CD Single Pulse Systems
Contents
1. Pulse Width Pulse Time 1 0mQLoad 15mQLoad 4 0m0 Load Dial Marker inms of energy ofenergy of energy 6 480ms 100 100 100 TABLE 2 CDIOOSP Energy release as a function of weld load and pulse width Aue Width ji Time 10mMQ Load 15m0Load 4 0mQ Load of energy ofenergy of energy 6 868ms 99 98 am TABLE 3 Peak weld current as a function of weld energy and external welding load Energy ws 1 00m2Load 15mMmQ Load 4 0mQ Load CD100 CD200 SE 0 1 0 2 25 50 50 1100 5590 4412 2256 75 150 6841 5411 2159 100 1 200 1906 6525 5162 es e sunstone TABLE 4 VVeld repetition rates in vvelds per minute Nominal Rep Rate Nominal Rep Rate CD100SP CD200SP welds min welds min Weld Energy of maximum energy TABLE 5 Weld pulse characteristics Min Max Min Max Minimum TABLE 6 Weld pulse characteristics CD100SP CD200SP ma fn s sunstone Appendix A Glossarv AWG American Wire Gauge is the standardized wire gauge svstem FAVING Faving surfaces are those that have been joined bv a weld PULSE A burst of electrical energy RESISTANCE Welders relv on aresistance between its terminals to generate the heat needed to melt metals Ohm s law states that Voltage Current X Resistance SPOT WELD A small weld done with two electrodes that leaves a circular or spot shaped weld nugget TERMINALS The copper bars protr2. Time s ch Er sunstone Figure 2 below shows an example of a micro scale surface profile On the micro scale material surfaces are rough and onlv contact in a limited number of locations In the first few Milli seconds 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 plavs the final role in the weld formation 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 insure good weld strength FIGURE 2 On the micro scale surface roughness limits surface to surface contact More contact points resultin a lovver contact resistance en A sunstone ELECTRODE CONFIGURATIONS Figure 3 shows several electrode configurations used in resistance welding Figure 3a is called a direct weld Current is passed from one electrode through both workpieces and out an opp
3. CUI Inc i N O Circuit FIGURE 4 External trigger wiring diagram looking at back 1 f welder for the welder back N O t Shield pe panel connector N O stands for Normallv Open WELDER BEEPS Sunstone CDSP welders are equipped with a beeper When enabled the welder will beep when the unit has reached its targeted weld energy This signifies that the unit is ready to weld Users can turn Welder Beeps on or off with a switch located on the back of the welder a EER sunstone THERMAL PROTECTION Sunstone capacitive Single Pulse welders are equipped with temperature sensors If the unit is close to overheating 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 signifving that the unit is again ready to weld These warning beeps will still occur even if the Welder Beeps option is turned off To ensure proper cooling the welder flow paths shown in Figure 5 should be unobstructed Please maintain a clear space of 6 inches around the welder vents FIGURE 5 For proper cooling ensure all vent locations are unobstructed PAN SHK Welder Setup QUICK START SET UP OF CDSP WELDER 1 Remove the vvelder from the box and place it on a secure work surface _ ch Oe sunstone 000 LO gt SON 000 00 NR 2 Turn Beep on or off according to user preference 3 Plug i
4. Power Supply Simple user friendly interface Quick energy release for vvelding highly conductive metals Small heat effected vveld zones Repeatable energy release independent of line voltage fluctuations Capable of extremely fine energy adjustment Infinitelv adjustable pulse width o sunstone Applications Capacitive Discharge CD resistance welders have manv advantages over other tvpes of welders One such advantage is the abilitv to achieve a quick energy release which can result in successfully welding highly conductive metals such as copper Also this quick energv release is verv concentrated at the weld spot thus creating a verv small heat affected zone Having a small heat affected zone means that delicate projects and heat sensitive applications can we welded without jeopardizing or damaging the welded pieces Some tvpical applications welded with Sunstone single pulse CD welders are Cross wires Thermocouples Strain gauges Electronic components Thin copper aluminum brass and steel wires and sheets Miscellaneous resistive welding applications Research amp development Sunstone capacitive discharge spot vvelders are the most effective precision fine spot resistance vvelders on the market KP sunstone What is Capacitive Discharge Resistance VVelding Capacitive discharge resistance vvelding uses capacitors to store energy for quick release Capacitive resistance vvelders also called capacitive
