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SUNSTONE CDDP-A - User Manual

SUNSTONE CDDP-A
92 pages
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CDDP-A
User Manual
Advanced Capacitive Discharge Dual Pulse Welder
For Models 200Ws, 400Ws, 600Ws, 1200Ws
Version 20210101 • Part #1176

Table of Contents

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Summary

Chapter 1: Overview of CDDP-A Welder

CDDP-A Welder Features

Details the key capabilities and advanced features of the Sunstone CDDP-A welders.

Understanding CD Welding Technology

Explains the principles of Capacitive Discharge (CD) resistance welding and its benefits.

Weld Formation Process

Describes the micro-scale surface profile and how weld formation occurs with CD welding.

Weld Pressure Considerations

Explains the impact of electrode pressure on contact resistance and weld strength.

Electrode Configurations and Weld Energy

Details various electrode configurations and how weld energy is adjusted.

Chapter 2: Setup and Installation Guide

Safety and Workspace Requirements

Covers essential safety precautions and workspace considerations for welder operation.

Power Requirements and Weld Actuation

Details voltage requirements and how the welder is actuated via external triggers.

Exploring Welder Components

Provides an overview of the welder's front, back, and side panel components.

Initial Welder Setup Procedure

Step-by-step instructions for setting up the welder for the first time.

Chapter 3: User Interface Overview

Navigation and Home Screens

Describes the navigation bar and the main home screen interface elements.

Core Operation Screens and Tabs

Details screens like Waveform, Pulse Settings, Comparator, and Control tabs.

Communication and PLC Features

Explains the Communications screen and its PLC automation capabilities.

Media and Data Management Screens

Covers Media, Applications, PDF, Training, and Save/Load screen functionalities.

Lock and Settings Screen Functions

Details the purpose of the Lock Screen and the Settings Screen.

Chapter 4: Home Screen Operation Guide

Waveform Display Explanation

Details the waveform display, showing voltage, pulse width, and energy per pulse.

Pulse Settings Configuration

Explains how to set energy values for Pulse 1, Pulse 2, and Total Stored Energy.

Chapter 5: PLC Automation Features

PLC Tab and Basic I;O Configuration

Describes the PLC tab, including Basic PLC I/O and pin state functions.

Remote Schedule Select Functionality

Details how to program and select up to four pre-saved weld schedules via PLC.

Alarms Tab for System Status

Explains the Alarms tab for monitoring power supply statuses and alarm settings.

Import;Export Tab for Data Management

Covers functions for exporting history, clone information, and importing data.

Chapter 6: Using Media Features

Accessing Media Content

Guides on accessing application videos, PDF documents, and training materials.

Chapter 7: Save and Load Weld Schedules

Chapter 8: Lock Screen Operation

How to Lock the Welder

Explains the process of locking the welder to prevent unauthorized setting changes.

Chapter 9: Making System Changes

Interface and System Settings

Details how to change interface settings and system configurations.

Chapter 10: Updating Welder Software

Software Update Methods

Guides on updating software via USB storage device or Wi-Fi connection.

Chapter 11: Configuring Ethernet Connection

Ethernet Setup and Configuration

Provides instructions for setting up an Ethernet connection for welder control.

Chapter 12: Back Panel Connector Details

Ethernet Port

Details the Ethernet port for PLC control and computer connection.

Accessory Port

Describes the port for connecting external accessories.

PLC Port

Details the PLC port for logic inputs and outputs.

E-Stop Port

Explains the Emergency Stop port functionality.

WH Control Port

Details the Weld Head control port.

Primary Trigger Port

Describes the port for connecting a foot pedal or switch.

Secondary Trigger Port

Details the port for connecting a secondary foot pedal or switch.

Negative Weld Terminal

Specifies the connection for the negative weld cable.

Positive Weld Terminal

Specifies the connection for the positive weld cable.

Fuse Information

Details the welder's fuse rating and type.

Power Inlet

Describes the port for plugging in the main power cord.

Appendix A: Connection Pin-Out Diagrams

PLC Pin-Out Details

Diagram and explanation of the PLC connector pin assignments.

E-STOP Pin-Out

Pin diagram and explanation for the E-STOP connector.

Weld Head Control Pin-Out

Pin diagram and explanation for the Weld Head Control connector.

Primary Trigger Pin-Out

Pin diagram and explanation for the Primary Trigger connector.

Secondary Trigger Pin-Out

Pin diagram and explanation for the Secondary Trigger connector.

Appendix B: Warnings and Alarms

Common Warnings and Solutions

Lists common warnings like Comparator Failures, Electrode Stuck, and Emergency Stop.

File Transfer and Firmware Warnings

Details warnings related to file transfers, firmware updates, and USB drive space.

Operational and Temperature Warnings

Covers warnings for temperature alarms, trigger errors, and welder overheating.

Appendix C: Modbus Data Tables

Supported Modbus Function Codes

Lists Modbus function codes supported by the CDDP-A with their Read/Write capabilities.

Modbus Data Structures

Defines the size and type for Coils, Discrete Inputs, Holding Registers, and File Records.

Modbus Register Types and Assignments

Details coils, discrete inputs, holding registers, and their specific assignments.

Input Register Index and Notes

Provides an index of input registers with their length and specific notes.

Custom Functions Reference

Schedule Weld Data Functions

Details custom functions for scheduling weld data using 16-bit registers.

Schedule Extra Weld Data Functions

Explains custom functions for scheduling extra weld data using 16-bit registers.

Comparator Custom Functions

Details custom functions related to comparator settings for pulses.

Alarm Settings Custom Functions

Explains custom functions for configuring alarm settings with 16-bit registers.

Basic PLC Settings Functions

Details custom functions for basic PLC settings using 16-bit registers.

General Information Custom Functions

Covers custom functions for general information like PLC states and RSS mode.

Weld Task States

Lists the different states for the weld task and their corresponding hex values.

Charge Task and Lock States

Details the states for charge tasks and lock statuses.

Previous Weld Results Functions

Explains custom functions for retrieving previous weld results.

CDDP-A Data Specifications Table

SUNSTONE CDDP-A Specifications

General IconGeneral
BrandSUNSTONE
ModelCDDP-A
CategoryWelding System
LanguageEnglish

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