Pro Spot i4s User manual

Resistance
Spot Welder
Instruction Manual
MNL-i4s-v1.5

Pro Spot International specializes in quality welding and repair products for the collision repair indus-
try. Pro Spot owns three patents for special welding equipment and applications, and works with the
largest auto manufacturers in the world. Pro Spot is a proud ‘MADE IN THE USA’ manufacturer in
Carlsbad, CA. The turnkey facility includes Design, Engineering, Machine and Sheet Metal Shops,
Powder Coating, Assembly, Training and Customer Support. The Pro Spot equipment line includes
resistance spot welders, aluminum & steel dent repair systems, pulse MIG welders, rivet guns and
tools, dust-free sanding systems, fume extraction and more.
Pro Spot provides on-going training to all of our distribu-
tors and their technicians, therefore, all owners of Pro Spot
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approved. Pro Spot has a fully equipped training facility at
their Headquarters in Carlsbad, CA for groups to come in and
train on all products. To stay up-to-date, Pro Spot offers their
unique my.prospot.com which includes interactive training
courses for shops and technicians to access online.
Pro Spot is constantly striving to improve. Whether that
means designing innovative equipment, implementing cut-
ting edge technical support or further improving their already
extensive training programs, Pro Spot is always looking for
ways to better our customer’s experience.
Pro Spot International, Inc.
5932 Sea Otter Place
Carlsbad, CA 92010
7ROO)UHH3526327
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.prospot.com

my.prospot.com
Technical Support Training Documents
Pro Spot wants to personalize your experience.
Come to my.prospot.com and register today! Gain access to exclusive product demonstration
videos, training, important product documents, and more. My.prospot.com is a site just for
you with an easy to use interface that is custom tailored based on the products you own. This
means quicker troubleshooting solutions, with less hassle. My Pro Spot is constantly evolving
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sure to check it out.

Table Of Contents
i4s Quick Start Instructions............................................................................ 1
1.0 Introduction................................................................................................ 2
2.0 Safety.......................................................................................................... 3
2.1 Important Warnings................................................................................... 4
2.2 Cooling System ......................................................................................... 5
3.0 Installation.................................................................................................. 6
3.1 Packaging & Delivery Inspection............................................................. 6
3.2 Welder Assembly....................................................................................... 6
3.4 Connecting The Electrical Supply ........................................................... 7
3.5 Connecting the Air Supply ....................................................................... 7
4.0 Operation.................................................................................................... 8
4.1 Before You Begin Welding........................................................................ 8
4.2 About Your Welder .................................................................................... 9
4.3 Turning On The i4s .................................................................................. 10
4.4 How To Login ............................................................................................11
4.5 i4s Home Screen...................................................................................... 12
4.6 i4s General Settings Menus.................................................................... 13
4.7 Administration Settings Menus.............................................................. 18
5.0 Double Sided Welding Programs........................................................... 26
5.1 Double Sided Welding Menu Guide....................................................... 27
5.2 Auto Mode Calibration ............................................................................ 28
5.3 Double Sided Welding Manual Mode..................................................... 29
5.4 Manual Mode Welding Menu Guide ....................................................... 30
5.5 Manual Mode Welding: Dual Weld Settings .......................................... 32
5.6 Manual Mode Welding: Pulse Weld Settings ........................................ 33
5.7 Creating A Custom Weld......................................................................... 34
6.0 Single-Sided Welding.............................................................................. 36
6.1 Single-Sided Welding Menu Guide ........................................................ 37
7.0 i4s Weld Gun............................................................................................ 38
7.1 i4s On Gun Screen & Gun Controls....................................................... 39
7.2 Extension Arms ....................................................................................... 41
7.3 Electrode Components ........................................................................... 42
8.0 Electrode Alignment, Removal & Maintenance .................................... 43
8.1 Removing Welding Electrodes............................................................... 44
8.2 Welding Electrode Maintenance ............................................................ 45

