KEKK K100 Portable DIY Spot Welder Control Board Kit User Manual

1. Introduction

This manual provides detailed instructions for the safe and effective use of your KEKK K100 Portable DIY Farad Capacitor Spot Welding 12V Control Board Kit. Please read this manual thoroughly before operation and retain it for future reference.

2. Safety Information

• Always wear appropriate personal protective equipment, including safety glasses, when operating the spot welder.
• Ensure the work area is well-ventilated and free from flammable materials.
• Do not touch the welding pens or the workpiece immediately after welding, as they may be hot.
• Verify that the power supply meets the specified requirements to prevent damage to the control board or injury.
• Keep the device away from children and pets.
• Never attempt to weld materials explicitly stated as prohibited.

3. Package Contents

Please check the package to ensure all items are present:

• K100 control board * 1
• Spot welding pen * 2 (10 AWG or 8 AWG optional, depending on your purchase)
• Input line * 2 (Note: Model aircraft battery version has no input line)
• Heat shrink tube * 3
• Several screws and nuts
• Nickel-plated sheet (approx. one meter for practice)

4. Specifications

5. Setup

5.1 Power Supply Requirements

The K100 spot welder control board requires a self-provided power supply. Ensure your power source meets the following criteria:

• Super Farad Capacitors: 2.7-2.8V, 3000F. Use 5-6 strings. The total voltage must not exceed 16V.
• Large Monomers: 3-4 strings, 10-100AH. If a protective plate is used, the capacity should exceed 150A.
• Lead-acid Battery (Old Power Type): 12V20AH - 100AH. A 20AH old lead-acid battery should not be more than one year old; older batteries should have higher capacity.
• Lead-acid Battery (New Power Type): 12V20AH - 45AH.

WARNING: Do not use switching power supplies, transformers, chargers, water batteries, or power banks to power the spot welder. Doing so will damage the circuit board.

5.2 Wiring Diagram

Connect the control board to your chosen power supply and welding pens as shown in the diagrams below:

6. Operation

6.1 Control Board Overview

The control board features a digital tube display and three control buttons: Minus (-), Settings (SEL), and Plus (+). Key connection points include the XT60 interface for input, IN+/IN- for battery input, and OUT+/OUT- for welding pen output.

6.2 Parameter Description

The digital display shows various parameters and their units:

• DLST (Delay time): The time after the solder pen touches the nickel piece to delay the trigger. A greater time means a later spot welding start time.
• TR1 (First spot welding): The MOS tube conduction time for the first spot weld. A greater time indicates higher spot welding power.
• INTI (Interval time): The interval time between the first and second spot weld. A greater time means the second spot weld starts later.
• TR2 (Second spot welding): The MOS tube conduction time for the second spot weld. A greater time indicates higher spot welding power.
• IN (Voltage): Real-time display of the supply input voltage. Working voltage range: 9-18V.
• °F (Temperature): Real-time monitoring of MOS tube temperature. 0-50°C is the normal operating temperature. If the temperature exceeds 50°C, suspend spot welding work until the temperature drops.

6.3 Setting Parameters

1. Set DLST (Delay time): While powered on, short press the SEL key to move the cursor to the DLST option. Short press +/- to micro-adjust the delay time. Long press +/- for quick adjustment.
2. Set TR1 (First spot welding): While powered on, short press the SEL key to move the cursor to the TR1 option. Short press +/- to micro-adjust the first spot welding pulse time. Long press +/- for quick adjustment.
3. Set INTI (Interval time): While powered on, short press the SEL key to move the cursor to the INTI option. Short press +/- to fine-tune the interval time. Long press +/- for quick adjustment.
4. Set TR2 (Second spot welding): While powered on, short press the SEL key to move the cursor to the TR2 option. Short press +/- to micro-adjust the second spot welding pulse time. Long press +/- for quick adjustment.
5. Display IN (Voltage): While powered on, short press the SEL key to move the cursor to the IN option to display the current power supply voltage.
6. Display °F (Temperature): While powered on, short press the SEL key to move the cursor to the °F option to display the current MOS tube temperature.

6.4 Power On/Off

• To turn off the power: In the power-on state, press and hold the SEL key.
• To turn on the power: When the power is off, press and hold the SEL key.

6.5 Spot Welding Process

The K100 supports both single and double pulse spot welding.

• Double pulse spot welding: Set both TR1 and TR2 parameters.
• Single pulse spot welding: Set either TR1 or TR2, and set the other to 0.

The thickness and effect of spot welding depend on the size of the discharge current and the pressure applied. It is recommended to practice spot welding on scrap material to find the optimal values for your specific application.

WARNING: Spot welding relies on discharge current. Do not increase the gear when the spot welding pens are firmly in place on the workpiece, as this may cause damage to the spot welder.

Note: Do not use excessive force when spot welding. Gently press the pens. Ensure that the nickel-plated sheet and the 18650 battery (or other workpiece) fit together without any gaps. After contacting the nickel sheet, the buzzer will sound and automatically trigger the spot welding after 1.5 seconds. After the trigger, the spot welding is automatically completed.

6.6 Welding Pens

• 10 AWG 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. The needles are not replaceable.
• 8 AWG 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. The needles can be replaced.

6.7 Compatible and Prohibited Materials

• Compatible Batteries: 14650, 17490, 18650, 21700, 26650, 32650 cylindrical lithium batteries, and nickel-metal hydride batteries.
• Prohibited Materials: Copper, aluminum, soft pack batteries, and lithium iron phosphate batteries.

7. Maintenance

• Keep the control board and welding pens clean and free from dust and debris.
• Store the device in a dry environment when not in use.
• Regularly inspect the welding pens and cables for any signs of wear or damage. Replace worn-out components promptly.
• If using 8 AWG welding pens, ensure the replaceable needles are securely fitted and replace them when they become dull or damaged.

8. Troubleshooting

• Poor Weld Quality: Ensure the nickel strip and battery are clean and free of oxidation. Adjust the TR1/TR2 (pulse time) and DLST (delay time) settings. Ensure firm contact and even pressure with the welding pens.
• No Weld Trigger: Check all connections, especially the power supply and welding pens. Ensure the pens are making good contact with the nickel strip and battery. The buzzer should sound after 1.5 seconds of contact.
• Device Not Powering On: Verify the power supply voltage is within the 9-16V range and that the connections are secure. Ensure the power source meets the specified current requirements.
• Overheating (Temperature > 50°C): Immediately suspend operation and allow the device to cool down. Check for proper ventilation around the MOS tubes.
• Welding Copper Strips: This device is not designed for welding copper strips. Welding copper or aluminum is explicitly prohibited and may lead to poor results or damage to the device.
• Using Lipo Batteries: While the manual mentions 'model aircraft battery version', ensure any Lipo battery used meets the voltage (9-16V) and current requirements (10-100AH, or >150A with protective plate).

9. User Tips

• Always start with lower power settings (TR1/TR2) and gradually increase them until you achieve a strong weld.
• Experiment with the delay time (DLST) to find the optimal setting for consistent welds.
• For best results, ensure the nickel strip is clean and flat against the battery terminal.
• If you are new to spot welding, practice on the included nickel-plated sheet and some old batteries before working on your main project.
• Consider using the 8 AWG welding pens for thicker materials, as their replaceable needles offer more flexibility.

10. Warranty and Support

For any issues or questions regarding your KEKK K100 spot welder, please contact the seller or manufacturer for support. Keep your purchase records for warranty claims.