Pro Spot PHS-101 Instruction manual

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.
The company owns numerous patents for our ingenious application tools, machines, and procedures.
Pro Spot training and services
Pro Spot Distributors and Sub-Distributors are carefully selected and are well trained in the collision repair industry. We offer
technical and service education at our world wide training facilities at
regular intervals so your local distributor will always be up to date and
able to pass on the latest in spot welding technology to our customers.
Customer service is an important part of any investment and
our distributors and sub-distributors will be there to support your
technical and service needs. We have a great customer service record, we tend to keep it that way.
Pro Spot is certified by CASE and a member of the ICAR Industry Training Alliance
Contact Information
Pro Spot International, Inc. U.S.A.
www.prospot.com
5932 Sea Otter Pl.
Carlsbad, CA 92010
2
Phone: +1 760-407-1414
Toll free (US only): 877- PRO SPOT
Fax: 760-407-1421
E-Mail: info@prospot.com
All Info Copyright © Pro Spot International Inc.
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
4.2.1 Welder Overview & Technical Specifications
4.2.2 Getting Familiar with your Welder
4.2.3 Hybrid Spot Control Panel
4.3 Turning on the Welder
4.4 Choosing the Weld Mode
4.5 Setting the Pneumatic Air Pressure
4.6 User Interface
4.7 System Menu and Advanced Features
4.7.1 Battery Status
4.7.2 Last Weld Info
4.7.3 Weld Count
4.7.4 Alert Set-up
4.7.4.1 Alert Thresholds
4.7.4.2 Alert Indicators
4.7.5 Advanced Set-up
4.7.6 Battery Test
4.7.7 Restore Defaults
4.8 Checking Weld Quality
4.9 Checking Battery
13
14
14
14
15
15
16
16
16
17
17
17
17
18
18
18
19
19
19
20
21
4.9.1 Checking the Battery Voltage
4.9.2 Battery Alerts
21
21
4.9.3 To Remove Side Panel Covers for Service
4.9.4 Checking Battery Water Levels
22
22
All Info Copyright © Pro Spot International Inc.
3
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
5.7.3 X-Adapter Configurations
29
30
30
6.0 Single-Sided Welding
6.1 Single Sided Welding Overview
6.2 Single-Sided Spot Welding
6.3 Bolt Welding
6.4 Nut Welding
6.5 Dent Pulling with Spot Hammer
6.6 Moulding Clip Rivet Welding
6.7 Dent Pulling with Washers and Slide Hammer with Hook
6.8 Contact Shrinking
6.9 Pro Pull Dent Pulling (optional)
6.9.1 Selecting Pro Pull Weld Mode
6.9.2 Pro Pull Component Diagram
6.9.3 Pro Pull Assembly
6.9.4 Dent Pulling with Pro Pull
6.9.5 Paintless Dent Pulling with Pro Pull
4
23
23
31
31
33
33
34
34
35
35
36
37
37
37
38
38
38
7.0 Troubleshooting
39
Notes
40
All Info Copyright © Pro Spot International Inc.
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.
Information provided in this manual describes the suggested best working practices and should in no way
take precedence over individual responsibilities or local regulations.
The Hybrid Spot Welder is designed to comply with all applicable safety regulations for this type of equipment. During operation, it is always each individual’s responsibility to consider:
• Their own and other’s personal safety.
• The safety of the welder through correct use of the equipment in accordance with the descriptions and
instructions provided in this manual.
1.3 WARNINGS AND IMPORTANT NOTICES
The following types of safety signs are used on the equipment and in Pro Spot’s instruction manuals:
Caution.
Read Instruction Manual.
Attention!
Lire Mode d’Emploi.
Prohibited.
Prohibits behaviour that can cause
injury.
Interdit.
Interdit aux comportements qui peuvent
provoquer des blessures.
Command.
Calls for a specific action.
Commande.
Appelle a une action spécifique.
Warning.
Notice of personal injury risk and or
damage to equipment.
Avertissement.
Avis de risque de blessure personnelle et /
ou d’endommager l’équipement.
Warning.
Some parts of the welder may become hot
long after prolonged use.
Avertissement.
Certaines parties du soudeur peuvent devenir
chaudes aprés une utilisation prolongée.
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
DANGER/POISON
SHIELD
EYES.
EXPLOSIVE
GASES CAN
CAUSE BLINDNESS
OR INJURY.
FLUSH EYES
SULFURIC
IMMEDIATELY
ACID
WITH WATER.
CAN
NO
CAUSE
GET
SPARKS
MEDICAL
FLAMES BLINDNESS OR
SMOKING SEVERE BURNS.
HELP FAST.
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.)
KEEP OUT OF REACH OF CHILDREN
All Info Copyright © Pro Spot International Inc.
5
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. The welder
might tip causing personal injuries or
serious damage to the welder.
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.
WARNING! All electrical connections
must be made by a qualified electrician.
Risk for electrical shock.
ATTENTION! Toutes les connexions électriques
doivent être faites par un électricien qualifié.
Risque de choc électrique.
WARNING! Loose cables and hoses
present tripping risks. Risk for injuries.
