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High Frequency Inverter Resistance Spot Welder

1. High Frequency Inverter Resistance Spot Welder Instruction Manual Version 3 6n JAH I II AI info Copyright Pro Spot International Inc Table Of Contents Quick start instructions a 3 1 Introduction 4 2 Safety 2 0 Safety amp Environmental Specifications 5 PEE ee nm a NA HABAN TIKA NG DT ee eee eee TREN ee 5 2 2 Warnings and important Notices aa 5 2 3 Safety devices o ooo a 7 Zo COON soap R R seus be T 2 3 2 Overheat protection s s s s ee eee ees T 3 Installation Dal GOnCIal nur angesehene Renee bar nee EE EE 8 3 2 Packaging and delivery inspection a 8 3 3 Welder assembly a 8 3 4 Connection of electrical supply 9 3 4 1 Electrical Plug Extension cords 9 3 5 Connection of pneumatic air supply 9 4 Operation 4 1 Before you begin Welding aa 10 4 2 About your welder s a 11 4 2 1 Welder Overview 8 Technical Specifications 11 4 2 2 Getting familiar with your welder 11 4 2 3 14 Control Panel nennen 12 4 2 4 Indications on the Control Panel a 12 4 2 5 14 Service Panel Window 12 4 3 Turning on the welder 13 4 4 Choosing the weld
2. D11 18V present D12 24V present Service Panel Window Control System Status Lamps Tool tray mat removal required to view Service Panel Window All Info Copyright Pro Spot International Inc 4 Operation Page 12 A 2 3 14 Control Panel Navigation button Up Navigation button Down Navigation button Closed Circle Navigation button Open Circle Display Screen Two Sided Single Sided Help Instructions Navigation Navigation spot gun button button button Left button Left button Right Figure 4 3 The i4 Control Panel 4 2 4 Indications on the Control Panel TWO SIDED WELDING SINGLE SIDED When two sided welding is selected a spot gun graphic appears in the upper left ge corner of the display screen fig 4 4 fr When single sided welding is selected a single sided gun graphic appears in the upper left corner of the display screen fig 4 5 Figure 4 4 Figure 4 5 All Info Copyright Pro Spot International Inc A Operation Page 13 4 3 Turning on the welder 1 Toggle the circuit breaker on the front panel to ON Three lights on the front panel should illuminate indicating 3 phase installation 2 lights for 1 phase installation fig 4 5 1 2 The display will go through the start up procedure 3 The i4 is now ready to use Figure 4 5 1 Gr Te IMPORTANT Make sure to read the instruction manual before operating the welder Only trained personnel should use this welder A IMPORTANT
3. Ph3 Primary voltage phase 3 Page 37 NOTES NOTES NOTES NOTES NOTES Pro Spot international Inc 2625 Temple Heights Dr Ste A Oceanside CA 92056 Toll Free 877 PRO SPOT Fax 760 407 1414 E mail info prospot com Web www prospot com Copyright Pro Spot International Inc 2005 2009
4. Air 2 fans Compressed air weld gun and weld cables Water Cooling inverter transformer welding gun i4 Upgradeable Software Platform 3731b 169kg Welding amperage Cable length Electrode Pressure Model Input 208 240V 3 Phase 60A 50 60 Hz Voltage Connect GREEN wire to EARTH ground Manufactured by PRO SPOT International Inc www prospot com Made in U S A CE Intertek Conforms to UL Std 60974 1 TES Certified to CSA Std E60974 1 Cooling system Micro processor Shipping Weight standard ed ght The name plate is at the rear of the welder unit The required voltage is indicated on the label a Welding output is rated at 15V 4 2 2 Getting familiar with your welder nz Tool Storage Tray Power Switch Display Screen Input Voltage Phase Indicator LED Lights should illuminate when Power switch on front panel is ON 2 lights for 1 phase or 3 lights for 3 phase Single Sided Gun Holder Two Sided Gun Holder Name Plate shows Input voltage Serial number etc Cable Holder Bracket Air Pressure Gauge Air Pressure Regulator Figure 4 1 i4 Front View WELD CABLES CONFIGURATION Two Sided spot gun cable Two Sided ground cable Single Sided Weld Gun cable O Single Sided ground cable Cooling Fan Air Input Connect filtered air Cable Holder 100 PSI 7 BAR min Figure 4 2 i4 Back View All Info Copyright Pro Spot International Inc 4 Operation Page 11 4 2
5. Double Acting Gun Push this button to close electrodes and weld Page 17 Push this button to open electrodes wide All Info Copyright Pro Spot International Inc 5 Double Sided Welding 5 2 Extension Arms The Pro Spot i4 comes with a variety of extension arms to accomodate any weld ing job situation Please refer to fig 5 3 for details on what welding electrodes to use with each extension arm distributor or online at www prospot com REMARQUE bras d extension portant la mention facultatif sont disponibles partir de votre Distributeur r gional ou en ligne www prospot com N NOTE Extension arms marked optional are available from your local Figure 5 2 i4 Extension Arms PS 306 PS 308 PS 305 PS 503 W optional optional 508mm Extension Arm optional PS 52 PS 307 PS 302 C Arm PS 403 optional Wheelhouse Arm optional C X Adapter 5 2 1 Switching to extension arms Loosen the handle and pull off the C arm Now insert the extension arm and tighten the handle All Info Copyright Pro Spot International Inc 5 Double Sided Welding Page 18 5 2 2 Extension Arms and Welding Electrodes Different extension arms require the use of different welding electrodes Use charts in fig 5 3 and 5 4 to determine the correct combination of extension arms and welding electrodes IMPORTANT Using incorrect welding electrodes with extension arms may result in weak welds and or damage to your welder IMPO
6. General The i4 Spot welder is inspected and tested prior to leaving the factory to guarantee consistent quality and the highest possible reliability Follow the instal lation tips and operating instructions below to ensure user safety and proper welder performance 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 IMPORTANT It is the responsibility of the owner to ensure that the equipment has been installed as specified in the instructions pro vided It is also the owner s responsibility to ensure that the welder is inspected in accordance with applicable regulations before it is put into service Do not use for thawing out frozen water pipes 17 1 gt P ATTENTION Ne pas faire fonctionner le soudeur pr s de l eau en voie humide ou l ext rieur Risque de blessures ou de dommages au soudeur ATTENTION Ne placez pas le soudeur sur un sol instable ou irr guli re Le soudeur peut tomber causant des dommages graves au soudeur Ne pas utiliser sur une pente de plus de 10 IMPORTANT C est la responsabilit du propri taire de s assurer que l quipement a t install comme sp cifi dans les instructions fournies C est aussi la responsabilit du propri taire de
7. Mode aaa 14 4 5 Setting the pneumatic air pressure 15 4 6 Setting Changing the weld program 15 4 7 Setting the weld time aaa 15 4 8 Setting the default weld programs 16 5 Double Sided Welding 5 1 PS 500 Double Acting Spot Gun aaa 17 5 1 1 PS 500 Component Diagram 17 5 1 2 Using the Double Acting Gun 2 2 aaa 17 9 2 EXIONSION ATM S Snu n risiet nnen E ly o 05 Od 06b SEE TEn EERON 18 5 2 1 Switching to extension arms 18 5 2 2 Extension Arms and Welding Electrodes 19 5 3 PS 500 Electrode Alignment 20 5 4 Removing Welding Electrodes 21 5 5 Welding Electrode Maintenance 22 5 6 Wheel House Arm 2 22 9 1 X Adapter optional 5 e 88 Jiao RR En ee hh wees eee aoe oo oe 23 5 7 1 Attaching the X Adapter anaa aaa anaa a 23 5 7 2 Using the X Adapter naana anaa ana aa 24 All Info Copyright Pro Spot International Inc Table Of Contents 5 Double Sided Welding Cont 5 7 3 X Adapter Configurations 24 6 Single Sided Welding 6 1 Single Sided Welding Overview s a 25 6 2 Single Sided Spot Welding a 27 6 3 Stud VVCIGING
