SUNSTONE CD200DP-A User Manual Download Page 12

12

Sunstone Welders 

User Manual

:  

CDDP-A

power outlet.
3. Attach weld head to negative and positive terminals.
4. Ensure either E-STOP bypass plug in plugged in or an E-STOP switch is plugged into the 6 DIN 
E-STOP connector labeled “E-STOP”on back panel.
5. Attach a foot pedal to secondary trigger on back panel.
6. Attach the weld head 4 DIN actuation cable to the 4 DIN connector labeled “WH Control” on back 
panel.
7. Turn the welder on by pressing in Power button on front panel.
8. On the main screen adjust your Total Stored Energy, Pulse 1 energy, and Pulse 2 energy.
9. On the control screen adjust your weld head control scheme to “Fully Manual”.
10. Enable welder, by pressing in Weld On button on front panel.
11. Trigger a weld with foot pedal.

CONFIGURATION 3:

 Using air actuated weld head and driven with the CDDP-A welder.

1. Remove the welder from the box and place it on a secure work surface.
2. Connect the female end of the power cord into the back of the welder and the male end into an AC 
power outlet.
3. Attach weld head to negative and positive terminals.
4. Ensure either E-STOP bypass plug in plugged in or an E-STOP switch is plugged into the 6 DIN 
E-STOP connector labeled “E-STOP”on back panel.
5. Attach a foot pedal to primary trigger on back panel.
6. Attach the weld head 3 DIN trigger cable to the secondary trigger on back panel.
6. Attach the weld head 4 DIN actuation cable to the 4 DIN connector labeled “WH Control” on back 
panel.
7. Turn the welder on by pressing in Power button on front panel.
8. On the main screen adjust your Total Stored Energy, Pulse 1 energy, and Pulse 2 energy.
9. On the control screen adjust your weld head control scheme to “Auto with Timing” or “Auto with 
Trigger”.
10. Enable welder, by pressing in Weld On button on front panel.
11. Trigger a weld with foot pedal.

Welder to Hand Held Attachment Setup

QUICK START SET UP OF HAND HELD ATTACHMENTS TO CDDP-A 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.
1a. Turn off welder and unplug AC power cord for safety.
1b. Remove hand held attachment from its package.

Summary of Contents for CD200DP-A

Page 1: ...Sunstone Welders User Manual CDDP A Sunstone Welders Advanced Capacitive Discharge Dual Pulse Welder User Manual for Models CD200DP A CD400DP A CD600DP A...

Page 2: ...ive Weld Terminal P 11 Fuse P 11 Power Inlet P 11 Welder to Weld Head Setup P 11 Configuration 1 P 11 Configuration 2 P 11 Configuration 3 P 12 Welder to Hand Held Attachment Setup P 12 Roll Spot Setu...

Page 3: ...eeding 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 do n...

Page 4: ...cuit Adjustable pulse width Energy storage adjustable from less than 1 to 100 capacity Up to 650 welds min using CD200DP A 110 or 220VAC input Simple user friendly interface Quick energy release for w...

Page 5: ...weld nugget Formation of the weld nugget occurs during the first few milliseconds of the welding process Sunstone s proprietary technology allows the energy to be discharged with very high peak curren...

Page 6: ...a lower contact resistance 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 res...

Page 7: ...ation can be found on p 14 of this manual FIGURE 4 Touch Screen Interface Chapter 3 Setup Pre Setup Information VOLTAGE AND POWER REQUIREMENTS Sunstone Advanced Capacitive Discharge Dual Pulse CDDP A...

Page 8: ...t will turn off Warning DO NOT turn the welder off during boot up Allow enough time for unit to completely boot up before turning unit off WELD ON OFF A latching push button that enables welding when...

Page 9: ...n action 5 Weld Ready Pull this pin up to 12V by connecting it with Pin 2 12V Signal will go low 0V when weld is ready 6 Alarm Pull this pin up to 12V by connecting it with Pin 2 12V Signal will go lo...

Page 10: ...to actuate Pin 4 GND Shield FIGURE 11 WH Control Connector SD 40LS PRIMARY TRIGGER MATES TO SD 50LP Pin 1 Variable Foot Pedal Connect this to Pin5 12VDC with a 10Kohm potentiometer Pin 2 Primary Trigg...

Page 11: ...Connect the female end of the power cord into the back of the welder and the male end into an AC power outlet 3 Attach weld head or hand attachment cables to negative and positive terminals 4 Ensure...

Page 12: ...er outlet 3 Attach weld head to negative and positive terminals 4 Ensure either E STOP bypass plug in plugged in or an E STOP switch is plugged into the 6 DIN E STOP connector labeled E STOP on back p...

Page 13: ...r 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 5 Roll Spot mode can be turned on or off in the Control...

Page 14: ...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...

Page 15: ...ypical time for this is between 1 and 50 milliseconds Pulse 1 The duration of this delay is dependent on the energy programmed on welder for Pulse 1 Cool The duration of delay is dependent on the time...

