This is an amazing tool for the DIY community for building batteries. Reliable, professional, and built to last!

Super Capacitor Spot Welder Instruction Manual

Introduction

This device is designed for precise spot welding, particularly for applications like building batteries using nickel strips. It utilizes super capacitors for quick, high-power discharges and comes with a standard US plug 12V 60W charger for easy recharging.

Key Features:

• Dual-pulse welding capability for improved weld quality.
• Adjustable parameters for pulse strength, spacing, and delay.
• Voltage monitoring to ensure optimal performance.
• Replaceable spot welder tips for longevity.
• Compact and user-friendly interface.

Safety Precautions:

• Always wear appropriate protective gear, such as safety glasses and gloves, when operating the welder.
• Ensure the device is placed on a stable, non-flammable surface.
• Do not operate in wet or humid environments to avoid electrical hazards.
• Keep away from children and pets.
• Disconnect the charger when not in use.
• Do not attempt to modify the device or use incompatible accessories.

What's Included

• Super Capacitor Spot Welder unit.
• Standard US plug 12V 60W charger.
• Replaceable spot welder tips.
• 18-inch length of 6AWG wire (for probes or connections).
• Approximately 12 inches of 0.15mm nickel strip for testing.

Initial Setup

1. Power On and Charging:
   • Plug the included 12V 60W charger into a standard US outlet and connect it to the spot welder.
   • Power on the device. The initial full charge will take about 10 minutes. The super capacitors will reach a full voltage of 6V.
   • Monitor the voltage display; it should show around 6V when fully charged. For continuous use, the charger will maintain sufficient voltage.
2. Language Selection:
   • Turn the yellow dial to the right until you see the language options.
   • Press the yellow button in and turn the knob to select "English."
   • Press the button again and turn the knob to the right to return to the main screen.

Main Screen and Parameters

Once set up, the main screen will display the following adjustable parameters and information:

• Pulse 1: Controls the strength of the first spot weld (range: 1-20). This is often referred to as the "warm-up" spot weld, which prepares the surface for a stronger bond.
• Space: Sets the time interval between the first and second pulses (range: 1-99 ms). If set to 0, there will be no second pulse, resulting in a single-spot weld only.
• Pulse 2: Controls the strength of the second spot weld (range: 1-30). This provides the main welding power following the first pulse.
• Delay: Defines the time from when both probes are placed on the nickel strip until the spot weld is triggered (range: 0-5 seconds). This allows for precise positioning before activation.
• Voltage: Displays the current voltage of the super capacitors. Full charge is 6V. If the voltage drops below 5V, pause operation and allow the device to recharge back to 6V. During normal steady use (e.g., building batteries), the connected charger should maintain adequate voltage without frequent interruptions.

Adjusting Parameters:

• Use the yellow dial or knob to navigate and adjust values as needed for your specific welding task.
• Test settings on the included 0.15mm nickel strip before applying to your project.

Operation

1. Preparing to Weld:
   • Ensure the device is fully charged (voltage at 6V).
   • Attach the probes using the included 6AWG wire if not pre-attached.
   • Place the nickel strip or material to be welded between the probes.
2. Performing a Spot Weld:
   • Position both probes firmly on the material.
   • The device will trigger the weld after the set Delay time.
   • If using dual pulses, the first pulse (Pulse 1) will fire, followed by the Space interval, and then the second pulse (Pulse 2).
   • Monitor the voltage after each weld. Recharge if it drops below 5V.
3. Tips for Best Results:
   • Start with lower pulse strengths and adjust upward based on material thickness and desired weld quality.
   • For single-pulse welds, set Space to 0.
   • Clean the tips regularly for consistent performance.
   • Replace tips as needed; they are designed to be easily swapped.
4. Shutting Down:
   • Power off the device when finished.
   • Unplug the charger from the outlet.

Maintenance and Troubleshooting

• Maintenance:
  • Keep the device clean and free of debris.
  • Inspect wires and tips for wear; replace as necessary.
  • Store in a dry, cool place.
• Troubleshooting:
  • No Power: Check charger connection and outlet. Allow time for initial charge.
  • Low Voltage: Wait for recharge or ensure charger is functioning.
  • Inconsistent Welds: Adjust parameters, clean tips, or check probe contact.
  • Language Issues: Repeat the language selection steps if the display reverts.

If issues persist, contact customer support for assistance.

Specifications

• Charger: 12V 60W, standard US plug.
• Capacitor Voltage: Up to 6V full charge.
• Wire: 18" 6AWG.
• Test Material: 12" of 0.15mm nickel.
• Tips: Replaceable.