8. Spot welder is used by body shops to duplicate the welding procedure used by the car manufacturers Use of the equipment that is contrary to the instructions in this manual can cause personal injury and or machine damage Pro Spot International Inc can in no way be held responsible for intentional or unintentional damage and consequent unlimited loss of profit loss of income loss of business opportunity loss of use etc that originates from incorrect use of this equipment ir its use in a man ner not intended Warranty Pro Spot International Inc offers a two year guarantee from the date of delivery of the new welder This guar antee covers material defects and assumes normal care and maintenance The guarantee assumes that e the equipment is correctly installed and inspected e the equipment has not been altered or rebuilt without approval from Pro Spot International Inc e genuine Pro Spot International Inc spare parts are used to make repairs e 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 specifications All claims must include the product type and serial number This data is stamped on the name plate 1 Introduction All Info Copyright Pro Spot International Inc Note This instruction manual
9. Welding STITCH WELDING 7 Figure 6 31 Figure 6 33 The i4 can also be fitted with a stitch weld adapter enabling the operator to lay staggered bead type welds While rolling the tip on the sheet metal edge the welder will automatically deliver an intermittent or pulsating current 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Stitch Welding Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Stitch Welding graphic appears on the screen fig 6 37 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the stitch electrode fig 6 33 5 Prepare the surface area by removing paint and primer 6 Ground the working area refer to section 6 1 Single Sided Welding Overview 7 Roll the tip on the sheet metal edge while keeping the trigger depressed The welder will automatically deliver an intermittent or pulsating current 8 Repeat as needed This procedure works well on stainless steel and therefore lends itself well to rust repair and patching It s easy to use and can be manipulated to fit any shape or form you require Tip You can use stitch electrode to weld pulling tabs onto areas that need to be pulled Astuce vous pouvez utiliser
10. and shank as shown in fig 5 6b 3 Twist the two to loosen and remove the welding cap A A rm Piston Electrode NOTE An optional welding electrode cap removal tool is available which makes cap removal easy fig 5 6c You can order the cap removal tool from your local distributor or online at www prospot com NOTE Une option d un outil pour enlever le bouchon est disponible Pour faciliter le retrait du bouchon fig 5 6c Vous pouvez commander cet outil de votre distributeur local ou en ligne a l adresse www prospot com Welding Cap Extension Arm Electrode Figure 5 6 Removing Welding Electrodes Page 21 5 5 Welding Electrode Maintenance To maintain structurally sound welds it is important to keep your welding electrodes clear from build up It is also important to maintain a 6mm weld nugget diameter Clean electrodes with a file and periodically replace weld ing caps as explained in Section 5 4 Removing Welding Electrodes WARNING The electrodes may be hot Use caution when handling them A ATTENTION Les lectrodes peuvent tre 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 PS 52 5 8 Wheel House Arm PS 1101 CM PS 1133 5 8 60mm Electrode Shank Electrode All Info Copyright Pro Spot International Inc 5 Double Sided Welding Page 22 5 7 X Adap
11. button The software will reboot with the preferences stored Page 34 7 14 Login Feature 7 4 Switching Passwords 11 12 13 14 15 Here we will explain how to switch to another Login User Password without powering the 4 down on the fly While the 4 is running make sure the Login function is on and the Login User password is set to 0001 Scroll to Custom B in the Double Sided weld menu Press System Settings closed circle button and you will arrive in the Login menu Press Change up arrow button to enter a new password Enter the desired existing Login Password ex 0002 If we enter a wrong number and press Done a WARNING Invalid login ID Try Again error message window will appear NOTE It is important that a valid password is entered or the machine will have to be rebooted 7 5 Setting Up Technician User Passwords 16 17 18 19 20 Only the Login Master Password 2625 can set up Login User Passwords from the Login menu While the 4 is running with the Login function on the Factory Password 1234 entered and the Login Master Password 2625 as the present login ID Scroll to Custom B in the Double Sided weld menu Press System Settings closed circle button and you will arrive in the Login menu Press Login ID Settings down arrow Navigate with the Left and Right Arrow and Open Circle buttons Set desired values ex 0003 with the Up and Down Arrow buttons Once done press
12. s assurer que le soudeur est inspect conforment la r glementation applicable avant qu il ne soit mise en service Ne pas utiliser pour d geler les conduites d eau congel es 17 1 gt BB grounded electrical plug must be installed refer to section 3 4 Connection of electrical supply 3 2 Packaging and delivery inspection Check the contents of the shipping container against the packing list consign ment note or other delivery documentation to verify that everything is included and in the correct quantity Check the i4 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 till the part is repaired or replaced If anything is missing please contact your supplier Remove all packaging material from the welder 3 3 Welder assembly For your convenience i4 welder ships fully assembled Due to differences in wiring codes and connection methods no electrical plug comes with the welder Consult a certified electrician for proper installation of the electrical plug Insert the support arm boom as shown in Figure 3 1 Figure 3 1 All Info Copyright Pro Spot International Inc 3 Installation Page 8 3 4 Connection of electrical supply The i4 Spot Welder requires one of the following voltage frequency combina tions v 208 240V 50 60 Hz U S A Canada Japan OR v 400 420V 50 60 Hz Europe Australia Note Make su
13. serious damage to the welder WARNING All electrical connections must be made by a qualified electrician Risk for electrical shock WARNING Loose cables and hoses present tripping risks Risk for injuries WARNING Make sure to use welding goggles when spot welding The sparks might otherwise injure the eyes WARNING Sparks from welding could start a fire Risk for injuries WARNING Risk for damage to materials close to the weld e g to glass or textiles WARNING For proper cooling efficiency never 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 Risk for electrical shock WARNING Unplug the welder from the wall outlet before servicing cleaning or maintenance Risk for electrical shock IMPORTANT The i4 welder may only be used by qualified personnel The user of the welder must have knowledge of spot welding and of alignment of collision damaged vehicles IMPORTANT Do not turn off the welder while cooling is activated IMPORTANT The air must be clean and free from oil and moisture Use filter gt Ad gt P gt gt BIG BIB 2 Safety ATTENTION Ne pas faire fonctionner le soudeur pres de l eau en voie humide ou l xterieur Risque de blessures ou de dommages au soudeur ATTENTION Ne placez pas le soudeur sur un sol instable ou irre
14. the Control Panel Select the welding pro gram by using the Left and Right navigaton buttons fig 4 9 The selected program is indicated by a highlighted black box over the program name fig 4 10 In any welding mode there are 6 power level programs 0 7mm 2 5mm To switch between programs press the Next Program button fig 4 7 Some programs require a double weld in one cycle fig 4 17 Those welds auto matically deliver Weld 1 programmed delay then Weld 2 This is a very sophisti cated weld feature for controlling exact temperature into the weld area and to pre heat it A Note Two Sided welding mode and Program No 1 are set by default when the 4 is turned on Note Mode recto verso de soudage et le programme de soudage n 1 sont d finies par d faut lorsque le i4 est allum 4 Operation Page 16 5 Double Sided Welding 5 1 PS 500 Double Acting Spot Gun The spot gun is used for the following weld programs e Two Sided spot welding HSS Galvanized steel Mild steel Weld Bonding Boron Steel Pulse welding and OEM Custom Modes see section 4 8 Setting the default welding programs 5 1 1 PS 500 Component Diagram PS 302 F 44 C Arm Release Trigger Switch F 44 a mara Weld Trigger Switch Weld Shaft PS 1101 CM 60mm Shank PS 5203 Clamping Handle PS 025 Welding Cap PS 103 CM 20mm Shank Figure 5 1 PS 500 Spot Gun Component Diagram 5 1 2 Using the
