Pro Spot i4s Instruction Manual
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Pro Spot i4s Instruction Manual

Resistance spot welder
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Instruction Manual
MNL-i4s-1.0

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Dom Pereira
February 4, 2025

Need to find anti Freeze filler Location on the I4S

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1 comments:
Mr. Anderson
February 10, 2025

The antifreeze filler location on the Pro Spot i4s is in the lower left-hand side on the back of the unit.

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Summary of Contents for Pro Spot i4s

  • Page 1 Resistance Spot Welder Instruction Manual MNL-i4s-1.0...
  • Page 2 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.
  • Page 3 My Pro Spot is constantly evolving and we have more exciting features to come. My.prospot.com is where you’ll find updates on new i4s related products and features so be sure to check it out.

  • Page 4: Table Of Contents

    5.2 Double Sided Welding Manual Mode 27 5.3 Creating A Custom Weld 6.0 Single-Sided Welding 30 7.0 i4s Weld Gun 31 7.1 i4s On Gun Screen & Gun Controls 32 7.2 Extension Arms 7.3 Electrode Components 8.0 Electrode Alignment, Removal & Maintenance 36 8.1 Removing Welding Electrodes...

  • Page 5: I4S Quick Start Instructions

    Quick Start Instructions WARNING! Read this manual in its entirety before attempting to weld with the i4s. Before turning on the ma- chine, make sure it is connected to the proper electricity by certified professionals. The water tank should be filled with a 50/50 water and antifreeze solution.

  • Page 6: 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.

  • Page 7: Safety

    Safety & Environmental Specifications 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.

  • Page 8: Important Warnings

    Risque de choc électrique. IMPORTANT! The i4s welder may only be used by qualified personnel. Individuals using the IMPORTANT! Le soudeur i4s peut seulement être welder must be educated in spot welding and utilisé...

  • Page 9: Cooling System

    The coolant tank is located in the rear of the unit, inside the center column. It should be filled with a 50/50 water & an- tifreeze solution. Be sure to turn off and disconnect the i4s from wall power before filling the coolant tank or changing weld arms to prevent spillage.

  • Page 10: Installation

    3.0 Installation 3.1 General 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.

  • Page 11: Connecting The Electrical Supply/ Connecting The Air Supply

    Risque de choc électrique. 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.

  • Page 12: Operation

    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.

  • Page 13: About Your Welder

    Forward Air Single-Sided Command Cable Pump Motor Fuses Double-Sided Command Cable Water Send Reverse Air Water Return Input Air Regulator Wraparound Handle Coolant Level Indicator Arm Storage Compartment Figure 4.2 i4s-Back View Figure 4.1 i4s-Front View 4.2 About Your Welder...

  • Page 14: Turning On The I4S

    IMPORTANT! Assurez-vous de lire le Mode d’Emploi avant d’opérer le soudeur. Seul le personnel qualifié devrait utiliser ce soudeur. WARNING! READ THE FOLLOWING BEFORE WELDING When in use - the i4s discharges a large Some parts of the welder may become magnetic field which can negatively hot after prolonged use.

  • Page 15: How To Login

    4.4 How To Login How To Login When the i4s is turned on, the user is presented with the Home Screen. Touch the login button to continue logging in. On Login Menu and you can select the account you wish to login into.

  • Page 16: I4S Home Screen

    4.5 i4s Home Screen Home Auto Welding Manual Welding Single-Sided Settings Menu Button Menu Menu Welding Menu System Updates Help User Profiles Menu Cooling Settings Home Screen Time & Date Training Log Menu Button WIFI Menu Menu Work Order System Updates...

