Orion 250i2 EV CNC User Manual

Orion Welder User Manual

250i EV CNC

Table of Contents

Chapter 1: Introduction ........................... p.3

Chapter 2: Welder and CNC Setup ................ p.4

Chapter 3: Electrode Setup ....................... p.10

Chapter 4: User Interface ......................... p.11

Chapter 5: Welding with Pendant ................. p.16

Chapter 6: Welding with Computer ............... p.25

Chapter 7: Operation .............................. p.35

Chapter 8: Welding Tips and Tricks ............... p.38

Chapter 9: Safety ................................. p.44

Chapter 10: FAQ ................................... p.49

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Orion Welders

250i EV CNC User Manual

Chapter 1: Introduction

ank you for choosing Orion Welders and congratulations on your purchase!

You are now the proud owner of a Orion 250i EV CNC System. is manual was designed to

have you welding safely within minutes of unpacking your new welder. Please read and follow

all safety precautions before proceeding with the welding process.

At Orion we are committed to producing quality products and ensuring complete owner

satisfaction. If you require assistance after reading this manual please contact us with the

information provided below.

Orion Welders.

1693 American Way Suite #5

Payson, UT 84651

Email: [e-mail]

1.877.786.9353 (toll free)

[phone] (international)

Fax: [phone]

NOTE: e information contained in this manual is subject to change as improvements are

made to our products. See the product specific page at www.orionwelders.com for the latest

version of this document.

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Chapter 2: Welder and CNC Setup

Step 1: Place CNC table onto workspace

• Clear a space on a sturdy table or work bench for the system to reside.

• e table should have a flat area cleared that is at least 36”(91 .5cm) wide and 24”(61cm) deep.

• Provide at least 40”(101 .6cm) of overhead clearance (above the tabletop).

• Ideally, locate the table near a 110VAC outlet.

• Connect power cord.

Step 2: Determine how to mount the Orion 250i2 welder

ere are two options. One option is to mount the welder next to the CNC table. is option is best when
planning to make hand-held welds in addition to making automated welds. e second option does not
involve the use of the microscope or hand held stylus. is option is best when only using the welder to
make automated welds on the CNC table.

OPTION 1: MOUNT THE WELDER NEXT TO THE CNC TABLE

STEP 1: ATTACH THE ARTICULATING ARM TABLE MOUNT

e Orion microscope arm table mount will clamp to any
tabletop. Simply place the table mount
on your tabletop in the desired location and then tighten the
screw located at the bottom of the table mount with an allen
wrench. Align the table mount screw with the center hole of the
included steel plate and then tighten. is steel plate will help
spread the weight of the system and provide more support.

STEP 2: INSERT THE ARM INTO THE MICROSCOPE ARM TABLE MOUNT

Insert the bottom end of the microscope arm into the
microscope arm table mount.

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STEP 3: CONNECT THE WELDER TO THE ARM

Insert the welder into
the top of the arm.
en use an Allen
wrench to secure the
welder in place on the
arm.

*If you purchased the microscope version follow steps 4 - 5

STEP 4: INSERT RUBBER EYEPIECE SHIELDS

Place the rubber eyepiece shields over the microscope
eyepieces.

STEP 5: CONNECT STYLUS

When connecting the stylus to the welder, line up the slit on
the stylus to the groove on the stylus port. en, push the
stylus into the port and twist the nut on the stylus until it stops.
Push in the stylus again and twist (repeat this until stylus is
secure). Now, insert the stylus into the stylus holder below the
microscope as seen above. Twist the knob below the stylus
holder to secure the stylus in place.

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OPTION 2: MOUNT THE WELDER TO THE SIDE OF THE CNC TABLE

STEP 1: CONNECT THE WELDER TO THE SIDE BRACKET ON THE CNC TABLE

Step 3: Connect the power cable and AC power

1. Plug the power
cable into the
back of the
welder.

2. Plug the other
end into the
power supply
box.

3. Now plug the
AC power cord
into the other
side of the power
supply box .

4. Last, plug the
end of the AC power cord into any standard 110-220VAC outlet.

1. 2.

3.

Step 4: Argon Setup

Use protective shielding gas, such as 99.996% pure Argon (Argon 4.6) or higher.

1. Ensure that your shielding gas tank is securely fastened to a stationary point near the
welding area.

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2. Turn the regulator dial COUNTER CLOCKWISE (closed) until it is fully
backed out to prevent over-pressurization of the line.

3. Screw the gas regulator onto the shielding gas tank.

4. Connect one end of the gas tubing into the gas regulator. It will stop
when it is fully connected. Tug gently on the tube to verify a tight fit.

5. Insert the other end of the gas tubing into the gas port on the top of
the weld head. It will stop when it is fully connected. Tug gently on the
tube to verify a tight fit.

6. Open the gas tank slowly. e dial on the right should pressurize and
the dial on the right should remain at zero (when the regulator dial is
fully backed out – see step 2).

7. Slowly turn the regulator dial CLOCKWISE until the gas pressure
reads between 7-10 psi. (is will adjust the dial on the left side of the
regulator.)

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Step 5: Connect the Janome to the welder

Use the provided cable that contains a 3 PIN and RJ-45
connector on one end and a 25 PIN parallel connector on the
other end to connect the Jonomi to the welder.

Plug the 3 DIN connector into the “Trigger” port on the back
of the welder and the RJ-45 cable into the “Shutter” port.

Plug the 25 PIN parallel connector into the I/O-1 port on the
back of the Janome.

Step 6: Connect the wires on the EV weld head to the welder

Using the wires on the weld head, connect the red wire to the positive port and the black wire to the
negative port.

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Step 7: Connect the EV weld head to the welder using the RJ-11 cable

Plug the RJ-11 jack
from the cable
chain wire harness
into the “Acc. Port”
on the back of the
welder then to the
port on the weld
head that reads “to
welder”.

Step 8: Plug in the weld head power cord

e weld head has a power cord coming out of the cable chain wire harness. Connect this to an electrical
outlet.

Step 9: Install the electrode in the nose cap

Remove the nose cap from the weld head and twist the electrode holder counter clockwise to open the
collet. Insert the electrode into the collet. Tighten the electrode holder clockwise to secure the electrode in
place. e electrode should protrude about a half inch out of the holder. Now replace the nose cap.

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Step 10: Power the welder and the EV weld head

Power the welder with the button on the bottom
of the welder, then turn on the weld head with
the switch found on the side. Once both are
powered the welder interface should display the
EV mode screen. If you don’t see this tab you
may be missing a connector or may have not
powered the weld head.

Chapter 3: Electrode Setup

Clean and Shape the Electrode

1. Attach the provided diamond disk to a dremel (or
similar type tool) . Power on the dremel and hold it in one
hand (close to your body to keep it steady) .

2. Place the electrode in your other hand between the
thumb and index finger .

3. Touch the electrode to the diamond disk (at your
desired angle) and rotate the electrode in the same
direction multiple times until it is clean/sharp .

4. Run the electrode shaft parallel with the rotating plate,
do not run it perpendicular to the electrode shaft.

Good Bad

*Desired angle is 15˚

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Chapter 4: User Interface

e Orion i2 automatically detects when an EV weld head is connected to the “Acc. Port” and is powered
on. If the 250i2 fails to detect the weld head, refer to the FAQ page in this user manual for common
solutions.

If a weld head is detected, the i2 will automatically enter the EV screen and hide the other options such as
“Arc”, “Tack”, and “Metals” tab. e auto trigger option is disabled along with seam and rapid fire modes.

