GX591 DIY Spot Welder Set Instruction Manual

1. Safety Warnings and Precautions

• Read all instructions carefully before using this product. Keep this manual for future reference.
• Do not use the product for any purpose other than its intended use. Misuse may cause injury, damage to the product, or other hazards.
• Keep this product out of the reach of children under 3 years, unless under direct adult supervision. Small parts may cause choking hazard.
• Do not disassemble, modify, or repair the product by yourself. Improper operation may cause electric shock, fire, or product failure. Contact professional maintenance personnel if needed.
• Dispose of the product and its packaging in accordance with EU WEEE (Waste Electrical and Electronic Equipment) Directive 2012/19/EU and RoHS Directive 2011/65/EU. Do not discard as household waste.
• Not suitable for children under 36 months. Contains small parts that may cause choking hazard. Use under adult supervision.
• Do not use the product near water or in humid environments. Avoid contact with liquids to prevent electric shock. Unplug the power supply when not in use or during cleaning.
• Protective equipment should be worn. This product requires high skills to avoid falls or collisions.

2. Product Overview

The GX591 DIY Spot Welder Set is a versatile control board designed for precise spot welding, particularly for 18650 batteries and nickel sheets. It features a high-speed microcontroller, 99 adjustable power gears, and a real-time digital display for monitoring battery voltage and current settings. The unit is equipped with 6 MOS tubes, enabling a peak welding current of up to 2400A for strong and clean welds.

3. Package Contents

Upon opening the package, verify that all components are present and undamaged. The standard package typically includes:

• 1 x GX591 Welding Machine Control Board
• Welding pens (flexible, 12AWG multi-strand high-temperature wire with thick pure copper and aluminum-copper needles)
• Connecting wires (red and black)
• Screws, nuts, and washers for assembly
• Heat shrink tubing
• Nickel strip sample
• Optional: Protective acrylic casing (may vary by kit)

4. Setup and Installation

Carefully install all product components following these steps. Ensure all connections are secure before operation.

1. Unpacking Inspection: After opening the package, verify that the product is complete and undamaged.
2. Assemble Protective Casing (if included): If your kit includes an acrylic protective casing, assemble it around the control board using the provided screws and standoffs.
3. Connect Welding Pens: Attach the flexible welding pens to the designated output terminals on the control board. Ensure a tight and secure connection. The 12AWG multi-strand high-temperature wires and pure copper/aluminum-copper needles provide optimal current flow.
4. Select Power Source: Choose one of the following power sources as the working power source. The total internal resistance of the power source should be less than 7 milliohms for optimal performance.
   • Lead Acid Battery: 2 * 20Ah electric vehicle battery, or a 36-405H new car starting battery.
   • Model Battery: 3S 4000mah 35C, 3S 5000mah 25C, or 3S 8000mah 20C.
   • Car Starting Power Supply: 11.5-14.8V, 36-60AH, with internal resistance >2.5 milliohms and <7 milliohms.
   • Self-assembled Battery: 11.5-14.8V, with total internal resistance <7 milliohms.
5. Connect Power Source: Connect your chosen power source to the input terminals (VIN) on the control board. Pay close attention to polarity (positive to positive, negative to negative). The board will automatically display the voltage when connected.

5. Operating Instructions

Once the spot welder is set up and powered, follow these steps for operation:

1. Power On: Connect the power source. The digital display will light up, showing the current battery voltage.
2. Adjust Power Gears: The unit features 99 adjustable power gears. Use the control buttons (SW1, SW2) on the board to cycle through and select the desired power level. Higher numbers indicate higher welding intensity. The real-time digital display will show the selected gear.
3. Select Working Mode (if applicable): The device supports three working modes: universal power mode, enhanced power mode, and super power mode. Refer to the specific button combinations or menu options (if available) to switch between these modes for different welding requirements.
4. Prepare Materials: Ensure the nickel sheet and battery terminals are clean and free of oxidation. Position the nickel sheet firmly against the battery terminal.
5. Perform Welding: Bring both welding pens into contact with the nickel sheet and battery terminal simultaneously. The automatic trigger welding function will initiate the weld. Apply firm, even pressure.
6. Inspect Weld: After welding, inspect the joint for strength and appearance. Adjust power settings as needed for subsequent welds.

The high-speed microcontroller design ensures intelligent and precise results, while the real-time display of battery voltage and welding gear enhances usability.

6. Maintenance

Proper maintenance ensures the longevity and optimal performance of your spot welder.

• Cleaning: Wipe off surface dust or stains promptly after each use with a dry, soft cloth. Do not use liquids or abrasive cleaners.
• Storage: When not in use, store the product in a dry, well-ventilated location, away from direct sunlight and high humidity.
• Environmental Conditions: Avoid using the product outdoors during rain or in high-humidity environments to prevent damage and ensure safety.
• Power Disconnection: Always unplug the power supply when the device is not in use or during cleaning.

7. Troubleshooting

If you encounter issues with your spot welder, consider the following:

Important: Do not attempt to disassemble or repair the device yourself. Unauthorized modifications can lead to electric shock, fire, or product failure and will void any potential warranty. If issues persist, contact qualified technical support.

8. Specifications

9. User Tips

• Test on Scrap Material: Before welding your final project, always perform test welds on scrap nickel strips and old batteries to fine-tune your power settings and technique.
• Optimal Power Source: The quality and internal resistance of your power source significantly impact welding performance. Using a power source with low internal resistance (e.g., below 7 milliohms) is crucial for strong welds.
• Cleanliness is Key: Ensure both the nickel strip and the battery terminals are perfectly clean. Any dirt, grease, or oxidation will result in poor weld quality.
• Consistent Pressure: Apply consistent and firm pressure to both welding pens simultaneously during the welding process for best results.
• Ventilation: Although the device has a low standby power consumption, ensure good ventilation in your workspace, especially when working with batteries.

10. Warranty and Support

This product is designed for DIY enthusiasts and requires careful handling. For technical assistance or inquiries regarding product functionality, please refer to the seller's support channels. Any unauthorized disassembly or modification will void the warranty.

A detailed user manual in PDF format is available for download: View User Manual (PDF)