Page 16: ...User can select between 1 and 100 milliseconds This time will be ignored if either pulse is disabled Pulse 2 The duration of this delay is dependent on the energy programmed on welder for pulse 2 Hold...

Page 17: ...will depend on the time needed to charge to the desired energy but will typically be between 50 and 5000 milliseconds minus the length of the hold time Automation The CDDP A units will come with a bas...

Page 18: ...ance Internal verifications can be performed but can only be accessed through a technical support screen This can be performed anytime the welder seems to be creating weak welds User will want to perf...

Page 19: ...r a All or part of this energy can be divided into Pulse 1 and Pulse 2 b In order for Part Check to work as intended a Total Stored Energy must be set to a minimum of 25WS for CD600DPA 20WS for CD400D...

Page 20: ...tor fails a User can choose to compare any or all of the different types 4 User can choose whether to use the comparator on the first or second pulse 5 Each pulse has an upper limit 6 Each pulse has a...

Page 21: ...ill appear instead of the single previous weld result 2 A histogram of previous weld results a It shows the upper and lower limit b Shows the median line between upper and lower limit c Green dots are...

Page 22: ...cess c Auto With Trigger i Squeeze Time is not used because weld head will trigger weld Hold Time is used ii Primary trigger starts the weld process 4 The time the weld head is given to squeeze weld p...

Page 23: ...f chosen both inputs are used and user can choose which saved welds are associated with the Remote Schedule Select slots in the Remote Schedule Select sub tab within the PLC tab d User can select betw...

Page 24: ...bit i Input PIN 1 high 0 and input PIN 2 high 0 will select schedule 0 ii Input PIN 1 high 0 and input PIN 2 low 1 will select schedule 1 iii Input PIN 1 low 1 and input PIN 2 high 0 will select sched...

Page 25: ...clear your weld results history 5 This will save all your welder settings including saved settings to a USB stick 6 This will take your saved welder settings from a USB stick load all current setting...

Page 26: ...latest files a Unit needs to be connected to Wi Fi b A dialog will display if you are up to date 4 Button can be pressed to delete all media videos and manuals 1 Download latest videos and manuals po...

Page 27: ...ed to go back or forward in time b Video can be paused or resumed c Video can be adjusted to any time by using the scroll bar 3 If the user would like to load and use the settings shown in the video t...

Page 28: ...mber and press done The PDF viewer will navigate to that page Save Load Screen 1 In this screen the user has the ability to save and or load weld settings a The waveform for current settings or select...

Page 29: ...ave Load screen 1 If user chooses to save a weld with the same name then this pop up will appear to notify the user that a 1 was attached to the title before being saved a User can only acknowledge th...

Page 30: ...ettings c The current lock state is listed on this screen 2 This button toggles between the screen being locked and unlocked 1 Lock Welder Pop up a User can choose a full or limited lock b User can ch...

Page 31: ...coming soon 4 User can adjust the volume of the speaker for audible sounds 5 User can adjust screen brightness on screen for different lighting environments 1 System Settings tab a In this screen use...

Page 32: ...re the file is on the usb drive and is not in a folder b Sometimes a little time is required between inserting the USB drive and pressing the update button Press Dismiss and try again 1 After pressing...

Page 33: ...a status of the download a Once the progress is at 100 this dialog box disappears and starts updating the software 1 This dialog pops up after user has chosen to update over USB a Once the progress i...

Page 34: ...p will automatically disappear if the electrode becomes unstuck If the emergency stop is active this pop up will appear Reasons for the pop up can include internal communication error voltage error on...

Page 35: ...is having hardware issues this pop up will appear If this pop up persists contact support While saving a weld this pop up will appear This lets the users know that time is needed to store the saved we...

Page 36: ...f the weld head doesn t send a response back to welder to weld this pop up will appear After overheating and once the welder is cooled this pop up will appear This error will appear if the capacitors...

Page 37: ...r this pop up will appear If a trigger was received from a different source than specified this pop up will appear If you are trying to export data to a USB drive and the drive is out of memory this p...

Page 38: ...ly seen when using hand held attachments CD200DP A CD400DP A CD600DP A 1 AWG4 Ft 6583 7625 8080 4 AWG 6Ft 5448 6310 6690 8 AWG 6 Ft 3038 3520 3730 Minimum Load 1mOhm using a smaller load may damage th...

Page 39: ...15VAC AC Current typ 8 5A 115VAC 5A 230VAC 8 5A 115VAC 5A 230VAC 8 5A 115VAC 5A 230VAC TABLE 5 Weld Pulse Characteristics Model Min and Max Output Pulse Width Rise Time to max voltage Min Pulse Height...

Page 40: ...40 Sunstone Welders User Manual CDDP A SUNSTONE ENGINEERING R D CORPORATION 1693 American Way Suite 5 Payson UT 84651 1 877 786 9353 toll free 1 801 658 0015 international SunstoneWelders com...

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