EV Screen - Control Area

is section contains the different controls to customize the i2 ‘s settings for welding output.

POWER CONTROL

is circular dial controls and selects the amount of weld energy or weld power used based on the
waveform selected.

Users can touch or slide along the circular path to adjust and set the weld energy. Notice that the dial’s
controls are non-linear—is allows users greater refinement and control when selecting lower level
settings. is means, when welding with the classic waveform, the first section of the dial represents

0.01 – 1.5 Joules; the next section represents 1.5 – 3 Joules, the third represents 3 - 5 Joules, the fourth
represents 5 - 30 Joules, and the final represents 30 - 200 or 250 Joules (depending on model).

Additionally, users can input weld energy settings via a number pad. To access the number pad, tap on
the weld energy numbers inside the dial. is allows users to directly enter the exact desired weld energy
values. Once the numeric value is entered, tap OK to set the value and exit the number pad.

WAVEFORM

e waveform selections determine and control how energy is released when welds are made.

CLASSIC  e classic waveform is the default waveform for welding on all Orion welders. It has a high peak

current, which is the peak of the energy level, followed by a curved discharge slope. e curved discharge
slope allows the weld spots to cool with less internal stress, and without surface ripples. Classic welds will
typically have a smoother surface than other waveforms.

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TRIANGLE  e Triangle waveform is similar to the classic waveform’s ability to make smooth and uniform

weld results. One key advantage of the triangle waveform is the ability to set the peak and the length
independently. Meaning, a weld could have a very high peak and a very short time, or a very low peak with
a very long time, or any other combination of these two parameters. A Triangle waveform’s weld power
will always go to zero. In comparison, adjusting the weld time in Classic Waveform to be shorter does not
guarantee that the weld energy discharges to zero. Instead, the energy is simply cut off and not allowed to
fully discharge.

SQUARE  Similar to the triangle waveform, a square waveform allows users to adjust the peak and the

length independently. Again, the user can select Square waveform so that a weld could have a very high
peak and a very short time, or a very low peak with a very long time, or any other combination of these two
parameters. e difference of this waveform compared to Classic and Triangle is the abruptness of power
at the start and end of each weld. e square waveform closely mimics the weld output of a typical laser
welder.

IGNITION

e ignition options control the electrode tips position at the moment the energy is released.

STANDARD  In the Standard ignition option, the energy discharge occurs at approximately the same time

as the tip lifts off the work-piece surface. Since the electrode is close to the work-piece when the weld
is formed, it’s easier to get a weld on any surface or angle. is mode provides the most accuracy, but
requires the operator to hold the work-piece steadily below the electrode. is mode is perfect for metal
types that do not require a pre-heat phase during the weld. Because the electrode is closer to the work­piece, the electrode may dull more quickly.

STANDARD+  In Standard+, the energy discharge happens well after the electrode tip lifts off the work-

piece surface. While similar to the Standard option, Standard+ includes a “pre-heat” function before the
main weld. During this time, a very low amount of energy flows through the electrode and work-piece. is
preheating of the tungsten electrode helps create a more efficient weld area in preparation to the main
weld. e Standard+ ignition helps provide better weld consistency by allowing more variation
in contact pressure before the weld takes place.

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AGITATION

During the weld, a high frequency agitation feature can be used to improve weld formation and strength.
Additional energy is added to the weld in the form of micro energy bursts. ese energy bursts occur at a
rate of up to 600 times per second. Using agitation can produce an audible, high-pitched “ping” noise.

NONE  With “None” selected, no agitation is added to the weld. is is the standard weld discharge curve

with a smooth slope.

SLOPED  e Sloped agitation option offers low levels of agitation. It has minimal impact on spot size

formation, but yields additional penetration and enhanced weld strength.

SUSTAINED  e Sustained option offers high levels of agitation for improved weld spot strength in some

metals. e high levels of agitation energy will affect the spot size because of the extra energy used in this
option. To compensate for this addition of agitation energy, it’s recommended to lower the overall weld
energy slightly when using this option.

*Sloped and Sustained Agitation can increase weld penetration with minimal effect to the size of the heat
affected zone. Enabling these can make a big difference in weld outcomes, so exercise caution.

LENGTH

Length adjusts the amount of time that the energy is discharged from the welder. In classic waveform
mode, the length will automatically adjust to the recommended time as the users adjust the power dial. In
the Triangle and Square waveform mode, the length will not adjust automatically. Users will set the length
and power independently in Triangle and Square waveform modes. Increasing or decreasing Length allows
for more or less total weld energy and will change the size and penetration of the weld spots.

WELD DISCHARGE SHAPE

After choosing the waveform, agitation, ignition, length and power you will have a weld discharge shape.
is shape is displayed on the screen in the blue section. As you adjust those 5 parameters the weld
discharge shape will change. e weld discharge shape and energy can be adjusted to fit the needs of
the metals being welded as needed. It is often best to start at a low energy with maximum length and no
agitation, then add energy in small increments as needed. Changing weld length will help fine tune the
results.

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PLAY/PAUSE, UNDO, AND RESET OPTIONS

PLAY/PAUSE  Pressing the Play/Pause icon, toggles between Play and pause. If the Play icon is green, the

welder is capable of making welds anytime a work-piece (connected to the positive alligator clip) makes
contact with the electrode. When paused (White Play icon), users are unable to weld.

UNDO  e Undo icon allows the user to go back through the 5 previous screen taps. is is helpful when a

change is accidentally made.

RESET  e Reset icon resets all the variables and parameters on the screen back to the factory default

settings.

Prepare the EV Screen to Make a Weld

Be sure to press the “Play” button in the lower left corner to enable welds.

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WELD INDICATORS

Power on the Orion 250i2. Once powered on, there are two indicator dots in the top left corner of the
screen. e top dot indicates the Weld Ready signal. e bottom dot indicates the Weld Good signal.

a. e Weld Ready dot will be red if the welder is not ready to weld, or green if the welder is ready to make
a weld.

b. e Weld Good dot will be red if the most recent weld was bad, green if the most recent weld was good,
or gray if a weld has yet been performed.

IGNITION SCREEN

Clicking on the “Ignition” button navigates to the screen pictured below where the user can adjust various
aspects of the weld discharge timing.

1. “LIFTOFF DELAY” controls the time between tip retraction and weld. Lower values will produce better

arc ignition consistency, but will contaminate the electrode tip more easily - resulting in shorter tip life.
Higher values will increase tip life, but will decrease the arc ignition consistency.

•If the EV unit seems to be misfiring often, clean and re-sharpen the tip of the electrode. If the problem
persists, try lowering the Lift-off Delay value. Make adjustments in increments of 10-20uS at a time,
because this delay can make a big difference.

•If the electrode seems to be sticking to the workpiece surface a lot, or the electrode tip seems unusually
contaminated, raise the Lift-off Delay value. Again, it is best to only adjust by 10-20uS at a time.

2. “MINIMUM TIME BETWEEN WELDS” controls the minimum amount of time that must transpire before

another weld can occur.

3. “TIP RETRACT DISTANCE” controls how far off the surface the electrode tip will be when a weld occurs.

Lower values will produce better arc ignition consistency.

4. “Head Travel Delay” controls how long it takes for the head of the nozzle cone to reach the welding
surface.

THE “STANDARD +” mode is recommended for most EV applications, but experimentation may show that

the other modes are better suited for specific applications.