ATTENTION! Câbles et tuyaux lâches présentent des
risques de déclenchement. Risque de blessures
WARNING! Make sure to use welding
goggles when spot welding. The sparks
might otherwise injure the eyes.
ATTENTION! Veuillez utiliser des lunettes de soudeur
sur place. Les étincelles pourraient autrement blesser
les yeux.
WARNING! Sparks from welding
could start a fire. Risk for injuries.
ATTENTION! Étincelles de soudure pourrait provoquer
une incendie. Risque de blessures.
WARNING! Risk for damage to materials
close to the weld, e.g to glass or textiles.
ATTENTION! Risque de dommages aux matériaux à
proximité de la soudure, par exemple verre ou textiles.
WARNING! For proper cooling efficiency,
never operate the welder without connecting
it to the compressed air source.
ATTENTION! Pour refroidissement efficace, ne jamais
soudeur sans attacher à la source d'air comprimé.
WARNING! All service and maintenance
must be carried out by Pro Spot service
personnel and service support. Risk for
electrical shock.
ATTENTION! Tout le service et l'entretien doivent être
effectués par personnel et soutien de service Pro
Spot. Risque de choc électrique.
WARNING! Unplug the welder from the
wall outlet before servicing, cleaning or
maintenance. Risk for electrical shock.
ATTENTION! Débranchez le soudeur de la prise
murale avant l'entretien, ou nettoyage. Risque de
choc électrique.
IMPORTANT! The welder may only be
used by qualified personnel. The user of
the welder must have knowledge of spot welding
and of alignment of collision-damaged vehicles.
IMPORTANT! Le soudeur peut seulement être utilisé
par personnel qualifié. L'utilisateur du soudeur doit
avoir une connaissance de soudage par points et
l'alignement des véhicules endommagés par collisions.
IMPORTANT! Do not turn off the welder
while cooling is activated!
IMPORTANT! N'éteignez pas le soudeur pendant que le
refroidissement est activé!
IMPORTANT! The air must be clean and
free from oil and moisture. Use filter.
IMPORTANT! L'air doit être propre et sans huile et
humidité. Utilisez un filtre
All Info Copyright © Pro Spot International Inc.
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.
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 to cause cancer and reproductive harm. Batteries also contain other chemicals known to the state of
California to cause cancer. Wash hands after handling.
Battery Warnings
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.
DANGER/POISON
SHIELD
EYES.
EXPLOSIVE
GASES CAN
CAUSE BLINDNESS
OR INJURY.
FLUSH EYES
SULFURIC
IMMEDIATELY
ACID
WITH WATER.
CAN
NO
CAUSE
GET
SPARKS
MEDICAL
FLAMES BLINDNESS OR
SMOKING SEVERE BURNS.
HELP FAST.
KEEP OUT OF REACH OF CHILDREN
1.4 SAFETY DEVICES
1.4.1 Cooling
When the Spot Gun is used continuously, the welding cables get hot. To prevent the welder from
malfunctioning due to overheating, activate the air cooling system. The air cooling system cools the
welding cables, cable ends and the spot gun.
In the Home Screen, rotate the Weld Control button to Cooling. Press the Weld Control button to turn
ON air cooling.Compressed air will flow through the weld
cables. It is not necessary to leave on at all times, but should be used when the weld cables are hot
to the touch.
For best results, let the welder rest when cables are too hot. Cooler weld cables result in better weld
performance.
All Info Copyright © Pro Spot International Inc.
7
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.
The following information will be needed when you call Pro Spot:
*MODEL TYPE: Hybrid Spot
*SERIAL NO:______________ (The serial number is located on the back of the unit)
For Parts or service contact your local distributor,
Local Number: ____________________________
or in the U.S. call toll free: 1-877 PRO SPOT or 1-760-407-1414
for a customer service representative.
Visit Pro Spot Online: my.prospot.com Email: info@prospot.com
NOTE: You can now order parts online at: prospot.com/store/
_________________________________________________________________________________________
The Hybrid Spot welder is used by body shops to
duplicate the welding procedure used by the car
manufacturers. Use of the equipment that is contrary
to the instructions in this manual can cause personal
injury and/or machine damage.
Pro Spot International, Inc. can in no way be held
responsible for intentional or unintentional damage,
and consequent unlimited loss of profit, loss of
income, loss of business opportunity, loss of use, etc.
that originates from incorrect use of this equipment
in its use in a manner not intended.
Warranty
Pro Spot International, Inc. offers a two-year
guarantee on the welder from the date of delivery.
This guarantee covers material defects and assumes
normal care and maintenance.
The guarantee assumes that:
• the equipment is correctly installed and inspected
• the equipment has not been altered or rebuilt without
approval from Pro Spot International, Inc.
• genuine Pro Spot International, Inc. spare parts are used to
make repairs.
• operation and maintenance has been carried out according
to the instructions in this manual.
All claims on warranty must verify that the fault has occurred
within the guarantee period, and that the unit has been used
within its operating range as stated in the specifications. All
claims must include the product type and serial number.
This data is stamped on the name plate.
8
NOTE: This instruction manual provides instructions
for installation, operation, maintenance and
troubleshooting.
__________________________________________
IMPORTANT! Read this manual carefully to become
familiar with the proper operation of the welder. Do
not neglect to do this as improper handling may result in
personal injury and damage to the equipment.
