Kerpu DSH Portable Spot Welder User Manual

1. Introduction

The Kerpu DSH Portable Spot Welder is a high-efficiency, compact, and versatile tool designed for assembling battery packs and welding various metal sheets. Featuring an upgraded enhanced system with 199 adjustable gears, it offers precise control and stable performance for both professional and hobbyist applications. Its portable design makes it ideal for use in various settings, from home workshops to field repairs.

The Kerpu DSH Portable Spot Welder is designed to be small and easy to carry, comparable in size to a mobile phone.

2. Package Contents

Please verify that all items listed below are included in your package:

• 1 x Kerpu DSH Portable Spot Welder Unit
• 1 x Pair of Welding Pens
• 1 x Type-C Charging Cable
• 1 x Sandpaper (for cleaning pen tips)
• 1 x Roll of Nickel-Plated Sheets
• 1 x User Manual (this document)

The complete package contents of the Kerpu DSH Portable Spot Welder.

A visual representation of the items included in your purchase.

3. Safety Information

To ensure safe operation and prevent damage to the device or injury, please adhere to the following safety guidelines:

• Always wear appropriate personal protective equipment, such as safety glasses, when operating the spot welder.
• Ensure the contact area between the nickel sheet and the battery is clean and flat before welding.
• Do not press excessively hard on the welding pens during operation; light pressure is sufficient for effective welding.
• Keep the device away from water and flammable materials.
• Do not attempt to disassemble or modify the device. Refer all servicing to qualified personnel.
• The device features built-in over-current, over-voltage, and over-temperature protection. If the temperature exceeds 60 ℃, the unit will automatically shut down to prevent damage.

The device is equipped with a temperature protection feature that automatically shuts down the unit if the internal temperature exceeds 60 ℃.

4. Setup

Follow these steps to set up your Kerpu DSH Portable Spot Welder:

1. Connect Welding Pens: Insert the red and black plugs of the welding pens into the corresponding ports on the spot welder unit. Ensure a secure connection.
2. Prepare Materials: Ensure the surfaces of the batteries and nickel sheets to be welded are clean and free of dirt, oil, or oxidation. Use the included sandpaper to clean the tips of the welding pens if necessary.
3. Position Batteries: Arrange your batteries as required for your battery pack assembly.
4. Place Nickel Sheet: Position the nickel sheet over the battery terminals where the welds are to be made.

The welding pens are approximately 16 inches (40 cm) long, providing flexibility during operation.

Proper setup of the spot welder with welding pens connected and nickel strip positioned on batteries.

5. Controls and Indicators

The Kerpu DSH Portable Spot Welder features intuitive controls and clear indicators:

• Power ON/OFF and Mode Switch Key: Long press for 2 seconds to power ON/OFF. Short press to switch between automatic and manual welding modes.
• Gear Adjustment Key: Used to adjust the output power. The device has 11 adjustable gears.
• Mode Indicators: A yellow light indicates automatic mode, while a blue light indicates manual mode.
• Gear Indicator Lights: Red lights indicate the selected gear (power level).
• Power Indicator Lights: Blue lights indicate the remaining battery charge (e.g., 4 lights for 75%-100%, 1 light for <5%).

Detailed view of the controls and indicators on the Kerpu DSH Portable Spot Welder.

The 11 adjustable gears allow for refined power adjustment to suit different materials and thicknesses.

6. Operating Instructions

Once the unit is set up, follow these steps for effective spot welding:

1. Power On: Long press the Power ON/OFF button for 2 seconds.
2. Select Mode: Short press the Power ON/OFF button to toggle between automatic (yellow light) and manual (blue light) modes. Automatic mode is recommended for beginners.
3. Adjust Gear: Use the Gear Adjustment key to select the appropriate power level (1-11 gears) for your material. Start with a lower setting and increase as needed. The device can weld metal sheets as thin as 0.1-0.2mm.
4. Perform Weld: Place both welding pen tips firmly but gently on the nickel sheet, ensuring good contact with the battery terminal underneath. Do not press hard. The device will automatically trigger the weld in automatic mode after a short delay (0.5s automation trigger). In manual mode, you will need to press the manual key to trigger the weld.
5. Inspect Weld: After each weld, visually inspect the joint to ensure it is strong and clean. A good weld will be difficult to remove without tearing the nickel strip.
6. Repeat: Continue welding along the nickel strip as required for your battery pack or metal assembly.

Play video

Official Kerpu video demonstrating the spot welding operation. Note the emphasis on not pressing too hard for optimal results.

The spot welder is ideal for assembling cylindrical battery packs.

It can also be used for repairing mobile phone batteries.

The device is versatile for welding various small metal pieces.

7. Maintenance

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

• Charging: Charge the unit using the provided Type-C charging cable. A full charge takes approximately 3 hours. The power indicator lights will show the charging progress and remaining battery level.
• Cleaning Welding Pens: Regularly clean the tips of the welding pens with the included sandpaper to remove any residue or oxidation. This ensures good electrical contact and consistent welds.
• Storage: Store the spot welder in a cool, dry place away from direct sunlight and extreme temperatures.

The 7500mAh large capacity battery ensures extended use, and it charges via a standard Type-C USB port (5V/2A).

The device supports convenient Type-C charging.

8. Troubleshooting

If you encounter issues with your Kerpu DSH Portable Spot Welder, refer to the following common problems and solutions:

• Weak or Inconsistent Welds:
  • Ensure welding pen tips are clean. Use sandpaper to remove oxidation.
  • Verify the nickel sheet and battery surfaces are clean and flat.
  • Increase the power gear setting.
  • Ensure you are applying light, consistent pressure. Excessive pressure can reduce weld quality.
  • Check that the welding pens are securely connected to the unit.
• Unit Not Turning On or Charging:
  • Ensure the charging cable is properly connected to both the unit and a working power source (5V/2A recommended).
  • Check if the charging cable or adapter is damaged. Try a different cable/adapter.
  • If the unit has been stored for a long time, the battery might be deeply discharged. Allow it to charge for an extended period.
• Overheating Shutdown:
  • The device has built-in temperature protection. If it shuts down due to overheating, allow it to cool down before resuming operation.
  • Avoid continuous, rapid welding for extended periods. Allow brief pauses between welding sessions.

9. Specifications

10. Warranty and Support

Kerpu is committed to providing high-quality products and excellent customer service. Your Kerpu DSH Portable Spot Welder comes with value-added services and hassle-free support.

• Welding Parameter Guidance: Free guidance is available to help you achieve optimal welding performance.
• Parts Replacement: If you are missing parts or require replacements in the future, please contact us.
• Custom Tooling Designs: Custom tooling designs may be available to meet specific production line needs.

For any inquiries, support, or to request parts, please contact us via email:

Email: tswaus@163.com