15. up window enter 1234 using the arrow keys Exit by pressing the Open Circle button The welder is in manual mode and weld programs can now be modified 4 7 Setting the weld time and current All Info Copyright O Pro Spot International Inc o l fs 6870A Figure 4 8 The time and current automatically change with each respective weld power mode Referring to fig 4 8 The top value indicates the time duration that will be applied during the weld and the bottom value indicates the weld power in weld amperage that will be applied during the weld 4 Operation Page 15 4 8 Setting the default weld programs Figure 4 9 Figure 4 10 e 10S 2245 Z AR 4670A 6610A Figure 4 11 All Info Copyright Pro Spot International Inc There are 17 weld programs featured in the i4 Spot Welder Ten of these pro grams are associated with the Single Sided Gun and seven are associated with the Two Sided Spot Gun Two Sided Programs HSS Mita Steel O Galu tb ii Programs rite Lito aR LAS Belt Mild Steel Welding Weld Bonding Boron Steel Welding Pulse Mode HSS Steel Galv Steel Welding Dent Pulling Contact Shrinking Nut Welding Bolt Welding Stitch Welding OEM Specific Programs Carbon Rod Shrinking Rivet Welding Washer Welding Custom Program Single Sided Spot Welding Pro Pull Dent Removal 898000900 66006066 The welding programs are selected on
16. weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Bolt Welding Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Bolt Welding graphic appears on the screen fig 6 10 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the magnetic stud adapter fig 6 12 5 Insert stud into the adapter fig 6 12 6 Prepare the surface area by removing paint and primer 7 Ground the working area refer to section 6 1 Single Sided Welding Overview 8 Position single sided gun over work area and push the trigger to weld 9 Repeat as needed All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 27 6 4 Nut Welding Figure 6 13 Figure 6 15 SPOT HAMMER Figure 6 16 Figure 6 18 Weld on nuts are common throughout the car body for attachments of interior tail lights door moldings etc and are applied with ease using the i4 Tip Different size nuts are available from your local Pro Spot distributor IN or on the web at Pro Spot online store Astuce noix de diff rentes tailles sont disponibles chez votre distribu teur local Spot Pro ou sur le web la boutique Pro Spot en ligne Nuts are held in place during welding with a shrink
17. 008 12 35 25 0 14 8 22 2008 12 36 08 0 17 8 23 2008 12 29 21 0 17 8 23 2008 12 30 20 0 17 All Info Copyright Pro Spot International Inc WT1 SC1 MCI wT sc2 Mc2 A 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 6801 PRO SPOT i4 WELD LOG LEGEND Process Log File Button Legend WCt Weld Count Prog 1 0 7mm 21 0mm 3 1 2mm 4 1 5mm 5 2 0mm 6 2 5mm Date Date of weld Eval Evaluation of weld OK passed or FAILED Time Time of weld Login User ID logged in at the time of weld WT1 Weld duration weld s Temp Temperature of heatsink of inverter SCT Set Current Weld 1 Amperage or a MC Measured actual current 1 Start Date 08 21 2008 WT2 weld duration weld 2 Technician name John Smith SC2 Set Current Weld 2 Amperage or Vehicle Number 12345678904321 MEE Meane ER ouro a Vehicle Make Model Honda Civic 2008 SSW Single sided weld DOO Insurance Company AllState Insurance WO 12345678904 USt Upslope Weld1ms US2 Upslope Weld 2 ms 7 sor US1 us2 sec A A WTy Prog Eval Login Temp ms ms ms ms ms 00 O0 m O0 m 00 m Weld Data Information Weld Log Header 8 i4 Log Feature WD Weld delay between Weld and Weld 2 in Dual mode DSt Downslope Weld ims DS2 Downslope Weld ms DS1 ms oo m m m OO o Pht Primary voltage phase 1 Ph2 Primary voltage phase 2
18. 4 Spot welder will ensure safer working conditions for themselves and their fellow workers 2 2 Warnings and important notices A All Info Copyright O Pro Spot International Inc Caution Read instruction manual Prohibited Prohibits behaviour that can cause injury Command Calls for a specific action Warning Notice of personal injury risk and or damage to equipment Warning Some parts of the welder may become hot after prolonged use The following types of safety signs are used on the equipment and in Pro Spot s instruction manuals A Attention Lire Mode d Emploi d Interdit Interdit aux comportements qui peuvent provoquer des blessures Commande Appelle a une action sp cifique Avertissement Avis de risque de blessure personnelle et ou d endommager l quipement Avertissement Certaines parties du soudeur peuvent devenir chaudes apr s une utilisation prolong e Page 5 2 Safety 14 The following warnings and important notices are used in the instruction manual gt gt BIB gt gt gt P PIG gt P All Info Copyright Pro Spot International Inc WARNING Do not operate or place the welder near water in wet locations or outdoors Risk for injuries or damage to the welder gt WARNING Do not place the welder on unstable or uneven ground The welder might tip causing personal injuries or
19. 5 Service Panel Window Control System Status Lamps Location Inside the i4 and PR 2000 tool amp accessory tray under the rubber mat Purpose To quickly determine the status of many internal systems without opening the welder The welder needs to be powered up Look down through the window There are several lights to watch for The Voltage Indicator windows have three LED lights in each window while the IGBT and Bus Bar windows have only one light per window NOTE D means diode while the number determines the device s board location 1 Buss High Voltage OK LED1 amp 2 indicate 300 volts DC present Both stay ON but often only one of them is seen unless top cover is removed DO6 present D26 present 2 IGBT Control System OK LEDs 1 2 3 4 indicate voltage present across each IGBT gate Each LED should stay ON LED 5 yellow indicates 15VDC control voltage and should stay ON These diodes are on a separate vertically mounted mini board D107 present D108 present D109 present D110 present D101 15V present 3 AC Input Voltage Drop Condition LEDs 4 5 6 indicate a problem if any of them comes ON during welding They all come on briefly during startup then stay OFF D23 Primary voltage drop 10 D22 Primary voltage drop 15 D21 Primary voltage drop 20 4 DC Voltage Indicators LED 1 2 3 indicate logic voltages generated and present They come ON during startup and stay ON D10 15V present
20. Assurez vous de lire le Mode d Emploi avant d op rer le soudeur Seul le personnel qualifi devrait utiliser ce soudeur 4 3 1 Login Procedure After the welder has been turned on and when the pre weld screen has appeared press the CHECKLIST Start Welding button closed circle PRO SPET 4 CHECKLIST SOFTWARE VERSION 13 033 Date 01 25 09 23 40 09 Weld Count 000000 0000 Hz 0100 C 0087 Y 0080 Y 0071 V SYSTEM SETTINGS y From this screen enter the desired login The 4 comes pre programmed with the login user ID 0001 0002 0003 and 0004 available by default a gt After the correct ID is entered press DONE to Z continue to the double sided weld feature LOGIN ID 000 USE L R ARROW TO SELECT DIGIT All Info Copyright Pro Spot International Inc A Operation Page 14 4 4 Choosing the weld mode Figure 4 6 The i4 is a multi functional resistance spot welder It is equipped with a four weld cable system for your convenience Two of the weld cables are connected to the Two Sided Spot Gun and the other two are connected to the Single Sided Weld Gun To select a weld mode press the respective mode button fig 4 6 Once the welding mode is selected a group of related weld programs become available to the user see section 4 8 Setting the default weld programs 4 5 Setting the pneumatic air pressure Pneumatic air is used for forcing the spot gun to close and open cooli
