U S SOLID USS-BSW00008 Battery Spot Welder User Manual

BATTERY SPOT WELDER
Capacitor Energy Storage Precision Welding Machine
**USS-BSW00008

User Manual
**

USS-BSW00008 Battery Spot Welder

Thank you for choosing the U.S. Solid ba ery spot welder.
Please check the package firstly to make sure it is not damaged in transit before use. For ques ons, please contact us at service@ussolid.com or 1-800-243-5428(M-F: 9:00 am-5:00 pm EST) for help.
To ensure the best user experience, we recommend reading the user manual thoroughly and keeping it for future reference.

Product Introduction

• The newly designed U.S. Solid USS-BSW00008 high-frequency inversion ba ery spot welder equips with the six super capacitors for energy storage and power supply for pulse welding. Unlike traditional AC transformer spot welders, it does not cause any interference to the electric circuit, elimina ng tripping problems.
• The low-consump on super energy-gathered millisecond pulse technology maximizes the pulse energy output in millisecond-level me, the welding spot is excellent and no damage to the battery.
• 42KW/7000A Super Welding Output – Suppor ng the large-capacity power ba ery of copper/aluminum terminals welding.
• LED Display Screen & Controlling Bu ons – Real- me capacitor voltage, charging current, power grade and actual welding current parameters are monitored. Convenient parameter adjustments can be made by pressing the boons.
• AT/MT’ Two Welding Modes – ‘AT’ automac mode for quick welding and ‘MT’ foot pedal controlling mode for beginners or precise welding.
• Mul ple welding pen accessories are available for different welding requirements. (Please no ce that the package only contains the default 75A-Plus welding pen for large- capacity power battery welding, additional purchase required for other-types welding pen)
• The newly added ‘Welding Spot Resistance Milliohm Meter’ func on allows for quick measurement of the resistance between the connecng piece and electrodes of the battey aerspot welding. The lower the resistance, the be er the welding effect, and it provides a convenient way to check for poor welding spots.

Usage Scenarios

Lithium battery pack quick building & maintenance for electric appliances, electric vehicles, etc.
Especially designed for the large-capacity power battery aluminum/copper terminals welding.
Circuit Board/Hardware/Electronic Components/Lead Wire spot welding.
(Tips: Different welding pen accessories additional purchase required, the package only includes the 75A-Plus welding pen for large batt ery welding).
Widely used for the common metal welding like stainless steel, iron, nickel, copper, aluminum, Tanium, molybdenum, etc.

Welding Reference Table

Notes:

1. The table is for reference only, the actual welding effect also influenced by the material size, surface flatness, oxidaon condion, etc.
2. The table lists the example data of large-capacity power baery welding situaon only, welcome to contact us for more welding scenarios consulta on or communica on.

Product Parameters

Package List

• Main Machine x 1 pc
• Power Cord x 1 pc
• Milliohm Resistance Measuring Pen x 1 pc
• 75A-Plus Separated-style Welding Pen x 1 pc
• 75A-Plus Replacing Welding Electrodes x 1 pair
• 75A-Plus Set Screws x 1 pair
• Foot Pedal Switch x 1 pc
• Pure Nickel – 0.15 x 8 x 100mm x 20 pcs
• Nickel-aluminum – 0.15 x 10 x 100mm x 20 pcs
• Pure Copper – 0.15 x 10mm x 5 m

Product Diagram

Screen

• Power Grade – 0-99 t (0.2 ms/t)
• ‘ms’ – Pulse Time(20 ms)
• ‘MT’ – Foot Pedal Controlling Mode
• ‘AT’ – Automatc Inducing Triggering Mode
• ‘SW’ – Instantly lights up when welding pulse is triggered
• ‘SD’ – Lights up a er the machine is on standby for 30 mins
• ‘PT’ – Lights up when there is a short circuit in the machine
• Charging Current – Real- me Charging Current(5-20 A)
• ‘DCV’ – Real- me Capacitor Voltage(0-6 V)

How To Use

Usage Diagram

1. Plug in the power cord and connect to the right power supply. (Tips: Confirm the power supply and plug type)

2. Switch on the machine.

3. Wait for the capacitor voltage to reach 5.6-6V.
   (Tips: 1. The machine has been discharged to the lowest voltage before leaving the factory for safety transportat on, charge the machine firstly for first me use.
   2. Machine will make normal sounds when charging.)