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GENERAL SETTINGS

GENERAL SETTINGS

Application Tip Shape Waveform Ignition Agitation Length Power

Copper (0.015 - 0.020) Flat Triangle Standard + None 40 ms 11 kW

IGNITION SETTINGS

Tip Lift Off Delay 60 µs
Retraction Distance 1.0mm

Chapter 5: Welding with Pendant

Step 1:

Connect the hand-held control unit/ pendant to the TPU port on the
front of the CNC table.

Step 2:

1. Plug in the power cord on the back of the CNC table.

2. Power on the CNC table using the power switch on the back of the
CNC table.

3. If not already on, turn on the Orion 250i2 and the weld head.

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Step 3:

Initialize the robot by pressing the “F4” button on the pendant. You will
notice the text right above the “F4” key indicating “INIT” on the screen.
e text above each of the “F” keys will always display their function.

Step 4:

Make sure the pendant is set in the ‘Teaching Mode. e
light under the “F2” button should be illuminated. If it is not
illuminated, press the “MODE” button, then use the cursor
arrows to highlight “Teaching Mode”. Once highlighted, press
the “ENTR” button.

Step 5:

2. e next few steps will focus on setting up the welding
parameters. First, choose the Triangle waveform.

3. Set the ignition to Standard+.

4. Set the agitation to None.

5. Set the power between 2-4kW. (is is only for setup
and training purposes. Normal power settings are
between 8-12kW).

6. Set the length between 30-40ms.

7. Press Play button to put welder in play. e Weld Ready
indicator dot will turn green.

17

Step 6:

1. Press the word “Ignition” to open the advanced settings
menu for the ignition settings.

1. Set the Lift-off Delay between 100-110 uS.

2. Set the Minimum Time Between Welds to 50ms.

3. Set the Tip Retract Distance to 0 .8mm.

4. Set the Tip Retract Delay to to 50ms.

5. When done, you can exit this advanced settings menu
by pressing the red “X” in the upper right corner (below
the graph portion of the screen).

Step 7:

Secure your fixture to the CNC table. M4 screws can be used
to mount directly to plate.

Step 8:

1. We will make a sample program, using Program 1. To select Program 1, pressing
the “PRG NO” button.

2. Press “1”.

3. en press “ENTR”.

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Step 9:

1. Press “F2” to select the “JOG” mode.

1. Next, pressing the XYZ arrow buttons will move the robot in each respective
direction. e X buttons will slide the plate forward (-) and backward (+) relative to
the front of the CNC table. e Y buttons will move the weld head left (-) and right
(+). e Z buttons will raise (-) and lower (+) the weld head.

2. Holding the shift key while pressing the XYZ buttons will increase the speed of
the movements.

Step 10:

Move the weld head (XYZ) to the location where the first weld will occur. When
setting the Z, lower the weld head until the force indicator on the side of the weld
head is set between the 3rd and 4th large tick marks (5th-7th total marks). Once
the XYZ are set, press “ENTR” to submit the coordinates for the first weld. is will
be saved as “Point 1.”

Step 11:

After pressing “ENTR” the screen will ask to choose a point type.
For welding, we will choose “Weld Point.” If “Weld Point” is not already
highlighted, use the cursor buttons in the bottom right of the pendant to
choose “Weld Point .” Once “Weld Point” is highlighted, press the “ENTR”
button to confirm choice.

Step 12:

Now you should be at this screen with “P2” displayed in the top right of the screen. To see the details of
Point 1 that we just created, press the left cursor (<-) button. e coordinates are displayed on the 3rd line
down on the screen. e 4th line shows that this point is a weld point. To create the next weld point, press
the right cursor (->) button.

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Step 13:

e screen should now show a “P2” in the top right corner. e robot is still at the “P1” coordinates. To
move to the next weld spot, make sure the “JOG” state is selected by pressing “F2.”

Step 14:

To move the robot to the next point:

1. e first movement needs to be to raise the weld head by pressing the Z
(-) button. is will raise the weld head away from the fixture and allow the
weld head to move in the X and Y without causing any damage. After the weld
head is raised, move the XYZ coordinates to
the next weld location. Remember that after the X and Y are set, the Z should
be lowered until the force indicator is set between the 3rd-4th large tick
marks.

2. Remember that you can use the “SHIFT” button to increase the movement speed of the axes
movements.

Step 15:

Once the nozzle cone is in place on the second position, press the “ENTR” button to submit position.

Step 16:

Chose “Weld Point” as your point type and press “ENTR.”

Step 17:

e screen should now display “P3” in the top right corner. Continue
setting the XYZ coordinates of any additional welds you wish to make
by using the same steps as above. For this training purpose we will
stop at 2 weld points.

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Step 18:

e next step is to press the “MENU” button to make additional
changes.
Choose “Individual Program Settings” and press “ENTR.”
Choose “Weld Settings” and press “ENTR” button. (Use the up/down
cursor buttons to navigate).

Step 19:

ese next settings will apply to each weld point coordinate in the
program.

1. Highlight “Weld Timeout,” press “ENTR,” press “6,” and press
“ENTR.”

2. Highlight Maximum Number of Weldings, press “ENTR,” press “5,”
and press “ENTR.”

3. Highlight “Action on Error, press “ENTR”, highlight “Stop at Point”,
press “ENTR .”

4. Highlight “Action After Error,” press “ENTR,” highlight “Next Point,” press “ENTR.”

Step 20:

Press the “ESC” button to exit the Weld Settings menu. Press “ESC” again
to exit the Individual Program Settings menu. Scroll down to “All Program
Common Settings” and press “ENTR.” Next scroll down to “PTP Condition”
and press “ENTR.”

Step 21:

Set the parameters as follows: PTP Speed = 100%. Line 2 = Relative Mode.
Z Move Height = 0.75in. Z Up Distance = 0.5in. Z Down Distance = 0.5in.
Once completed, press the “ESC” button three times until the words
“Program 1” can be seen in the top left corner of the pendant.

21

Step 22:

Nothing that has been done so far has been saved to memory, so press
the “SAVE” button at this point. You will see the screen display “Saving
Data.” Wait a moment and it will return to your previous screen.

Step 23:

At this point we have two weld points saved. (Possibly more if you added
additional points).

1. Press the left cursor button until the words “Common Work Home” can
be seen in the top right corner of the screen.

2. Next press the “GO” button. CAUTION: is will move the robot back to
the home position, so don’t be in the way of the robot arm.

Step 24:

e robot should look something like this, back at home position. It is now
possible to scroll through home position and each of the weld points we
previously created. To do so, use the left/right cursor buttons to select a weld
point (P1 or P2 in the top right corner). Pressing “GO” on the pendant will move the
robot to the coordinates of that weld point. Scroll right to P1 and press “GO.” is
will move the robot to the first weld point. Scroll right to P2 and press “GO.” e
robot will now move to the second weld point.

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Step 25:

PLC inputs and outputs
Next we will experiment with the PLC inputs and outputs.

1. If not already set, pick a weld point and press “GO” to move the robot to one of
the already configured weld points.

2. Press the “UTILITY” button.

3. Scroll down to “Test Menu” and press the “ENTR” button.

Step 26:

Scroll down to “I/O Test” with the cursor buttons and press the “ENTR” button.

Step 27:

is screen displays and give access to all the PLC inputs and outputs.

1. e cursor buttons can be used move around this screen and the “ENTR” button
can be used to trigger the outputs.