5. _ ch Er sunstone 2a Single Probe Dual Probe and Tweezer Hand Held Attachments Connect the Hand Held Attachment cables to the negative and positive terminals on the front of the welder then connect the 3 pin actuation foot pedal cable to the back of the welder 2b Pressure Actuated Hand Attachments Connect the Hand Held Attachment cable to either of the terminals on the front of the welder and the grounding clip cable to the other terminal Then attach the trigger cable to the back of the welder 3 Plug the welder power cable into an AC power outlet 4 Turn the welder on and set the desired energy settings e IN sunstone Chapter 4 Operating Instructions LCD Screen LCD DISPLAVED MESSAGES Messages are shown on the LCD display to indicated that a change is being made to the welder Here are a list of messages and what they indicate POWER ON This message is displayed when the welder has been turned on READV This message is displaved after vou weld and the unit is readv to weld again Beep On Off Shows up when vou toggle the Beep Enabled switch Vou will hear audible beeps when on Weld On Off Shows up when vou toggle the Pulses switch The welder will not weld with this switch off P1 On Off Will be displayed when pulse 1 has been switched off or on P2 On Off Will be displaved when pulse 2 has been switched off or on No Pulse This indicates that both pulses ha
6. discharge or CD vvelders have many advantages over other vvelder tvpes Quick energy release for vvelding highly conductive metals such as copper Small heat effected vveld zones Repeatable energy release independent of line voltage fluctuations Capable of extremely fine energy adjustment e IE sunstone Weld nugget formation takes place during the first few Milli seconds of the welding process A CD welder allows extremely fast energy release with large peak currents This means that more of the energv goes into weld formation and less into heating surrounding material The heat affected zone where rapid heating and cooling have changed the properties of the metal is localized to a small area around the weld spot The quick discharge rate of CD welders also allows electrically and thermally conductive materials such as Copper or aluminum to be welded Capacitive welders deliver repeatable welds even during line voltage fluctuations because weld energyis stored before use WELD FORMATION Spot welding relies on metal resistivitv 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 There are two phases to the melting process The welder must overcome both the material contact resistance and the bulk resistance of the material FIGURE 1 Sample Capacitor Discharge Curve o 001 0 02 08 0 04 0 05
7. for sunstone damage or bare wiring replace immediatelv if damaged bare wiring can kill Check ground conductor for continuitv Turn off all equipment when not in use Use onlv well maintained equipment and repair or replace damaged parts at once PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND ARC RAYS It is essential for every person in the immediate work area to wear utilize proper Personal Protection Equipment There is a etd possibility that sparks can fly off from the weld joint area therefore take the necessary precautions to avoid trapping a Spark within your own clothing Wear protective garments such as oil free flame resistant leather gloves heavy shirt cuff less trousers high shoes and a cap Avoid synthetic fibers as they melt easily Use an approved face shield or safety goggles with side shields when welding or when observing others performing welds SAFETY PRECAUTIONS FOR HOT METAL AND CABLES Welding material that has a high thermal conductivity will cause metal to heat rapidly Repetitive welds in the same location can also cause metal to heat rapidly Avoid touching weld spots immediately after the weld has been performed as they will be hot Do not touch hot weld areas barehanded Allow sufficient cooling time before handling welded pieces sunstone Welding cables can become extremelv hot After extended use be cautious when handling the weld cables SAFETV PR
8. ECAUTIONS FOR FUMES AND GASES Welding can produce fumes and gases Breathing these fumes and gases can be hazardous to vour health Sunstone welders produce minimal fumes and gases when compared to large scale welders Though not required some form of ventilation is recommended Keep fumes awav from face Do not breathe the fumes Ventilate the area and or use local forced ventilation at the weld spot to remove welding fumes If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safetv Data Sheets MSDS and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Do not weld in locations near degreasing cleaning or spraving operations The heat and ravs of the weld can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the work area is well ventilated and the operator is wearing an air supplied respirator The coatings and anv metals containing these elements can give off toxic fumes if welded sunstone SAFETV PRECAUTIONS FOR FALLING EQUIPMENT Use a working surface of adequate physical strength to support the welding unit during operation or storage Secure welding unit during transport so that it cannot tip or fall MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES Wearers of pacemakers a
