable weld nugget. This dual-pulse approach enhances weld quality, consistency, and repeatability, especially in applications where surface conditions might otherwise compromise the weld. The welders are microprocessor-controlled, ensuring precise energy delivery and consistent performance.
Important Technical Specifications:
The CDDP series offers a range of models with varying energy capacities, impacting their performance characteristics:
- Energy Capacities: 200Ws, 400Ws, 600Ws, 1000Ws, 1100Ws.
- Input Voltage: All models support 110/220VAC switching power supply.
- Frequency Range: 47-63Hz for all models.
- Power Factor (typical): PF>=0.94/230VAC, PF>=0.99/115VAC.
- AC Current (typical): Ranges from 8.5A/115VAC, 5A/230VAC for the CD200DP to 8.5A/115VAC, 5A/230VAC for the CD1100DP.
- Min/Max Output:
- CD200DP: 5 Ws - 200 Ws
- CD400DP: 5 Ws - 400 Ws
- CD600DP: 5 Ws - 600 Ws
- CD1000DP: 5 Ws - 1000 Ws
- CD1100DP: 5 Ws - 1100 Ws
- Pulse Width: Infinitely adjustable, ranging from 0.53 - 43.2 ms (CD200DP) to 0.23 - 55.4 ms (CD1100DP).
- Rise Time (to Max Voltage): 0.2 ms for all models.
- Min Pulse Height: Ranges from 2.5 V (CD200DP) to 2.2 V (CD1000DP/CD1100DP).
- Max Pulse Height: Ranges from 15.8 V (CD200DP) to 22.4 V (CD600DP).
- Peak Current for 1 AWG 6': Ranges from 7905 A (CD200DP) to 11180 A (CD600DP).
- Peak Current for 4 AWG 6': Ranges from 6081 A (CD200DP) to 8600 A (CD600DP).
- Peak Current for 8 AWG 6': Ranges from 3162 A (CD200DP) to 4472 A (CD600DP).
- Footprint (HXWXD):
- CD200DP, CD400DP, CD600DP: 26.7X30.5X34.3 cm (10.5X12X13.5 in.)
- CD1000DP, CD1100DP: 28X47.6X35.6 cm (11X18.75X14 in.)
- Weight: Ranges from 34 lbs./16kg (CD200DP) to 56 lbs./26kg (CD1000DP/CD1100DP).
- Weld Repetition Rates: Up to 600 welds per minute, depending on the energy setting and model. Specific speeds are provided for different cable gauges (1 AWG, 4 AWG, 8 AWG) and energy settings (10 Ws to 600 Ws). For example, a CD200DP at 10 Ws can achieve 185 welds/min with a 1 AWG cable, while a CD1100DP at 10 Ws can achieve 149 welds/min with the same cable.
Usage Features:
The Sunstone CDDP welders are designed for ease of use with an intuitive and user-friendly interface, making them suitable for both experienced operators and newcomers.
- Single or Dual Pulse Operation: Users can select between single or dual pulse modes, offering flexibility for various welding requirements. The dual pulse mode is particularly beneficial for materials with surface contaminants.
- Adjustable Energy Storage: The energy storage is adjustable from 9% to 100% capacity, allowing for fine-tuning of weld strength. The energy is displayed in watt-seconds (Ws) or Joules on the front panel LCD screen.
- Adjustable Pulse Width: The pulse width is infinitely adjustable, providing precise control over the duration of the energy release, which is crucial for different material types and thicknesses.
- Pulse Controls (Pulse 1 and Pulse 2):
- Pulse 1 energy is adjustable between 1% and approximately 30% of the total stored energy. It's used for pre-weld cleaning and seating electrodes.
- Pulse 2 energy is adjustable between 1% and 99% of the remaining power after Pulse 1. It delivers the main welding energy.
- The combination of Pulse 1 and Pulse 2 energies cannot exceed the total weld energy set by the Weld Energy knob.
- LCD Screen Messages: The LCD provides clear feedback on the welder's status, including "POWER ON," "READY," "BEEP ON/OFF," "WELD ON/OFF," "P1 ON/OFF," "P2 ON/OFF," "NO PULSE," "NEW P1/P2," and "COOLING/ENABLED."
- Compatibility with Attachments: The CDDP welders are compatible with Sunstone's line of weld heads (parallel and opposed configurations) and various hand attachments (Single Probe, Dual Probe, Tweezer, Pressure Actuated). This versatility allows the welder to be adapted to numerous applications.
- Roll Spot Functionality (Upgrade): An optional upgrade enables roll spot welding, allowing for continuous welds as long as the trigger signal is maintained. In this mode, the "Pulses" switch re-purposes to toggle between Single Fire (SF) and Roll Spot (RS) modes. Pulse 1 controls the minimum weld delay between welds, and Pulse 2 controls the weld time (pulse width) of each individual weld.
- External Trigger Port: The welder can be actuated via an external trigger, typically a foot pedal, connected to the Ext. Trigger port on the back panel.
- Audible 'Ready' Notification: An audible beep signals when the welder is ready for the next weld, enhancing operational efficiency. This feature can be turned on or off.
- Repeatable Energy Release: The system ensures repeatable energy release, independent of line voltage fluctuations, contributing to consistent weld quality.
- Quick Energy Release: Designed for quick energy release, making it ideal for highly conductive metals.
- Small Heat Affected Weld Zones: The precise energy control minimizes the heat-affected zone, which is critical for sensitive materials and applications.
Maintenance Features:
The CDDP welders incorporate features designed for internal monitoring and protection, contributing to their longevity and reliable operation.
- Thermal Protection Circuit: An internal thermal protection circuit monitors the welder's temperature. If the unit overheats, it will temporarily cease operation and display "COOLING" on the LCD screen until it reaches an operable temperature, then display "ENABLED." This prevents damage from excessive heat.
- Cooling Ventilation: To ensure proper cooling and prevent overheating, it is recommended to maintain a clear space of six or more inches around the welder's vents.
- Fuse Protection: The welder includes a 10A, 250VAC fuse (5mm x 20mm) for electrical protection.
- Durable Construction: The robust design and microprocessor control contribute to the overall reliability and low maintenance requirements of the device.
In summary, the Sunstone CDDP welder series offers a powerful, versatile, and user-friendly solution for precision spot welding. Its dual-pulse technology, wide range of energy settings, and compatibility with various attachments make it suitable for a diverse array of applications, from battery pack manufacturing to delicate component assembly, ensuring high levels of consistency and quality control.
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