PHS-101 HYBRID SPOT WELDER Instruction Manual Version 1.0 All Info Copyright © Pro Spot International Inc.
About Pro Spot Pro Spot International, Inc., based in Carlsbad, California, manufactures resistance spot welding equipment spe-cializing in applications for the collision repair industry. The company began in 1986. The company owns and manages an on site machine shop, research & development department, a fabrication facility and production lines for the various welders Pro Spot International exports its products worldwide, export sales are managed through our headquarter office.
Table of Contents 1.0 SAFETY INFORMATION 1.1 Safety & Environmental Specifications 1.2 General 1.3 Warnings & Important Notices 1.4 Safety Devices 1.4.1 Cooling 5 5 5 7 7 7 2.0 INTRODUCTION 8 3.0 INSTALLATION 10 QUICK START INSTRUCTIONS 3.1 General 3.2 Packaging & Delivery Inspection 3.3 Welder Assembly 3.4 Battery Installation 3.5 Connection of Pneumatic Air Supply 4.0 OPERATION 9 10 10 10 11 12 13 4.1 Before you begin Welding 4.2 About your Welder 4.2.
5.0 PS-500 Double-Acting Spot Gun 23 5.1 PS-500 Double Acting Spot Gun 23 5.1.1 PS-500 Component Diagram 5.1.2 Using the Double-Acting Gun 5.2 Extension Arms 24 5.2.1 Switching to Extension Arms 5.2.2 Extension Arms and Welding Electrodes 24 25 5.3 PS-500 Electrode Alignment 5.4 Removing Welding Electrodes 5.5 Welding Electrode Maintenance 5.6 Wheel House Arm 5.7 X-Adapter (optional) 26 27 28 28 29 5.7.1 Attaching the X-Adapter 5.7.2 Using the X-Adapter 5.7.
SAFETY 1.0 1.1 SAFETY & ENVIRONMENTAL SPECIFICATIONS The Hybrid Spot welder is designed for indoor use. The Hybrid Spot Welder is designed to operate from 10° C to 40° C. Do not operate the unit on a slope of more than 10°. 1.2 GENERAL The Hybrid Spot welder has been designed and is tested to meet strict safety requirements. Please read the following instruction carefully before operating the unit and refer to them as needed to ensure the continued safe operation of the welder.
SAFETY 1.0 The following warnings and important notices are used in the instruction manual: 6 WARNING! Do not operate or place the welder near water, in wet locations or outdoors. Risk for injuries or damage to the welder. 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. WARNING! Do not place the welder on unstable or uneven ground.
SAFETY 1.0 1.3 WARNINGS AND IMPORTANT NOTICES (cont’d.) SHIELD EYES EXPLOSIVE GASES Can cause blindness or injury. NO SPARKS, FLAMES OR SMOKING SULFURIC ACID Can cause blindness or severe burns. FLUSH EYES IMMEDIATELY With Water. 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.
2.0 INTRODUCTION Congratulations on acquiring your New Hybrid Spot Welder! Team Pro Spot looks forward to supporting you. You have a welder and support group that will increase your productivity. The integrated features, ease of use, speed and quality welds that your Hybrid Spot offers will become an important part of your business.
INTRODUCTION 2.0 Quick Start Instructions Set-up: 1. Connect compressed air no greater than 135 psi to the air inlet located on the back panel. 2. Adjust the regulator knob until the pressure gauge reads 90 psi. Turn Welder On/Off 1. To Turn On: Press Weld Control Button 2. To Turn Off: Unplug Welder, Press and Hold Weld Control Button Welding 1. Rotate the Weld Control button until the cursor points to Weld Time. 2. Press the Weld Control button then rotate it to adjust the Weld Time.
3.0 INSTALLATION 3.1 GENERAL The Hybrid Spot welder is inspected and tested prior to leaving the factory to guarantee consistent quality and the highest possible reliability. Follow the installation tips and operating instructions below to ensure user safety and proper welder performance. WARNING! Do not operate or place the welder near water, in wet locations or outdoors. Risk for injuries or damage to the welder.
INSTALLATION 3.0 3.4 BATTERY INSTALLATION Preferred Recommended Batteries - Centennial Commercial C-31-10AP CCA1100 Other Recommended Batteries - Deka 31P, P# - 1231PMF, CCA1000, RES 185, REF 1190 When you first receive your hybrid battery spot welder you will need to purchase 4 - Group 31 batteries at >=1000A that have pole style car battery terminals. Remove the 7 screws on both side panels and then remove the panels.