21. O O O O O senses 27 6 4 Nut Welding 2 eee eens 28 6 5 Dent Pulling with Spot Hammer s s a 28 6 6 Moulding Clip Rivet Welding 29 6 7 Dent Pulling with Washers and Slide Hammer with Hook 29 6 8 Contact Shrinking s a 30 6 9 Carbon Rod Shrinking Stretching 30 6 10 Sitech Welding EE RL erheben ehesten 31 6 11 Pro Pull Dent Pulling optional s a 32 6 11 1 Selecting Pro Pull Weld Mode 32 6 11 2 Pro Pull Component Diagram 32 6 11 3 Pro Pull Assembly 33 6 11 4 Dent Pulling with Pro Pull 33 6 11 5 Paintless Dent Pulling With Pro Pull 33 7 14 Login Feature 7 1 14 Login Overview 0 0 0c ee teens 34 7 2 Turning the Login Function Off aa 34 7 3 Turning the Login Function On 1 aa 34 7 4 Switching Passwords 35 7 5 Setting Up Technician User Passwords 35 8 i4 Log Feature 8 1 14 LOG INSWUCUONS ca ha AA FRED HE as BAGAHE wen eer aden 6 0 eben 36 8 2 Download the Log file for print lt aa 37 All Info Copyright Pro Spot International Inc Page 2 Quick start instructions WARNING Before turning the welder on make sure it is connected to proper e
22. RTANT En utilisant des lectrodes de soudage inexactes au bras d extension peut donner des soudures faibles et ou endommager votre soudeur PS 302 PS 1101 CM PS 103 CM PS 52 5 8 PS 1101 CM PS 1133 5 8 PS 403 see Sec 5 7 3 see Sec 5 7 3 PS 305 PS 1101 CM PS 129 CM PS 503 W PS 1101 CM PS 128 CM Figure 5 3 Extension arm Welding electrode configuration chart Electrode Shank PS 025 Welding Cap MM s De PS 103 CM lt 40 mm gt PS 102 CM lt 60 mm gt PS 1101 CM lt 80 mm gt PS 128 CM lt 100 mm gt PS 129 CM lt 120 mm gt PS 130 CM lt 160 mm gt length with Welding Cap attached 20mm w o cap Figure 5 4 Welding electrode selection chart 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 tre achet s en paquets de 15 a partir de votre distributeur local ou en ligne a www prospot com A A All Info Copyright Pro Spot International Inc 5 Double Sided Welding Page 19 5 3 PS 500 Electrode Alignment Use the set screws A B C to align the electrodes Ex to move electrode down loosen screw C and tighten screws A and B Figure 5 5 Electrode Alignment CORRECT so may result in weak substandard welds IMPORTANT Toujours maintenir l alignement des lectrodes appro pri es Ne pas le faire p
23. al contact when performing Single Sided welding 5 Ground the working area refer to section 6 1 Single Sided Welding Overview 6 Apply about 33 44 lbs of pressure on the Single Sided gun and push the trigger to weld Reposition and weld again Note Make sure that Single Sided electrode is clean If it isn t use a file or tip dresser to clean it If the weld cap shows considerable wear it should be replaced refer to section 5 4 Removing Welding Electrodes Remarque Assurez vous que electrode C te Unique est propre Si ce n est pas utilisez une lime pour le nettoyer Si le bouchon de soudure est considerablement us il devrait tre remplac voir la section 5 4 Enl vement d Electrodes de soudage 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 i4 threaded studs can be welded on in factory style This type of stud is also common throughout the car body for attachments of interior tail lights door mold ings etc Tip A threaded stud can also be used to fasten the ground clamp directly IN to the panel minimizing the area needed for grinding Astuce Un goujon filet peut galement tre utilis pour fixer la pince directement sur le panneau ce qui r duit la surface n cessaire au broyage Studs are held in place during welding with magnetic adapter electrode 1 Push the Single Sided
24. d Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Spot Hammer Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Spot Hammer graphic appears on the screen fig 6 16 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the spot hammer fig 6 18 5 Prepare the dent surface area by removing paint and primer 6 Ground the working area refer to section 6 1 Single Sided Welding Overview 7 Position the spot hammer tip at the bottom of the dent and push the trigger to weld the electrode onto the metal 8 Pull out a dent then release by twisting the hammer 9 If needed reposition weld and pull again When more pulling power is needed simply increase the current Note Check spot hammer tip periodically to make sure it is in good working order If the tip looks worn replace it with a new one Note Contr lez le bout marteau p riodiquement pour s assurer qu il est en bon tat de marche Si le bout semble us le remplacer par un nouveau All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 28 Figure 6 19 Figure 6 21 WASHER WELDING Figure 6 22 Figure 6 24 6 6 Moulding Clip Rivet Welding This function will weld on factory type clips for the window mouldin
25. e Protection Degree IP21S The i4 Spot welder is designed to operate from 10 C to 40 C The unit may be stored and transported in an ambient temperature from 20 C to 55 C The unit can be operated at 95 Relative Humidity RH For operation above 1000m consult the manufacturer Do not operate the unit on a slope of more than 10 The unit meets the requirements of IEC EN60974 1 2005 third edition and UL60974 1 2nd edition E M C classification is C1SPR11 NOTE Heating tests were performed at room ambient temperature and the duty cycle at 40 C has been determined by simulation The i4 Spot welder has been designed and is tested to meet strict safety require ments Please read the following instructions carefully before operating the i4 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 prac tices and should in no way take precedence over individual responsibilities or local regulations The i4 Spot Welder is designed to comply with all applicable safety regulations for this type of equipment During operation it is always each individual s responsibil ity to consider e Their own and other s personal safety e The safety of the welder through correct use of the equipment in accordance with the descriptions and instructions provided in this manual By observing and following the safety precautions users of the i
26. e Sided Programs dr u Joan komo uf ro 00 6 0 O O O O O O Single Sided spot welding Pro Pull Dent Removal Dent Pulling Contact Shrinking Nut Welding Bolt Welding Stitch Welding Carbon Rod Shrinking Rivet Welding Washer Welding Figure 6 5 i4 Single Sided Weld Programs Page 26 SINGLE SIDED WELDING fr Figure 6 6 i Figure 6 9 6 3 Bolt Welding Figure 6 10 Figure 6 12 6 2 Single Sided Spot Welding Single Sided spot welding is used where Two Sided spot welding cannot be used N Important The Single Sided spot welding is not permitted on supporting YN frameworks of a vehicle It is only permitted for cosmetic purposes Important Le soudage de C t Unique par points n est pas autoris e sur les cadres de soutien d un v hicule Il est seulement permis a des fins cosmetiques 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 3 Fit the Single Sided Gun with Single Sided electrode fig 6 9 4 Grind between the inner and the outer body sheets to remove paint primer and rust This ensures good electric