9. e contact us vvith the information provided belovv Sunstone Engineering RED Corp 1693 American Way Suite 5 Pavson UT 84651 Email sales SunstoneEngineering com Voice 801 658 0015 Fax 866 701 1209 NOTE The information contained in this manualis subject to change as improvements are made to our products Visit www SunstoneSpotWelders com for the latest version of this document sunstone sunstone Welding Safety amp Precautions Read Before Welding The following safetv advice is generalized advice for the welding industrv These safetv precautions are not allinclusive All users should exercise caution while using this device The following groups of symbols are warning svmbols CAUTION ELECTRIC SHOCK HAZARD EVE PROTECTION REQUIRED A N Consult these svmbols and the related instructions listed next to the symbols for proper action when dealing with these hazards READ INSTRUCTIONS Read the owner s manual before using the welder Only personnel trained and certified by the manufacturer should service the unit Use oniv genuine replacement parts from the manufacturer Never open welder to perform anv maintenance operation inside the unit sunstone SAFETV PRECAUTIONS FOR FIRE OR EXPLOSION There is a possibility that flving sparks hot work pieces and or hot equipment can cause fires and burns Ensure that vour work area is clean and safe for welding before starting anv weld job Wear approp
10. ed on Additionallv the internal capacitors remain charged for a period of time after the welder is turned off and or power is disconnected Incorrectiv installed or improperlv grounded equipment is a hazard Do not operate welder in a wet damp environment Care should be taken not to short across the positive and negative terminals At full power the weld current carries thousands of amps and is dangerous if the terminals are accidentally bridged All welds are performed at low voltage for increased safety of operation Do not wear metal jewelrv when welding The terminals are safe to touch without fear of arcing as long as no metalis on your hands When altering or maintaining anv part of the welding path such as swapping electrodes or cables turn the unit off Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Properly install and ground this equipment refer to the grounding codes and specifications of the area vou live in Do not weld with wet hands or wet clothing Alwavs verifv the supplv ground check and be sure that the input power cord ground wire is properlv connected to a ground terminal in the disconnect box or that the input power cord plug is connected to a properly grounded receptacle outlet Do not remove or bypass the ground prong Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect the input power cord and ground conductor
11. n the external Trigger 4 Attach weld head or hand attachment cables to negative and positive terminals 5 Plug the power cord into the back of the welder and into an AC power outlet 6 Turn the welder on Weld Head Setup QUICK START SET UP OF WELD HEADS TO CDSP WELDERS Sunstone Engineering manufactures a variety of Weld Heads to accommodate a diverse range of welding applications Both our parallel and opposed Weld Heads provide a great amount of control and precision sunstone 1 Remove the Weld Head from the box and place it on a secure work surface 2 Attach weld head cables to negative and positive terminals 3a Manual Models See weld head user manual for setup Sb Pneumatic Models Plug the welder power cable into the female porton the pneumatic foot pedal cable then plug the pneumatic foot pedal cable into an AC power outlet 4 Turn the welder on actuate the Welder FootPedal AC Power weld head and set the desired energy Power Cable Cable Outlet setting on the weld head 5 See weld head user manual for more precise setup information Hand Held Attachment Setup QUICK START SET UP OF HAND HELD ATTACHMENTS TO CDSP 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 1 Remove the Hand Held Attachment from its package
12. nd other implanted medical devices should keep away Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations OVERUSE CAN CAUSE OVERHEATING Allow a cooling period between strenuous welding schedules follow rated duty cycle e IF overheating occurs often reduce duty cycle before Iss starting to weld again PRINCIPAL SAFETY STANDARDS Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh sunstone PA 5250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov National Electrical Code NFPA Standard 70 from National Fire Protection Association P O Box 9101 Quincv MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Canadian Electrical Code Part 1 CSA Standard C22 1 from Canadian Standards Association Standards Sales 5060 Mississauga Ontario Canada L4W SNS phone 800 463 6727 or in Toronto 416 747 4044 websi
13. neengineering com Web www SunstoneEngineering com Mail Sunstone Engineering R amp D Corporation 1693 W American Wav Unit 5 Pavson UT 84651 sunstone _ ch Er sunstone ee A sunstone sunstone engineering Sunstone Engineering R amp D Corporation 1693 VV American Way Unit 1 Payson UT 84651 1 877 786 9353 sunstoneengineering com
