250i2 EV User Manual
Thank you for choosing Sunstone Welders and congratulations on your purchase!
You are now the proud owner of a Sunstone 250i2 EV System. This 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 Sunstone 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.
1693 American Way Suite #5
Payson, UT 84651
1.877.786.9353 (toll free)
NOTE: The information contained in this manual is subject to change as improvements are
made to our products. See the product specific page at www.SunstoneWelders.com for the
latest version of this document.
250i2 EV User Manual
Set Up Weld Head
1. (Air Cylinder Inlet): High pressure ¼” blue tubing that goes to (11A) Left Air flow regulator out
2. (Air Cylinder Inlet): High pressure ¼” blue tubing that goes to (11B) Right Air flow regulator
3. (RJ11): Comes from Welder unit (Communication)
4. (LED): Should be lit when switch (7) Switch is on
5. (4 PIN DIN): Wires come from argon valve and air valve
6. (AC INLET): Ac inlet that accepts 90-240VAC single phase. Uses a 4A fuse.
7. (Switch): Turns unit on and off
8. (Argon Weld Inlet): Comes from (13) Argon Out
9. (+ Terminal): Red 60 inch 12 AWG Weld cable comes from welders + terminal. (- Terminal):
Black 60 inch 12 AWG Weld cable comes from welders – terminal
10. (Air Valve Inlet): High pressure ¼” blue tubing come from air compressor
11. A and 11B (2 Air flow regulator out): High pressure ¼” blue tubing going from 11A to (1) Air
Cylinder Inlet and from 11B to (2) Air Cylinder Inlet. Both air regulators can adjust flow by
turning nut and knob on the bottom of the valves. Turning the knob clockwise will decrease
flow and turning it counter-clockwise will increase the flow. This allows the weld head to
raise and lower at a desired speed. Both of them will be preset to a desired flow at our
12. (Argon In): Clear 1/4” tubing coming from Argon tank. When pressurizing for the first time
be sure to check for leaks between Argon tank and valve. Argon can displace oxygen in the
13. (Argon Out): Goes to (8) Argon Weld Inlet
14. (Fan): Is always on. Don’t stick objects in slits.
15. (Head Height Adjustment Knob): You can turn knob Counter-Clockwise in order to loosen
and move head up or down or Clockwise to tighten.
16. (Head Height Adjustment Knob): You can turn knob Counter-Clockwise in order to loosen
and move head up or down or Clockwise to tighten.
17. (Bottom plate): Can be moved forward and backward. An isolated pad has been provided on
the top of this bottom plate. Work piece being welded must be isolated electrically from this
plate and from the mounting metal arm.
18. (Air pressure adjustment Knob): You can adjust this knob by pulling down on it and turning
it. Turning it Clockwise direction will increase pressure and turn the opposite direction will
19. (Air pressure gauge): Shows the pressure allowed into the weld head.
Set Up Welder
1. (+) terminal from EV weld head
2. (-) terminal from EV weld head
3. Gas inlet for Orion i2. This will
receive same argon air as EV weld
head before valve.
Accessory port on Orion i2 for connection to EV weld head.
5. (+) terminal from Orion i2
6. (-) terminal from Orion i2
7. Gas inlet after valve for EV
8. Shifted RJ11 Jack from Welder for
Refer to Orion i2 user manual in the interface section to find out how to use the non-EV weld
settings. Notice that once you plug in and turn on your EV weld head the Orion i2 will automatically
detect that the EV weld head is connected. If this doesn’t happen refer to the FAQ page for
common answers to problems. You will notice how you no longer have the ability to adjust
“Metals” or “Tack” settings. Also in the settings screens some options that are not needed in “EV”
weld state have been removed. You only have the option of “Foot Pedal” trigger and single fire in
“EV” weld state.
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, however will produce lower arc ignition
• If you notice that your EV unit is misfiring a lot check your tip shape first and then you
can also try to adjust this value down. Try to only adjust by 10-20uS at a time, because
this delay can make a big difference.