27. ee above click DONE to proceed click EXIT fo twice go back to the Weld Screens All Info Copyright Pro Spot International Inc 8 14 Log Feature Page 36 4 8 i4 Log Feature 8 2 Download the Log file for print Open ad_log directory O O1 BAON Take flash card out of the i4 and insert in a PC flash card reader Open the ADVANCED directory Find PROSPOT LOG file and copy it to your hard drive Open Weld Log directory locate Weld Log v1 2 xlt template Open the template click blue box Process Log File select the PRO SPOT LOG file that you just copied to your hard drive 7 The data should fill in respective rows and columns NOTE i4 Data Log will not process if header information has not been properly entered for reference please see the previous page of this document Also make sure that atleast one weld has been made on the machine before processing Data Log IMPORTANT Do not save over Weld Log template file Use the Save As function to save a copy Sample of Pro Spot Weld Log template DDN CDAT es PE s EL dl 2 QUALITY WELDING SYSTEMS WCt Date Time sec A 8 20 2008 12 25 10 0 17 8 20 2008 12 29 20 0 17 8 20 2008 12 39 10 0 16 8 20 2008 13 29 00 0 17 8 21 2008 06 12 20 0 15 8 21 2008 06 12 30 0 17 8 21 2008 06 13 20 0 16 8 21 2008 06 17 09 0 13 8 22 2008 12 29 20 0 17 8 22 2008 12 31 20 0 13 8 22 2008 12 33 10 0 15 8 22 2008 12 34 20 0 17 8 22 2
28. eut conduire aux soudures faibles de qualit inf rieure N IMPORTANT Always maintain proper electrode alignment Not doing All Info Copyright Pro Spot International Inc Double Sided Welding Page 20 5 4 Removing Welding Electrodes Figure 5 68 Removing Piston Electrode Figure 5 6b Removing Welding Cap Figure 5 6c Optional Weld Cap Removal Tool All Info Copyright Pro Spot International Inc 5 Double Sided Welding Removing Extension Arm Electrode The extension arm electrodes can be easily removed by lightly tapping them with a pin and hammer as shown in fig 5 6 To remove the piston electrode 1 Grip piston electrode with a set of pliers or vise grips fig 5 6a 2 Rock the pliers back and forth to loosen the electrode from the holder 3 Remove the electrode Note Vise Grips shown in fig 5 6a are specially designed to hold round objects without damaging or scarring them You can purchase a set from your local distributor or online at www prospot com A A IMPORTANT Do not attempt to remove the electrode by hitting it This could damage the electrode and the spot gun IMPORTANT N essayez pas de retirer l lectrode en la frappant Cela pourrait endommager l lectrode et le pistolet Removing Welding 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 cap
29. g Overview 7 Position the contact shrinking electrode over the high spot apply some pres sure and push the trigger to weld 8 Repeat as needed 6 9 Carbon Rod Shrinking Stretching CARBON SHRINK Figure 6 28 Figure 6 30 All Info Copyright Pro Spot International Inc 6 Single Sided Welding Carbon Rod is used to shrink or stretch metal on a vehicle The carbon rod can also be used on sharp dents caused by such things as hail 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Carbon Shrink Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Carbon Shrink graphic appears on the screen fig 6 28 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit the Single Sided Gun with Carbon Electrode fig 6 30 5 Clean the metal surface area 6 Ground the working area refer to section 6 1 Single Sided Welding Overview 7 Position carbon rod over the work area and push the trigger to start welding Keep trigger depressed to continue welding Move the carbon rod in such a way as to heat up the entire working area to the appropriate temperature Release the trigger to stop welding 8 Cool the surface with a wet rag or compressed air Page 30 6 10 Stitch
30. g The clips that hold the moulding do not usually come on the replacement parts Rivets are held in place during welding with magnetic adapter electrode 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Rivet Welding Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Rivet Welding graphic appears on the screen fig 6 19 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 3 Fit Single Sided gun with the magnetic rivet adapter fig 6 27 4 Insert rivet into the adapter fig 6 27 5 Prepare the surface area by removing paint and primer 6 Ground the working area refer to section 6 1 Single Sided Welding Overview 7 Position Single Sided gun over work area and push the trigger to weld 8 Repeat as needed 6 7 Dent Pulling with Washers and Slide Hammer with Hook The slide hammer with hook optional can be used in conjunction with washers to repair car body dents Tip You can purchase a slide hammer with hook from your local Pro Spot IN distributor or on the web at Pro Spot online store A Astuce Vous pouvez acheter un marteau glissant avec crochet de votre distributeur locale Pro Spot ou sur le web a la boutique Pro Spot en ligne Washers are held in place during
31. guliere Le soudeur peut basculer causant des lesions corporelles ou des dommages graves au soudeur ATTENTION Toutes les connexions electriques doivent tre faites par un lectricien qualifie Risque de choc lectrique ATTENTION Cables et tuyaux laches pr sentent des risques de declenchement Risque de blessures ATTENTION Veuillez utiliser des lunettes de soudeur sur place Les etincelles pourraient autrement blesser les yeux ATTENTION Etincelles de soudure pourrait provoquer une incendie Risque de blessures ATTENTION Risque de dommages aux materiaux a proximite de la soudure par exemple verre ou textiles ATTENTION Pour refroidissement efficace ne jamais soudeur sans attacher a la source d air comprim ATTENTION Tout le service et l entretien doivent tre effectu s par personnel et soutien de service Pro Spot Risque de choc lectrique ATTENTION Debranchez le soudeur de la prise murale avant l entretien ou nettoyage Risque de choc lectrique IMPORTANT Le soudeur i4 peut seulement tre utilis par personnel qualifi L utilisateur du soudeur doit avoir une connaissance de soudage par points et l alignement des v hicules endommag s par collisions IMPORTANT N teignez pas le soudeur pendant que le refroidissement est active IMPORTANT L air doit tre propre et sans huile et humidit Utilisez un filtre Page 6 2 3 Safety devices 2 3 1 Cooling When the Spot Gun is used continuous
32. ing electrode 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Nut Welding Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Nut Welding graphic appears on the screen fig 6 13 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the Shrink Electrode fig 6 15 5 Prepare the surface area by removing paint and primer 6 Ground the working area refer to section 6 1 Single Sided Welding Overview 7 Press weld on nut to the metal with Contact Shrinking electrode apply some pressure and push the trigger to weld 8 Repeat as needed 6 5 Dent Pulling with Spot Hammer Spot hammer dent pulling is used to repair dents on a vehicle body The spot hammer welds directly onto the work area and pulls the dent Tip The replaceable welding tip should last for over one thousand welds IN Contact your local distributor to order replacement tips or order on the web at Pro Spot online store Astuce Le bout de soudage remplacable devrait durer plus d un millier IN soudures Contactez votre distributeur local pour commander pointes de rechange ou commandez sur la Web Pro Spot au magasin en ligne 1 Push the Single Sided weld mode button fig 6 3 Single Side
33. l lectrode de point a souder tirant des onglets sur des endroits qui ont besoin d tre tir s All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 31 6 11 Pro Pull Dent Pulling optional Pro Pull is a patented innovative tool for fast and accurate dent pulling It features paintless dent removal functionality see sec 6 3 5 Paintless Dent Pulling With Pro Pull 6 11 1 Selecting Pro Pull Weld Mode PRO PULL DENT PULLING SYSTEM Figure 6 6 Selecting Pro Pull weld mode 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Pro Pull Welding Program by pressing the Left or Right Navigation Buttons fig 4 9 Make sure that Pro Pull Welding graphic appears on the screen fig 6 6 Make sure the ground plate is clamped firmly in place on the inside of a A clean metal surface as near as possible to the weld location NOTE Do not attach the ground to the metal you re about to weld on When performing other weld tasks such as dent pulling etc the ground attachment location becomes less critical Assurez vous que la plaque de terre est serr fermement en place a A l int rieur d une surface propre de metal le plus pr s que possible au lieu de soudure NOTE Ne fixez pas le terre et le m tal que vous tes sur le point de soudre Lors de l ex cutio
