Modifing a Battery Spot Welder because of Controller Issues

[stj]

Re: Modifing a Battery Spot Welder because of Controller Issues

maybe put a tin shield over the board and earth it.

[redwire]

Re: Modifing a Battery Spot Welder because of Controller Issues

I think that particular spot welder board model is NY-D04, with dual LED displays.

Likely the MCU side is not earth-grounded and the EMI from a spot weld causes it to crash. I would add a 0.02uF cap parallel with 1MEG, from DC(-) (at the filter cap or 5V reg) to the enclosure chassis/earth ground so the MCU does not experience high level EMI. The display/keypad board may also pick that up. The ribbon cable is also vulnerable. Mains wiring needs to be away from the MCU and keypad and ribbon.

One guy got his board to work better by beefing up the snubber and adding a cap for noise filtering. Have to see the board's values for those parts. Is your 9-12VAC power transformer decent, not sagging.

The big 100A triac BTA100-800B I think has a live tab so you need an insulated heatsink or insulated mounting kit. But it apparently doesn't heat up much, as it is only on for a few 100 msec and many seconds rest.

[sam_sam_sam]

I keep having the same exact issue with these battery spot welder controller boards

They either do one of two things

One the controller does not send the signal for the transformer fire which is a very common problem with this controllers micro controller failure

Or

The controller has some malfunction which means that it does not cycle the pluses more than once or none at all and should do it any where from 1 pluse to 20 pluses because you can not change the setting does not respond to its input micro controller failure

This seems to happen about a year or so of use

Transformer failure is very rare
However they had some problems when I first started buying them that they use the wrong type of transformer because it would trip your circuit breaker even on lowest setting you had to put two transformers in series and it would work half way decent but but when they improved this the controller board failure increased because they also increased the amount of pluses that they put out and you get a much better weld but at the cost of the controller board

They still do not the right combination for these units to have any real life to them as of yet

I just bought another one because I need the small little table that goes under the welder tips this setup works very well except that the table is very very small and if you want to make a big battery pack it a real pain in the a**

Because I want to have a bigger Bakelite table I ordered another battery spot welder that has this setup so I can make a bigger table ( I do have a bigger Bakelite board so this part is not a problem )

I will probably end up going back to a controller out one of there earlier versions that to me had better controller

But the problem with that version was that the transformer was not big enough to get it hot enough to make a good weld because it only does two pluses instead of a maximum of 20 pluses

I seem to think that because the newer controller can do more pluses that is power spiking the controller some how

This battery spot welder that has the table also has a foot pedal that bring the welding pins to the battery versus you bring the battery to the welding pins a lot better design in that you get a lot better weld on your batteries

Not all boards use a optic sensor or I can not find a chip that says by it part number that it is a optic sensor because a lot of ic chips that information is removed from the ic chips

Now I have found battery welder controller that use a very beefy tirac and an optic sensor setup but I have a few problem to work out on how to make this unit electrically safe to use and this has been very hard to do so far

I will have some pictures of the battery spot welder controller boards and the case that you can buy for them but they have no way to mount the tirac to a heat sink unless you mount it on the outside of the unit or inside the unit but then you have to have hook up wire to the tirac

One problem that this board has is that the tirac is not mounted on the edge of the board it is in a ways from the edge of the board so trying to mount the tirac makes it very difficult to to mount

I have even thought about cutting the board where the optic sensor is but the part number of optic sensor seem to show it as surface mount item only now if I could find an optic sensor that has the same specifications as one on the board now it would make it easier to mount the tirac

Now if anyone has any really good ideas on how to do this and make it electrically safe I am very open to ideas and this is the main reason for this post