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

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Figure 5: Charging Cables
Figure 6: Air connections
4. Using pliers, disconnect the two red
wires from the power resistor shown
in Figure 7. The resistor may be
mounted on control module base or
on the charging tray.
Figure 7: Power resistor
5. Loosen (A) (4) screws holding the control module two or three turns (see Figures 8 and 9
for locations). If necessary remove the back left screw labeled “B” completely to remove
the green ground wire.
Figure 8: Forward screw locations
Figure 9: Rear screw locations
J4
A
A
A
B
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.

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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. Locate the wiring
harnesses from the kit shown in Figures 11 and 12.
Figure 11: (C) Positive charging harness Figure 12: (D) Negative charging harness
C
D

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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. Do this until
all 4 wires are replaced with the new (C) positive charging harness wires.
Figure 13: Contactor 1 and 2 terminals Figure 14: Contactor 3 and 4 terminals
Once the old wires are replaced then
tighten the nuts with the 17mm
socket. Note: Double check that the
wires are correct by using Chart A
on the right.
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Wire 13 → Contactor 3
Wire 14 → Contactor 4
8. Remove the nut from the stud in the center of the copper plate shown in Figures 15 and
16 (Blue arrows) using 11/32 socket with a 6” extension. Remove the red wires
connected there and replace with the two remaining red wires on (C) the new positive
charging harness. Reinstall the nut.
Figure 15: Center stud location
Figure 16: Center stud (shown for clarity)
Wire 11 → Contactor 1
Wire 12 → Contactor 2
Wire 13 → Contactor 3
Wire 14 → Contactor 4
Chart A

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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). Re-
install the nut on the terminal post.
Figure 17: Negative terminal post location
10. Remove the old positive & negative charging harnesses that were disconnected in the
previous steps from the unit and mount the replacement control module (Figure 1) onto
top of the unit (See figure 10). To do this, lower the control module over the screws that
were loosened to remove the original module in step 6. Slide the replacement module
until it stops against the screws, then tighten (A) (See Figure 8) screws to secure the
module in place. Note: Make sure that the control module is flush with the back of
the unit. Connect green safety ground wire that is attached to the rear panel to the left
rear screw (B) (See Figure 9) by completely removing the screw & placing the ring
connector around the screw then tightening.
11. Locate the three battery compartment access holes at the front of the control module.
Pull all air hoses and electrical connectors from the battery compartment up through the
middle hole. See Figure 5 for reference.
12. Reconnect the air hoses in the same order as they were labeled in step 4. “A” to “A” then
“B” to “B” etc. See Figure 6 for reference.
13. Connect (D) negative charging
harness from the battery
compartment to the matching
connector with black wires in the
control module. Note: Secure 4-pin
charging connectors with zip ties
as shown in Figure 18.
Figure 18: 4-pin negative charging connector

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14. Connect (C) Positive charging
harness connector to the 9 pin
connector that is in the control
module as shown in Figure 19.
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
the control module as shown in
Figure 20 to the right. Note: Make
sure that this cable is routed
correctly to allow it to reach to the
rear of the control module.
Figure 19: Contactor cable location
Figure 20: Contactor cable location
Figure 21: Power resistor connection
16. Connect last red wire from the (C)
positive charging harness to the
power resistor using pliers. The
connection is shown by the blue
arrow in Figure 21. Note: Make
sure that this connection is secure.
It should pop into the
corresponding connector.
C

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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).
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
the front panel as shown in Figure
23.
Figure 22: Trigger cable adaptor
Figure 23: Trigger cable connection & wires
19. Important!!! Only complete
this step if the wiring between
the Trigger cable adaptor
(Figure 22) & the Trigger
cable connection & wires
(Figure 23) are not the same.
Connect the trigger cable adaptor
between the existing trigger cable
and socket J1 on the CB-101 PC
board which is located on the front
panel.

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Figure 24: Battery locations
Figure 25: Normal charging display
21. Once all batteries are charged to at least 14.0V, run test welds using the double sided gun (no metal
between the tips) with each battery (one at a time) to ensure that the welder is fully functional.
Procedure for the test welds are as follows:
a. Connect air & turn power switch on the front panel control to “ON”
b. Turn the Weld switch to “WELD”
c. Turn one of the battery switches to “ON” and other three battery switches to”OFF”.
d. Depress & hold the Weld Trigger Switch on the double sided gun.
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.
20. Reconnect battery cables by matching up the
labels on the cables to the appropriate battery
location. See Figure 24 for battery numbering
order on the negative cable side. Plug the Hybrid
Battery Welder into an AC outlet. The batteries
should start to charge. See Figure 25. The
voltage and current should be displayed. The
charging current is also displayed on the analog
meters.
Battery 2
Battery 1
Battery 3
Battery 1
Battery 1
Battery 4
Battery 1
Battery 1
Note: Batteries should begin charging at about 9 Amps.
As the battery approaches full charge the current to that
battery will start to reduce. IF THE VOLTAGE ON ANY
BATTERY EXCEEDS 15.5 VOLTS FOR AN EXTENDED
PERIOD OF TIME, UNPLUG WELDER AND CONSULT
FACTORY.

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22. Once operation is verified reassemble top cover. Open the tool tray lid on the top cover and apply
the new maintenance sticker with “LCD Display Alerts” shown on the top left corner over the old
sticker.
23. Attach the double sided gun holder using the nylon washers & screws.
24. Attach the side panels & tool holder panels. The welder upgrade is now complete. Note: Allow the
batteries to charge at least four hours before resuming welding.
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
to
Pro Spot International
2625 Temple Heights Dr
Oceanside CA 92056
The old Rear Panel can be discarded.