1
i4s Quick Start Instructions
WARNING! Read this manual in its entirety before attempting to weld with the i4s. Before turning on the ma-
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!
A
Weld Gun Check
Login Navigation
How To Calibrate The i4s Spot
Welding Gun Start Welding
System Checks and Power On
1
3 4
5 6
2
Verify that the hoses are secure in place.
Select User Login.
The i4s touch screen is used to navigate
through menus and select options.
Enter the password and
select the green check
button.
Note: The default user
password is 1234
Verify the presence of air pressure.
Verify all 3-phase lights are illuminated.
Turn power
on.
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See Section 4.2.1 for more information.
A
A
A
A
B
B
C
i4s Quick Start Instructions
*CAUTION* DO NOT PUT MATERIAL BETWEEN ELECTRODES
DURING CALIBRATION
1. Press the calibrate button to enter calibration mode.
2. Press and hold the reverse button (top-left) on the gun.
3. Press and hold the weld trigger and the top right button
on the gun to calibrate.
1. Place the stackup between the weld caps and
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weld.
2. Press and hold the weld trigger and top right
button on the gun to weld.
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• Every arm change
• Every time Auto Mode is entered.
Weld Trigger
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B
Verify that the arm handle is tightened.
B

2
1.0 Introduction
With the i4s and its connected support system, you will experience a rapid increase in productivity. The integrated and
user friendly features, paired with superior speed and overall weld quality will quickly make the i4s a vital element of your
business.
Team Pro Spot looks forward to supporting you.
For videos on products, training and tips, visit our YouTube Channel: www.youtube.com/prospotinternational
To speak to a customer service representative visit www.prospot.com or e-mail us at [email protected].
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The following information will be needed when you call Pro Spot:
*MODEL TYPE: i4s
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Congratulations on your new Pro Spot i4s Spot Welder!
The i4s Spot Welder is used by body shops for the
purpose of duplicating weld procedures implemented by
vehicle manufacturers.
Pro Spot International, Inc. will not be held responsible in
any way for intentional or unintentional damage caused
by incorrect use of this equipment or using the equipment
for an unintended application.
Warranty
Pro Spot International, Inc. offers a limited two-year guar-
antee initiated on the date of delivery of the new welder.
This guarantee covers material defects and assumes
normal care and maintenance.
This guarantee assumes that:
• The equipment is correctly installed and inspected by a
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• The equipment has not been altered or rebuilt without
approval from Pro Spot International, Inc.
• Genuine Pro Spot International, Inc. parts and consum-
ables are used to make repairs.
• Preparation 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
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and serial number. This data is stamped on the name
plate.
Note: This instruction manual provides advice as well as
instructions for installation, operation, maintenance and
troubleshooting.
,03257$175HDGWKLVPDQXDOFDUHIXOO\WR
become familiar with the proper operation of
the welder. Do not neglect to do this as im-
proper handling may result in personal injury
and damage to the equipment.
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fonctionnement du soudeur. Ne négligez pas
de le faire puisque une mau-vaise manipula-
tion peut conduire aux blessures et dommag-
es à l’équipement.
This manual is to be used for illustrative purposes only. It
does not necessarily include the design of the equipment
available on the market at any given time. The equipment
is intended for use in accordance with current trade prac-
tice 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.
The information featured in this publication 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 way without Pro Spot International,
Inc.’s written consent.
Conformity with directives and standards: i4s complies
with CE standards.
CONTACT US
PRODUCT
WARRANTY & LIABILITY
INSTRUCTIONAL MANUAL
!
!
1.0 Introduction