__________________________________________
IMPORTANT! Lisez ce Mode d’Emploi attentivement
afin de vous familiariser avec le bon fonctionnement
du soudeur. Ne négligez pas de le faire puisque une manvaise
manipulation peut conduire aux blessures et dommages à
l’équipement.
__________________________________________
The drawings in this manual are presented for illustrative 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 accordance with current trade practice and appropriate safety regulations. The equipment illustrated
in the manual may be changed without prior notice.
The contents in this publication can be changed
without prior notice.
This publication contains information that is protected by copyright laws. No part of this publication
may be reproduced, stored in a system for information
retrieval or be transmitted in any form, in any manner,
without Pro Spot International, Inc.’s written consent.
All Info Copyright © Pro Spot International Inc.
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. For double-sided welding,
adjust Weld Time to 260-300 and, for single-sided welding, adjust Weld Time to 120.
3. Press the Weld Control button to commit the change.
4. Repeat steps 1-3 to set your Weld Power. For double-sided welding, adjust Weld Power to Medium or
High and, for single-sided welding, adjust weld power to Low or Medium.
5. Place the welding gun at the weld area then press and hold the lower trigger to weld. Press the upper
trigger to spread the electrodes open for better access.
Charging
1. Plug the power cord in to either 120VAC or 240VAC single phase power to initiate the charge cycle.
If the power cord is already plugged in, the charge cycle will begin after a minute of no welding.
2. Unplug the power cord or weld to interrupt the charge cycle.
System Display.
Shows battery voltage and charge current.
WELD TIME:
180 mS
WELD POWER: LOW
COOLING:
OFF
System Menu
Air Pressure
Weld Control
Button
Air Pressure
Regulator
Turn Welder On/Off
To Turn On : Press Weld
Control Button
READY
To Turn Off : Unplug
Welder Press + Hold
Weld Control Button
All Info Copyright © Pro Spot International Inc.
9
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.
ATTENTION! Ne pas faire fonctionner le soudeur
prés de l’eau, en voie humide ou à l’extérieur.
Risque de blessures ou de dommages au
soudeur.
WARNING! Do not place the welder on unstable
or uneven ground. The welder might fall causing
personal injuries and damage to the welder. Do
not operate on a slope of more than 10°.
ATTENTION! Ne placez pas le soudeur sur un sol
instable ou irréguiliére. Le soudeur peut tomber
causant des dommages graves au soudeur. Ne
pas utiliser sur une pente de plus de 10°.
IMPORTANT! It is the responsibility of the owner
to ensure that the equipment has been installed
as specified in the instructions provided. It is also
the owner’s responsibility to ensure that the
welder is inspected in accordance with
applicable regulations before it is put into
service. Do not use for thawing out frozen water
pipes (17.1).
IMPORTANT! C’est la responsabilité du propriétaire de s’assurer que l’équipment a été installé
comme specifie dans les instructions fournies.
C’est aussi la responsabilité du proprietaire de
s’assurer que le soudeur est inspecté conforment
à la réglementation applicable avant qu’il ne soit
mise en service. Ne pas utiliser pour dégeler les
conduites d’eau congelées (17.1).
A grounded electrical plug must be installed (refer to section 3.4 “ Connection of electrical supply”).
3.2 PACKAGING AND DELIVERY INSPECTION
Check the contents of the shipping container against the packing list, consignment note, or other
delivery documentation to verify that everything is included and in the correct quantity. Check the
Spot Welder carefully to make sure that no damage has occurred during transport. If anything is
damaged or missing, the welder may be unsafe to use until the part is repaired or replaced. If anything is
missing, please contact your supplier. Remove all packaging material from the welder.
3.3 WELDER ASSEMBLY
Insert the support arm (boom) as shown in Figure 3.1
Figure 3.1
10
All Info Copyright © Pro Spot International Inc.
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.
Insert batteries from the left
side, be sure to check the
labels (circled in the image)
and set the battery poles
facing the correct direction:
Negative on RIGHT, Positive
on LEFT.
The rear lower battery has to
be installed from the opening
in the back of the welder.
Place the leads (red on positive and
black on negative) on the battery
terminals and tighten with a 1/2”
socket. Do not over tighten.
All Info Copyright © Pro Spot International Inc.
11
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.
IMPORTANT! L’air doit être propre sans huile et humidité, Utilisez un filtre.
Air supply port
Figure 3.2
12
All Info Copyright © Pro Spot International Inc.
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.
ELECTRICITY ONLY: The welder uses only electricity to create the welds unlike the MIG welder which uses
an arc from a feeding wire to build a weld nugget using inert gas and the feeding wire material.
PRESSURE: The welder has a built in air cylinder that compresses the Double-Sided Gun’s welding tips
together automatically when triggered. The compression is an important part of a good resistance weld.
The pressure is adjustable from the Control Panel. The optimum welding pressure varies between
60 - 90 PSI (4-6.5 BAR). 90 PSI seems to be a common starting pressure. As a rule, increase pressure with
thicker metals but remember that too much pressure could decrease the resistance of the metal
between 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 layers of sheet metal. The resistance in the
metal causes the area to heat up and fuse the sheets together into a nugget.
