1. Introduction
This manual provides essential instructions for the safe and effective use of the EVTSCAN Z99 Mini DIY Spot Welder Circuit Board. This device is designed for precision spot welding of various cylindrical lithium batteries, including 18650, 26650, and 32650, as well as nickel-hydrogen and nickel batteries. It features real-time voltage monitoring, MOS tube temperature protection, and 99 adjustable power settings for versatile application.
2. Safety Information
Read all safety warnings and instructions carefully before use to prevent electric shock, fire, or serious injury.
- Power Supply Requirements:
- Use only a 12V DC power source.
- Recommended power sources include:
- Acid battery 12V, 20 to 40AH.
- Model batteries or large single cells (3S to 4S LiPo), with a capacity (AH) multiplied by discharge rate (e.g., 60C) between 100 to 300.
- 12V car EC5 interface start, ensuring the peak current does not exceed 600A.
- Prohibited Power Sources: Do NOT use switching power supplies, transformers, chargers, or water batteries to power the spot welding machine. Doing so will damage the control circuit.
- Ensure the internal resistance of the battery used as a power source is lower than 7 milliohms.
- Voltage Monitoring: The device features real-time voltage monitoring. If the input voltage falls outside the 8-17V range, a "UE" alarm code will be displayed. Disconnect power and check your power source immediately.
- Temperature Monitoring: Real-time MOS tube temperature monitoring is included. If the MOS tube temperature exceeds 45°C, a "CE" alarm code will be displayed. Allow the device to cool down before continuing operation.
- Welding Safety: Always wear appropriate personal protective equipment, including safety glasses, when operating the spot welder.
- Connection Safety: Ensure all connections are secure and correctly polarized to prevent damage to the device or power source.
3. Package Contents
Verify that all items listed below are present in your package:
- 1 x Z99 Spot Welder Circuit Board
- 2 x Connection Cables (for power input)
- 2 x Heat Shrink Tubes
- 4 x Nuts
- 4 x Screws
- 1 x Nickel Bar (for welding practice/use)
- 2 x Spot Solder Pens (welding probes)
Figure 1: Complete package contents including the Z99 circuit board, connection cables, heat shrink tubes, nuts, screws, nickel bar, and spot solder pens.
4. Product Overview
The EVTSCAN Z99 Spot Welder Circuit Board is a compact and efficient tool for battery spot welding. Key features include:
- Precision Welding: Capable of welding nickel strips with thicknesses from 0.1mm to 0.2mm.
- Digital Display: A 3-digit digital tube displays real-time information, including power adjustment settings and alarm codes.
- Adjustable Power: Offers 99 gears (power adjustment settings) for fine-tuning welding intensity.
- Safety Features: Integrated real-time voltage monitoring (8-17V range) and MOS tube temperature protection (alarm at >45°C).
- Durable Components: Equipped with 10AWG welding wire and oxidized copper spot welding needles for optimal current capacity and longevity.
- Wide Application: Suitable for 18650, 26650, 32650 lithium batteries, nickel-hydrogen, and nickel batteries.
Figure 2: Top-down view of the Z99 circuit board, showing the digital display, control buttons, MOS tubes, and connection points.
Figure 3: Close-up of the 3-digit digital display and the two control buttons (SW1, SW2) used for adjusting settings.
5. Setup Instructions
- Prepare Power Source: Ensure your 12V DC power source meets the requirements outlined in the Safety Information section (e.g., 12V 20-40AH acid battery, 3S-4S LiPo with appropriate discharge rate, or 12V car EC5 interface with peak current not exceeding 600A).
- Connect Power Cables:
- Identify the "BAT+" and "BAT-" terminals on the circuit board.
- Connect the red connection cable to the "BAT+" terminal and the black connection cable to the "BAT-" terminal.
- Connect the other ends of these cables to your 12V DC power source, ensuring correct polarity (red to positive, black to negative).
- Warning: Incorrect polarity can damage the circuit board.
- Connect Spot Solder Pens:
- Identify the "OUT+" and "OUT-" terminals on the circuit board, which are for the spot solder pens.
- Connect the spot solder pens to these terminals. The pens are typically color-coded (red for positive, black for negative) or can be connected to either terminal as they are the output for welding.
- Ensure connections are tight and secure.
- Initial Power On: Once all connections are secure, power on your 12V DC source. The 3-digit digital display on the circuit board should illuminate, showing the current voltage or welding gear setting.
Figure 4: Image showing the "BAT+" and "BAT-" input terminals and "OUT+" and "OUT-" output terminals for the welding pens.
6. Operating Instructions
- Power Adjustment:
- The Z99 spot welder has 99 adjustable power gears.
- Use the two control buttons (SW1 and SW2, typically labeled on the board or near the display) to increase or decrease the welding power.
- The digital display will show the current gear setting. Start with a lower setting and gradually increase until the desired weld strength is achieved.
- Welding Procedure:
- Place the nickel strip onto the battery terminal you wish to weld.
- Hold both spot solder pens firmly against the nickel strip, ensuring good contact with the battery terminal underneath. The pens should be close together but not touching each other.
- The spot welder will automatically detect contact and initiate a weld pulse.
- Observe the weld quality. If the weld is too weak, increase the power gear. If it burns through the nickel strip or battery, decrease the power gear.
- Practice on scrap nickel strips and batteries first to find the optimal settings.
- Real-Time Monitoring:
- The digital display continuously monitors the input voltage and MOS tube temperature.
- Pay attention to any alarm codes (see Troubleshooting section) and address them promptly.
7. Troubleshooting
This section addresses common issues and alarm codes you may encounter during operation.
| Problem/Alarm Code | Description | Solution |
|---|---|---|
| "UE" Alarm Code | Input voltage is outside the safe operating range of 8-17V. |
|
| "CE" Alarm Code | MOS tube temperature exceeds 45°C, indicating overheating. |
|
| No Weld/Weak Weld | The spot weld is not strong enough or does not occur. |
|
| Burn Through/Excessive Sparking | The weld is too strong, damaging the nickel strip or battery. |
|
8. Specifications
| Feature | Detail |
|---|---|
| Model | Z99 |
| Material | PCB and Copper |
| Working Voltage | 12V DC (8-17V safe operating range) |
| Welding Peak Current | 1500A maximum |
| Weld Nickel Thickness | 0.1 to 0.2mm |
| Power Gears | 99 gears |
| Display | 3-digit digital tube display |
| Wire Gauge | 10AWG (welding wire) |
| Standby Power Consumption | <0.5mA |
| Voltage Monitoring | Real-time, "UE" alarm if outside 8-17V |
| MOS Tube Temperature Alarm | "CE" alarm if temperature exceeds 45°C |
| Item Weight | 8.8 ounces |
9. Maintenance
- Cleaning: Keep the circuit board and welding pens clean and free from dust, debris, and welding splatter. Use a soft, dry cloth for cleaning.
- Welding Pen Tips: Periodically inspect the tips of the spot solder pens. If they become dull or oxidized, clean them with fine sandpaper or a file to ensure good electrical contact.
- Storage: Store the spot welder in a dry, cool place, away from direct sunlight and moisture. Disconnect it from the power source when not in use.
- Cable Inspection: Regularly check all connection cables for signs of wear, fraying, or damage. Replace any damaged cables immediately.
10. Warranty and Support
For warranty information or technical support, please refer to the product packaging or contact the manufacturer directly. Keep your purchase receipt as proof of purchase.