14. osing electrode Figure b shows a step electrode configuration This configuration is used when there is access to only one side of the workpiece and an electrode can be placed on both materials Figure Sc is a series configuration Electrodes can only be placed onone metal surface from one side Current is divided between the two parts This weld configuration requires more weld energy FIGURE 3 Examples of resistance welding electrode configurations a direct b step c series WELD ENERGV Sunstone capacitive Single Pulse welders allow adjustment of the stored energy via an energy adjustment dial The energy is then displaved in watt seconds Joules on the front panel Weld Energv _ ch Er sunstone Chapter 3 Setup Pre Setup Information VOLTAGE AND POWER REQUIREMENTS Sunstone Capacitive Discharge Single Pulse CDSP welders are equipped with universal power supplies and can be used with both 110 220V AC wall power No voltage selection is required prior to connecting and powering onthe welder The welder will detect the voltage and make the appropriate adjustments automatically WELD ACTUATION The CDSP welders are actuated by means of an externaltrigger port located on the back of the welder see Figure 4 The trigger uses a DIN 3 connector and requires shielded wire Figure 4 shows the proper pin placement for custom externaltrigger cables The standard externaltrigger cable connector is an SD SOLP made by
15. rials that have diverse thermal and electrical properties There are several factors that should be considered when selecting the correct pulse width setting For example when welding highlv conductive materials such as copper the peak weld current must be higher than resistive materials e g steel Thus welding a thin copper part mav require high weld energy displayed on the screen high peak current but a small pulse width to produce a small total energv released Converselv a thin steel part mav require a lower displaved weld energv peak current and longer pulse width to provide enough energy Figure 8 shows how voltage peak current and energy relate It should be noted that the energy stored can also be thought of as capacitor voltage in this diagram FIGURE 8 A single pulse capacitive discharge curve The pulse width setting allows both the peak current and total energv discharged to be specified Voltage stone EI sunstone The weld energy knob is used to set the total welder energy storage and is also used to set the peak weld current The pulse widths are then adjusted to provide the appropriate weld energy released during each weld See Table 2 for additional details including weld repetition rates ns o sunstone Chapter 5 Technical Data CDSP Data Sheet Info VVELDER DATA See the follovving tables for CDSP technical data TABLE 1 CD100SP Energy release as a function of weld load and pulse width
16. riate eve protection at all times while using the welder Do not install or operate unit near combustible surfaces Do not install or operate unit near flammables Do not weld where flying sparks can strike flammable material Remove all flammable materials from the welding area If this is not possible tightly cover them with approved covers Protect vourself and others from flving sparks and hot metal Do not weld where the atmosphere mav contain flammable dust gas Or vapors Remove any combustibles such as butane lighters or matches from your person before doing any welding Watch for fire and keep a fire extinguisher nearby Do not overload your building s electrical wiring be sure the power distribution system is properly sized rated and protected to handle this unit Do not exceed the equipment s rated capacity Use only correct fuses or circuit breakers Do not oversize or bypass them SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK Sunstone capacitive single pulse welders are equipped with universal power supplies and can be used with both 110 220V AC wall power No voltage selection is required prior to connecting and powering on the welder The welder sunstone will detect the voltage and make the appropriate adjustments automaticallv Touching live electrical parts can cause fatal shocks or severe burns The input power circuit and the internal circuits of the Sunstone welder are live when the power switch is turn
17. sunstone engineering Sunstone Capacitive Discharge Welders www SunstoneEngineering com sunstone sunstone sunstone CD Single Pulse Table of Contents POE anedae thie p 5 Manufacturer s Contact Information p 5 Welding Safety amp Precautions venen p 7 Chapter 1 Welder Overview 1 cece eee p 14 KOS e p 14 ADDNGINON e shen een anna p 15 Chapter 2 Resistance Welding p 16 What is Resistance VVelding 7 nana enen p 16 Se E E EE p 18 Chapter 3 Set Up t rrakuestuziitojiit tease denen p 20 PEESELUDINIO L isrtiptatetioozetzzjjnbar in be ain p 20 Welder SCtUD misset trennen p 21 Weld Head ioc votes anette sisa ba dei bella p 22 Hand Held Attachments nanen p 25 Chapter 4 Operating Instructions 6 p 25 Chapter 5 Technical Data 6 p 30 Appendix A Glossary aa p 53 Appendix B Warranty 1 nen p 54 sunstone Foreword Thank Vou for Choosing Sunstone Welders and congratulations on vour purchasel Vou are now the proud owner of a Sunstone Capacitive Discharge CD Single Pulse SP Welder This manual was designed to have vou welding safelv within minutes of unpacking vour new welder Please read and follow all safetv 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 pleas