WELD PROGRAM: Maintaining the air pressure after the current shuts off allows the weld to cool down
under pressure resulting in a harder, stronger weld. This feature is built in to the welder’s weld control
program and is engaged automatically during a weld cycle.
TIME: The Timer controls the duration of the current applied during the weld cycle. The idea is to get a
weld that uses higher current and shorter time to control heat buildup.
WELD CYCLE CHART
welder
All Info Copyright © Pro Spot International Inc.
13
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. The required voltage is
indicated on the label. Welding
output is rated at 15V.
(weld gun and weld cables)
Shipping Weight (standard): 515lb (234kg) - 4 Batteries 240lb (112kg)
4.2.2 Getting Familiar with your welder
Double-Sided
Gun Holder
Tool Box
Single-Sided
Gun Holder
Air Pressure
Guage
Air Pressure
Regulator
Weld
Control
Button
Cooling Fans
Cable Hook Bracket
Fuses
Power
Input
Tool Tray
Connect
Filtered
Air 100 PSI
7 BAR (min)
1 3
2 4
WELD CABLES CONFIGURATION
1. Two-Sided Spot Gun Cable 3. Single-Sided Weld Gun Cable
2. Two-Sided Ground Cable 4. Single-Sided Ground Cable
14
All Info Copyright © Pro Spot International Inc.
Back Panel
Tool Board
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. When the LED next to the Weld Control Button lights up green, the unit is ready to weld.
IMPORTANT! Make sure to read the instruction manual before operating the welder. Only trained
personnel should use this welder.
IMPORTANT! Assurez-vous de lire le Mode d’Emploi avant d’opérer le soudeur. Seul le personnel
qualifié devrait utiliser ce soudeur.
All Info Copyright © Pro Spot International Inc.
15
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. These settings will select
the number of batteries used to produce the weld, as shown in the table below:
Weld Power
Number of Batteries
Double-Sided
Single-Sided
Low
2
1
Medium
3
2
High
4
3
No action is necessary to switch between Single and Double-Sided modes. Simply push the trigger on
the gun you want to use, and the welder will automatically select the right number of batteries. Note
that in Single-Sided mode, the “Low” power setting should be used for most applications, otherwise
excessive heating and burn-through can result.
When fewer than 4 batteries are used for a weld, the PHS-101 uses battery management software to
determine which batteries have the highest remaining charge so that the strongest possible weld is
delivered every time. This balancing software also ensures that the batteries are used evenly, so that no
single battery wears down faster than the others.
4.5 SETTING THE PNEUMATIC AIR PRESSURE
Pneumatic air is used for:
- forcing the spot gun to close and open
- cooling the welding cables that are connected to the spot gun.
The air pressure is regulated with the air regulator, and the set pressure is indicated on the pressure
gauge. Default pressure is 90 PSI.
Change the air pressure as follows:
1. Unlock the pressure regulator by pulling on the adjustor knob till it snaps into the unlocked position.
2. Turn the pressure regulator knob clockwise to increase or counter-clockwise to decrease the air
pressure.
3. Lock the pressure regulator by pushing the knob into the lock position.
4.6 USER INTERFACE
The PHS-101 uses a Weld Control Button to scroll through menu options on the LCD and to change
settings. Rotating the Weld Control Button back and forth will move the cursor up and down on the
LCD. To use the selected menu option, press the Weld Control Button once (do not hold). If the chosen
selection is a numeric setting, the will change appearance to a dark cursor on a light background,
indicating that the editing mode is active. Once in this mode, rotate the button until the desired setting
is shown, then press the button one more time to save the value and leave editing mode.
16
All Info Copyright © Pro Spot International Inc.
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.
To set the weld power, move the
procedure as shown above.
cursor to the WELD POWER line of the LCD, then use the same
To turn cooling on or off, move the cursor to the COOLING line of the LCD, then press the Weld
Control Button to toggle the setting.
4.7 SYSTEM MENU AND ADVANCED FEATURES
By clicking on the “System Menu” option at the bottom of the Home screen, the user can access all of
the more advanced features and settings available on the PHS-101. These features include diagnostics,
operator alerts, and fine-tuning parameters that allow the user to customize the welder to best fit their
application.
4.7.1 Battery Status
-
Selecting this menu option will display the voltage and charging current for all 4 batteries. If the
chargers are unplugged, the charge current will show 0. Pressing the Weld Control Button again will
return the user to the Home screen.
4.7.2 Last Weld Info
The PHS-101 has an integrated current sensor that monitors the true weld current and stores the results
of the last weld for diagnostic purposes. Selecting Last Weld Info will display the recorded voltage and
weld current for the last weld. Pressing the Weld Control Button again will return the user to the Home
screen.
4.7.3 Weld Count
Selecting this menu option will display the total number of welds (both Double and Single-Sided) that
have been performed on the welder. This is similar to an odometer in that it cannot be reset, even by
disconnecting the batteries from the unit. Pressing the Weld Control Button again will return the user
to the Home screen.
All Info Copyright © Pro Spot International Inc.
17
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. Single-Sided welding is heavily affected by the surfaces being welded and the placement of the
ground electrode, making visual inspection more effective than current monitoring in this mode.
