Pro Spot Hybrid Spot Instruction Manual Download

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Page 2

READ BEFORE OPERATING WELDER!

Connect all 4 cables to negative

battery terminals Before using.

To access terminals, open right

side cover.

(The four cables to the negative battery terminals are

disconnected during shipping.)

Table Of Contents

6 Single-Sided Welding

6.1 Single-Sided Welding Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27-28

6.2 Single-Sided Spot Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

6.3 Bolt Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

6.4 Nut Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6.5 Dent Pulling with Spot Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

6.6 Moulding Clip Rivet Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

6.7 Dent Pulling with Washers and Slide Hammer with Hook . . . . . . . . . . . . . . . . . . . .31

6.8 Contact Shrinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

6.9 Pro Pull Dent Pulling (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.9.1 Selecting Pro Pull Weld Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.9.2 Pro Pull Component Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

6.9.3 Pro Pull Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

6.9.4 Dent Pulling with Pro Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

6.9.5 Paintless Dent Pulling With Pro Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

5.6 Wheel House Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.7 X-Adapter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.7.1 Attaching the X-Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

5.7.2 Using the X-Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

5.7.3 X-Adapter Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

7 Troubleshooting

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

KEEP OUT OF REACH OF CHILDREN

DANGER/POISON

SPARKS

FLAMES

SMOKING

FLUSH EYES

IMMEDIATELY

WITH WATER.

SULFURIC

ACID

CAN

CAUSE

BLINDNESS OR

SEVERE BURNS.

GET

MEDICAL

HELP FAST.

SHIELD

EYES.

EXPLOSIVE

GASES CAN

CAUSE BLINDNESS

OR INJURY.

OPEN CIRCUIT VOLTAGE AS IT RELATES TO STATE OF CHARGE

Open Circuit Voltage*

State of Charge

12.80 or greater.............................100%

12.60..................................75%

12.30..................................50%

12.00..................................25%

12.00....................................0

* The actual stabilized OCV can only be determined after the

battery has been disconnected from the charger for 24 hours.

Battery Warnings

Hybrid Spot

Summary of Contents for Hybrid Spot

Page 1: ...Hybrid Spot Battery Powered Resistance Spot Welder All Info Copyright Pro Spot International Inc Instruction Manual Version 1 7 ...

Page 2: ...ng familiar with your welder 13 4 2 3 Control Panel 14 4 2 4 Indications on the Control Panel 14 4 3 Turning on the welder 14 4 3 1 Checking Charging battery voltage 15 4 3 2 Battery Alerts 15 4 3 3 Removing Battery Covers for Service 16 4 3 4 Checking Battery Water Levels 16 4 4 Choosing the weld mode 17 4 5 Setting the pneumatic air pressure 17 4 6 Setting Changing the weld program 17 4 7 Settin...

Page 3: ... 6 9 2 Pro Pull Component Diagram 33 6 9 3 Pro Pull Assembly 34 6 9 4 Dent Pulling with Pro Pull 34 6 9 5 Paintless Dent Pulling With Pro Pull 34 5 6 Wheel House Arm 24 5 7 X Adapter optional 25 5 7 1 Attaching the X Adapter 25 5 7 2 Using the X Adapter 26 5 7 3 X Adapter Configurations 26 7 Troubleshooting Troubleshooting 35 KEEP OUT OF REACH OF CHILDREN DANGER POISON NO SPARKS FLAMES SMOKING FLU...

Page 4: ...ower switch on the front panel ON Fig 1 1 2 Connect Air to the air inlet located on the back panel 5 Place the welding gun at the weld area and press the lower trigger button to weld The upper weld button is for spreading the electrodes open for better access The welder is now ready to operate Make sure air pressure is set at 90 PSI NOTE When the welder is not being used turn the power switch off ...

Page 5: ...glect to do this as improper handling may result in personal injury and damage to the equipment The drawings in this manual are presented for illustra tive purposes only and do not necessarily show the design of the equipment available on the market at any given time The equipment is intended for use in accor dance with current trade practice and appropriate safety regulations The equipment illust...