  • Page 17: I4S General Settings Menus

    4.6 i4s General Settings Menus To access the i4s System Settings Menu, select the Settings tab on the top right of the screen. WIFI Menu The WIFI Menu will let you connect to any wireless network available in your area. Select the network you wish to connect.
  • Page 18 Cooling Menu The Cooling Menu allows the user to add extra cooling features for Single Sided Welding and Double Sided Welding as well as a Fixed Cool Time for the machine. The Single Sided Air and Double Sided Air Cooling are switched o/off by sliding the toggle buttons.
  • Page 19 Date & Time Menu 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. Brightness Menu The Brightness Menu allows the user to select the brightness level of the LCD screen (range 20-100).
  • Page 20 My Account Menu Under the My Account Menu you will find the Change Password Menu and the Display Units Menu. Change Password Menu In the Change Password Menu you are able to change your User Profile Password. Display Units 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).
  • Page 21 Version Info Menu The Version Info Menu displays the version of software the machine is operating on. This information may be useful when looking to see if your machine is up to date. System Update Menu The System Update Menu allows you to check for software updates and to download the latest updates from Pro Spot.

  • Page 22: Administration Settings Menus

    4.7 i4s Administration Settings Menus To access the Administration Settings: 1. Select the Settings tab. 2. Once you’re on the Setting tab, select Administration (Figure 1). 3. Once you see the Administration Menu, you will be prompted with a password screen (Figure 2).
  • Page 23 Work Orders The Work Orders Menu allows you to create work orders which correspond to each individual job. While a work order is active, each weld that is performed will be logged and associated with that specific work order. After creating a work order, it can be assigned to a technician.
  • Page 24 Figure 6. How To Export A Work Order: 1. Select the work order you wish to export from the Work Order Menu and hit Export on the top right. 2. Once you press the export button you will be taken to the Export Work Order prompt (Figure 7). 3.
  • Page 25 How To Allow Users To Add Work Orders: 1. Navigate to the Work Orders Admin Menu (Figure 8). 2. Select the Cog Button located above the Add Work Order Button. 3. This will bring up the Work Order Settings (Figure 9). 4.
  • Page 26 Users Menu In the User Menu the Administrator can add, edit and remove user profiles. Add A New User: 1. Navigate to the User Menu and select the red Create User Button in the bottom right (Figure 12). 2. Once you select Create User, a new user prompt will pop up and ask you for the new user details (Figure 13). 3.
  • Page 27 Alerts Menu The Alerts Menu allows users to adjust the Current Tolerance, Gun Pressure, Idle Line Voltage and Weld Line Voltage (Figure 15). Figure 15. Factory Reset Menu The Factory Reset Menu will give you the option to reset weld programs, user preferences, system alerts and a complete factory reset (Figure 16).
  • Page 28 The Factory Calibration Menu allows you to calibrate the machine to optimal performance. WARNING! These functions are for factory calibration only and should not be used by anyone other than authorized Pro Spot personnel. Current Calibration The electrode pressure calibration setting is used to verify that the welder is receiving sufficient air pressure.
  • Page 29 The Voltage Calibration will help users measure the AC voltage between phases with a multimeter. WARNING! These functions are for factory calibration only and should not be used by anyone other than authorized Pro Spot personnel. How To Calibrate Voltage: 1.

  • Page 30: Double Sided Welding Programs

    Auto Mode on the i4s automatically detects the thickness and resistance of most metals and coatings / adhesives. Once properly calibrated, the user only needs to press and hold the weld trigger and the top right button on the gun and to allow the i4s to determine the correct power levels and duration.

  • Page 31: Auto Mode Calibration

    WARNING: It is NOT recommended that factory settings be modified. Measurement Only Mode: The Caliper icon sets the i4s to Measurement Only Mode. While in Measurement Only Mode, the Caliper icon will be highlighted in green. Measurement Only Mode allows you to measure the thickness and resistance of steel without welding it.

  • Page 32: Double Sided Welding Manual Mode

    5.2 Double Sided Welding Manual Mode Manual Mode is for users that want complete control over their weld settings. Every aspect of a weld scenario can be established in Manual Mode. As with Semi-Auto Mode Manual Mode comes with 16 pre-loaded common weld programs that can be over written by the user and can be reset in the global settings if necessary (Figure 5).