3
2.0 Safety
The i4s Spot Welder is designed for indoor use - Protection Degree IP21S.The i4s Spot Welder is designed to oper-
ate from -10º C to 40º C. The unit may be stored and transported in an ambient temperature from -20º C to +55º C.
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The i4s Spot Welder has been designed and is tested to meet strict safety requirements. Please read the following
instructions carefully before operating the i4s 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 pre-
cedence over individual responsibilities or local regulations.
The i4s Spot Welder is designed to comply with all applicable safety regulations for this type of equipment. During
operation, it is the responsibility of each individual user to consider:
• The personal safety of themselves and others.
• The safety of the welder through the proper use of the equipment and in accordance with the descriptions and
instructions provided in this manual.
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themselves and others.
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General
2.1 Warnings & Important Notices
2.1 Warnings & Important Notices
The following types of safety signs are used on the equipment and in Pro Spot’s instruction manuals:
! !
! !
Caution.
Read instruction manual.
Prohibited.
Prohibits behavior that can
cause injury.
Command.
Calls for a specic action.
Warning.
Notice of personal injury risk
and or damage to equipment.
Warning.
Some parts of the welder may
become hot aer prolonged use.
Attention!
Lire Mode d’Emploi.
Interdit.
Interdit aux comportementsqui peu-
vent provoquer des blessures.
Commande.
Appelle à une action spécique.
Avertissement.
Avis de risque de blessure personnelle
et / ou d’endommager l’équipement.
Avertissement.
Certaines parties du soudeur peuvent
devenir chaudes après une utilisation
prolongée.
2.0 Safety

4
WARNING! Do not operate or place the welder
near water, in wet locations or outdoors. Risk
for injuries or damage to the welder.
WARNING! Do not place the welder on un-
stable or uneven ground. The welder might tip
causing personal injuries or serious damage to
the welder.
WARNING! Risk of electrical shock. All electri-
electrician.
WARNING! Loose cables and hoses present
tripping risks and possible injuries.
WARNING! Always use welding goggles when
spot welding. Sparks are capable of causing
injury to the eyes.
WARNING! Sparks from welding could start a
WARNING! Risk of damage to materials close
to the welder, e.g to glass or textiles.
WARNING!
operate the welder without connecting it to the
compressed air source.
WARNING! All service and maintenance must
be carried out by Pro Spot service personnel
and service support.
WARNING! Risk for electrical shock. Unplug
the welder from its electrical outlet before ser-
vicing, cleaning or maintenance of any kind.
IMPORTANT! The i4s welder may only be used
welder must be educated in spot welding, colli-
sion repair and proper usage of the unit.
IMPORTANT! Do not turn off the welder while
cooling is activated!
IMPORTANT! The air must be clean and free
WARNING! Do not place any body parts be-
tween the electrode tips. Doing so will cause
serious injury.
WARNING! When holding the gun, only hold
it by the plastic handle on top and the rubber
handle on the arm.
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! Toutes les connexions électriques
de choc électrique.
ATTENTION! Câbles et tuyaux lâches présentent
des risques de déclenchement. Risque de bless-
ures
ATTENTION!sur place. Les étincelles pourraient
autrement blesser les yeux.
ATTENTION! Étincelles de soudure pourrait provo-
quer une incendie. Risque de blessures.
ATTENTION! Risque de dommages aux matériaux
à proximité de la soudure, par exemple verre ou
textiles.
jamais soudeur sans attacher à la source d’air
comprimé.
ATTENTION! Tout le service et l’entretien doivent
être effectués par personnel et soutien de service
Pro Spot. Risque de choc électrique.
ATTENTION! Débranchez le soudeur de la prise
murale avant l’entretien, ou nettoyage. Risque de
choc électrique.
IMPORTANT! Le soudeur i4s peut seulement être
-
deur doit avoir une connaissance de soudage par
points et l’alignement des véhicules endommagés
par collisions.
IMPORTANT! N’éteignez pas le soudeur pendant
que le refroidissement est activé!
IMPORTANT! L’air doit être propre et sans huile et
IMPORTANT! Ne placez aucune partie du corps
entre les pointes d’électrode. Cela le fera causer
des blessures graves.
IMPORTANT! Lorsque vous tenez le pistolet, tenez
seulement par la poignée en plastique sur le des-
sus et le caoutchouc gérer sur le bras.
2.1 Important Warnings