34. lable in each weld mode Navigate with the Right and Left arrow buttons and select weld power with the Next Program button Up Navigation button 8 Press the Help button anytime for instructions 9 Turn the water cooling switch ON for welding jobs over 7 welds Turn it OFF 5 min after completion Figure 1 1 Figure 1 2 Navigation button Up Navigation button Down Navigation button Closed Circle Navigation button Open Circle Display Screen Two Sided Single Sided Help Instructions Navigation Navigation spot gun button button button Left button Left button Right All Info Copyright Pro Spot International Inc Page 3 1 Introduction Congratulations on acquiring your new PRO SPOT i4 welder Team Pro Spot looks forward to supporting you You have a welder and support group that will increase your productivity The integrated features ease of use speed and quality welds that your i4 offers will become an important part of your business The following information will be needed when you call Pro Spot MODEL TYPE i4 SERIAL NO The serial number is located on the back of the unit For parts or service contact your local distributor Local number or in the U S call Toll free 1 877 PRO SPOT or 1 760 407 1414 for a customer service representative Visit Pro Spot On Line www prospot com E mail info prospot com NOTE You can now order parts online at prospot com store The i4
35. lectricity by certified people Connect air to the air inlet on back panel ATTENTION Avant d allumer le soudeur verifiez qu il est connect a AM l lectricit propre par des personnes certifi es Connectez l air a l entr e d air au panneau d arri re 1 Turn the power switch on the front panel ON 2 Connect Air to the air inlet located on the back panel 3 During the test procedure a Push Help to change language prompt appears on the display screen Click the Help button to access the System settings screen NG Bi where the language can be changed Select desired language by clicking the nu L Sees Change Language button then exit 4 After login procedure the software defaults to HSS Galv Two Sided weld mode 5 The welder is now ready to operate Make sure air pressure is set at 90 PSI Place the welding gun at the weld area and press the lower trigger button to weld The upper weld button is for spreading the electrodes open for better access 6 There are 6 different power levels pre programmed into the i4 The software defaults to 0 7mm weld program the thickness of one of the two layers of metal you are welding To change between preset power settings press the Up Navigation button fig 1 1 The programs will switch between 0 7 1 0 1 2 1 5 2 0 and 2 5mm metal thickness 7 To go to the next weld mode Mild Steel press the Right Navigation button fig 1 2 The same weld power levels are avai
36. ly the welding cables and the power trans former get hot To prevent the welder from malfunctioning due to overheating it is cooled using the built in air and liquid cooling systems The air cooling system cools the welding cables and the water cooling system coold the transformer inverters cable ends and the spot gun PRO SPAT PRESS HELP BUTTON TO CHANGE LANGUAGE u i4 features an air cooling system that cools all four welding cables There are two different Cooling Modes AUTO default and MANUAL In the AUTO mode the air cooling system turns on automatically after 15 30 welds and forced air starts to flow through the cable In the MANUAL mode the cooling system oper ates continuously To switch to MANUAL mode 1 Restart the software and press HELP button while start up screen is dis played System Settings screen will display fig 2 1 2 Select System Settings by pressing the Navigation button Up fig 2 2 3 Select Manual Cooling by pressing the Navigation button Down fig 2 3 Figure 2 3 AIR COOLING will activate The Liquid Cooling system is turned ON and OFF with the switch on the Front Panel fig 2 3a The water tank is located in the rear of the unit inside the center column The watertank should be filled with a 50 50 water amp antifreeze solution fig 2 3b Figure 2 3a Figure 2 3b 2 32 Overheat protection The built in overheat protection is de
37. n d autres t ches comme la soudure dent de traction etc le terre du lieu de saisie devient moins critique 6 11 2 Pro Pull Component Diagram Pro Pull comes with three different Blocking Plates with Quick Connect design Block window size 2 5 63mm x 1 5 38mm PP 10 04 A Large openings for great visual control Retrofit point for different end adapters Available for most weld guns not included See prospot com for more information of the pulling area Block window size 1 75 44mm x 1 25mm PP 10 03 CLT 55 Electrode Block window size 0 75 19mm dia PP 10 01 De CLP 75 Removable weld shaft The weld current is transferred through the shaft and NO CABLE is required to transfer the current All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 32 6 11 3 Pro Pull Assembly approx 0 7 17mm E 1 Attach the Weld Gun D to Weld Shaft C Secure Lock Bolt G 2 Slide weld shaft and gun to standard distance E 3 Attach desired block plate A 4 Position the weld tip in the bottom of the dent weld then pull the handle F to initiate the pulling action Use the shortest weld TIME possible to prevent extensive weld marks 6 11 4 Dent Pulling with Pro Pull Aim position amp fire Pull dent with Auto Twist gun to release tip Blocking 6 11 5 Paintless Dent Pulling With Pro Pull Glue Adapter for Paintles
38. national Inc 5 Double Sided Welding Page 23 5 7 X Adapter optional cont 5 7 2 Using the X Adapter Push the upper switch to open electrodes wide 5 7 3 X Adapter Configurations X Adapter PS 404 90 Electrode Upper PS 411 90 Electrode Lower Pivot Axle Tapered PS 412 PS 406 Electrode PS 405 Figure 5 7 90 Arm Set Push the lower switch to close electrodes and weld 45 Electrode Upper PS 421 45 Electrode Lower PS 422 Figure 5 8 45 Arm Set Page 24 All Info Copyright Pro Spot International Inc 5 Double Sided Welding 6 Single Sided Welding 6 1 Single Sided Welding Overview The Single Sided Weld System allows the operator to carry out welding tasks using a Single Sided Weld Gun The Single Sided weld procedure requires contact only from one side compared to two sides in Two Sided welding A ground plate must be connect ed to the panel to be welded for it to work fig 6 1 You can also use an optional magnetic ground plate to easily attach the ground cable to the metal fig 6 1b ground plate JS N NOTE Make sure the ground plate is clamped firmly in place on the inside of a clean metal surface as near as possible to the weld location Do not attach the ground to the metal you re about to weld on When performing other weld tasks such as dent pulling etc the ground attachment location becomes less critical Figure 6 1 REMARQUE Assurez vo
39. ng the welding cables that are connected to the spot gun The air pressure is regulated with the air regulator and the set pressure is indicat ed 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 snaps into the unlocked position 2 Turn the pressure regulator knob clockwise to increase or counter clockwise to decrease the air pressure 3 Lock the pressure regulator by returning the knob to the lock position 4 6 Setting Changing the weld program E K VI k i NEXT PROGRAM SAWE PROGRAM b SYSTEM SETTINGS Figure 4 7 The 4 features 6 different strength weld power modes It defaults to 0 7mm pro gram To change weld program press Next Program fig 4 7 The program box indicates the weld power thickness For example when welding two HSS Galv metals that are 1 2mm thick you should use the 1 2mm program If more power is desired press Next Program to reach the next level NOTE The Factory Password 1234 must be entered in order to modify weld programs To enter the Factory Password press the Help button while booting at the third screen to access the System Settings menu The text located near the Down Arrow button reads WELD SETTING CONTROL MODE AUTO MANUAL Auto is selected by default Press the Down Arrow button to enter Manual mode In the PASSWORD REQUIRED pop