18. te www csa international org Safe Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 8002 phone 212 642 4900 website Sunstone Experience At Sunstone we are committed to producing quality products and ensuring complete owner satisfaction If you require assistance after reading this manual please contact us with the information provided below Sunstone Engineering R amp D Corp 1693 American Way Suite 5 Payson UT 84651 Email custservice SunstoneEngineering com Voice 801 658 0015 Fax 866 701 1209 ME sunstone Chapter 1 Welder Overview Features Sunstone spot welders are simple to use with an intuitive and user friendly interface Each of the Single Pulse CD vvelders can be adjusted and fine tuned to match the requirements of countless applications A digital screen displays total vveld energy ensuring detail and precision When combined with Sunstone s new line of weld heads or hand attachments CD welders perform strong and repeatable vvelds for high levels of consistency and quality control Available vvith 100 or 200 vvatt seconds of energy Single Pulse Operation Microprocessor Controlled Thermal Protection Circuit Internal Monitoring Audible Ready Notification Adjustable pulse vvidth Energy storage adjustable from 0 1 to 100 capacity Up to 600 vvelds7 min 1107 220VAC Switching
19. tion display easy to use Pulse Width and VVeld Energy controls hook up bars that allow 14 studs an On Off switch and 1107 220VAC voltage selection Eren Pulse Width Eney Adjustment Display Adjustment Weld Cable Hook up On Off stone EI sunstone FIGURE 7 Welder back panel External trigger port 5A fuse 110 or 220VAC voltage input and Beep On Off ready notification External Trigger 110 220 VAC Beep On Off SETTING THE PULSE The Pulse energy setting should be chosen such that the parts adhere weakly To determine the pulse 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 ENERGY ADJUSTMENT Each Sunstone welder is fully adjustable between its minimum and maximum energy Sunstone Capacitive Single Pulse welders have weld repetition rates of up to 600 welds min See Table 3 for additional details on weld repetition rates The weld energy knob is used to set the total welder energy storage and is also used to set the peak weld current The pulse widths are then adjusted to provide the appropriate weld energy released during each weld en o sunstone Controlling energy storage and pulse width allows the user to manage both the energy released during the vvelding process and the peak electrical current experienced by the vveld material These parameters are important when welding mate
20. uding from the case marked with a and are the terminals sunstone Appendix B Warrantv AU Sunstone Products come with a 1 vear warrantv Sunstone Engineering will repair all defects in craftsmanship without charge during this time period excluding the cost of shipping This warrantv does not cover damage caused bv improper use of Sunstone products This warrantv does not include consumable items such as welding electrodes Sunstone Engineering is dedicated to keeping our products operating at peak performance for vears to come Anv repairs needed after the 1 year warranty period are performed at cost typically less than 50 USD Sunstone Engineering offers a 30 day return policy on all of our products Before sendinga product back please contact Sunstone Engineeringto receive an RMA number The RMA number should appear clearly on the outside of the package Customer refunds are accomplished via check Please note that a 6 restocking fee will apply to all returns Equipment damaged by improper use or insufficient shipping precautions will be charged additional fees sunstone sunstone Sunstone Engineering is dedicated to providing qualitv products and support Please feel free to call with anv questions before or after purchasing our products Phone 1 801 658 0015 Fax 1 866 701 1209 E mail Sales sales sunstoneengineering com Technical Support tech sunstoneengineering com Customer Service custservice sunsto
21. ve been turned off Atleast one pulse has to be on in order to weld NEW P1 P2 This message will display when either pulse 1 or pulse 2 is adjusted Cooling Enabled When the unit overheats it will display Cooling until it has reached an operable temperature Then the welder will displav Enabled to let you know that it is done cooling Pulse Control SINGLE PULSE WELDING Sunstone Single Pulse welders have one pulse width energv control The blue back lit LCD displavs the pulse percent of total stored energv and the total e Se sunstone stored energy in Joules J The pulse can be adjusted separately or turned off if desired The pulse is adjustable between 1 and approximately 30 of the total stored energy Sunstone single pulse vvelders allow a large degree of control over the entire welding process The energy stored and released with each weld discharge can be adjusted down to very fine increments for welding very small parts The pulse width dial allows fine control over the duration of the weld pulse and the energy released vvith each pulse The vveld energy knob controls the total vvelder energy storage and also sets the peak vveld current Typical values of peak current vvith vveld energy and load are givenin Table1 The amount of energy released for each pulse width setting is shown in Table 1and is also a function of the welding load resistance FIGURE 6 Welder front panel features Blue LCD energy indica
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