5
2.2 Cooling System
IMPORTANT!
shuts off three minutes after the last weld IS completed. Make sure the water lines are connected properly.
coolant it is recommended that a funnel be used to prevent unnecessary spills. When handling antifreeze or 50/50 solution,
avoid contact of with skin, eyes, or mouth. See antifreeze directions for proper handling instructions.
The Coolant Level Indicator
(located on the back, lower left
hand side of the unit), should
be checked regularly to main-
tain 1.5 Gal (6L) minimum in
the tank.
Make sure the water cooling
hoses are securely clipped into
place before welding. Water
will leak if the water feed and
return hoses are not properly
connected (see cooling hose
connections).
Always make sure the welding
arm is installed correctly, and the
The i4s is equipped with a closed
loop cooling system, 2.5 Gal
(10L) tank, radiator with high
powered fan cooling all the way
to the tip of the electrodes.
IMPORTANT! Make sure the water cooling hoses are securely clipped into place
before welding.
IMPORTANT! Turn off the power to the water pump before disconnecting water
hoses from the weld gun.
IMPORTANT! The i4s welder comes without coolant to ease transportation, be sure
IMPORTANT! If the thermal breaker has switched off the welder, please contact Pro
Spot’s authorized service personnel.
IMPORTANT! N’éteignez pas le soudeur pendant que le système de refroidisse-
ment est activé!
IMPORTANT! Si le disjoncteur thermique a éteint le soudeur, s’il vousplaît contac-
tez personnel de service autorisé Pro Spot.
!
2.2 Cooling System
1.5 Gal (6L) of 50/50 solution at all times and do not overfill. When filling

6
3.0 Installation
The i4s 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.
General
WARNING! Do not operate or place the welder near water, in wet locations or outdoors. Risk for
injuries or damage to the welder.
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 degrees.
WARNING! When moving the welder, always check to make sure the wheel-locks are disengaged.
Move the welder by grabbing the wraparound handle. Lock wheels in place prior to welding.
IMPORTANT! It is the responsibility of the owner to ensure that the equipment has been installed
and inspected in accordance with applicable regulations, and all users are trained on safety and
usage before it is put into service.
ATTENTION! Ne pas faire fonctionner le soudeur près de l’eau, en voie humide ou à l’extérieur.
Risque de
ATTENTION! Ne placez pas le soudeur sur un sol instable ou irrégulière. Le soudeur peut tomber
causant
désengagés des dommages graves au soudeur. Ne pas utiliser sur une pente de plus de 10º
IMPORTANT! C’est la responsabilité du propriétaire de s’assurer que l’équipement a été installé
s’assurer que lesoudeur est inspecté conforment à la réglementation applicable avant qu’il ne
soit mise en service.en service. Ne pas utiliser pour dégeler les conduites d’eau congelées (17.1)
blessures ou de dommages au soudeur. et que vous les déplacez en saisissant la poignée envel-
oppante.
!
!
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 quanti-
ty. Check the i4s 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 as items may be wrapped in packing materials. .
3.1 Packaging & Delivery Inspection
3.2 Welder Assembly
For your convenience, the i4s welder ships fully assembled,
with the exception of the support arm (boom).
Due to differences in wiring codes and connection methods,
electrician for proper installation of the electrical plug.
Insert the support arm (boom) as shown in Figure 3.1
Figure 3.1
3.0 Installation 3.1 Packaging & Delivery Inspection 3.2 Welder Assembly