2. e “I/0-1 IN” line has 8 spaces, and the 3rd from the left should display “1.”
is indicates that the welder is ready to weld (the play button is pressed and the
welder is ready to weld). Repeatably pressing the “Play” button on the welder will
make the “1” appear and dissappear. Put the welder in “Play” (make sure the “1” is
visible).
e 1st space from the left on the “I/O-1 IN” line indicates that a weld has
occurred and it was good. Since we have not made a weld yet, this first space
should be blank.

3. e “I/0-1 OUT” line has 8 spaces. Move the cursor to the 1st space from the left. is output is used to
trigger a weld on the welder.

2. With the cursor in the 1st position from the left on the “I/O-1 OUT” line, press the “ENTR” button to
trigger a weld manually.

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Step 28:

1. After the weld has finished you will notice how both the 1st and 3rd spaces of the “I/O-1 IN” now have a
“1.” is indicated that the welder is ready again and the previous weld was good.

2. e 1st space of the “I/O-1 OUT” line is now displaying a “1.”

3. While still highlighting the 1st space of the “I/O-1 OUT,” press the “ENTR” button again to dismiss the “1”
and stop triggering the welder.

4. If the previous weld is not registering as ‘good,’ make sure the weld length is set between 30-40ms.

4. Once completed and the system is functioning as desired, press the “ESC” button until the words
“Program 1” is displayed in the top left of the screen.

Step 29:

In the top left of the Orion 250i2 screen, the PLC weld ready and weld good
signals are displayed for your convenience. ese two dots will display the
same information we just looked at on the I/O Test screen on the pendant.

Step 30:

To run the entire program and make welds at all the weld points we previously programmed, press the
“Utility” button. Next, highlight “Test Menu” and press “ENTR.”
Next, highlight “Test Run” and press “ENTR.” is will put the CNC robot into a test run cycle.

Step 31:

To being the test run, press the “F4” button. is will go to each weld point and
make a weld. If everything functioned as expected you can now go back by
pressing the “ESC” button a few times and program the rest of your weld points.
(Press the right cursor button and use the XYZ buttons to position the weld head).

If something isn’t working please refer to the FAQ section of the user manual or
contact customer support.

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Chapter 6: Welding with Computer

Step 1:

To use the Janome with a PC computer, it must be connected through
a local area network (LAN). First, hook up the Ethernet RJ45 cable from
your network or router. e second step requires us to find the IP
address of the Janome. is can be found in two different ways: (1) by
using the hand held pendant, or (2) by looking at the list of connected
devices on your LAN or router. Contact your IT department for help
looking up the IP on the LAN or router. Otherwise, follow the next
steps to find the IP address using the pendant.

Step 2:

Using the pendant to finding the IP address:
Connect the pendant to the TPU port on the front of the Janome.
If not already done, plug in the AC power cord to the back of the Janome, and power it using the power
switch.

Step 3:

Next, press the “ESC” button a few time to make sure the pendant is on the home screen. Next, press
the “MODE” button, scroll down and highlight “Administration” and then press “ENTR.” Highlight
“Administrative Settings Mode” and press “ENTR.”

Step 4:

Next, scroll down and highlight “Ethernet Settings” and press “ENTR.” e IP address should be listed.
Write this down as you will need to enter it into the PC computer. If the IP address doesn’t look right, make
sure the robot has been plugged into a LAN that has a router or gateway. Contact your IT department with
any issues or questions.

25

Step 5:

Once you have the IP address, you will need to disconnect the hand
held pendant and connect the Bypass Connector into the TPU
connector on the Janome before proceeding with setup.

Step 6:

2. e next few steps will focus on setting up the
welding parameters. First, choose the Triangle
waveform.

3. Set the ignition to Standard+.

4. Set the agitation to None.

5. Set the power between 2-4kW. is is only
for setup and training purposes. Normal power
settings are between 8-12kW.

6. Set the length between 30-40ms.

7. Press Play button to put welder in play. e Weld
Ready indicator dot will turn green

Step 7:

1. Press the word “Ignition” to open the advanced
settings menu for the ignition settings.

1. Set the Lift-off Delay between 100-110 uS.

2. Set the Minimum Time Between Welds to 50ms.

3. Set the Tip Retract Distance to 0.8mm.

4. Set the Tip Retract Delay to to 50ms.

5. When done, you can exit this advanced settings
menu by pressing the red “X” in the upper right
corner (below the graph portion of the screen).

26

Step 8:

Setup your fixture to the table. M4 screws can be used to mount directly to plate.

Step 9:

Install the JR-C-Points (Sunstone) software. Next, open the software.
Click on “Robot” in the menu bar, and then drop down and click on “Ethernet
Settings.”

Step 10:

Click the “Register” button, then type in the IP address of the
Janome. e Robot Name can be changed.

Step 11:

Next, select the robot by clicking on it, and then click “Set Target.” en close the
window by clicking “Close.”

27

Step 12:

Click on “Robot” in the menu bar again. Drop down and then click
on “Receive C&T Data.”

Step 13:

A popup windown will appear. Click the “Receive” button to
initiate communication between your PC and the Janome.

Step 14:

Once the PC and Janome finish communicating, another popup window will appear. Click the “OK” button.
If this step is not completed successfully, contact your IT department to help you setup the IP Address.

Step 15:

Next we will create a weld program. Click on “Robot” in the
menu bar. Next drop down and click “Meca Initialize.” is will
initialize the robot and move the X,Y, and Z parameters to the
‘Home’ position. CAUTION: is will move the robot to the home
position, so don’t be in the way of the robot arm.

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Step 16:

is is home position.

Step 17:

Click on “Edit” in the menu bar. Drop down and click on “Add
Point.”

Step 18:

Under the point that was just created, click the drop down for
“Type” and select “Weld Point.”

Step 19:

Click the “JOG” icon. is will pull up a JOG window that gives
access to move the Janome Robot around.

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Step 20:

1. ese cursors are used to move the robot head around. Click
on the buttons to move the robot. For this particular robot
the “X” controls the plate movement. e “Y” and “Z” controls
the head movement. Click a button to move the head in that
direction. Note that holding down the “Shift” key on the keyboard
while clicking on these cursor buttons will move the head more
quickly.

Step 21:

After moving the X,Y,Z coordinates, the values update to display
the values of the current position of each axis.
Use the jog buttons to move the weld head to the location where
the first weld will occur.

Step 22:

When setting the Z, lower the weld head until the force indicator
on the side of the weld head is set between the 3rd and 4th large
tick marks (5th-7th total marks).
(Add photo of force indicator on side of CNC EV head)
e CNC EV head has a force indicator on the right side to show
you how much the head is depressed.

Step 23:

is is the position of the head for Point 1 on this setup.

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Step 24:

In order to get the x, y, and z coordinates from the JOG window
to the point window, you will need to copy them by highlighting
the number in the JOG window and right clicking with the mouse
and clicking “Copy.”

Step 25:

You can then paste the number by right clicking the
corresponding axis and left clicking “Paste.”
Alternatively, you can manually type each value by clicking in the
box and typing in the value that is currently dispalyed in the job
window.

Step 26:

Once completed the x, y, z, on the Point window should
correspond to the x, y, z on the JOG window.

Step 27:

To add another point, click on “Edit,” then “Add Point,” or
simply right click in the space next to the Point 1 parameters
and click “Add Point.” Move the x, y, and z coordinates to the
next weld location. When moving the weld head, it is strongly
recommended to move the z up before moving x and y. Failing
to do so may damage your workpieces.

Step 28:

is would be a good time to save your progress by clicking on
the “Save” icon.
You can chose where to save the file and you can name it what
you want. After giving the file a name click on the “Save” button.

