Pro Spot Hybrid Series Quick start guide

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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. Warning for Battery End Stops Sticker
9. Battery Cable Labels
10. Tool Box Maintenance Sticker
11. Screws M6 & M5, Nylon Washers for Double Sided Gun
12. #3 S Screw Driver
13. Zip Ties
Tools & Supplies required for the Upgrade
1. Power Drill with #2 & #3 Phillips Head bits
2. #2 & #3 Hand Screw Drivers
3. ½ “ Socket with 5” Extension, 17mm Socket, 11/32 socket with a 6”
extension
4. Distilled Water, Flashlight & Small Funnel
5. Rubber Hammer
6. Small wire cutters

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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
If it is low then fill with water to the edge of the vent well. Do not fill more
than 1/8” (2mm) from the bottom of the vent well. See Figure B
Do not overfill Batteries!
Figure A
Figure B

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Step 2
Remove (7) M6 screws on each of the side panels using a
power drill with a #3 bit or a #3 hand screw driver. Remove
the side panels from the unit.
Step 3
Loosen the (4) Phillips head screws at the rear of the “Wrap
Around Handle” by using a #3 hand S driver provided with
the upgrade kit. Note: These screws are longer than the
other screws and have washers. Please save for reassembly
of the unit.
Step 4
Once the screws are loosened then you can remove them
using a power drill with a #3 bit and a 4” extension or a #3
hand screw driver.
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.
Remove all the tools from the black tool holder panels then
remove the black tool holder panels from the sides and the
rear by hitting the bottom of the panels and pulling the tabs
out of the slots that are in the side and rear panels.
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.

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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 all the
batteries using a ½ “socket with a 4-5” extension.
Step 7
Remove the wing nuts and remove the top battery hold
down bracket.
Step 8
Carefully detach the cables from the battery then remove
the top battery from the Hybrid Welder. Note: Keep the
battery as level as possible when removing.

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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” long. You will need to
position the wheel appropriately to access the screws.
Remove (2) screws on each side of the Rear panel.
Step 9
Remove the (2) M6 Screws from the back of the Rear Panel
that are connected to the shelf as shown.
Step 12
Remove the old rear panel by pulling it down and out.

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Step 15
Slide the top of the new Rear Panel between the “Wrap
Around Handle” and the Top Shelf then pull on the “Wrap
Around Handle” around 2-3” to allow the bottom of the new
Rear Panel to clear the heads of the (2) partially reinstall M6
screws. Once it is cleared then slide the Rear Panel onto the
screws. Do not tighten the M6 screws.
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. Apply sticker “
WARNING: DO NOT LET ACID…” to the battery end stops.
Note: Apply supplied labels to the battery cables if they
are not labeled. Detach the cables from the 3 bottom
batteries then remove the bottom three batteries and place
them on the ground.
Check the water levels on all four batteries (See Addendum
A). After the water levels have been checked then place the
batteries back into the unit. Secure the batteries with the
battery holder bracket and replace the battery end stops.
Note: Do not reconnect the batteries at this
time.
Step 14
Partially reinstall the (2) M6 screws

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Step 16
Reinstall (4) M6 Screws on the sides of the Rear Panel as
shown. (2 screws on each side)
Step 19
Install the new Rear Panel Cover as shown. Slide over the (2)
partially installed screws at the bottom of the Rear Panel.
Step 18
Install the (4) M6 Screws at the bottom sides of the Rear
Panel as shown using #3 bit with 4” long extension. You will
need to position the wheel appropriately to access the
screws. Install (2) screws on each side of the Rear panel.
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. Note: These screws
are longer than the other screws.

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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.
Assembly of the new Rear Panel is now complete.
Continue on with the Control Module assembly.
Step 21
Remove (2) M6 screws using #3 Phillips bit from the
double sided gun holder and remove the gun holder.
Note: Keep the nylon washers and M6 screws with the
gun holder. Remove (7) M5 screws from the top cover
using #2 Phillips bit and remove the top cover from the
unit.

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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
1. MAKE SURE THAT THE POSITIVE POWER CABLES ARE DISCONNECTED
FROM ALL THE BATTERIES BEFORE PROCEEDING
2. Disconnect contactor cable (J4) and the trigger cable (J1) from the CB101 PC Board
located on the front panel. Cut any zip ties that hold the contactor cable (J4) to the front
panel. See Figures 3 and 4 for locations.
Figure 3: Contactor cable location
Figure 4: Trigger cable location
J4
J1
B. Control Module Replacement Instructions