1. Introduction
The SUNKKO 737DH is an intelligent precision pulse spot welder designed for efficient and accurate welding of battery packs, particularly 18650 lithium batteries. It features high power output, induction delay, and automatic pulse welding capabilities, making it suitable for various applications from DIY projects to factory assembly lines. This manual provides essential information for safe and effective operation of your new spot welder.
2. Safety Instructions
- Always wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and protective clothing, when operating the spot welder.
- Ensure the work area is well-ventilated and free from flammable materials.
- Do not operate the machine in wet conditions or expose it to rain.
- Keep children and unauthorized personnel away from the operating area.
- Before any maintenance or adjustment, ensure the machine is powered off and unplugged from the main power supply.
- Never touch the welding electrodes or workpieces immediately after welding, as they will be hot.
- Use only original or approved replacement parts and accessories.
- If any unusual noise, smell, or smoke is detected, immediately turn off the machine and disconnect it from the power supply.
3. Package Contents
Verify that all items listed below are included in your package:
- Host Unit (Spot Welder)
- 70BN Spot Welding Pen (Mobile Welding Pen)
- Foot Switch
- Needle Grinding Machine
- Six-Section Fixture
- Nickel Strips (0.1*4*100mm, 0.15*8*100mm)
- Pairs of Solder Pins
- Pairs of Small Solder Pins
- Bumpers
- Hexagon Wrench
- Description and Warranty Card Book
4. Specifications
| Feature | Specification |
|---|---|
| Model Number | 737DH |
| Rated Duty Cycle | 4.3KW |
| Rated Capacity | Lithium Battery Spot Welder |
| Max. Welding Thickness | 0.35mm |
| Dimensions | 140*230*200mm |
| Weight | 7kg |
| Input Voltage | AC220V/110V (depending on model) |
| Welding Current | 120-1200A |
| 4-Pulse Time | 2-20ms |
| 2-Pulse Time | 1-10ms |
| 8-Pulse Time | 8-50ms |
| Adjustable Telescopic Arm Distance | 0.15-0.30mm |
| Welding Thickness (Fixed Welding Head) | 0.05-0.25mm |
| Welding Pen Cable Area | 16mm² |
| Welding Pin Size | Ø1.5mm x 77mm |
| Adjustable Welding Pin Distance | 2-7mm |
| Total Length of Removable Welding Pen | ≥580mm |
| Certification | CE |
5. Setup
- Power Connection: Connect the power cord to the back of the main unit and then to a suitable power outlet (110V or 220V, depending on your model).
- Main Power Switch: Locate the main power switch on the back of the machine and turn it to the 'ON' position.
- Front Panel Power Button: Press the 'POWER' button on the front panel to activate the spot welding function. The button will illuminate.
- Connect Mobile Welding Pen: Insert the mobile welding pen (70BN) into the designated quick-plug ports on the front panel. Ensure a secure connection.
- Foot Pedal (Optional): If using the foot pedal for welding, connect it to the foot control interface on the back of the unit.
6. Operating Instructions
6.1. Pulse Welding Power Adjustment
The machine's pulse spot welding power can be precisely adjusted using the 'SUPER PULSE' knob on the front panel. Turn clockwise to increase power and counter-clockwise to decrease it. The digital display shows the actual welding current value (KA) and current pulse settings (2P, 4P, 6P, 8P).
- Pulse Settings: The machine offers 2, 4, 6, and 8 pulse settings. For optimal results, it is recommended to use 4P/6P/8P super pulse cluster (initially).
- Power Adjustment Range: The knob allows for fine-tuning of the welding power. Avoid adjusting the pulse power beyond 70% of the entire range to prevent machine overheating and to ensure a smooth start and stop.
6.2. Welding Modes (AT/MT)
The 737DH offers two welding modes: Automatic Triggering (AT) and Manual Triggering (MT) via foot pedal.
- AT Mode (Intelligent Auto-Triggering Spot Welding):
Press the AT/MT switch button. When 'AT' on the panel turns green, the automatic welding mode is ready. In this mode, the welding pen automatically triggers a weld when both electrodes make contact with the workpiece. This mode is ideal for quick, repetitive tasks. - MT Mode (Foot Pedal Controlling Spot Welding):
Press the AT/MT switch button again. When 'AT' on the panel turns red, the spot welding with the foot pedal switch is ready. In this mode, you control the welding trigger using the foot pedal, providing precise timing for each weld.
6.3. Time-Delay Spot Welding
The intelligent time delay function allows for precise control over the welding duration. You can select between 0.4s, 0.5s, and 0.6s settings, with superposition up to 1.5s. This feature helps achieve consistent and strong welds.
6.4. Using the Mobile Welding Pen
The S-70BN enhanced mobile welding pen features DIS inductive spot welding technology. This allows for welding without needing to press a switch; simply touch the two electrodes of the pen to the metal surface to trigger the current and complete the weld.
6.5. Built-in LED Light
The spot welder includes a built-in LED light fixture that enhances visibility during welding, especially in low-light conditions or at night, ensuring precise spot welding.
7. Maintenance
- Regular Cleaning: Keep the machine clean and free from dust and debris. Use a dry cloth to wipe down the exterior.
- Electrode Inspection: Regularly inspect the welding electrodes for wear and tear. Replace them if they become dull or pitted to ensure consistent weld quality. The needle grinding machine can be used to sharpen electrodes.
- Cable Check: Periodically check all cables and connections for any signs of damage or loose connections.
- Storage: Store the spot welder in a dry, cool place, away from direct sunlight and moisture, when not in use.
- Ventilation: Ensure the ventilation slots on the machine are not blocked to prevent overheating.
8. Troubleshooting
- No Power: Check the main power switch on the back, the front panel power button, and the power outlet connection. Ensure the power cord is not damaged.
- Weak Welds: Adjust the 'SUPER PULSE' knob to increase welding power. Ensure electrodes are clean and sharp, and that the nickel strip and battery surfaces are clean. Verify proper contact pressure.
- Overheating: If the machine feels excessively hot, turn it off and allow it to cool down. Check that ventilation slots are clear. Reduce the welding frequency or power settings if continuously overheating.
- Inconsistent Welds: Ensure consistent pressure on the welding pen. Check electrode condition and alignment. Verify that the workpiece is stable and not moving during welding.
- Mobile Welding Pen Not Triggering (AT Mode): Ensure the AT/MT button is set to AT (green light). Check that both electrodes are making firm and simultaneous contact with the metal surface.
9. User Tips
- Practice on Scrap Material: Before welding your final battery pack, practice on similar scrap materials to fine-tune your power and pulse settings.
- Clean Surfaces: Always ensure the nickel strips and battery terminals are clean and free of oxidation or debris for the best weld quality.
- Consistent Pressure: Apply consistent and firm pressure to the welding pen for uniform welds.
- Electrode Maintenance: Sharpen or replace electrodes regularly to maintain optimal performance.
- Start with Lower Settings: When unsure, start with lower power and pulse settings and gradually increase them until you achieve the desired weld strength.
10. Warranty and Support
This product comes with a standard manufacturer's warranty. Please refer to the included warranty card for specific terms, conditions, and duration. For technical support, troubleshooting assistance, or to inquire about replacement parts, please contact the seller or manufacturer directly using the contact information provided with your purchase.