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Step 29:

Click on “Program” in the menu bar. Drop down and click on
“Individual Program Settings.”

Step 30:

On the “Individual Data” tab, click on the “Weld Settings” button.

Step 31:

Click each of the values above and change them to the following:
Weld Timeout = 6 seconds. Maximum Number of Weldings =

5. Action on Error = “Stop at Pont.” Action After Error = “Next
Point.” Click “OK” when completed.

Step 32:

Click on the PTP Condition tab and make sure the check box
“Individually set Program data” is checked. Change the settings
to match the following: PTP speed = 100%. Type
= Relative Mode. Z move Height = 20mm. Z up Distance = 15mm.
Z down Distance = 15mm. If your fixture requires more Z height
movement you can adjust these to heights that are needed for
your fixture. Press the “OK” button when completed.

32

Step 33:

At this time we will save our data again by clicking on the “Save”
icon. Next we will send the data to the Janome robot. To do so,
click on “Robot” in the menu bar, and then click on “Send C&T
Data.”

Step 34:

On the popup window, click the “Send” button.
e program will show a progress bar. Once
complete, click “OK” on the new popup window.

Step 35:

To move the weld head to one of the programmed weld points,
click on the point, and then click the “Go Move” icon. e robot
will move to that location, but will not yet send a signal to Orion
i2 CNC EV to weld.

Step 36:

Next click on “Robot,” then drop down and click on “External
I/O.” is new screen displays the status of the weld ready
signal, the good weld signal, and give access to manually
trigger a weld.

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I/O-1-IN pin 06 is the Weld Ready signal. I/O-1-IN pin 08 is the
Weld Good signal. I/O-1-OUT pin 8 is a button that can be used
to trigger a weld. Both indicators are off, so this indicates that
the welder is not ready and the welder hasn’t welded yet, or that
the last weld was bad. When you first
get to this screen, I/O-1-IN pin 08 should be gray (OFF) and I/O-1-IN pin 06 should be red (ON). Once you
click on I/O-1-OUT pin 8 it will change the text from “OFF” to “ON.” Once the welder has triggered you will
need to click this again to change the text back to “OFF.”

During a weld, all the inputs will be gray (OFF) and the output will
be red (ON). Once you click the output button again, it will go gray
(OFF), which has to happen before the next weld. Both inputs,
Weld Ready and Weld Good should be red (ON) if the weld was
good and the welder is ready to
weld again. is will be what normally happens. If I/O-1-IN pin 08 is gray (OFF) after welding, then the
previous weld was bad. is could happen for various reasons:

• e weld head is not in position so a dry fire happened.

• e electrode is not in the collet of the nozzle cone.

• e electrode stuck to the surface.

• If this happens you will want to increase the lift off delay in the ignition settings screen on the Orion

250i2 screen.

• e electrode was too far from the surface, so you will want to decrease the lift off delay in the

ignition settings screen on the Orion 250i2 screen.

In the top left of the Orion 250i2 screen, the PLC Weld Ready and Weld Good
signals are displayed for your convenience. ese two dots will display the
same information we just looked at on the I/O Test screen on the pendant.
Green means ready and good weld and red means not ready and bad weld.

34

Step 37:

If you click the “Point Playback” icon the robot will go to
the currently selected point and make a weld. In this case
you will not need to trigger the weld, because the robot will
automatically do this for you.

Step 38:

You can have the robot automatically run though each point and
weld and then return to home by clicking on the “Test Run” icon.

Step 39

Once ready to use robot in run mode, click on “Robot,” drop
down and click on “Change Mode.” Click on “Switch Run Mode”
and click “O” twice. Now the green button on the Janome
robot will start the weld process and run through each of the
programmed weld points and then return home when finished.

Chapter 7: Operation

Power Up

• Press the power button on the lower right side of the i2 to power up the machine.

• Flip the rocker switch on the front of the weld head to the “ON” position. e green LED should

illuminate and the i2 should detect the weld head and switch to EV mode.

• Flip the rocker switch on the back of the robot to power up the system and make sure the

emergency stop button is not depressed. e screen should light up and the teach pendant should
be active.

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Preparation

SYSTEM CHECK

• Remove the brass gas cone and check the length/condition of the electrode. e electrode

should extend past the steel collet nut approximately ½”. Make sure the tip is free of build-up and
sharpened according to the weld application. Replace the brass gas cone.

• Open up the valve on the argon tank and set the regulator between 10-15psi. A read-out on the

upper right corner of the i2 screen will help verify that argon is reaching the unit.

FIXTURE

• Attach any fixture plates/base plates to the Robot “Y” axis mount plate as needed for the weld

application. Note: be sure the selected base/fixture is able to keep the workpiece stable during rapid
movement, and that it accounts for weld heat (a plastic base placed below two thin sheets can often
melt due to the heat of the weld).

• Place workpiece in/on fixtures and double check stability.

POSITIONING

• Use the Robot Teach Pendant to jog the weld head until the brass gas cone is directly above the

intended weld area (refer to Robot User Manual for directions).

• Jog the Z axis down until the tip of the Gas Cone is resting about an 1/8” above the workpiece and

use the Pendant to set the start height.

• Make sure the i2 is not in “Play” mode. Jog the Z axis down until the tip of the gas cone touches the

part. Continue jogging down and use the scale on the right side of the unit to determine the amount
of force being applied. e more depth from the Z axis, the more force the unit will apply to the part.
Typically, about half force will be sufficient. Note: do not exceed a Z depth of 7/8” as it could create
an “over-force” situation that could damage the workpiece or weld head.

• Create a weld path program following the “Robot Programming Guide” section. Note: it can often be

a good idea to do a dry run of the program without a part loaded to ensure correctness.

• Load the workpieces to be welded onto the “Y” axis slide plate.

Test Settings

• Typical applications will be performed in “Triangle Weld Mode” on the i2 screen. Note: Usually, it is a

good idea to set the length to max and start with a low power setting (refer to the Orion 250i2 user
interface section for more information on each setting). Increase the power in small increments until
the “ideal” setting can be determined.

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• Press the triangle button in the lower left corner of the i2 screen (the button and waveform graph

will change colors and the word “Play” will appear below the triangle).

• Use the Pendant to jog the head to a desired weld location.

• Jog the head down until the brass gas cone makes contact with the workpiece and compresses the

spring to the desired distance (as gauged by the scale on the side of the weld head).

• As soon as the gas cone makes contact with the surface, the weld cycle will be initiated.

• e electrode will begin its descent toward the work surface and continue descending until it

touches the workpiece.

• Once the electrode completes the “touch” circuit, the focus arc will initiate and the electrode will

begin to retract.

• e main energy discharge will take place once the set amount of time has transpired. is is the

“Weld” and a small flash may escape from beneath the tip of the gas cone if there are any gaps. e
weld should be audible.

• Once the weld takes place, use the pendant to jog the Z axis up until the gas cone is no longer in

contact with the work surface.

• Examine the weld and verify success (refer to the Tips and Tricks section and i2 Interface Section for

more information about obtaining ideal weld results).

• Repeat as necessary until satisfied with results.

Run Program

• Press the “Play” button in the lower left corner of the i2 screen.

• Make sure the workpieces being welded are loaded and secure.

• Make sure the emergency stop button is not pressed on the robot or pendant.

• Select desired program.

• Make sure there are no obstructions in the path of the robot.

• Press the green “Start” button on the front of the robot.

• e robot will move to each programmed location to place welds each time it lowers. If a weld

does not take place once the head lowers, the unit will automatically signal the robot to repeat the
downward movement at that spot until a weld takes place or the system times out. In order to use
this feature the robot will need to be programmed to wait for this signal before moving on.