4.7.4.1 Alert Thresholds
In this menu the user can set low-current warning levels for each of the 3 power levels. If the
weld current drops below the set threshold for a specific power level, the welder will take the
action(s) specified in the Alert Indicators Menu.
4.7.4.2 Alert Indicators
If the welder detects a low current condition based on the thresholds mentioned above, it will
respond based on the following settings:
Show Feedback
This setting controls the display of weld results on the LCD. Pushing the weld control knob
multiple times will cycle through the following options:
1. OFF: Weld results are never shown after a weld, and alerts are disabled. Audible Alert and
Weld Cutoff menu options will be hidden.
2. ERR: Results will only be shown if a low current condition is detected.
3. ALL: Results will be shown after all Double-Sided welds, regardless of measured current.
Audible Alert
When this option is set, an alarm will sound when a low current condition is detected.
Weld Cutoff
When selected, this option will prevent further welds after a low current condition until the
operator presses the weld control knob, returning the unit to the Home screen. The Ready LED
will also flash amber during this time. If this option is disabled and the Show Feedback option is
set to ERR or ALL, the weld results will be displayed during the cooldown period, reverting
automatically to the Home screen when the Ready LED is lit.
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All Info Copyright © Pro Spot International Inc.
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. This
setting only applies to Double-Sided mode. In Single-Sided mode, the operator should maintain
pressure on the weld for at about ¼ second after the weld ends to ensure adhesion.
3. Cool Time: The delay between welds to allow the weld cables and gun to cool. The Ready LED will
go dark until the cool time has passed, and then illuminate green again.
These settings have all been optimized at the factory for best welder performance, so they should only
be adjusted if required by a specific application.
4.7.6 Battery Test
Selecting this function will run a series of tests to determine the health of the batteries. As a safety
feature, the unit will prompt the operator to pull the Double-Sided trigger before the test starts. Make
sure that hands and clothing are clear of the weld tips before proceeding. Do not place any metal
between the tips, otherwise the test results will be inaccurate.
Once the trigger is pushed, the tips will close and the unit will fire 4 welds in a row, one for each battery.
When the test is complete, the tips will open automatically and the unit will display the results for
battery 1 on the screen. The weld control knob can be used to scroll back and forth to show results for
the other three batteries. For a healthy, fully charged battery the measured current should be ≥ 2.8kA
and the measured voltage should be ≥ 2.70V. If these criteria are not met, the battery may be worn out
or may have too high of an internal resistance to use in the PHS-101.
4.7.7 Restore Defaults
To return all welder settings to factory defaults, use this menu option. The unit will prompt the operator
before continuing to avoid unintentional loss of custom settings. This function does not clear the weld
counter or the current sensor calibration data.
All Info Copyright © Pro Spot International Inc.
19
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. The charger cooling fans on the back of the unit will turn on automatically
when any charger is delivering more than 5 Amps to a battery, and will turn off when no charger is
delivering more than 4 Amps. This may happen several times during a single charging cycle.
It is possible to weld while the charging is activated; the charger will automatically switch off when
welding. The chargers will turn back on 1 minute after the last weld is made.
NOTE: While the welder is plugged in, it is not possible to turn the unit off using the Weld Control Button
on the front panel. To turn the welder off, first unplug the power cord. If the Weld Control Button was not
pressed during charging, the welder will turn off automatically a few seconds after power is removed.
Otherwise, press and hold the Weld Control Button as normal to turn the unit off.
The welder may be left plugged in constantly; this will not damage the batteries.
4.9.2 Battery Alerts
During the charge cycle or welder operation, the LCD may display status alerts to indicate when user
action is necessary to keep the batteries in good condition. These alerts are described below:
Batt1
Batt2
Batt3
Batt4
Low Battery
12.40V
0.0A
12.40V
0.0A
12.40V
0.0A
Fig. 2
Batt1
Batt2
Batt3
Batt4
12.40V
0.0A
SERVICE
12.40V
0.0A
12.40V
0.0A
Fig. 3
LOW VOLTAGE
This alert indicates that the battery has reached the maximum safe discharge level
and needs to be charged (Fig. 2). The welder will disable the depleted battery and
sound an audible alert if the operator tries to use this battery to weld. Any batteries
not showing this alert can still be used to weld. To clear this alert, plug in the
power cord and allow the batteries to charge. When any low battery is recharged
to at least 13.8V, the alert will clear automatically and welding can resume.
SERVICE
This alert indicates that the battery voltage has fallen below 11.5V and the battery
needs to be replaced (Fig.3).
All Info Copyright © Pro Spot International Inc.
21
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.
Tool Board
Side Panel
Fig. A
Rear Panel
Side Panel Removal:
Remove 7 bolts located on side panel (Fig. B). To
remove panel, pull away from welder and maneuver
downward to clear the handle on the welder.
Repeat for opposite side.
4.9.4 Checking Battery Water Levels (Always refer first to the battery manufacturers safety and Maintenance manual)
The charging process can result in a normal gradual depletion of the water levels in the welder batteries.
It is very important to keep the distilled water level within specification. Do not let the water level go too
low, this will reduce battery life and could destroy the battery. When the cell inside the battery have
been exposed to air, the cell is most likely damaged and cannot be recovered even if water is filled.