4. Plug in the 75A-plus separated-style welding pen.

5. Secure the connexon by screwing in the set screws hotly.

6. Press the ‘ ’ button to start the parameter setting.

7. Press the ‘ ’ buttons to switch the power grade adjustment or welding modes selec on.

8. Press the ‘ ’ buttons to adjust the power grade values or select ‘AT/MT’ welding modes. 

9. Press the ‘ ’ button again to save all settings and exit.
   (Tips: The parameter settings are not saved when screen displays the flickering values, press the ‘ ’ button to confirm the adjustment.)

10. Shut down the machine when not using and unplug it.

‘AT’ – Automatc Welding Mode

Set the ‘AT’ mode Apply enough and uniform pressure on two welding electrodes, the welding pulse will be triggered in 300ms delayed me Check the welding effect

‘MT’ – Foot Pedal Controlling Mode

Set the ‘MT’ mode Plug in the foot pedal switch

Apply enough and uniform pressure on two welding electrodes, step on the pedal switch and welding pulse is triggered instantly

Check the welding effect
Notes:

1. ‘AT’ Automatc mode is for quick welding and ‘MT’ foot pedal controlling mode is for the beginner or precise welding. The welding effect needs to be checked in AT quick welding mode to avoid the neglected bad welding spots.

2. Apply enough and uniform pressure on two welding electrodes to get the welding pieces and welding surface fully contacted for op mal welding effect.
   (Apply different pressure according to different materials and thickness).

3. Not enough pressure applied on the welding electrodes or slow opera on exceeding the 300ms pulse delayed me in ‘AT’ mode will cause large sparks.

Special Notice for Welding Effect Test of Large-capacity Batteries of Aluminum Terminals
Because the aluminum metal is softer than stainless steel and copper, so the welding effect test method of batteries of aluminum terminals is different. The welding pieces should be flat pulled but not torn off because the metal joints cannot hold the pulling force.

Welding Spot Resistance Milliohm Meter

1.  Press the ‘ ’ button to turn on the func on
2. Plug in the milliohm measuring pen
3. Measure the resistance between the connecng piece and the electrode of battery after spot welding
4. The resistance is 0.07mΩ (0-200 mΩ)

Notes:

1  Assisting in efficiently inspecting poor welding spots in ‘AT’ welding mode.
2. Electrifiers objects like battery cannot be measured.
3. The lower resistance, the better welding effect, which means the better battery pack performance.

75A-Plus Separated-style Welding Pen
Diagram

Usage Notices

Never contact the two electrodes

Never contact the positive and negative terminals at the same time

Correct operation

Welding Electrodes Replacement

| | |
---|---|---|---
Fix the welding pen tail| Use plier to twist off the electrodes| Replace new electrodes| Twist and tighten the connection

Notes:

1. Clean or replace the welding electrodes regularly for optimal welding effect.
2. Lubricating oil can be smeared on the welding electrodes to prevent oxidisation.
3. The package only contains the default 75A-Plus welding pen for large-capacity power battery welding, additional purchase required for other-types welding pen.