40. pres sure with thicker metals but remember that too much pressure could decrease the resistance of the metal between the 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 through the lay ers 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 resulting in a harder stronger weld This fea ture is built in to the 4 s weld control program and is engaged automatically dur ing a weld cycle TIME The Timer controls the duration of the current applied during the weld cycle The ideal is to get a weld that uses higher current and shorter time to con trol heat buildup All Info Copyright Pro Spot International Inc 4 Operation Page 10 4 2 About your welder 4 2 1 Welder Overview amp Technical Specifications The welder is supplied with one of the following voltage and frequency combinations Input voltage 3 phase 208 240V 50 60 Hz OR 400 420 480V 50 60 Hz The actual voltage and frequency is stated on the rear panel name plate Open circuit output voltage 20v max E M C classification is C1SPR 11 12500A max 3 phase 8 2 5m standard At 7 bars 90 PSI 280 DaN 616 Lb At 9 5 bars 135 PSI 420 DaN 924 Lb
41. prompted 2625 Scroll to Custom B in the Double Sided weld menu Press System Settings closed circle button and you will arrive in the Login menu From here we can turn the Login off by pressing LOGIN ON OFF closed circle button The software will reboot with the preferences stored 7 3 Turning the Login Function On When we turn the i4 on it will not prompt for any User password if the Login function is turned off 6 T To turn the Login function on we have to enter the Factory Password 1234 while booting 8 Push the Help button while booting at the third screen to access the System Settings menu The text located near the Down Arrow button reads WELD SETTING CONTROL MODE AUTO MANUAL Auto is selected by default Press the Down Arrow button to enter the Manual mode In the PASSWORD REQUIRED pop up window enter 1234 using the arrow keys Exit by pressing the Open Circle button 9 In the System Settings menu press Exit open circle button The software will reboot and arrive at the first Status screen Press the Start Welding button closed circle and you will access the weld menu without being prompted for a User password Login function is still off 10 Scroll to Custom B in the Double Sided weld menu Press System Settings closed circle button and you All Info Copyright Pro Spot International Inc 7 14 Login Feature will arrive in the Login menu From here we can turn the Login on by pressing LOGIN ON OFF closed circle
42. provides advice as well as instructions for installation operation maintenance and troubleshooting IMPORTANT Read this manual carefully to A become familiar with the proper operation of the welder Do not neglect to do this as improper handling may result in personal injury and damage to the equipment IMPORTANT Lisez ce Mode d Emploi attentivement afin de vous familiariser avec le bon fonctionnement du soudeur Ne negligez pas de le faire puisque une mau vaise manipulation peut conduire aux blessures et dommages a l quipement The drawings in this manual are presented for illustra tive purposes only and do not necessarily show the design of the equipment available on the market at any given time The equipment is intended for use in accor dance with current trade practice 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 This publication contains information that is protected by copyright laws No part of this publication may be repro duced stored in a system for information retrieval or be transmitted in any form in any manner without Pro Spot International Inc s written consent Conformity with directives and standards 14 complies with CE standards Page 4 2 Safety 2 0 Safety amp Environmental Specifications 2 1 General The i4 Spot welder is designed for indoor us
43. re that the facility supply voltage and frequency are the same as shown on the welder name plate see section 4 2 About your welder The power supply must have a ground connection The supply must also be protected as follows v The 208 240V 3 Phase or Single Phase require 60A breaker v The 400V and 420V supply require a 32A slow blow fuse Circuit breaker 32D WARNING All electrical connections must be made by a qualified electrician Risk for electrical shock A ATTENTION Toutes les connexions lectrigues doivent tre faites par un lectricien qualifi Risque de choc lectrique 1 Connect the green wire to ground Note Make sure that the supply cable is at least 6 AWG at 208V and 400 V The i4 is rated for over voltage category Ill and polution degree 3 3 4 1 Electrical Plug Extension cords 2 If an extension cord is used with the welder ensure that the length of the extension cord does not exceed 10 m 30 ft and it meets the specifications of Item 1 above The cord must also be grounded Consult an electrician for safe and proper installation of the electrical plug NOTE When connecting the welder to Single Phase input power install Red and White wires Connect Green to earth ground Leave out the black wire Insulate and store the black wire properly 3 5 Connection of pneumatic air supply The i4 Spot welder must be connected to a pneumatic air network 100 PSI to 130 PSI the rear of the welder u
44. s Dent Removal All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 33 7 14 Login Feature 7 1 Overview PRO SPST 4 SOFTWARE VERSION 130322 Date 0112509 23 40 09 Weld Count 000000 Freq 0000 Hz Temp 0100 C Phi 0087 Y Ph2 0080 V Phi 0071 M USE LIR ARROW TO SELECT DIGIT SYSTEM SETTINGS After the welder has been turned on and when From this screen enter the desired login The i4 comes pre programmed with the login user ID 0001 the pre weld screen has appeared press the Start Welding button closed circle 0002 0003 and 0004 available by default After the correct ID is entered press DONE to continue to the double sided weld feature The i4 software versions 1 3 03 and up utilizes three levels of access a Factory Password Login Master Password and Login User Passwords Login Master Password 2625 Login User Password Selectable between 0001 9999 Only the Login Master Account has access to the Technician password configuration menu There are 20 passwords arranged in a 5x4 matrix with initial values of 0001 The displayed 0001 represents an active password Selecting any other number 0001 9999 will activate it The Login Master Password can activate up to 20 Login User Passwords 7 2 Turning the Login Function Off 3 4 5 After startup press Start Welding at the first Status screen closed circle button Login with the Manager Account when
45. signed to prevent damage to the welder caused by overheating The system will automatically shut off the welder when a pre programmed temperature is reached fig 2 4 DO NOT turn off the welder It needs the cooling air to cool the machine faster Wait until the display returns to normal usually 4 8 min Shorter duty cycles due to short weld times and rest Figure 2 4 periods between welds will allow the cooling system to function better and may prevent the auto shut off Consistently check weld strength by performing destructuive tests For continuous use do not exceed 3 welds per minute For operation not exceeding 60 minutes 6 welds per minute Welding current 9270A for continuous use 12 500A maximum at 1 weld per minute for 5 minutes max IMPORTANT Do not turn off the welder while the cooling system is activated IMPORTANT If the thermal breaker has switched off the welder please contact Pro Spot s authorized service personnel IMPORTANT Leave the water cooling ON for faster cool down IMPORTANT N teignez pas le soudeur pendant que le systeme de refroidissement est activ IMPORTANT Si le disjoncteur thermique a teint le soudeur s il vous plait contactez personnel de service autoris Pro Spot IMPORTANT Laissez couler l eau de refroidissement a l intention de se refroidir plus rapidement gt e eD D All Info Copyright Pro Spot International Inc 2 Safety Page 7 ee SYSTEMS 3 Installation 3 1
