Equipment - Capacitive Discharge Welders

Capacitive Discharge, Fine-Spot Resistance Welder Datasheet
CD100SP / CD200SP CD SPOT WELDER

 

  • Energy storage from 0.015 watt-seconds to 200 watt-seconds
  • Infinitely adjustable pulse width (energy released)
  • Peak weld currents of up to 6400A (1mOhm load)
  • Minimum weld currents of 80A (1mOhm load or lower with increased load)
  • Available in 100 and 200 watt-second versions
  • Peak repetition rates of 166 welds/minute with external power supply
  • Standard repetition rates of 30 or 13 welds / minute (100ws or 200ws, respectively, operating at max power)
  • Simple and intuitive welder interface
  • Up and running in minutes without any prior welding experience

Sunstone Single Pulse research and light production resistance welders are engineered to provide a wide range of welding flexibility. They can provide as little as a few milli-joules of energy for welding microscopic wires and parts, or can deliver up to 100 or 200 Joules for stronger welds. The Sunstone welder is versatile and easy to use. Its interface lets the user quickly select weld settings for a wide variety of welding projects. The welder is designed for use in a research laboratory or light production environment and can be operated up to 166 welds/minute. At Sunstone our goal is to provide quality resistance welding products at affordable prices for small and large businesses.

The Advantages of a CD Spot Welder

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 affected weld zones
  • Repeatable energy release independent of line voltage fluctuations
  • Capable of extremely fine energy adjustment

CD welders are one of the most cost-effective welding solutions for fine-spot resistance welding. Whether you are manufacturing battery packs or microscopic assemblies, Sunstone CD resistance welders are the most affordable, precision fine-spot resistance welders on the market.


Table 1: Energy storage in watts*seconds (Joules) as a function of weld voltage.
Model Voltage (volts)
0.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16.5
CD100SP 0.015 0.4 1.6 3.6 6.4 10 14.4 19.6 25.6 32.4 40 48.4 57.6 67.6 78.4 90 102 109
CD200SP 0.032 0.8 3.2 7.2 12.8 20 28.8 39.2 51.2 64.8 80 96.8 115 135 157 180 205 218

Table 2: Percent energy release as a function of weld cable gauge number (AWG) and Pulse dial setting. Four and eight AWG cabling are typically seen when using hand held attachments.
  CD100SP CD200SP
Pulse Width Dial Marker Pulse Time (ms) 1 AWG
(% discharge of stored energy)		 4 AWG
(% discharge of stored energy)		 8 AWG
(% discharge of stored energy)		 Pulse Time (ms) 1 AWG
(% discharge of stored energy)		 4 AWG
(% discharge of stored energy)		 8 AWG
(% discharge of stored energy)
1 0.26 27% 20% 12% 0.47 25% 19% 10%
1.5 0.28 29% 22% 12% 0.50 26% 20% 11%
2 0.45 42% 33% 19% 0.81 39% 30% 17%
2.5 0.59 51% 40% 24% 1.07 48% 37% 22%
3 0.75 60% 48% 29% 1.34 56% 44% 27%
3.5 0.90 67% 55% 35% 1.63 63% 51% 32%
4 1.06 72% 60% 39% 1.90 69% 56% 36%
4.5 1.43 82% 71% 49% 2.57 79% 67% 45%
5 2.23 93% 86% 65% 4.02 91% 83% 61%
5.5 3.54 99% 95% 81% 6.37 98% 94% 78%
6 4.80 100% 98% 89% 8.65 99% 98% 87%
6.5 5.51 100% 99% 92% 9.92 100% 99% 90%
7 5.54 100% 99% 93% 9.98 100% 99% 90%

Table 3: Peak weld current as a function of weld voltage and external cabling AWG gauge number (assumes 6 total feet of cabling). Four and eight AWG cabling are typically seen when using hand held attachments.
Voltage 1 AWG
0.8mOhm Load
(Amps)		 4 AWG
1.6mOhm Load
(Amps)		 8 AWG
4.0mOhm Load
(Amps)		 Voltage
(continued) 		1 AWG
0.8mOhm Load
(Amps)		 4 AWG
1.6mOhm Load
(Amps)		 8 AWG
4.0mOhm Load
(Amps)
0.2 98 70 38 10 4878 3509 1805
1 488 351 190 15 7317 5263 2857
5 2439 1754 952 16.5 8049 5789 3143

Table 4: Weld speed in welds per minute at 100% energy discharge. Nominal repetition rate and increased repetition rate with PS25A power supply (PS) booster are given.
Energy set-point
(% of maximum energy)
NOMINAL
Rep Rate
CD100SP
(welds/min)
NOMINAL
Rep Rate
CD200SP
(welds/min)
PS BOOSTER
Rep Rate
CD100SP
(welds/min)
PS BOOSTER
Rep Rate
CD200SP
(welds/min)
100% 29 (100 ws) 13 (200 ws) *166 (100 ws) *72 (200 ws)
75% 33 (75 ws) 15 (150 ws) *166 (75 ws) *98 (150 ws)
50% 41 (50 ws) 21 (100 ws) *166 (50 ws) *166 (100 ws)
25% 45 (25 ws) 23 (50 ws) *166 (25 ws) *166 (50 ws)
MIN 9 (0.015 ws) 7 (0.3 ws) NA w/PS25A NA w/PS25A
*See instruction manual for maximum continuous-use and cool-down periods.

Table 5: Weld pulse characteristics.
Model Min and Max Energy Set-Point Pulse Width Rise Time
(to max. voltage)		 Min. Pulse Height
CD100SP 0.015 ws - 100 ws Min 0.26 ms 0.15 ms 0.2 V
Max 5 ms
CD200SP 0.03 ws - 200 ws Min 0.47 ms 0.15 ms 0.2 V
Max 10 ms

Table 6: Sunstone Single Pulse welder physical characteristics.
  CD100SP CD200SP
Inches cm Inches cm
Height 8 20.3 8 20.3
Width 8.5 21.6 8.5 21.6
Depth 11 28 11 28
Weight 17 lbs (8 kg) 19 lbs (9 kg)

Spotwelding Consultants Inc.

4209 Industrial
Rowlett, Texas 75088
Toll Free: 888-255-6780
Phone: 972-475-0874
Fax: 972-475-5024