1. Introduction
This manual provides detailed instructions for the safe and effective use of your KEKK K99 Portable 99 Gear 12V DIY Spot Welder Kit. The K99 is designed for spot welding nickel-plated sheets with high current, suitable for various battery types. Please read this manual thoroughly before operation to ensure proper setup and to prevent damage to the device or injury.
2. Safety Information
- Always ensure proper ventilation when operating the spot welder.
- Wear appropriate personal protective equipment, including safety glasses, to protect against sparks and molten metal.
- Do not touch the welding pens or the workpiece during operation.
- Ensure the power supply is correctly connected before use. Incorrect polarity can damage the control board.
- Keep the device away from flammable materials.
- This device generates high current; exercise extreme caution.
- Prohibited materials for spot welding include copper, aluminum, soft pack batteries, and lithium iron phosphate batteries.
3. Product Overview and Components
The K99 spot welder control board features a digital display and 99 adjustable gears for precise control over welding intensity. It is designed for DIY enthusiasts and professionals for battery pack assembly.
3.1 Main Components
- Input Cathode: Connects to the battery negative electrode.
- Input Anode: Connects to the positive electrode of the battery.
- Output Cathode: Connects to the black welding pen.
- Output Anode: Connects to the red welding pen.
- XT60 Interface: For specific power supply connections (e.g., model aircraft batteries).
- Digital Tube: Displays the current gear setting.
- Power On/Off Button: To activate/deactivate the device.
- Gear Increase Button: Adjusts welding intensity upwards.
- Gear Down Button: Adjusts welding intensity downwards.
- MOS Tubes: Power transistors responsible for current delivery.
3.2 Parts List
- K99 Control Board (x1)
- Spot Welding Pen (x2) - available in 6 square or 10 square options.
- Super Soft Silicone Input Cable (x2) - Note: Model aircraft battery version does not include input lines; car starter version includes an EC5 female input line.
- Heat Shrinkable Sleeves (x3)
- Screws and Nuts (several)
- Nickel-plated Sheet (approx. 1 meter, for practice)
4. Specifications
| Feature | Specification |
|---|---|
| Model Number | K99 |
| Gear Settings | 99 gears (0-99, 99th is highest) |
| Display | Digital Tube Display |
| Max. Welding Thickness | 0.05-0.3mm Nickel-plated sheets (varies by welding pen type) |
| Max. Current (5 MOS tubes) | Up to 1700A (Type A, B, C, D) |
| Max. Current (10 MOS tubes) | Up to 3400A (Type E) |
| Working Voltage | 9-16V |
| Working Current | Approx. 90-180A |
| Weight | 0.2-0.3KG |
| Origin | Mainland China |
4.1 Spot Welding Pen Options
- 6 Square Spot Welding Pen: Wire length 25 cm, copper tube plus pen 10 cm, total length 35 cm. Can spot weld nickel-plated sheets with a thickness of 0.05-0.2mm.
- 10 Square Spot Welding Pen: Line length 30 cm, copper tube plus pen 10 cm, total length 40 cm. Can spot weld nickel-plated sheets with a thickness of 0.05-0.3mm.
5. Setup and Installation
5.1 Power Supply Connection (Self-Provided)
The K99 spot welder requires a self-provided 9-16V power supply capable of delivering 90-180A. Choose one of the following types:
- Lead-Acid Battery Version:
- Old power type lead-acid battery: 12V20AH--100AH. If the battery is more than one year old, it should have higher capacity.
- New power type lead-acid battery: 12V20AH--45AH.
Figure 4: Lead-Acid Battery Connection Diagram - Model Aircraft Battery Version:
- 3S-4S 25C-90C battery with an XT60 head and output lines to 6-10 square.
Figure 5: Model Aircraft Battery Connection Diagram - Car Starter Version:
- A normal 12V car starter. It must have an EC5 interface, and the peak current should not exceed 1000A.
Figure 6: Car Starter Connection Diagram - 10-Tube Super Farad Capacitors Version:
- 2.7-2.8V, 3000F. Use 4-6 strings of super Farad capacitors, ensuring the total voltage does not exceed 16V.
- Alternatively, 3-4 strings of large monomers (10-100AH) with a protective plate (current should exceed 150A).
- Can also use a power type lead-acid battery power supply.
Do NOT use switching power supplies, transformers, chargers, water batteries, or power banks to power the spot welder. This will damage the circuit board.
5.2 Protective Shell Installation
A transparent protective case is available to prevent damage to the control board from short circuits. Follow these steps for installation:
- Place the control board onto the bottom acrylic plate.
- Align the side panels and secure them with the provided screws and nuts.
- Place the top acrylic plate, ensuring all components are enclosed.
- Tighten all screws to secure the protective case.
6. Operation
6.1 Power On and Gear Adjustment
- Connect your chosen power supply to the input terminals (IN+ and IN-) of the control board, ensuring correct polarity.
- Connect the red welding pen to the output anode (OUT+) and the black welding pen to the output cathode (OUT-).
- Press the 'Power On/Off' button to activate the device. The digital display will show the current gear setting.
- Use the 'Gear Increase' and 'Gear Down' buttons to adjust the welding intensity from 0 to 99. The first gear is the lowest, and the 99th gear is the highest. Increase gears in turn to find the optimal setting for your material.
6.2 Spot Welding Process
Spot welding works by applying high current locally to rapidly melt and cool nickel sheets, creating a strong bond.
- Place the nickel sheet onto the battery or workpiece to be welded.
- Hold the welding pens firmly, ensuring good contact with the nickel sheet and the underlying material.
- Press the welding pens onto the nickel sheet. The device will automatically initiate the weld.
- Check the weld strength. If the weld is not strong enough, increase the gear setting and try again.
The K99 can firmly spot weld 14650, 17490, 18650, 21700, 26650, 32650 cylindrical lithium batteries, and nickel-metal hydride batteries.
6.3 Video Demonstration
7. Maintenance
- Keep the control board clean and free from dust and debris.
- Regularly inspect the welding pens and cables for any signs of wear or damage. Replace if necessary.
- Store the device in a dry, cool place when not in use.
- Ensure all connections are tight before each use.
8. Troubleshooting
- Problem: Spot welding is not strong.
Solution: This usually indicates insufficient current. Please ensure your power supply meets the recommended specifications (9-16V, 90-180A) and try increasing the gear setting on the control board. - Problem: Device does not power on.
Solution: Check all power supply connections for proper polarity and secure contact. Ensure the power supply itself is charged and functional. - Problem: Device overheats.
Solution: Allow the device to cool down. Ensure adequate ventilation during operation. Avoid continuous, prolonged welding without breaks.
9. User Tips
- For optimal results, experiment with different gear settings to find the perfect balance for the specific thickness of nickel sheet and battery type you are welding.
- Ensure the welding pens are clean and have sharp tips for consistent welds.
- When using a lead-acid battery as a power source, an older battery (more than one year) may require higher capacity to achieve desired welding strength.
- The E2 model (10-tube super Farad capacitors version) can indeed work with a suitable lead-acid battery power supply, provided it meets the voltage and current requirements.
10. Warranty and Support
For any issues or questions regarding your KEKK K99 Spot Welder Kit, please contact the seller or manufacturer's customer support. Keep your purchase receipt for warranty claims.