46. sing a standard connector 2 If not already set adjust the air pressure setting on the welder front panel to 60 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 gt IMPORTANT L air doit tre propre sans huile et humidite Utilisez un filtre Figure 3 2 Air supply port All Info Copyright Pro Spot International Inc 3 Installation Page 9 4 Operation 4 1 Before you begin welding Before you begin welding be sure to read and understand the following instruc tions The Pro Spot i4 is a state of the art Inverter Resistance Spot Welder that was designed for the collision repair industry It duplicates the welding procedure used by the car manufacturers It is important to understand the design and function of this welder before operating it ELECTRICITY ONLY The i4 uses only electricity to create the welds unlike the MIG welder which uses an arc from a feeding wire to build a weld nugget using inert gas and the feeding wire material PRESSURE The i4 has a built in air cylinder that compresses the Double Sided Gun s welding tips together automatically when triggered The compression is an important part of a good resistance weld The pressure is adjustable from the Control Panel The optimum welding pressure varies between 60 90 PSI 4 6 5 BAR 90 PSI seems to be a common starting pressure As a rule increase
47. ter optional C TYPE GUN The advantage of the C Type Spot Gun is that when making vertical pinch welds on quarter panels rocker panels door pillars etc the spot gun is positioned perpendicular to the work area Easy to reach Easy to use X TYPE GUN The X type design is used on certain applications where the C type can t reach 90 of all welding needs can be done with the C type but for some radiator sup port and truck bed pinch welds the X Adapter works better This new invention from Pro Spot makes it possible to weld where you never could before 5 7 1 Attaching the X Adapter Loosen the handle and pull Follow instructions in Sec 5 4 Insert the X Adapter onto the out C arm to remove piston electrode gun Tighten handle A Insert the Tapered Electrode B Tighten the Collar D set screw into the Shaft C Apply air carefully to put pressure on the electrodes so that Tapered Electrode seats firmly in the shaft before tightening the Collar D set screw A IMPORTANT Do not tighten the Collar before 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 Electrode IN Retreci dans le tube Le collier est con u pour emp cher Electrode Retreci de tomber du tube quand le pistolet est completement ouvert All Info Copyright Pro Spot Inter
48. the Closed Circle button Passwords can now be added changed There is a maximum of 20 possible Login User Passwords available to be active All Info Copyright O Pro Spot International Inc 7 4 Login Feature Page 35 8 i4 Log Feature 8 1 i4 Log Instructions To access the LOG menu screen on the welder Hild Weld Boron Pulse Custom 1 In the Welding screens navigate with side arrow gt to CUSTOM B Sie an maa sear os A 2 Click SYSTEM SETTINGS gt 3 Move cursor with side arrow to LOG LLOGIN LOG J MODE SETUP SLOPE TEMP 4 Click LOG MENU The following options are available SEND LOG TO USB HEADER CLEAR LOG EXIT o Click HEADER to edit Information that will appear on top of the weld data report 6 Click INCREASE t to select a character from A 0 7 Click DECREASE to select a character from A 0 click Right side arrow to accept character and move right Click Left Arrow to go back Click NEXT VALUE o to move to the next subject Vehicle Number etc click DONE to proceed The entered information is now placed in the LOG as a new heading The previous logs with previous headings will remain in the log without being erased Header info can be edited in MS Excel 8 Click EXIT o twice go back to the Weld Screens To Clear Log 9 Click CLEAR LOG from the LOG MENU to erase previous weld data in the log and to start a new header with no weld data in the log Fill out the log s
49. une baguette par les rondelles et en tirant la tige avec le marteau glissqnt avec crochet All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 29 6 8 Contact Shrinking CONTACT SHRINKING T 1 1 1 LI j y J Figure 6 25 Figure 6 27 Dent pulling with washers creates high spots in the metal Until now the common practice would have been to grind the surface resulting in a loss of sheet metal thickness With the i4 use the shrinking tip instead of a grinder to remove the high spots leaving a smooth and clean surface that s every bit as thick and strong as before Shrinking electrode also acts as a nut adapter refer to section 6 4 Nut Welding With this electrode you get two convenient tools in one 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Contact Shrinking Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Contact Shrinking graphic appears on the screen fig 6 25 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the contact shrinking electrode fig 6 27 5 Prepare the surface area by removing paint and primer 6 Ground the working area refer to section 6 1 Single Sided Weldin
50. us que la plaque de terre est serr solide ment en place l int rieur d une surface m tallique propre aussi pr s que possible du lieu de soudure Ne fixez pas le terre et le m tal que vous tes sur le point de soudure En accomplissant d autres t ches comme la soudure dent de traction etc le lieu de saisie devient moins critique Figure 6 1b In the Single Sided weld mode the following weld procedures are available for the 14 NG gt gt Single Sided Welding Carbon Rod Shrinking nn Stitch Welding Washer Welding ji N UU Nail Welding a and Nut Welding Rivet Welding Contact Shrinking Spot Hammer Dent Pulling Pro Pull Dent Removal Figure 6 2 Single Sided applications All Info Copyright Pro Spot International Inc 6 Single Sided Welding Page 25 weld mode SINGLE SIDED WELDING rn 50 10s Figure 6 3 Selecting Single Sided NEXT PROGRAM P SAVE PROGRAM P SYSTEM SETTINGS P TIMES CURRENT P E TY Figure 6 4 All Info Copyright O Pro Spot International Inc 6 Single Sided Welding 1 Make sure the welder is turned on Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 2 Use the navigation buttons Left or Right to select desired weld program refer to section 4 8 Setting the default weld program or fig 4 9 The display screen shows the currently selected program fig 6 4 Singl
51. welding with magnetic adapter electrode 1 Push the Single Sided weld mode button fig 6 3 Single Sided Weld Programs will display on the screen fig 6 5 The i4 software defaults to Single Spot Weld Mode fig 6 6 2 Select Washer Welding Program by pressing the Left or Right Navigatioin Buttons fig 4 9 Make sure that Washer Welding graphic appears on the screen fig 6 22 3 Choose weld power level by pressing the Next Program button repeatedly refer to section 4 6 Setting the weld program 4 Fit Single Sided gun with the magnetic washer adapter fig 6 24 5 Insert washer into the adapter fig 6 24 6 Prepare the dent surface area by removing paint and primer When welding on washers you only need to clean the area where the washer touches the metal since the grounding system is connected through a separate cable 7 Ground the working area refer to section 6 1 Single Sided Welding Overview 8 Position the washer at the bottom of the dent and push the trigger to weld the washer onto the metal 9 Hook the washer with the slide hammer and pull out the dent 10 Repeat as needed Tip You can also pull multiple washers by welding on a row of washers IN at the bottom of the dent inserting a rod through the washers and pulling the rod with the slide hammer with hook Astuce Vous pouvez galement tirer plusieurs rondelles par soudage sur YN une rang e de rondelles au bas de la Dent insertant

High Frequency Inverter Resistance Spot Welder

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