3.0 INSTALLATION 3.5 CONNECTION OF PNEUMATIC AIR SUPPLY The Hybrid Spot welder must be connected to a pneumatic air network. (100 PSI to 130 PSI) 1. Connect the welder to the air supply via the threaded input port at the rear of the welder using a standard connector. 2. If not already set, adjust the air pressure setting on the welder front panel to 90 PSI (4-5 bar) (refer to section 4.5 “Setting the pneumatic air pressure”). IMPORTANT! The air must be clean and free from oil and moisture. Use a filter.
OPERATION 4.0 4.1 BEFORE YOU BEGIN WELDING Before you begin welding, be sure to read and understand the following instructions. The Hybrid Spot is a Resistance Spot Welder that was designed for the collision repair industry. It duplicates the welding procedure used by the car manufacturers. It is important to understand the design and function of this welder before operating it.
4.0 OPERATION 4.2 ABOUT YOUR WELDER 4.2.1 Welder Overview & Technical Specifications The welder is supplied with four high performance 12V batteries. Input Voltage: 120VAC or 240VAC 1 Phase 10A Open circuit output voltage 15V max. Welding Amperage: 10,000A max Cable Length: 8’ (2.5m) standard Electrode Pressure: At 6 bars (90 PSI)-280 DaN (616 Lb) At 8 bars (116 PSI)-320 DaN (720 Lb) Cooling System: Air (2 fan), Compressed air The name plate is at the rear of the welder unit.
OPERATION 4.0 4.2.3 Hybrid Spot Control Panel Batt1 Batt2 Batt3 Batt4 12.40V 12.40V 12.40V 12.40V 1.5A 1.5A 1.5A 1.5A Turn Welder On/Off To Turn On : Press Weld Control Button READY To Turn Off : Unplug Welder Press + Hold Weld Control Button 4.3 TURNING ON THE WELDER To turn on the unit, press the weld control knob on the front panel (do not hold). The welder will run a short self diagnostic then display the HOME screen, when shows the weld time, weld power, and cooling status on the LCD.
4.0 OPERATION 4.4 CHOOSING THE WELD MODE The Hybrid Spot is a multi-functional resistance spot welder. It is equipped with a four weld cable system for your convenience. Two of the weld cables are connected to the Double-Sided Spot Gun and the other two are connected to the Single-Sided Spot Gun. The unit has 3 possible power settings in each mode: Low, Medium, and High.
OPERATION 4.0 Home Screen: The home screen displays the weld power, weld time, cooling status, and provides an entry point to the System Menu. To set the weld time: 1. Rotate the weld control button to move the cursor to the WELD TIME line on the LCD. 2. Press the Weld Control Button once to enter editing mode, then rotate the knob to adjust weld time in 5 millisecond increments. 3. Once the desired time is shown press the Weld Control Button once to save the setting and exit editing mode.
4.0 OPERATION 4.7.4 Alert Set-up In addition to providing diagnostic information, the built-in current sensor can be used to trigger low-current warnings to alert the operator that current may have been insufficient to form a weld. The Alert Setup menu brings up two sub-menus, Alert Thresholds and Alert Indicators, which allow the trigger levels and alert actions to be set independently. Note that alerts only apply to Double-Sided mode.
OPERATION 4.0 4.7.5 Advanced Set-up From this menu, selecting the Weld Timing option will allow the operator to adjust the following settings: 1. Squeeze Time: The time between the trigger press and the start of weld current to allow the pneumatic cylinder to reach full pressure. This setting only applies to Double-Sided mode. Single-Sided mode uses a fixed half-second delay between the trigger press and the weld. 2. Hold time: The time that the pneumatic gun remains closed after weld current has stopped.
4.0 OPERATION 4.8 CHECKING WELD QUALITY Peel Test To perform destructive weld testing: Make a weld on two test pieces and tear them apart using a Vise & Vise-Grip pliers. Note the strenth 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 weld nugget as the two metals are peeled apart. IMPORTANT: Use the same metal as you are welding. 20 All Info Copyright © Pro Spot International Inc.
OPERATION 4.0 4.9 Battery Maintenance 4.9.1 Checking the Battery Voltage 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 between 120VAC and 240VAC.