7
The i4s Spot Welder is purchased based on voltage supply available at the shop. The i4s can be purchased in the
following voltage / frequency combinations:
208-240V 50/60 Hz U.S.A., Canada, Japan
400-420V 50/60 Hz Europe, Australia
460-480V 50/60 Hz U.S.A., Canada
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Note: Make sure that the facility supply voltage and frequency are the same as shown on the welder name plate.
The power supply must have a ground connection. The supply must also be protected as follows:
The 208-240V 3-Phase requires a 60A breaker.
The 400-420V 3-Phase supply requires a 32A slow blow fuse (circuit breaker 32D).
The 460-480V 3-Phase supply requires a 32A slow blow fuse (circuit breaker 32D).
3.3 Connecting The Electrical Supply
3.4 Connecting the Pneumatic Air Supply
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electrical shock.
ATTENTION! Toutes les connexions électriques doivent être faites par un électricien qual-
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1. Connect the green wire to ground.
Note: Make sure that the supply cable is at least 6 AWG at 208V and 400V. The i4s is rated for over voltage category III
and pollution degree 3.
2. If an extension cord is used with the welder, ensure that the length of the extension cord does not exceed 10m (30ft)
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proper installation of the electrical plug.
Input Air
Regulator
The i4s Spot Welder must be connected to a pneumatic air
network (80 PSI to 130 PSI).
Connect the air supply via the 1/4 NPT input port on the input reg-
ulator at the rear of the welder using a standard connector.
IMPORTANT! The air must be clean and
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IMPORTANT! L’air doit être propre sans
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!
Figure 3.2
3.4 Connecting The Electrical Supply 3.5 Connecting the Air Supply

8
4.0 Operation
4.1 Before You Begin Welding
Before you begin welding, be sure to read and understand the following instructions.
The Pro Spot i4s is a state-of-the-art Resistance Spot Welder that was designed for the collision repair industry. It is
important to understand the design and function of this welder before operating it.
Before you begin welding with the i4s:
Squeeze Force: The i4s double-sided gun contains an air cylinder that is capable of compressing the weld caps against
the weld stack up to 1000 lbs. In Auto Mode, the i4s automatically adjusts the squeeze force to maximize fusion of ma-
terials and minimize expulsion during the welding.
Energy: In Auto Mode, the i4s controls and monitors the amount of energy delivered to each weld which ultimately
determines the overall quality of the weld. Perform regular destructive tests on the metal you are welding to validate the
weld no matter which mode you are in.
Current: Another important aspect of a weld is the current applied through the work piece. A weld is created when the
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 in a nugget.
Weld Program: Maintaining the air pressure after the current shuts off makes the weld cool down under pressure re-
sulting in a harder, stronger weld. This feature is built in to the i4s weld control program and is engaged automatically
during a weld cycle.
Time: The Time controls the duration of the current applied during the weld cycle.
4.0 Operation 4.1 Before You Begin Welding

9
4.2 About Your Welder
The welder is supplied with one of the following voltage and frequency combinations:
Input Voltage:
Welding Amperage:
Cable Length:
Electrode Force:
Cooling System:
Microprocessor:
3 phase
208-240V 50/60 Hz.
400-480V 50/60 Hz.
12,500Amp max (3-phase)
Input 30’ (10m)
Weld cable 8.75’(2.67m)
1243 lbs. max (565 daN)
Radiator / Pump Active Loop
Cooled to the Weld Caps
i4s Wirelessly Upgradeable
Protection: IP 21
Software Platform
Shipping Weight (standard):
Weld Head Weight:
385 lb (175 kg)
26 lb (12 kg)
The actual voltage and frequency is stated on the rear panel name plate.
Open circuit output voltage 20V max. E.M.C. classification is CISPR 11.
Double-Sided Gun
Weld Caps
Weld Arm Handle
Wireless Antenna
Single-Sided Gun
Wraparound Handle
Arm Storage
Compartment
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.
Double-Sided Gun Front Panel
Speakers
Bracket For
Overhead Boom
Wireless Antenna
Wraparound
Handle
Coolant Level
Indicator
i4s Weld Spot
Welding Gun
Input Air
Regulator
Pump Motor Fuses
Single-Sided Command Cable
Water Send
Forward Air
Double-Sided
Command Cable
Reverse Air
Water Return
Arm Storage
Compartment
Figure 4.2 i4s-Front View
Figure 4.1 i4s-Overview
Figure 4.3 i4s-Back View
4.2 About Your Welder