• If you notice that your electrode is sticking a lot to the surface or that you are getting
too much contamination on your tip, adjust this value up. Try to only adjust by 10-20uS
at a time, because this delay can make a big difference.
2. “Tip Retract Distance” controls how far the tip will be off the surface when a weld occurs.
Lower values will produce better arc ignition consistency.
3. “Minimum Time Between Welds” controls the minimum amount of time that has to expire
before another weld can occur.
WHAT IF MY WELD HEAD TRAVELS DOWN/STAYS DOWN WHEN COMPRESSED AIR IS HOOKED
UP/ WHAT IF MY WELD HEAD TRAVELS UP WHEN FOOT PEDAL IS PRESSED?
1. This would indicated that the air lines have been swapped. Disconnect the compressed
air and switch the tubes that are connected to the air cylinder on the top of the weld head.
Once swapped, reapply compressed air and your weld head should act normal.
WHAT IF MY WELD SPOT LOOKS DISCOLORED OR DARK?
1. Make sure the argon tank is turned on and that you have enough pressure going into the
WHAT IF THE WELD HEAD COMES DOWN BUT IT’S NOT WELDING?
1. Check your weld path. Make sure both the (+) red welding cable and (-) black welding cable
are in place.
2. The bottom limit switch could be worn out and need to be replaced.
WHAT IF I TRIGGER A WELD WITH THE FOOT PEDAL AND NOTHING HAPPENS?
1. Check that the foot pedal is plugged into the welder.
2. Make sure the RJ11 cable is plug in from the weld head to the welder.
3. Make sure that the welder is in “Play” or is enabled.
WHAT IF MY UNIT WAS WELDING QUICKLY BETWEEN WELDS AND NOW TAKES A LOT LONGER TO
WELD BETWEEN WELDS?
1. Check the weld path and makes sure that both (+) and (-) terminals are connect to the red
and black cables.
2. The upper limit switch could be worn out and need to be replaced.
WHAT IF MY ORION I2 WELDER DOES NOT AUTOMATICALLY DETECT THE EV WELD HEAD?
1. Make sure the EV weld head is plugged into power and has a fuse installed.
2. Make sure the RJ11 communication cable is plugged into both the EV weld head and Orion i2
3. Make sure the power switch on the EV weld head is turned on and the LED is lit.
Warning: When weld head is triggered and operating it is important not to place hands or body
extremities underneath nozzle cone. It will make sudden movements and could pinch/smash
hand or body extremity between shaft and bottom plate.
Caution: If the weld head needs to be adjusted in height, make sure to hold the weld head firmly
when loosening the knobs. If you do not hold the weld head when loosening the weld head, it
could damage a workpiece under the nozzle cone or pinch/smash anything underneath it. When
tightening, tighten firmly by hand. Do not use a tool, as this will break the knob.
Warning: If side plate is removed, you will be exposed to AC lines. Make sure unit is unplugged
before taking side panel off. Also, if you do this it will void the warranty.
Caution: Do not over pressure the air system after the provided pressure regulator to over 90 PSI.
This could damage air hoses and connections in the system. Once damaged, the air hoses and
connections could cause bodily harm.
Caution: The air input can only accept up to 125 PSI, so do not provide more than this. Providing
more than 125 PSI could result in failure of the connection point to the pressure regulator. Once
damaged, the air hose and connection could cause bodily harm.
Warning: If air hoses on the outside top cylinder need to be removed or replaced, make sure to
put them back the same way. If swapped, the shaft with the nozzle cone will move downwards
with force when air is applied to the system. If this happens it could pinch/smash hand or body
extremity between shaft and bottom plate.
Caution: When adjusting the speed of upward and downward motion of the nozzle, make sure to
test the new speed adjustment by adjusting the weld head position high enough that the nozzle
cone will not make contact with the bottom plate. Move everything off of the bottom plate and
then trigger a weld. Do t