4.0 OPERATION 4.9.3 To remove side panel covers for service: NOTE: Remove all tools from tool boards on side & rear panels before proceeding. Fig. B Bolts (7) Rear Panel Removal: Start with rear toolboard panel removal, tap bottom Tool Board of toolboard with rubber mallet in an upward motion to loosen from slots (Fit. A). After toolbard is removed, remove two top screws in rear panel cover plate and loosen two bottom screws - remove panel. NOTE: do not remove battery cables to check water levels.
DOUBLE-SIDED WELDING 5.0 5.1 PS-500 DOUBLE-ACTING SPOT GUN The spot gun can be used to weld the following metals: • HSS Galvanized Steel, Mild Steel, Weld Bonding, Boron Steel. 5.1.1 PS-500 Component Diagram PS-302 C-Arm F-44 Release Trigger Switch F-44 Weld Trigger Switch Weld Shaft PS-103-CM 20mm Shank PS-025 Welding Cap PS-1101-CM 60mm Shank PS-5203 Clamping Handle Figure 5.1 PS-500 Spot Gun - Component Diagram 5.1.2 Using the Double-Acting Gun Push this button to open electrodes wide.
5.0 DOUBLE-SIDED WELDING 5.2 Extension Arms The Hybrid Spot comes with a variety of extension arms to accomodate any welding configuration. Please refer to 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. REMARQUE: bras d’extension portant la mention <> sont disponibles à partir de votre Distributeur régional ou en ligne à www.prospot.com Figure 5.
DOUBLE-SIDED WELDING 5.0 5.2.2 Extension Arms and Welding Electrodes Different extension arms require the use of different welding electrodes. Use charts in Fig. 5.3 and 5.4 to determine the correct combination of extension arms and welding electrodes. IMPORTANT! Using incorrect welding electrodes with extension arms may result in weak welds and/or damage to your welder.
5.0 DOUBLE-SIDED WELDING 5.3 PS-500 Electrode Alignment Use the set screws (A, B, C) to align the electrodes. Ex: to move electrode down, loosent screw (C) and tighten screws (A and B). Figure 5.5 Electrode Alignment CORRECT WRONG IMPORTANT! Always maintain proper electrode alignment. Not doing so may result in weak, substandard welds! IMPORTANT! Toujours maintenir l’alignement des électrodes appropriées.
DOUBLE-SIDED WELDING 5.0 5.4 REMOVING WELDING ELECTRODES Removing Extension Arm Electrode Figure 5.6a: Removing Piston Electrode The extension arm electrodes can be easily removed by lightly tapping them with a pin and hammer as shown in Fig. 5.6 To remove the piston electrode: 1. Grip piston electrode with a set of pliers or vise-grips (Fig. 5.6a) 2. Rock the pliers back and forth to loosen the electrode from the holder. 3. Remove the electrode NOTE: Vise-Grips shown in Fig. 5.
5.0 DOUBLE-SIDED WELDING 5.5 WELDING ELECTRODE MAINTENANCE To maintain structurally-sound welds it is important to keep your welding electrodes clear from build-up. It is also important to maintain a 6mm weld nugget diameter. Clean electrodes with a file and periodically replace welding caps as explained in Secion 5.4 “Removing Welding Electrodes”. Also Available: Pro Spot PLT-50/A Pneumatic Low Profile Dresser sharpens your dull tips without having to remove the arm (Fig.
DOUBLE-SIDED WELDING 5.0 5.7 X-ADAPTER (optional) C-TYPE GUN The advantage of the C-Type Spot Gun is that when making vertical pinch welds on quarter panels, rocker panels, door pillars, etc., the spot gun is positioned perpendicular to the work area. Easy to reach! Easy to use! X-TYPE GUN The X-type design is used on certain applications where the C-type can’t reach.
5.0 DOUBLE-SIDED WELDING 5.7.2 Using the X-Adapter Push the upper switch to open electrodes wide. Push the lower switch to close electrodes and weld. 5.7.3 X-Adapter Configurations X Adapter (PS-404) 90° Electrode - Upper (PS-411) PS-024 Welding Cap Collar (PS-407) 90°Electrode - Lower Pivot Axle (PS-412) (PS-406) Figure 5.7 90° Arm Set 30 45° Electrode - Upper (PS-421) Tapered Electrode (PS-405) 45°Electrode - Lower (PS-422) Figure 5.