10
4.3 Turning On The i4s
Power
Switch
3 Phase
Indicator
1. The 3-phase indicator (3 LEDs on the front panel) should always be illuminated while the welder
is plugged in (verify this before turning on the power). Switch the circuit breaker on the front panel
to “ON”.
2. The display will go through the start-up procedure.
3. The i4s is now ready to use.
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
!
When in use - the i4s discharges a large
effect medical implant devices such as
pacemakers.
When in use - The i4s discharges a large
electronics and attract metal to the gun.
Unplug the welder from the wall
outlet before servicing, cleaning, or
maintenance. Risk of electrical shock.
Some parts of the welder may become
hot after prolonged use.
Always wear eye protection when
welding. Showers of sparks will
welded.
Be wary of pinch points on the i4s such
as the electrodes / weld caps on the
double-sided gun.
WARNING! READ THE FOLLOWING BEFORE WELDING
4.3 Turning On The i4s
Figure 4.4

11
4.4 How To Login
From the Home Screen, touch the
Login button to login (Figure 4.5).
From the Login Menu, select the
user account you wish to login into
(Figure 4.6).
Enter the user password, then
press the green check mark to
continue to the i4s Home Screen
(Figure 4.7).
NOTE: Default user password is -
1234
How To Login
4.4 How To Login
Figure 4.5
Figure 4.6
Figure 4.7

12
4.5 i4s Home Screen
Home
Button Auto Welding
Menu
Manual Welding
Menu
Single-Sided
Welding Menu
Settings Menu
System Updates
Home Screen
Button Training
Menu
Work Order
Menu
Log
Menu
Help
Menu
System Updates
Button
Cooling Settings
Time & Date
WIFI Menu
Phase 1 Voltage
Phase 2 Voltage
Phase 3 Voltage
???
Diode Temperature
Cable Temperature
Daily Weld Counter
???
4.5 i4s Home Screen
Figure 4.8
Figure 4.9

13
4.6 i4s General Settings Menus
WIFI Menu
To access the i4s System Settings
Menu, select the Settings tab on
the top right of the screen (Figure
4.10).
The WIFI Menu will let you connect
to any wireless network available in
your area. Select the network you
wish to connect (Figure 4.11).
After selecting your network, you
will prompted to enter the network
password (Figure 4.12).
4.6 i4s General Settings Menus
Figure 4.10
Figure 4.11
Figure 4.12

14
Cooling Menu
The Single Sided Air and Double Sided Air Cooling are switched on/off by sliding the toggle buttons
(Figure 4.13).
By default, the slider is set to the left which mean Optimized Cool Time is active. With Optimized Cool
Time enabled, the machine will set the cool time automatically based on several performance-related
parameters in order to optimize the duty cycle. When the slider is set to the right, Fixed Cool Time
(Figure 14) is enabled and there is a cool time parameter you can set. If the time is set to 3.0s, that
means you will need to wait 3 seconds after a weld has been completed before you can weld again.
will turn on automatically once the machine reaches a certain temperature. The Single Sided Air slider turns the air for
single sided welding on or off. The Double Sided Air slider turns the air for double sided welding on or off. The Water
Pump button turns the water pump on or off.
Figure 4.14
Figure 4.13

15
Brightness Menu
Date & Time Menu
The Brightness Menu allows the user to select the brightness level of the LCD screen with a range between 20-100
(Figure 4.16).
The Date & Time Menu allows the user to set the time and date. It also allows the user to choose whether they wish
to see a 12 Hour or 24 Hour Clock display by selecting the Change Display Unit button (Figure 4.15).
Figure 4.15
Figure 4.16

16
Preferences Menu
My Account Menu
Change Password Menu
In the Display Units Menu you are able to change the way the machine displays temperature, Celsius or Fahrenheit,
and the clock settings, 12 Hour or 24 Hour (Figure 4.18).
Figure 4.17
Figure 4.18