• Several weld programs can be saved to the robot for different applications.

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CNC EV Compression Force Table

COMPRESSION

DISTANCE

1/8” 1/4” 3/8” 1/2” 5/8” 3/4”

RESULTING SPRING

FORCE

1.5 3 4.5 6 7.5 9

Chapter 8: Welding Tips and Tricks

Electrode

MAINTENANCE

e condition of the electrode tip can greatly affect weld quality. As weld slag and oxidation builds up on
the electrode, the weld spots can become erratic in size and shape and the arc generation can be affected.

• Keep the tip as clean as possible throughout the weld process.

• Ignition settings can be tweaked to help prevent tip erosion and contamination during the welds

(refer to Ignition Section).

• Periodically check the electrode during the first weld cycles of a new weld application to establish a

baseline for the number of welds that can take place before the tip needs attention. It is a good idea
to make electrode maintenance part of the SOP for the weld process.

TIP SHAPE

e geometric shape of the electrode can have an effect on weld penetration and quality, depending on
the metals being welded and the application .

• Flat Tip - A perfectly flat tip is useful when welding “splashy” metals such as silver and aluminum.

Typically, metals that flow well when molten are best suited for a flat tip.

• Tapered Tip - e tip can be tapered into a flat to help focus the energy for more penetration and

better arc starts, but continue to minimize expulsion during a weld.

• Sharp Tip - Sharp tips are ideal for applications that need high weld penetration depth, or for

increased arc start capability. e sharper the tip, the easier it is to start the arc. If welds are
continually missed throughout a weld cycle, try sharpening the tip.

38

GRINDING

• e electrode should be sharpened using the included diamond grinding wheel in a high speed

rotary tool.

• Hold the electrode at about a 15° angle off horizontal and spin the electrode between the thumb and

forefinger as it grinds.

• Make sure the diamond grains on the wheel are dragging across the electrode parallel to the length,

not perpendicular. is grinding technique allows the plasma to flow off the tip in a more uniform
manner during arc generation – leading to more uniform weld spots.

Gas Cone

e gas cone is the first point of contact the weld head will make with the parts to be welded. It acts as the
positive leg of the weld circuit and also applies pressure to the weld site to ensure good contact between
layers during the weld.

• Keep the tip of the gas cone as clean as possible. It is a good idea to check it during every electrode

change, since build up and contamination can minimize electrical contact and lead to weak welds or
missed actuations.

• A size 1 drill bit can serve to clean out the weld splash material from the inner diameter of the tip.

• 600 grit sand paper on a flat surface can serve to clean up the tip and remove any contamination. Be

sure to keep the cone level during the sanding process (if the tip is sanded on an angle, the electrical
contact could be minimized).

Metals

e size (shape and thickness), configuration, and alloys/types of metals can be highly influential on
successful welds.

SIZE/ CONFIGURATION

• Ideally, the two components being welded should be similar in thickness and size.

• If one of the components is thicker than the other, it is usually best to place the thinner component

on top.

• Some size combinations will be difficult to achieve.

• Very thick bottom with thin top will lead to blow outs on the top layer.

• Very thick top and bottom parts will not allow sufficient weld penetration.

• Sometimes a layer of copper can be penetrated with sufficiently high weld energies, but if the

bottom layer is too thin (some battery cans) the heat necessary to get through the copper will blow

39

through the bottom layer (puncture the battery can). In this case, a thinner layer of copper should be
selected.

ALLOYS

Some metal combinations produce weld results that are less than desirable.

• Titanium to Stainless Steel leads to brittle welds.

• Aluminum to Copper welds are often weak.

• Aluminum to Stainless Steel welds can be brittle.

• Copper to Copper welds can require a lot of energy and create a lot of heat in the components.

• Most Brass welds are challenging because of the Zinc content causing uneven temperatures and

leaving soot upon evaporation.

• Nickel can often be used as an intermediary layer between two metals that don’t work too well

together (i .e . aluminum to copper).

Spring Force

• Typically, 10-12lbs of spring force is ideal for performing welds.

• e spring force may need to decrease if the parts are fragile and can’t withstand high forces.

• e spring force may need to increase if a weld spot forms on the top layer, but the bottom layer

remains unaffected.

• e spring force can also be lowered if weld cycle time needs to be reduced (the weld head won’t

need to take as much time to lower at the lower force ranges), but it is important to maintain some
pressure at the weld location for ideal results.

Orion 250i2 EV CNC Settings

Experimenting with weld parameters can be very educational and lead to a better understanding of
welding applications. Many different factors can have an effect on the way the welder will behave for
any given combination of settings (i .e . types of metal being used, thickness of metal, geometry of
components, gaps between mating surfaces, electrode size and shape, gauge of ground wire, argon
coverage, etc.). For this reason it can be somewhat difficult to produce a fail- safe settings schedule that
will work every time.

e best way to find the correct settings for a given application is to start low in energy and increase the
settings incrementally until the welds are strong enough and have the desired texture/size. e weld
results can be tweaked by changing the various settings available.

40

e following parameters can be set on the Orion 250i2 EV CNC:

MODE

e Orion 250i2 EV CNC can discharge energy following three different “Modes.”

• Triangle mode is used for the majority of the applications. e initial peak voltage is high and tapers

off in a straight, angled line.

• Square mode has lower peak voltages than the triangle mode, but can sustain the peak voltage for

the duration of the energy discharge. is mode can be useful for “delicate” workpiece welding or
for “splashy” metals such as silver or aluminum that become very liquid in the molten state.

• Classic mode mimics the discharge curve of typical capacitive discharge arc welds. e peak voltage

is high initially, but discharges in a parabolic curve which will drop off faster than in Triangle mode.
Classic mode can be useful when the amount of overall heat in the weld needs to be limited.

POWER

e Power setting, in conjunction with Length, controls how much energy will be released as the weld is
discharged.

• e higher the power, the more heat will be put into the weld. is typically leads to larger weld

spots with more penetration.

• A general rule of thumb is the depth of penetration equals approximately 1/3 the diameter of spot

size.

• When selecting power settings, it is a good idea to start low and increase incrementally until results

are achieved.

• Some of the more conductive metals like copper or silver will require higher power settings than

other metals.

LENGTH

e weld length setting dictates how long the discharge of energy lasts (in milliseconds).

• For most applications, the length can be set at the maximum for smooth weld puddles and good

penetration.

• Decreasing the length will lower the overall amount of energy entering the weld spot, which leads to

decreased heat into the weld area.

• In Triangle and Classic modes, decreasing the length can sometimes cause the welds to seem

“punchy” since the voltage is cut off closer to the peak (not allowing the lower voltages to “smooth”

41

the weld puddle and finalize the discharge).

• For very small components, sometimes it is helpful to decrease the length to limit the amount of

energy entering the weld.

AGITATION

Agitation is a secondary high frequency wave form that is superimposed over the main energy discharge
to help increase penetration and strength.

• ere are two pre-set agitation modes - “Sloped” and “Sustained.”

• Sloped agitation is the more mild of the two presets since the intensity of the discharge decreases

in conjunction with the main energy discharge. It is often highly useful for welding steel and similar
metals, but metals like aluminum and silver are not great candidates for agitation due to the highly
liquid nature in their molten states.

• Sustained agitation is very forceful and should be used only with larger workpieces that require high

penetration since the overlay discharge remains at the same intensity throughout the duration of
the main discharge. Some metals will exhibit molten metal expulsion from the weld site due to the
force of sustained agitation.