Usage Notices

• Precious metals like gold, silver and jewelry cannot be welded.
• Never contact the two welding electrodes of welding pen.
• Never contact the battery positive and negative terminals at the same time.
• Do not set the power grade too high, otherwise will cause large sparks and penetrate the battery.
• Welding sparks may occur, wear goggles and keep a safe distance.
• Charge the machine firstly for first time use and wait the capacitor voltage reaches 5.6-6V. (The machine has been discharged to the lowest voltage before leaving the factory for safety transportation).
• ‘AT’ automatic mode is for quick welding and ‘MT’ foot pedal controlling mode is for the beginner or precise welding. The welding effect needs to be checked in AT quick welding mode to avoid the neglected bad welding spots.
• Apply enough and uniform pressure on two welding electrodes to get the welding pieces and welding surface fully contacted for optimal welding effect. (Apply different pressure according to different materials and thickness).
• Keep the welding pieces and welding surface clean and flat to avoid poor welding effect.
• Clean or replace the welding electrodes regularly for optimal welding effect.
• Twist and tighten the welding electrodes firmly for best conductivity.
• Do not take down the plastic shell of the welding pen.
• Lubricating oil can be smeared on the welding electrodes to prevent oxidization.
• The package list only contains the default 75A-Plus welding pen for large-capacity power battery welding, additional purchase required for other-types welding pen.
• Only use the welding accessories(welding pen, electrodes) from U.S. Solid.
• Only charge the machine with the original power cord.
• Keep the machine plugged in for working.
• Normal meter cannot measure the actual instant welding current(pulse).
• The milliohm meter function cannot measure the electriferous object(battery).
• Shut down the machine when not using and unplug it.
• Do not take part and modify the machine personally, doing so may cause danger.
• Do not use the machine if lacking of related knowledge and experience.
• Do not use in inflammable, explosive dangerous environments.
• Keep out of reach of children.

Special Notice for Welding Effect Test of Large-capacity Batteries of Aluminum Terminals
Because the aluminum metal is softer than stainless steel and copper, so the welding effect test method of batteries of aluminum terminals is  different. The welding pieces should be flat pulled but not torn off because the metal joints cannot hold the pulling force.

Troubleshooting Table

Error Type – 1E01′
(welding signal triggered but
no welding current)| welding material not supported| check the material
welding material too thick| check the thickness
the welding pen electrodes, welding pieces and welding
surface are not clean, stains or oxides exist;| clean the welding components or replace new welding electrodes
internal circuit board broken (machine short circuit: contact  the welding pen two electrodes; contact  the battery  positive and negative terminals at the same time)| replace new circuit board
Error Type – ‘E02
(welding signal continuously
triggered in shortme)| step on the pedal switch always or too fast| step by interval time
the pedal switch is broken(stuck)| repair or replace new pedal switch
Weak Welding| low capacitor voltage| charge and wait the voltage reaches 5.6-6V
set the power grade too low| turn up the power grade
welding pen or its welding electrodes not plugged in firmly| check the connection
Large Welding Spark| not enough pressure applied on the welding pieces| apply enough pressure
exceed the pulse delayed time quicken the welding operation
Welding Spots Not Uniform| not uniform pressure applied on the welding pieces| apply uniform pressure
Battery Penetrated| set the power grade too high| turn down the power grade

For troubles cannot solved by this table or needing of replacement accessories, please contact us at service@ussolid.com for help.
Please provide the pictures or video of the broken machine if possible, which will help us analyze and solve the problems.

One Year Limited Warranty

U.S. Solid warrants your battery spot welder to be free from defects in materials or workmanship under normal use and service for one year from the date of original purchase. All defective devices under normal use will be repaired or replaced for free. All parts, except for consumable welding accessories, will be covered under this warranty.
This warranty shall not apply to any U.S. Solid battery spot welder that:

• is defective due to misuse, neglect or accident;
• is used for a purpose that the device is not designed for;
• has been repaired or altered in a way that adversely affect its performance and reliability;
• is serviced by unauthorized parties;
• Is intended for commercial or professional use.

This warranty is only applicable to the original purchaser.
U.S. Solid would not assume or authorize any person to assume any other liability in connection with its product. No responsibility is assumed for any consequential damages that may result from the use of a U.S. Solid product, nor for damages due to accident, abuse, lack of care, affixing of unauthorized attachment, loss of parts or subjecting this unit to any but the specified voltage.
If your product is broken and meets the warranty requirements, please email us to service@ussolid.com with the original receipt showing the purchase date and the description of the problem for customer service.
Please note should any return or replacement be incurred, transportation and packing costs are the responsibility of the customer.
This warranty gives you specific legal rights, you may have other rights that may vary from state to state.
For More High-quality Products From U.S. Solid, Please Visit www.ussolid.com
Contact Info
Website: www.ussolid.com
Email: service@ussolid.com
Address: 1200 E 55th St. Cleveland, OH 44103, USA

U.S. Solid Battery Spot Welder
USS-BSW00008 Manual, Version 3.1, 2023.7.24
www.ussolid.com

References

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