Pro Spot PHS-101, Instruction Manual

Page 1: ...All Info Copyright Pro Spot International Inc Instruction Manual Version 1 0 PHS 101 HYBRID SPOT WELDER ...

Page 2: ...U S A www prospot com 5932 Sea Otter Pl Carlsbad CA 92010 Phone 1 760 407 1414 Toll free US only 877 PRO SPOT Fax 760 407 1421 E Mail info prospot com Contact Information Pro Spot is certified by CASE and a member of the ICAR Industry Training Alliance Pro Spot International Inc based in Carlsbad California manufactures resistance spot welding equipment spe cializing in applications for the collis...

Page 3: ... 2 Getting Familiar with your Welder 14 4 2 3 Hybrid Spot Control Panel 15 4 3 Turning on the Welder 15 4 4 Choosing the Weld Mode 16 4 5 Setting the Pneumatic Air Pressure 16 4 6 User Interface 16 4 7 System Menu and Advanced Features 17 4 7 1 Battery Status 17 4 7 2 Last Weld Info 17 4 7 3 Weld Count 17 4 7 4 Alert Set up 18 4 7 4 1 Alert Thresholds 18 4 7 4 2 Alert Indicators 18 4 7 5 Advanced ...

Page 4: ...ing the X Adapter 30 5 7 3 X Adapter Configurations 30 6 0 Single Sided Welding 31 6 1 Single Sided Welding Overview 31 6 2 Single Sided Spot Welding 33 6 3 Bolt Welding 33 6 4 Nut Welding 34 6 5 Dent Pulling with Spot Hammer 34 6 6 Moulding Clip Rivet Welding 35 6 7 Dent Pulling with Washers and Slide Hammer with Hook 35 6 8 Contact Shrinking 36 6 9 Pro Pull Dent Pulling optional 37 6 9 1 Selecti...

Page 5: ...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 equip ment During operation it is alway...

Page 6: ...rious 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 ...

Page 7: ...H 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 t...

Page 8: ... 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 specific...

Page 9: ...ust 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 ...

Page 10: ...ing 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...

Page 11: ...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 ...

Page 12: ...sing 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 INSTALLATION 3 0 Air supply port Figure 3 2 All Info Copyright Pro Spo...

Page 13: ...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 th...

Page 14: ...5lb 234kg 4 Batteries 240lb 112kg 4 2 2 Getting Familiar with your welder OPERATION 4 0 Tool Tray Double Sided Gun Holder Weld Control Button Cooling Fans Cable Hook Bracket Air Pressure Regulator Air Pressure Guage Single Sided Gun Holder Tool Box 1 2 3 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 Fuses B...

Page 15: ...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 soudeu...

Page 16: ...G 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 s...

Page 17: ...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 Las...

Page 18: ... 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 o...

Page 19: ... 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 we...

Page 20: ...se 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 OPERATION 4 0 All Info Copyright Pro Spot International Inc 20 ...

Page 21: ...omatically 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 alert...

Page 22: ...ove battery cables to check water levels 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 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 Re...

Page 23: ...the Double Acting Gun Push this button to open electrodes wide Push this button to close electrodes and weld Figure 5 1 PS 500 Spot Gun Component Diagram 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 DOUBLE SIDED WELDING 5 0 All Info Copyright Pro Spot International Inc 23 ...

Page 24: ...t com REMARQUE bras d extension portant la mention facultatif sont disponibles à partir de votre Distributeur régional ou en ligne à www prospot com 5 2 1 Switching to extension arms DOUBLE SIDED WELDING 5 0 Figure 5 2 Hybrid Spot 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 Loosen the handle and pull off ...

Page 25: ...res faibles et ou endommager voltre soudeur 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 DOUBLE SIDED WELDING 5 0 Figure 5 3 Extension arm Welding electrode configuration chart Figure 5 4 Wel...

Page 26: ...NT Always maintain proper electrode alignment Not doing so may result in weak sub standard welds IMPORTANT Toujours maintenir l alignement des électrodes appropriées Ne pas le faire peut conduire aux aoudures faibles de qualité inférieure DOUBLE SIDED WELDING 5 0 Figure 5 5 Electrode Alignment CORRECT WRONG All Info Copyright Pro Spot International Inc 26 ...

Page 27: ...trode 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 or...

Page 28: ...lable 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 5 6 WHEEL HOUSE ARM The wheel house adapter allows access to hard to reach areas such as the wheel house DOUBLE SIDED WELDING 5 0 Fig...

Page 29: ...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 DOUBLE SIDED WELDING 5 0 Loosen the ha...

Page 30: ...trode Upper PS 411 90 Electrode 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 Collar PS 407 Push the upper switch to open electrodes wide Push the lower switch to close electrodes and weld All Info Copyright Pro Spot International Inc 30 ...

Page 31: ...bout to weld on When performing other weld tasks such as dent pulling etc the ground attachment location becomes less critical 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...

Page 32: ... 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 ham...

Page 33: ...st 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...

Page 34: ...nd 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 1 Select Weld Po...

Page 35: ...ospot com 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 b...

Page 36: ...Shrinking electrode also acts as a nut adapter 6 4 Nut Welding With this electrode you get two convenient tools in one 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...

Page 37: ...ieur 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 SINGLE SIDED WELDING 6 0 Pro Pull comes with three different Blocking Plates with Quick ...

Page 38: ...ld 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 6 9 5 Paintless Dent Pulling With Pro Pull SINGLE SIDED WELDING 6 0 A F C E D approx 0 7 17mm Aim position fire Pull dent with Auto Blocking Twist gun to release tip 1 2 3 Glue Adapter for Paintless Dent Removal All Info Copyright Pro Spot In...

Page 39: ...ck 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 cl...

Page 40: ...NOTES All Info Copyright Pro Spot International Inc 40 ...

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Page 42: ...NOTES All Info Copyright Pro Spot International Inc 42 ...

Page 43: ...NOTES All Info Copyright Pro Spot International Inc 43 ...

Page 44: ...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 ...