ADDITIONAL SETTINGS

Users can customize the frequency, duty cycle, and intensity of the agitation discharge by pressing the
word “Agitation” on the weld screen to enter a settings screen.

• Frequency - dictates the number of voltage spikes during the weld discharge. Lower frequency

agitation seems to work well for copper tabs to batteries. Higher frequencies can sometimes
improve the weld quality on metals that tend to crack during the weld.

• Duty Cycle - dictates the duration of each voltage spike. Higher duty cycles seem to be more

effective in most applications.

• Intensity (Voltage) - dictates the height of each voltage spike. e higher the voltage, the more

intense the agitation result.

• It can be helpful to look at the onscreen graphic representation while making changes to the

settings to visualize the effect on the discharge curve. Take note of the resulting welds.

IGNITION TIMING PRESETS

Timing can be important for proper arc formation and weld discharge. e Orion 250i2 EV CNC comes with
four timing presets.

42

• Standard mode is useful when using the Orion 250i2 EV CNC in Arc Mode (no weld head plugged in)

and welding small wires that can’t withstand the focus arc present in the other modes.

• Standard+ ignition mode should be used for most applications and includes a focusing “pre- arc”

that helps initiate the flow of plasma for the main energy discharge.

• Tip Saver mode also utilizes a pre-arc, but releases the main energy discharge such that the

electrode is further away from the surface when the energy is released. is can help prevent tip
contamination and degradation. If the system is misfiring on multiple occasions or creating surface
welds only, it may be necessary to revert to the Standard+ ignition mode.

ELECTRODE TIMING SETTINGS

EV mode on the Orion 250i2 EV CNC allows users to customize the timing of electrode movement by
pressing the word “Ignition” from the main tab.

MODES

• Lift-off Delay is in microseconds and is the amount of time between when the tip retracts and when

the weld occurs.

• Time between welds is in milliseconds and is a delay after a welds occurs and before another weld

can happen.

• Tip Retract Distance is in millimeters and is the amount of distance between the electrode tip and

the weld surface at the time of discharge. (is allows for less contamination on the electrode tip,
but with smaller energies there will need to be less distance otherwise a weld will not occur).

• Head Travel Delay is in milliseconds and is the time it takes the nozzle cone to travel and make

contact with the weld surface, after the delay happens the electrode will then come down and make
contact with the weld surface and weld.

43

Chapter 9: Safety

Read Before Welding

ONLY PERSONNEL TRAINED AND CERTIFIED BY
THE MANUFACTURER SHOULD SERVICE THE UNIT.

Use only genuine replacement parts from the manufacturer.
**Contact Sunstone Engineering before opening the unit for any reason**

SAFETY PRECAUTIONS

e below safety advice is generalized advice for the welding industry. ese safety precautions are not
all inclusive. All users should exercise caution while using this device. e following groups of symbols are
warning symbols:

SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION

ere is a possibility that flying sparks, hot work pieces, and/or hot equipment can cause fires and burns.
Ensure that the work area is clean and safe for welding before starting any weld job.

• Wear appropriate eye protection while using the weld head.

• Do not install or operate unit near combustible surfaces.

• Do not install or operate unit near flammables.

• Do not weld where flying sparks can strike flammable material.

• Remove all flammable materials from the welding area. If this is not possible,

tightly cover them with approved covers.

• Protect yourself and others from flying sparks and hot metal.

• Do not weld where the atmosphere may contain flammable dust, gas, or vapors.

• Remove any combustibles, such as butane lighters or matches, from your person before doing any

welding.

• Watch for fire and keep a fire extinguisher nearby.

• Do not overload your building’s electrical wiring – be sure the power distribution system is properly

sized, rated, and protected to handle this unit.

44

• Do not exceed the equipment’s rated capacity.

• Use only correct fuses or circuit breakers. Do not oversize or bypass them.

SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK

Touching live electrical parts can cause fatal shocks or severe burns. Incorrectly installed or improperly
grounded equipment is a hazard. Do not operate weld head in a wet/damp environment.

• Care should be taken not to short across the positive and negative terminals. At full power, the

weld current carries thousands of amps and is dangerous if the terminals are
accidentally bridged.

• All welds are performed at low voltage for increased safety of operation.

• Do not wear metal jewelry when welding. The terminals are safe to touch without

fear of arcing as long as no metal is on your hands.

• When altering or maintaining any part of the welding path (such as swapping electrodes or cables),

turn the unit off.

• Do not touch live electrical parts.

• Wear dry, hole-free insulating gloves and body protection.

• Properly install and ground this equipment. (Refer to the grounding codes and specifications of the

area you live in)

• Do not weld with wet hands or wet clothing.

• Always verify the supply ground – check and be sure that the input power cord ground wire is

properly connected to a ground terminal in the disconnect box or that the input power cord plug is
connected to a properly grounded receptacle outlet. Do not remove or bypass the ground prong.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect the input power cord and ground conductor for damage or bare wiring – replace

immediately if damaged – bare wiring can kill. Check ground conductor for continuity.

• Turn off all equipment when not in use.

• Use only well-maintained equipment and repair or replace damaged parts at once.

45

PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND
ARC RAYS

It is essential for every person in the immediate work area to wear/utilize proper
personal protection equipment. ere is a possibility that sparks can fly off from the weld
joint area; therefore, take the necessary precautions to avoid trapping a spark within your
own clothing.

• Wear protective garments such as oil-free, flame-resistant leather gloves, heavy shirt, cuff-less

trousers, high shoes, and a cap. Avoid synthetic fibers as they melt easily.

• Use an approved face shield or safety goggles with side shields when welding or when observing

others performing welds.

SAFETY PRECAUTIONS FOR HOT METAL AND CABLES

Welding material that has a high thermal conductivity will cause metal to heat rapidly. Repetitive welds in
the same location can also cause metal to heat rapidly.

• Avoid touching weld spots immediately after the weld has been performed as

they will be hot.

• Do not touch hot weld areas barehanded.

• Allow sufficient cooling time before handling welded pieces.

• Welding cables can become extremely hot. After extended use, be cautious when handling the

weld cables.

SAFETY PRECAUTIONS FOR FUMES AND GASES

Welding can produce fumes and gases. Breathing these fumes and gases can be hazardous to your
health. Sunstone weld heads produce minimal fumes and gases when compared to large-scale weld
heads. ough not required, some form of ventilation is recommended.

• Keep fumes away from face.

• Do not breathe the fumes.

• Ventilate the area and/or use local forced ventilation at the weld spot to remove

welding fumes.

• If ventilation is poor, wear an approved air-supplied respirator.

• Read and understand the Material Safety Data Sheets (MSDS) and the manufacturer’s instructions

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for metals, consumables, coatings, cleaners, and degreasers.

• Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the

weld can react with vapors to form highly toxic and irritating gases.

• Do not weld on coated metals, such as galvanized, lead, or cadmium-plated steel, unless the

coating is removed from the weld area, the work area is well ventilated, and the operator is wearing
an air-supplied respirator. The coatings and any metals containing these elements can give off
toxic fumes if welded.

SAFETY PRECAUTIONS FOR FALLING EQUIPMENT

Use a working surface of adequate physical strength to support the welding unit

•

during operation or storage.

• Secure welding unit during transport so that it cannot tip or fall.

MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES

Wearers of pacemakers and other implanted medical devices should keep away.