Check level every six months. To check water level, follow steps below.
Only slide
battery
halfway out.
Inspect 3 cells,
repeat on
other side.
DO NOT
REMOVE
BATTERY
CABLES
when
servicing
batteries.
To check water levels, remove side panel covers
from welder (reer to 4.3.2). Slide each battery out
one at a time approximately 6 inches from tray,
enough to expose 3 battery cells. Remove the three
cell caps that are accessible, check water level with
flashlight and fill if necessary. If low, fill with distilled
water to the edge of vent well. Do not fill more than
1/8” (2mm) from the bottom of the vent well.
Repeat steps to service remaining 3 cells.
WARNING: DO NOT LET ACID TOUCH SKIN OR EYES
Remove
L-Bracket
Only
NOTE: Only slide 1 battery out at a time.
Turn each fill-plug counter
clockwise and remove.
Do not fill more than
1/8” (2mm) above the
bottom of the vent
well. Overfilling will
cause battery failure.
1/8” (2mm)
DO NOT OVERFILL
22
All Info Copyright © Pro Spot International Inc.
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.
Push this button to close electrodes and weld.
All Info Copyright © Pro Spot International Inc.
23
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 <<facultatif>> sont disponibles à partir de votre
Distributeur régional ou en ligne à www.prospot.com
Figure 5.2 Hybrid Spot Extension Arms
PS-306
(optional)
PS-305
508mm Extension Arm
PS-52
Wheelhouse Arm
PS-302 C-Arm
PS-503-W
(optional)
PS-403 (optional)
C-X Adapter
5.2.1 Switching to extension arms
Loosen the handle and pull off the C-arm...
24
Now, insert the extension arm and tighten the handle.
All Info Copyright © Pro Spot International Inc.
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.
IMPORTANT! En utilisant de électrodes de soudage inexactes au bras d’extension peut donner des
soudures faibles et / ou endommager voltre soudeur.
A
A
B
C
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
Figure 5.3 Extension arm - Welding 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
REMARQUE: PS-025 caps de soudure peuvent être achetés en paquets de 15 à partir de votre distributeur
local ou en ligne à www.prospot.com
All Info Copyright © Pro Spot International Inc.
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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. Ne pas le faire peut conduire
aux aoudures faibles de qualité inférieure!
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All Info Copyright © Pro Spot International Inc.
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. 5.6a 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.
Figure 5.6b: Removing
Welding Cap
IMPORTANT! N’essayez pas de retirer l’électrode en la frappant. Cela pourrait
endommager l’electrode et le “pistolet”.
Rmoving Weld Caps
To remove a welding cap:
1. Hold piston electrode with a set of pliers or vise-grips.
2. Grip welding cap with another set of pliers or wedge side cutters between caps and
shank as shown in Fig. 5.6b
3. Twist the two to loosen and remove the welding cap.
NOTE: An optional welding electrode cap removal tool is available, which makes
cap removal easy (Fig. 5.6c). You can order the cap removal tool from your local
distributor or online at: www.prospot.com
Figure 5.6c: Optional Weld
Cap Removal Tool
NOTE: Une option d’un outil pour enlever le bouchon est disponible, Pour faciliter
le retrait du bouchon (Fig 5.6c) Vous pouvez commander cet outil de votre
distributeur local ou en ligne à l’adresse: www.prospot.com
Welding Cap
Piston Electrode
Extension Arm
Electrode
Figure 5.6 Removing Welding Electrodes
All Info Copyright © Pro Spot International Inc.
Pin
27
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. 1)
WARNING! The electrodes may be hot. Use caution when handling them.
ATTENTION! Les électrodes peuvent être chauds. Soyez prudent lors de
leur manipulation.
Fig. 1
5.6 WHEEL HOUSE ARM
The wheel house adapter allows access to hard to reach areas such as the wheel house.
PS-52-5/8:
Wheel House Arm
PS-1101-CM:
60mm Electrode Shank
28
PS-1133-5/8:
Electrode
All Info Copyright © Pro Spot International Inc.
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.
90% of all welding needs can be done with the C-type but for some radiator
radiator support and truck bed pinch welds, the X-Adapter works better. This new
invention makes it possible to weld where you never could before!
5.7.1 Attaching the X-Adapter
1
2
3
A
Loosen the handle and pull
out C-arm...
4
C
B
Follow instructions in Sec. 5.4
to remove piston electrode
Insert the X-Adapter onto the
gun.Tighten handle (A).
5
D
D
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.
Tighten the Collar (D) set screw.
IMPORTANT! Do not tighten the Collar before the inserting Tapered
Electrode into the shaft. The collar is designed to prevent the Tapered
Electrode from falling out of the Shaft when the gun is fully opened.
IMPORTANT! Ne serrez pas le collier avant de glisser l’ Électrode
Rétreci dans le tube. Le collier est conçu pour empêcher l’ Électrode
Rétreci de tomber du tube quand le pistolet est completement ouvert.
All Info Copyright © Pro Spot International Inc.
29
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 5.8 45° Arm Set
All Info Copyright © Pro Spot International Inc.
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).
You can also use an optional magnetic ground plate to easily attach the ground
cable to the metal (Fig. 6.1b).