Page 6: ...y precautions users of the Hybrid Spot Spot welder will ensure safer working conditions for themselves and their fellow workers The following types of safety signs are used on the equipment and in Pro Spot s instruction manuals Prohibited Prohibits behaviour that can cause injury Caution Read instruction manual Command Calls for a specific action Warning Notice of personal injury risk and or damag...

Page 7: ...damage to the welder could start a fire Risk for injuries while cooling is activated ATTENTION Ne pas faire fonctionner le soudeur près de l eau en voie humide ou à l éxterieur Risque de blessures ou de dommages au soudeur ATTENTION Ne placez pas le soudeur sur un sol instable ou irrégulière Le soudeur peut basculer causant des lésions corporelles ou des dommages graves au soudeur ATTENTION Toutes...

Page 8: ...ater Get medical help fast IF SWALLOWED Drink as much water or milk as possible Get medical help fast IF SPILLED Spread baking SODA over spill then dilute with large amounts of water KEEP OUT OF REACH OF CHILDREN Do Not Tip Keep Vent Caps Tight And Level PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California...

Page 9: ...kaging material from the welder For your convenience the welder ships fully assembled Insert the support arm boom as shown in Figure 3 1 Figure 3 1 IMPORTANT It is the responsibility of the owner to ensure that the equipment has been installed as specified in the instructions pro vided It is also the owner s responsibility to ensure that the welder is inspected in accordance with applicable regula...

Page 10: ...chase 4 31P batteries at 1000A that have pole style car battery terminals Remove the 7 screws on both side panels and then remove the panels Preferred Recommended batteries Centennial Commercial C 31 10AP CCA1100 Other Recommended batteries Deka 31P P 1231PMF CCA1000 RES 185 REF 1190 The rear lower battery has to be installed form the opening in the back of the welder Place the leads red on positi...

Page 11: ...r doit être propre sans huile et humidité Utilisez un filtre Battery charging system The Hybrid Spot welder is equipped with an on board charging system that will charge all 4 batteries at once To activate charging simply plug in the power cord to the outlet on the back of the welder Fig 3 2 and the supply 120VAC or 240VAC for Europe Australia and China The power supply switches automatically betw...

Page 12: ... seems to be a common starting pressure As a rule increase pres sure with thicker metals but remember that too much pressure could decrease the resistance of the metal between the electrodes resulting in poor weld penetration CURRENT Another important aspect of a weld is the current applied through the work piece A weld is created when a large current is transferred through the lay ers of sheet me...

Page 13: ...air 100 PSI 7 BAR min Power Input Back Panel Tool board Cooling Fan 1 2 3 Single Sided ground cable Two Sided spot gun cable Single Sided Weld Gun cable Two Sided ground cable WELD CABLES CONFIGURATION 4 The name plate is at the rear of the welder unit The required voltage is indicated on the label Welding output is rated at 15V Page 11 4 2 2 Getting familiar with your welder 4 2 1 Welder Overview...

Page 14: ... on all four batteries 4 The weld toggle switch must be in position WELD to perform welding duties Start with 3 batteries ON BAT 1 2 3 switches ON and adjust the weld time to 260 300 If more power is required turn BAT 4 ON 5 Increase the WELD TIME knob if a longer weld time is needed NOTE An increased weld time will drain the batteries quicker Also always clean and sharpen weld electrodes to maint...

Page 15: ...e charging cycle After 10 hours of charging the voltage will be reduced to 13 8V to provide a float charge If the charger is left plugged in for more than 24 hours it will go into standby mode In this mode the charger will provide a topping voltage to the batteries every 4 days to ensure that the welder will always be ready for immediate use The welder may be left plugged in constantly this will n...

Page 16: ... cables are connected to the Two Sided Spot Gun and the other two are connected to the Single Sided Weld Gun For Two Sided welding use 3 to 4 batteries in the ON position For Single Sided welding use 1 battery in the ON position Using more than one battery for Single Sided welding will result in burn through due to excessive weld power Pneumatic air is used for forcing the spot gun to close and op...