•

• Implanted medical device wearers should consult their doctor and the device

manufacturer before going near arc welding, spot welding, gouging, plasma arc
cutting, or induction heating operations.

OVERUSE CAN CAUSE OVERHEATING

Allow a cooling period between strenuous welding schedules; follow rated duty

•

cycle.

• If overheating occurs often, reduce duty cycle before starting to weld again.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents
(phone: [phone], website:www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal
Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office,

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Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 5250-7954 (phone: [phone])
(there are 10 Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101,
Quincy, MA 02269-9101 (phone: [phone], website: www.nfpa.org and www.sparky.org).

Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian Standards Association, Standards
Sales, 5060 Mississauga, Ontario, Canada L4W 5NS (phone: [phone] or in Toronto 416-747-4044,
website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from
American National Standards Institute, 25 West 43rd Street, New York, NY 10036–8002 (phone: 212-642­4900, website: www.osha.gov).

Precautions for the CNC Table

Warning: During weld head operation/program RUN it is important not to place hands or body extremities

directly below the Gas Cone or inside the travel envelope of the XYZ Table. e weld head makes sudden
movements and could pinch/smash/impact hands or other body extremities as it travels.

Caution: Always check the Z height settings prior to initiating a program. If the Z depth is set too low, the

unit can enter an Over-Force state that could damage the workpiece or weld head components.

Warning: Always disconnect the AC power cord before removing any cover panels. ere are live AC

connections inside the unit that could be an electrocution risk if the unit is plugged in. Note: removal of the
covers could void the warranty.

Caution: e electrode is often used in a sharpened state for weld applications. When removing the brass

Gas Cone for electrode maintenance, be aware that the electrode will be exposed and is a sharp object
that can puncture the flesh.

Warning: Keep fingers and clothing away from the cable chain while the unit is running.

Caution: During weld discharge, a bright flash can sometimes escape from beneath the tip of the brass

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Gas Cone. Looking directly at the flash could cause discomfort to the eyes.

Caution: e brass Gas Cone and Weld Cables can become hot to the touch during the weld process.

Exercise caution when handling directly after welding.

Chapter 10: Frequently Asked Questions

Q. WHAT IF MY WELD SPOT LOOKS DISCOLORED AND DARK OR HAS A LOT
OF PITTING?

•Make sure the argon tank is turned on and that you have at least 10psi going into the system.

•Make sure there are no kinks in the argon tubing.

•Check for leaks in the argon tubing. To do so, open the valve on the regulator until the system
pressurizes, then turn off the valve. If the PSI drops dramatically, there is most likely a leak.

•Make sure the inner diameter of the gas cone is cleaned from debris and that nothing is obstructing the
flow of Argon from the tip of the cone.

•Clean and re-sharpen the electrode.

•Clean the surface of the workpiece being welded and remove any coating/oxidation that may be present
at the weld location.

•Check the weld penetration depth. Make sure the material that the workpiece is resting on is not being
affected by the weld. Sometimes, if the weld penetration is deep enough to pass all the way through both
sheets being welded, non-metallic base materials or internal layers of a battery can actually melt and
become entrained in the weld spot.

Q. WHAT IF THE GAS CONE MAKES CONTACT WITH THE WORKPIECE, BUT
NO WELD TAKES PLACE?

•Clean and maintain the electrode (sometimes build-up on the electrode can interfere with arc
generation).

•Check Weld Timing on the Orion250i2 EV CNC. If the values are not correct, an arc may not be able to
initiate.

•Make sure the Orion 250i2 EV CNC is in “Play” mode (button on the lower left corner of the screen).

•Make sure the weld energy levels are set high enough for the material being welded.

•Make sure the green LED light on the front of the weld head is illuminated. e weld head must be plugged
in and powered on for a weld to take place.

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•Check the weld path. Make sure the (+) welding cable is firmly attached to the gas cone, and that both
welding cables are connected securely in the labeled locations on the back of the Orion 250i2 EV CNC.

•Make sure the top layer of the workpiece (the one coming into contact with the gas cone) does not have
any coating on it at the weld location. e gas cone and electrode must be able to establish an electrical
path through the top workpiece layer in order for a weld to initiate.

•Inside the weld head, a momentary limit switch signals the 250i2 EV CNC that the gas cone has made
contact with the workpiece. If the Z depth is not set low enough, the limit switch will not trigger and a weld
cannot take place. Failure of this limit switch would also cause failure of weld initiation.

•Try power cycling the Orion 250i2 EV CNC and weld head to reset any programming hiccups.

Q. WHAT IF THE ORION 250I2 EV CNC WELDER DOES NOT AUTOMATICALLY
DETECT THE WELD HEAD UPON DATA CABLE INSERTION?

•Make sure the EV weld head is plugged into power and has a fuse installed.

•Make sure the power switch on the weld head is in the on position and the green LED on the front cover is
lit.

•Make sure the RJ11 communication cable is firmly plugged into the “Acc. Port” on the back of the Orion
250i2 EV CNC welder and that the opposite side of the cable is plugged in to the weld head correctly. If the
cable is damaged, call Sunstone for replacement (normal RJ11 cables should not be used).

Q. WHAT IF THE ELECTRODE KEEPS STICKING TO THE SURFACE OR LEAVING
“FLAGS” OF METAL?

•Clean and re-sharpen the electrode.

•Increase the delay time.

•Increase the distance setting.

•Make sure movement of components is not being hindered (cover removal may be necessary).

•Verify that the electrode is retracting (cover removal necessary).

•Check the Tip Retract Delay in the “Ignition Menu.” Increase this time a little to decrease sticking.

Q. WHAT IF THE WELD SPOT SIZE IS INCONSISTENT OR IF THE SYSTEM
KEEPS MISSING WELDS?

•Clean and re-sharpen the electrode.

•Make sure contamination has not built up inside the gas cone.

•Clean the weld surface prior to welding (remove grease, oxidation, dirt, etc.).

•Make sure the tip of the gas cone is contacting the workpiece in a consistent, even manner.

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•Check the Tip Retract Delay in the “Ignition menu.” Decrease this time a little to increase successful welds.

Q. WHAT IS THE THICKEST SHEETING THAT CAN BE WELDED?

•Weldable sheet thickness varies depending on the type of material.

•Highly conductive materials like copper can generally be welded up to 0.020” thick.

•More resistive metals may be slightly thicker than the conductive metals.

•e relative size of the two components being welded should be comparatively similar.

•in conductive sheets welded onto thick conductive bases will be less successful (the bottom portion
acts as a heat sink and wicks energy away from the weld site) than thin sheet to thin sheet.

•If the top layer is too thick, the weld will not fully penetrate to the bottom sheet.

•Sometimes it can be useful to experiment with which material acts as the top layer when the application
permits.

•COPPER to ALUMINUM – since the melting temperature of aluminum is lower than that of copper, it is
best to use the copper as the top layer to avoid blowing holes in the aluminum.

•If the top layer is NICKEL or NICKEL COATED, the nickel can stick to the electrode and cause erratic weld
behavior over time. Ideally, the NICKEL would be used as the lower layer.

•COPPER to STEEL - it is generally best to have the copper layer on top since it will absorb the majority of
the energy.

•Some metals combine to form an alloy that is not as strong as the original metals. In this case it can be
useful to insert a third metal between the two layers to act as a binder. Nickel tabs work well in several
circumstances.

•With experimentation, one can determine how many layers can be welded at one time.

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ORION WELDERS

1693 American Way Suite #5

Payson, UT 84651

1.877.786.9353 (toll free)

+1.801.658.0015 (international)

OrionWelders.com