NOTE: Make sure the ground plate is clamped firmly in place on the inside
of a clean metal surface as near as possible 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.
Figure 6.1
REMARQUE: Assurez-vous que la plaque de terre est serré solidement en
place a l’intérieur d’une surface métallique propre aussi prés que possible
du leu du soudure. Ne fixez pas le terre et le métal que vous êtes sur le point
de soudure. En accomplissant d’autres tâches comme la soudure dent de
traction, etc, le lieu de saisie devient moins critique.
Figure 6.1b
In the Single-Sided weld mode the following weld procedures are available for the
Hybrid Spot:
Single-Sided Welding (cosmetic repair only)
Washer Welding
Nail Welding
Contact Shrinking
Bolt and Nut Welding
Rivet Welding
Spot Hammer Dent Pulling
Pro Pull Dent Removal
Figure 6.2 Single-Sided applications
All Info Copyright © Pro Spot International Inc.
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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. If less power is needed,
try to seperate 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.
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All Info Copyright © Pro Spot International Inc.
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. Select Weld Power to Low (Medium use 250ms, Avoid using too much pressure
or you will punch through the hood)
2. Fit the Single-Sided Gun with Single-Sided electrode (Fit. 6.9).
3. Grind between the inner and outer body sheets to remove paint, primer and
rust. This ensures good electrical contact when performing Single-Sided welding.
4. Ground the working area (refer to section 6.1 “Single-Sided Welding Overview”).
5. Apply about 33-44 lbs of pressure on the Single-Sided gun and push the tirgger
to weld. Reposition and weld again.
NOTE: Make sure that Single-Sided electrode is clean. If it isn’t, use a file
or tip dresser to clean it. If the weld cap shows considerable wear, it should
be replaced (refer to section 5.4 “Removing Welding Electrodes”).
REMARQUE: Assurez-vous que l’électrode Côté Unique est propre. Si ce
n’est pas, utilisez une lime pour le nettoyer. Si le bouchon de soudure est
considerablement usé, il devrait être remplace (voir la section 5.4
“Enlévement d’Electrodes de soudage”).
6.3 BOLT WELDING
Many of today’s car bodies come with factory equipped threaded studs. After a
collision, the studs may be lost or do not accompany the replacement part. With
the Hybrid Spot, threaded studs can be welded-on in factory style. This type of
stud is also common throughout the car body for attachments of interior, tail lights,
door moldings, etc.
Figure 6.12
TIP: A threaded stud can also be used to fasten the ground clamp directly
to the panel, minimizing the area needed for grinding.
Astuce: Un goujon fileté peut également être utilisé pour fixer la pince
directement sur le panneau, ce qui réduit la surface nécessaire au broyage.
Studs are held in place during welding with magnetic adapter electrode.
1. Select Weld Power to Low (Wider Bolts use 200ms, Smaller Bolts use 120ms).
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 area by removing paint and primer.
5. Ground the work area (refer to section 6.1 “Single-Sided Welding Overview”)
6. Position Single-Sided gun over work area and push the trigger to weld.
7. Repeat as needed.
All Info Copyright © Pro Spot International Inc.
33
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.
Nuts are held in place during welding with a shrinking electrode.
1. Select Weld Power to Low (200-250ms)
2. Fit Single-Sided gun with the Shrink Electrode (Fig. 6.15).
3. Prepare the surface area by removing paint and primer.
4. Ground the working area (refer to section 6.1 “Single-Sided Welding Overview”).
5. Press weld-on nut to the metal with Contact Shrinking electrode, apply some
pressure and push the trigger to weld.
6. Repeat as needed.
6.5 DENT PULLING WITH SPOT HAMMER
Spot hammer dent pulling is used to repair dents on a vehicle body, The spot
hammer welds directly onto the work area and pulls the dent.
TIP: The replaceable welding tip should last for over one thousand welds.
Contact your local distributor to order replacement tips, or order online
at: www.prospot.com
ASTUCE: Le bout de soudage remplaçable devrait durer plus d’un millier
soudures. Contactez votre distributeur local pour commander pointes de
rechange, ou commandez sur la Web Pro Spot au magasin en ligne.
Figure 6.18
1. Select Weld Power to Low/Medium (100ms)
2. Fit Single-Sided gun with the spot hammer (Fig. 6.18).
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.
NOTE: Check spot hammer tip periodically to make sure it is in good working
order. If the tip looks worn, replace it with a new one.
NOTE: Contrôlez le bout marteau pèriodiquement pour s’assurer qu’il est en
bon ètat de marche. Si le bout semble usè, le remplacer par un nouveau.
34
All Info Copyright © Pro Spot International Inc.
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. 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 (Fit. 6.21).
5. Insert rivet into the adapter ( Fig. 6.21).
6. Prepare the surface area by removing paint and primer.
7. Ground the working area (refer to section 6.1 “Single-Sided Welding Overview”).
8. Position Single-Sided gun over work area and push the trigger to weld.
9. Repeat as needed.
6.7 DENT PULLING WITH WASHERS AND SLIDE HAMMER WITH HOOK
The slide hammer with hook (optional) can be used in conjunction with washers
to repair car body dents.