Page 17: ... cables are connected to the Two Sided Spot Gun and the other two are connected to the Single Sided Weld Gun For Two Sided welding use 3 to 4 batteries in the ON position For Single Sided welding use 1 battery in the ON position Using more than one battery for Single Sided welding will result in burn through due to excessive weld power Pneumatic air is used for forcing the spot gun to close and op...

Page 18: ... test pieces and tear them apart using a Vise Vise Grip pliers Note the strength of the weld It is important to test the same materials that you would normally use for repair in a weld destructive testing procedure Expect to tear a hole around the weld nugget as the two metals are peeled apart IMPORTANT Use the same metal as you are welding 18 Hybrid Spot ...

Page 19: ... Gun Component Diagram Page 17 All Info Copyright Pro Spot International Inc F 44 Release Trigger Switch F 44 Weld Trigger Switch PS 103 CM 20mm Shank PS 302 C Arm PS 025 Welding Cap PS 1101 CM 60mm Shank PS 5203 Clamping Handle Weld Shaft Push this button to open electrodes wide Push this button to close electrodes and weld 5 1 2 Using the Double Acting Gun 5 1 1 PS 500 Component Diagram 5 1 PS 5...

Page 20: ...o fig 5 3 for details on what welding electrodes to use with each extension arm NOTE Extension arms marked optional are available from your local distributor or online at www prospot com 5 2 1 Switching to extension arms 5 2 Extension Arms PS 52 Wheelhouse Arm PS 305 508mm Extension Arm PS 306 optional PS 503 W optional PS 302 C Arm PS 403 optional C X Adapter REMARQUE bras d extension portant la ...

Page 21: ...g electrode configuration chart Figure 5 4 Welding electrode selection chart NOTE PS 025 Welding Caps can be purchased in packages of 15 from your local distributor or online at www prospot com A B C PS 302 PS 1101 CM PS 103 CM PS 52 5 8 PS 1101 CM PS 1133 5 8 PS 403 see Sec 5 7 3 see Sec 5 7 3 PS 305 PS 1101 CM PS 129 CM PS 503 W PS 1101 CM PS 128 CM A B C IMPORTANT En utilisant des électrodes de...

Page 22: ... doing so may result in weak substandard welds Figure 5 5 Electrode Alignment Use the set screws A B C to align the electrodes Ex to move electrode down loosen screw C and tighten screws A and B CORRECT WRONG IMPORTANT Toujours maintenir l alignement des électrodes appro priées Ne pas le faire peut conduire aux soudures faibles de qualité inférieure 22 Hybrid Spot ...

Page 23: ... 5 6a are specially designed to hold round objects without damaging or scarring them You can purchase a set from your local distributor or online at www prospot com IMPORTANT Do not attempt to remove the electrode by hitting it This could damage the electrode and the spot gun Removing Welding Caps To remove a welding cap 1 Hold piston electrode with a set of pliers or vise grips 2 Grip welding cap...

Page 24: ...ith a file and periodically replace weld ing caps as explained in Section 5 4 Removing Welding Electrodes WARNING The electrodes may be hot Use caution when handling them 5 6 Wheel House Arm 5 5 Welding Electrode Maintenance The wheel house adapter allows access to hard to reach areas such as the wheel house ATTENTION Les électrodes peuvent être chauds Soyez prudent lors de leur manipulation Fig 1...

Page 25: ... arm Insert the X Adapter onto the gun Tighten handle A Follow instructions in Sec 5 4 to remove piston electrode 3 2 1 5 7 1 Attaching the X Adapter 5 7 X Adapter optional A Insert the Tapered Electrode B into the Shaft C Apply air carefully to put pressure on the electrodes so that Tapered Electrode seats firmly in the shaft before tightening the Collar D set screw 4 C B D Tighten the Collar D s...

