Complete Welding Kit (kWeld)
New design featuring C14500 (tellurium copper) CNC’ed electrode system for better heat handling capacity and improved handling:
The assembly and operating manuals are available on this website for download
(https://www.keenlab.de/wp-content/uploads/2018/07/kWeld-assembly-manual-r5.0.pdf – https://www.keenlab.de/wp-content/uploads/2018/07/kWeld-operation-manual-r3.0.pdf).
Purchase this item if you want to receive everything that is needed to build a kWeld unit. Complete the kit using basic tools, add a suitable power source, and start welding.
If you want to source some parts from e.g. your local hardware store, then this article may not give you the necessary flexibility and options; in this case, you can order the individual components from the shop instead, and use the description below for an overview of what is needed to build a complete kit.
The kit includes:
>td >Cables, electrode holders, and electrodes>td >CNC machined bus bars>td >Mechanical parts
| Electronics | This is the brain of the kWeld battery spot welder. You purchase a professionally reflow soldered, tested and programmed electronic module. See https://www.keenlab.de/index.php/product/kweld-electronics/ for more details. |
| Cables, electrode holders, and electrodes | All bits and pieces that are required to fully assemble the kWeld cabling, including a pair of electrode holders and a pair of electrodes. (See https://www.keenlab.de/index.php/product/kweld-cable-electrode-holders/ and https://www.keenlab.de/index.php/product/kweld-electrode-set/ for details.) The power input connection consists of loose cable ends, you need to add a connector that matches your power source. Suitable XT150 power connectors are available in the shop. Choose the supplied loose option if you have the time and tools do do the necessary assembly steps yourself, saving some money. Check out the assembly manual for an overview of the involved work. If you are in doubt, choose the assembled option here. |
| Fuse | A 300A high current fuse (type ANL) that needs to be mounted on the kWeld electronic module and protects the system from the consequences of unlikely catastrophic failures. |
| Foot switch | The pulse trigger switch of the kWeld system. It has a rugged construction, and uses a real micro switch that is also easy to service. The cable length is 2.0m. |
| CNC machined bus bars | These need to be bolted to the electronics module and provide a low impedance path between the switch transistors and the cable system. |
| Mechanical parts | All bits and pieces that are required to fully assemble the kWeld electronics module with the LCD, the cabling, the fuse, and the bus bars. See https://www.keenlab.de/index.php/product/kweld-mechanical-parts/ for more details. |
Please note that a power supply is not part of the kit. The following high current power supplies have been tested with the kWeld system and can be recommended:
- Turnigy nano-tech 3S/5000mAh/130C Lithium Polymer battery. I have stress tested one of them for several complete discharge cycles, and it shows no visible swell thereafter. The measured current is 1300-1500 amperes.
The power supply must be able to deliver at least 800A (recommended: at least 1000A) to ensure proper functionality of the device.
IMPORTANT: Lithium Polymer batteries are potentially dangerous. If they fail internally, they can spontaneously self-ignite. It is therefore strongly advised to permanently supervise them during use and also while charging them, and to store them in a fire safe container when not using them.
WARNING:
You are dealing with very high energy levels when using this system, which may result in personal injury or fire when handled improperly. Take appropriate safety measures and use this system with caution. Never leave it unattended while being powered.
This product contains small parts, keep out of reach of children!
This system produces significant magnet fields, do not use it when you have a cardiac pacemaker!
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