TIP: You can purchase a slide hammer with hook from your local Pro Spot
distributor or on the web at: www.prospot.com
Figure 6.24
ASTUCE: Vous pouvez acheter un marteau glissant avec crochet de votre
distributeur locale Pro Spot ou sur le web à la boutique Pro Spot en ligne.
Washers are held in place during welding with magnetic adapter electrode.
1. Select Weld Power to Low (175ms)
2. Fit Single-Sided gun with the magnetic washer adapter (Fig. 6.24).
3. Insert washer into the adapter (Fig. 6.24).
4. Prepare the dent surface area by removing paint and primer.
When welding on washers, you only need to clean the area where the washer
touches the metal since the grounding system is connected through a seperate
cable.
5. Gound the working area (refer to section 6.1 “Single-Sided Welding Overview”).
6. Position the washer at the bottom of the dent and push the trigger to weld the
washer onto the metal.
7. Hook the washer with the slide hammer and pull the dent out.
8. Repeat as needed.
TIP: You can, also, pull multiple washers by welding on a tow of washers at
the bottom of the dent, inserting a rod through the washers and pulling
the rod with the slide hammer with hook.
ASTUCE: Vous pouvez, ègalement, tirer plusieurs rondelles par soudage sur
une rangèe de rondelles au bas de la Dent, insertant une baguette par les
rondelles et en tirant la tige avec le marteau glissqnt avec crochet.
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35
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”). With this electrode you get two convenient tools in one.
Figure 6.27
36
1. Select Weld Power to Medium (150-200ms)
2. Fit Single-Sided gun with the contact shrinking electrode
3. Prepare the surface area by removing paint and primer.
4. Ground the working area (refer to section 6.1 “Single-Sided Welding Overview”).
5. Position the contact shrink electrode over the high spot, apply some pressure
and push the trigger to weld.
6. Repeat as needed.
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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”).
6.9.1 Selecting Pro Pull Weld Mode
Make sure the ground plate is clamped firmly in place on the inside of a
clean metal surface as near as possible to the wld location
NOTE: Do not attach the ground to the metal you’re about ot weld on.
When performing other weld tasks such as dent pulling, etc., the ground
attachment location becomes less critical.
Assurez-vous que la plaque de terre est serrè fermement en place à
l’intèrieur d’une surface propre de mètal le plus près que possible au ieu
de soudure.
NOTE: Ne fixez pas le terre et le mètal que vous êtes sur le point de soudre.
Lors de l’exècution d’autres tâches comme la soudure dent de traction, etc,
le terre du lieu de saisie devient moins critique.
6.9.2 Pro Pull Component Diagram
Pro Pull comes with three different
Blocking Plates with Quick-Connect design.
Block window size:
2.5"(63mm) x 1.5"(38mm)
PP-10-04
Retrofit point for different end adapters.
Available for most weld guns.
(not included) See prospot.com for more
information.
Large openings for
great visual control
of the pulling area.
Block window size:
1.75"(44mm) x 1"(25mm)
PP-10-03
CLT-55
Electrode
Block window size:
0.75" (19mm) dia.
PP-10-01
N-38
Nut
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CLP-75
Removable weld shaft.
The weld current is
transferred through the shaft
and NO CABLE is required
to transfer the current
37
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.
6.9.4 Dent Pulling with Pro Pull
1
2
Aim, position & fire!
3
Pull dent with Auto
Blocking.
6.9.5 Paintless Dent Pulling With Pro Pull
Glue Adapter for Paintless
Dent Removal
38
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Twist gun to release tip.
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. To clear “Low Voltage” alert
and continue welding with remaining batteries, turn off the switch (Batt 2 in this example) and welding can
continue. When Battery 2 reaches 13.8V it will be available to use again when the switch is turned on.
2. The display shows “SERVICE” on Batt 3 display line.
This alert indicates that the batter voltage has fallen below 11.5V and the batter needs to be replaced.
3. Low weld power & Batteries not charging; Fan is not on, but otherwise the welder
appears normal.
- Check power cable for voltage reading.
- Check small breakers on back panel, the breakers are resettable by pushing the breaker.
4. Single-Sided gun trigger does not work or seems intermittent.
The welder is programmed with 5 sec delay between welds to conserve power and prevent overheating.
5. The Double-Sided gun opens by itself and the LCD displaces “SHORTED CONTACTOR”
warning.
Under rare circumstances, one or more battery contactors may remain closed after a weld is completes. The
software will detect this condition and automatically retract the tips to prevent damage to the welder. If you
see this warning, take the following steps:
1. Turn the unit off by pressing and holding the weld control knob.
2. Disconnect air from the unit and remove the side panels of the welder as shown in section 3.4.
3. Visually inspect the contactors to see if any of them appear to be stuck closed. If any contactor
appears stuck, please contact Pro Spot technical support for further instructions. If no contactor is
stuck, simply turning the welder back on will clear the warning and allow welding to resume.
6. Double-Sided Spot Gun isn’t closing
Single-Sided trigger push or Single Sided Positive is touching ground cable.
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39
NOTES
40
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NOTES
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41
NOTES
42
All Info Copyright © Pro Spot International Inc.
NOTES
All Info Copyright © Pro Spot International Inc.
43
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. 2013