  • Page 33: Creating A Custom Weld

    5.3 Creating a Custom Weld How To Create A Custom Weld: PS-025 1. Select the Weld Type and Cap by pressing the Weld Cap Selection Button on the Manual Mode Screen, then select the appropriate weld cap. PS-027 PS-026 2. Select one of the 3 weld types in the Main Manual Mode Screen: •...
  • Page 34 If you selected Dual Weld, you will see the following options: Weld Weld Weld Current (1) Time (1) Force How much pressure is applied Amount of time applied to the first How much current is applied to to the weld. pulse the first pulse Weld...

  • Page 35: Single-Sided Welding

    6.0 Single Sided Welding Single Sided Mode can be used for many different applications in auto repair, such as rust and dent repair. With the i4s, you’re able to access 16 programs associated with each selectable SS weld tip. Set Weld Time...

  • Page 36: I4S Weld Gun

    7.0 i4s Weld Gun Double-Acting Spot Gun (Part # PS-700W) The spot gun is used for Double Sided Welding programs: HSS Galvanized Steel, Mild Steel, Weld Bonding, Boron Steel, Pulse Welding, OEM Required Programs and Cus- tom Programs. Double-Acting Spot Gun Component Diagram...

  • Page 37: I4S On Gun Screen & Gun Controls

    7.1 i4s On Gun Screen & Gun Controls The i4s gun has an on-gun screen that can show the user exactly which settings and what kind of welds they are producing. This feature gives users the options to make changes to weld settings directly from the gun without needing to go back to the machine.
  • Page 38 Gun Weld Feedback Screen The Weld Feedback screen will show up on the i4s screen and the i4s gun screen after a weld has been performed. The Weld Feedback screen indicates to the user if the weld passed or failed. It also displays the Measured Preheat Current and the Measured Weld Current.

  • Page 39: Extension Arms

    7.2 Extension Arms The i4s comes with a variety of extension arms to accommodate most welding applications. NOTE: Extension arms marked “optional” are available through your local distributor or online at www.prospot.com. REMARQUE: bras d’extension portant la mention «facultatif» sont disponibles à...

  • Page 40: Electrode Components

    7.3 Electrode Components IMPORTANT! Using incorrect welding electrodes with extension arms may result in weak welds and/or damage to your welder. IMPORTANT! En utilisant des électrodes de soudage inexactes au bras d’ex- tension peut donner des soudures faibles et / ou endommager votre soudeur. PSW-080 SHANK/CAP COMPONENTS 1.

  • Page 41: Electrode Alignment, Removal & Maintenance

    8.0 Electrode Alignment, Removal & Maintenance The machine must always have the electrodes aligned. Improper alignment of the electrodes can lead to poor welds that will not pass OEM requirements. To adjust the electrode on the machine, use the set screws to set alignment (Figure 1). Use an Allen Wrench to make slight adjustments to the set screws.

  • Page 42: Removing Welding Electrodes

    Grip the handles and twist them in opposite directions. 2. If twisting the cap and electrode doesn’t work, you can gently tap them with a hammer (Pro Spot ALU-9 Aluminum Hammer shown) while maintaining control of the electrode by holding one of the vice grips firmly with one hand.

  • Page 43: Welding Electrode Maintenance

    Note: The PLT-51 (meant for the OEM weld caps) is distinguishable from the PLT-50 by the lack of green mark on the neck of the grinding head. Cap cleaning: 1. Turn off the i4s 2. Connect the PLT-51 tip sharpener to a compressed air hose 3.
  • Page 44 Pro Spot International, Inc. 5932 Sea Otter Place Carlsbad, CA 92010 Toll Free (US Only): (877) PRO SPOT Phone: (760) 407-1414 Fax: (760) 407-1421 E-mail: info@prospot.com Web: www.prospot.com...

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