Sunstone Dual Pulse Resistance Welders

Capacitive resistance welders, also called capacitive discharge or CD welders, have many advantages over other welder types:
  • Quick energy release for welding highly conductive metals such as copper
  • Small heat effected weld zones
  • Repeatable energy release independent of line voltage fluctuations
  • Capable of extremely fine energy adjustment
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. More of the energy goes into weld formation and less into heating surrounding material. The heat affected zone, where the properties of the metal have been changed by rapid heating and cooling, 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 energy is stored before use. Weld very small parts by turning down the weld energy to less than 1% of its full value. Tables 1-4 give additional technical details. 		Battery Pack Welding
Stranded Copper to Copper Crimp
Copper Contactor to Stainless Steel

Table 1: Sunstone Dual Pulse Resistance Welder Technical Specifications

Feature CD150DP / CD300DP / CD450DP / CD700DP
Dual Pulse Yes
Pulse 1 Energy Adjustment (% of set-point energy) 1% - 50%
Pulse 2 Energy Adjustment (% of set-point energy) 1%-100%
Peak Current 4000 - 5000 Amps


Table 2: Weld speed in welds per minute by Dual Pulse model number at maximum energy set-point.

Pulse Width
(at max energy) 		Rep Rate
CD150DP
welds/min
(pulse energy) 		Rep Rate
CD300DP
welds/min
(pulse energy) 		Rep Rate
CD450DP
welds/min
(pulse energy) 		Rep Rate
CD700DP
welds/min
(pulse energy)
5% 166 (7.5ws) 166 (15ws) 166 (23ws) 166 (38ws)
25% 166 (38ws) 166 (75ws) 166 (113ws) 166 (188ws)
50% 166 (75ws) 166 (150ws) 150 (225ws) 120 (375ws)
100% 166 (150ws) 89 (300ws) 59 (450ws) 36 (700ws)


Table 3: Weld Pulse Characteristics

Model Min and Max
Output		 Capacitor Bank Pulse Width Rise Time
(to max voltage)		 Min Pulse Height
CD150DP 0.2 ws - 150 ws 800,000 uF Min 0.1 ms 0.4 ms 0.5 V
Max 10 ms 0.4 ms 0.5 V
CD300DP 0.4 ws - 300 ws 1,600,000 uF Min 0.1 ms 0.4 ms 0.5 V
Max 20 ms 0.4 ms 0.5 V
CD450DP 0.6 ws - 450 ws 2,400,000 uF Min 0.1 ms 0.4 ms 0.5 V
Max 30 ms 0.4 ms 0.5 V
CD700DP 0.6 ws - 700 ws 2,400,000 uF Min 0.1 ms 0.6 ms 0.5 V
Max 30 ms 0.6 ms 0.5 V


Table 4: Physical Characteristics

CD150DP CD1300DP CD450DP CD700DP
Inches cm Inches cm Inches cm Inches cm
Height 10.5 26.7 10.5 26.7 10.5 26.7 10.5 26.7
Width 12.0 30.5 12.0 30.5 12.0 30.5 12.0 30.5
Depth 13.5 34.3 13.5 34.3 13.5 34.3 13.5 34.3
Weight 35 lbs.   (16 kg) 38 lbs.   (17 kg) 40 lbs.   (18 kg) 45 lbs.   (21 kg)