1. Before Spotwelding, measure the voltage of the cells and make sure they are the same to the tenths place. Putting cells that have wildly different voltages in parallel could be catastrophic.
2. Align cells within spacer in the configuration that you wish for them to be welded in, ensuring that the terminal ends of all cells are parallel and flush to each other.
3. Take a nickel strip and cut it to a length that is slightly shorter than the total length of the row of cells you wish to weld together, ensuring that nickel is not hanging off the edges of the end cells.
4. Properly align the nickel strip on top of the row of cells so that each cell is making even and symmetrical contact with the strip.
5. Ensure that the “CH” indicator (charging) is not present on the machine screen and that the voltage is reading at least 5.4 V.
6. Grab the welding pen and hold down the nickel strip in the set position while placing the two welding pins on the strip at a spot on the center of the first cell you wish to weld.
- - If you are welding a long strip that contacts more than two cells in a row, it is recommended that the first cell that you weld is one at the center of the strip, making it easier to align the strip with the rest of the cells.
7. With a spot chosen and contact made, ensure that the two pins of the pen are making level and even contact, and that the pen is aligned as perpendicular as possible to the strip.
8. While keeping the pen as level as possible, push down and apply pressure onto the strip with the pen until a click is heard and felt within the pen. Apply a small amount of extra pressure after.
- - Generally, the more pressure that is used, the better the weld, but ensure to not apply so much pressure that the material is completely pierced through, which could damage the cell.
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9. When ready, press down on the foot pedal to weld.
10. During the welding, pay attention to any sparks that fly out and what direction they fly in.
- - If there is an exaggerated volume of sparks, you may have set the pulse time too high, or you may not be applying enough pressure.
- - If there is a small amount of sparks, the pressure you applied may have been slightly unlevel or uneven between the two pins. The direction in which the sparks flew generally indicates the direction you want to lean the pen slightly towards to account for this and reduce sparks.
- - Less sparks generally indicates a higher quality weld.
11. After the welding is done, continue to hold down the pen and apply pressure for about 1-2 seconds, which allows the weld to remain compressed as it begins to cool.
12. Ensure that the voltage has recharged to at least 5.4 V and repeat steps 6-10 for the same cell but with the pins of the pen aligned to be perpendicular with the weld just done on the same cell, creating a “cross” weld pattern.
13. Ensure that pins are clean (if not, clean with abrasive pad) and that voltage is recharged to at least 5.4V before repeating these steps on the other cells.
14. When finished spotwelding, make sure to store cells in a place where their terminals cannot touch any metal or other cells as this could cause a short and lead to fire.