Page 26: ...ode Lower PS 412 Pivot Axle PS 406 Tapered Electrode PS 405 X Adapter PS 404 45 Electrode Upper PS 421 45 Electrode Lower PS 422 PS 024 Welding Cap 5 7 3 X Adapter Configurations 5 7 X Adapter optional cont Collar PS 407 Push the upper switch to open electrodes wide Push the lower switch to close electrodes and weld 5 7 2 Using the X Adapter 26 Hybrid Spot ...

Page 27: ...ossible to the weld location Do not attach the ground to the metal you re about to weld on When performing other weld tasks such as dent pulling etc the ground attachment location becomes less critical In the Single Sided weld mode the following weld procedures are available for the Hybrid Spot Page 25 All Info Copyright Pro Spot International Inc Figure 6 2 Single Sided applications ground plate ...

Page 28: ...eries in the ON position as the weld power will be too high Start with 1 battery in the ON position and the lowest weld time For dent pulling use 1 battery and the lowest time setting available If less power is needed try to separate the ground cable further away from the weld area to create more power resistance and or use the pointed spot hammer tip to spread out the heat zone 28 Hybrid Spot ...

Page 29: ...hreaded studs can be welded on in factory style This type of stud is alsocommon throughout the car body for attachments of interior tail lights door mold ings etc Studs are held in place during welding with magnetic adapter electrode 1 Select 1 2 Batteries in the ON position 2 Fit Single Sided gun with the magnetic stud adapter fig 6 12 3 Insert stud into the adapter fig 6 12 4 Prepare the surface...

Page 30: ...18 3 Prepare the dent surface area by removing paint and primer 4 Ground the working area refer to section 6 1 Single Sided Welding Overview 5 Position the spot hammer tip at the bottom of the dent and push the trigger to weld the electrode onto the metal 6 Pull out a dent then release by twisting the hammer 7 If needed reposition weld and pull again Figure 6 18 Tip The replaceable welding tip sho...

Page 31: ... do not usually come on the replacement parts Rivets are held in place during welding with magnetic adapter electrode 1 Select 1 Battery in the ON position minimum weld time 2 Select Rivet Welding Program by pressing the Left or Right Navigation Buttons 3 Choose weld power level by pressing the Next Program button repeatedly 4 Fit Single Sided gun with the magnetic rivet adapter fig 6 21 5 Insert ...

Page 32: ... as thick and strong as before Shrinking electrode also acts as a nut adapter refer to section 6 4 Nut Welding With this electrode you get two convenient tools in one 1 Select 2 Batteries in the ON position 2 Fit Single Sided gun with the contact shrinking electrode fig 6 27 3 Prepare the surface area by removing paint and primer 4 Ground the working area refer to section 6 1 Single Sided Welding ...

Page 33: ...the weld location NOTE Do not attach the ground to the metal you re about to weld on When performing other weld tasks such as dent pulling etc the ground attachment location becomes less critical Pro Pull can be fitted to most resistance spot welders or dent pullers Welder Adapters not included Pro Pull is a patented innovative tool for fast and accurate dent pulling It features paintless dent rem...

Page 34: ... distance E 3 Attach desired block plate A 4 Position the weld tip in the bottom of the dent weld then pull the handle F to initiate the pulling action Use the shortest weld TIME possible to prevent extensive weld marks D approx 0 7 17mm Aim position fire Pull dent with Auto Blocking Twist gun to release tip 6 9 4 Dent Pulling with Pro Pull 6 9 3 Pro Pull Assembly 1 2 3 Glue Adapter for Paintless ...

Page 35: ...e battery or charger to overheat 3 The display says Check Battery Water Levels This indicates that it is time to perform a battery water level check see section 4 3 4 This alert is triggered based on accumulative battery charge time It is extremely important to maintain correct water levels Failure to do so will result in failure of batteries and warranty is voided 4 Low weld power Batteries not c...

Page 36: ...Pro Spot International Inc 5932 Sea Otter Place Carlsbad CA 92010 Toll Free 877 PRO SPOT Fax 760 407 1414 E mail info prospot com Web www prospot com ...

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