SINGLE-SIDED WELDING 6.0 6.1 SINGLE-SIDED WELDING OVERVIEW (Not recommended for structural welding, for cosmetic only.) ground plate The Single-Sided Weld System allows the operator to carry out welding tasks using a Single-Sided Weld Gun. The Single-Sided weld procedure requires contact only from one side compared to two sides in Two-Sided welding. A ground plate must be connected to the panel to be welded for it to work (Fig. 6.1).
6.0 SINGLE-SIDED WELDING Single Sided Welding Reference: For single sided welding with the Hybrid Spot, it is important to not use too high of a power for the first time setting, otherwise the current will burn through the weld surface and leave a hole. As a general guideline for most single sided welds, start with Weld Power set to LOW and the weld time set to 120 mS. For dent pulling only, start with the lowest time setting available.
SINGLE-SIDED WELDING 6.0 6.2 SINGLE-SIDED SPOT WELDING Single-Sided spot welding is used where Two-Sided welding cannot be used. IMPORTANT: The Single-Sided spot welding is not permitted on supporting frameworks of a vehicle. It is only permitted for cosmetic purposes. IMPORTANT: Le soudage de Côté Unique par points n’est pas autorisée sur les cadres de soutien d’un véhicule. Il est seulement permis a des fins cosmétiques. Figure 6.9 1.
6.0 SINGLE-SIDED WELDING 6.4 Nut Welding Weld-on nuts are common throughout the car body for attachments of interior, tail lights, door moldings, etc. and are applied with ease using the Hybrid Spot. TIP: Different size nuts are available from your local Pro Spot distributor or on the web at: www.prospot.com Figure 6.15 ASTUCE: noix de diffèrentes tailles sont disponibles chez votre distributeur local Spot Pro ou sur le web à la boutique Pro Spot en ligne.
SINGLE-SIDED WELDING 6.0 6.6 MOULDING CLIP RIVET WELDING Figure 6.21 This function will weld on factory type clips for the window moulding. The clips that hold the moulding do not, usually, come on the replacement parts. Rivets are held in place during welding with magnetic adapter electrode. 1. Select Weld Power to Low (100ms) Recommendation: When welding Clip Rivets, move the ground cable as far away from the weld area as possible. 2.
6.0 SINGLE-SIDED WELDING 6.8 CONTACT SHRINKING Dent pullng with washers creates high spots in the metal. Until now, the common practice would have been to grind the surface, resulting in a lot of sheet metal thickness. With the Hybrid Spot, use the shrinking tip instead of a grinder to remove the high spots, leaving a smooth and clean surface that is every bit as thick and strong as before. Shrinking electrode also acts as a nut adapter (6.4 “Nut Welding”).
SINGLE-SIDED WELDING 6.0 6.9 PRO PULL DENT PULLING (Optional) e ll can b Pro Pu most to d e tt fi ers ot weld nce sp resista nt pullers. or de ters & Adap Welder luded. c in not Pro pull is a patented, innovative tool for fast and accurate dent pulling. It features paintless dent removal functionality (see sec. 6.3.5 “Paintless Dent Pulling with Pro Pull”). 6.9.
6.0 SINGLE-SIDED WELDING 6.9.3 Pro Pull Assembly C A D approx. 0.7”(17mm) F E 1. Attach the Weld Gun (D) to Weld Shaft (C). Secure Lock Bolt (G). 2. Slide weld shaft and gun to standard distance (E). 3. Attach desired block place (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. 6.9.
7.0 TROUBLESHOOTING This chart will assist you in resolving common problems you may encounter. These are not all the possible solutions. 1. The Display says “Low Voltage” on Batt 1 display line. This indicates that Battery 2’s voltage line reached the minimum safe operating voltage and has been disabled. The battery is not available for welding and is being charged automatically (if welder is plugged in). An alarm will sound when attempting to weld if “Low Voltage” alert is displayed.
NOTES 40 All Info Copyright © Pro Spot International Inc.
NOTES All Info Copyright © Pro Spot International Inc.
NOTES 42 All Info Copyright © Pro Spot International Inc.
NOTES All Info Copyright © Pro Spot International Inc.
Pro Spot International, Inc. 5932 Sea Otter Place Carlsbad, CA 92010 Toll Free: (877) PRO SPOT Phone: (760) 407-1414 Fax: (760) 407-1421 E-mail: info@prospot.com Web: www.prospot.com Copyright © Pro Spot International, Inc.
