Subscribe to Our Youtube Channel
Related Manuals for Pro Spot Hybrid Series
Summary of Contents for Pro Spot Hybrid Series
- Page 2 Hybrid Welder Upgrade Kit Contents 1. Hybrid Welder Upgrade Instructions for Rear Panel & Control module replacement. 2. Instruction Manual Verizon 1.55 3. Control Module 4. Rear Panel 5. Rear Panel Cover 6. Positive & Negative Power Harnesses 7. Trigger Cable Adaptor 8.
- Page 3 Addendum A Procedure for checking the Water Level of the Batteries The best time to remove the batteries to check the water level is at Step 13 of the “A. Rear Panel Replacement Instructions”. Remove one of the cell caps & check the water levels by using a flashlight. See Figure A ...
- Page 4 A. Rear Panel Replacement Instructions The purpose of this procedure is to replace the old rear panel with a new rear panel which has a cutout to allow access to service the bottom rear battery. Step 1 Disconnect power and air from the back of the unit. Put the single and double sided guns and their cables on the floor.
- Page 5 Step 5 Remove the screw of one of the battery end stops on the top battery by using a #2 bit. Remove the battery end stop. Step 6 Loosen the positive and negative power bolts on batteries using a ½ “socket with a 4-5” extension. Step 7 Remove the wing nuts and remove the top battery hold down bracket.
- Page 6 Step 9 Remove the (2) M6 Screws from the back of the Rear Panel that are connected to the shelf as shown. Step 10 Remove the (4) M6 Screws from the sides of the Rear Panel as shown. (2 screws on each side) Step 11 Remove the (4) M6 Screws from the bottom sides of the Rear Panel as shown using #3 bit 4”...
- Page 7 Step 13 Do not skip this step since it will be more difficult to remove the batteries at a later time! Remove the wing nuts and remove the battery holder bracket for the bottom 3 batteries. Remove all the battery end stops for the bottom 3 batteries.
- Page 8 Step 16 Reinstall (4) M6 Screws on the sides of the Rear Panel as shown. (2 screws on each side) Step 17 Install (4) M6 Phillips head screws with washers at the rear of the “Wrap Around Handle”. Tighten by using the #3 hand S driver provided with the upgrade kit.
- Page 9 Step 20 Install (2) M6 screws in the middle of the Rear Panel Cover as shown using a #3 bit. Tighten the (2) M6 screws on the bottom of the Rear Panel Cover as shown using a #3 bit. Step 21 Remove (2) M6 screws using #3 Phillips bit from the double sided gun holder and remove the gun holder.
- Page 10 B. Control Module Replacement Instructions The purpose of this procedure is to replace the original battery charger with a microprocessor controlled system that controls the battery voltage and charging currents to ensure long battery life and minimum maintenance. Figure 1: Replacement Control Module Figure 2: Control Module rear view MAKE SURE THAT THE POSITIVE POWER CABLES ARE DISCONNECTED FROM ALL THE BATTERIES BEFORE PROCEEDING...
- Page 11 3. Disconnect charging connectors (Orange Arrows) and air lines (Blue Arrows) that run to the battery compartment. See figures 5 and 6. Note: When disconnecting the air lines, be sure to label each air hose to show the connection order when installing the replacement control module.
- Page 12 6. Push the control module forward and lift off. The unit should now look like Figure 10. Figure 10: Unit with control module removed 7. Some of the wiring in the battery compartment will need to be replaced. This is done to ensure the new charger monitors the batteries in the correct order.
- Page 13 On (C) positive charging harness (Figure 11), there are four red wires with large ring terminals marked 11, 12, 13, and 14. To connect these terminals, loosen the top nuts from all four contactors as shown below by using a 17mm socket. Remove a wire then replace it with the appropriately numbered wire according to Chart A below.
- Page 14 9. Remove the nut using 11/32 socket with a 6” extension in the center of the negative plate (shown by the green arrow in Figure 17) and remove all the attached wires. Connect 2 black wires 15 and 17 from (C) positive charging harness and the ring terminal of (D) negative charging harness (Figure 12).
- Page 15 14. Connect (C) Positive charging harness connector to the 9 pin connector that is in the control module as shown in Figure 19. Figure 19: Contactor cable location 15. Connect the original contactor cable that was disconnected from the front panel board (CB-101) in step 2 to socket J1 on (CB-103) Battery Charger Board located in the rear of...
- Page 16 17. Compare the wiring of the trigger cable connector (Figure 23) to the wiring of the male end of the included trigger cable adaptor (shown to the right in Figure 22). Figure 22: Trigger cable adaptor 18. If the wire color order is identical, the adaptor is not needed and the trigger cable should be re-connected to the CB-101 PC board located on...
- Page 17 As the weld occurs, a voltage drop of 2 or more volts should be observed on the readout for the selected battery. Repeat the above procedure until all the batteries have been tested. If welder does not operate as expected, contact Pro Spot technical support for assistance.
- Page 18 Assembly of the new Control Module is now complete. Please ship the old Control Module back to using the original box that the new control module was shipped in Pro Spot International 2625 Temple Heights Dr Oceanside CA 92056 The old Rear Panel can be discarded.
Need help?
Do you have a question about the Hybrid Series and is the answer not in the manual?
Questions and answers