Sunstone Welders250i2 EV User Manual

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Introduction:

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.

Sunstone Welders.

1693 American Way Suite #5

Payson, UT 84651

Email: sales@SunstoneWelders.com

1.877.786.9353 (toll free)

+1-801-658-0015 (international)

Fax: 866-701-1209

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.

Sunstone Welders250i2 EV User Manual

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Setup

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

out 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

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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 facility.

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 room.

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 decrease pressure.

19. (Air pressure gauge): Shows the pressure allowed into the weld head.

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Set Up Welder

1. (+) terminal from EV weld head2. (-) terminal from EV weld head3. 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.

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5. (+) terminal from Orion i26. (-) terminal from Orion i27. Gas inlet after valve for EV weld head.

8. Shifted RJ11 Jack from Welder for Communication

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User Interface

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.

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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 consistency.

• 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.

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FAQ

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 system.

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

welder.3. Make sure the power switch on the EV weld head is turned on and the LED is lit.

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PrecautionsWarning: 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 this so as to not damage a workpiece under the nozzle cone or pinch/smash anything underneath it. This will move the head down and up and then you can adjust speed accordingly.

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Power Supply

Energy (min-max in Joules) 0.01 - 250

Current (min-max in Amps) 6 - 1000A

Power Settings 20,000

Length (min-max) 0.1 - 100ms

Length Settings 6000

Weld Spot Diameter Range≈ 0.1 - 4.5mm

High Frequency Agitation Multiple/Advanced

Pulse Shaping Advanced

*Max Welding Speed (Hz) 30Hz

*Max Charging Time 1.2s

Internal Weld Monitoring yes

Display (Touch Screen)10” Full

Languages 25 +

Welder (L x W x H) 4.9” x 4.9” x 27”

Weld Programs 16

Save Settings Spaces 1000

CE Certificate yes

USB Upgradable Software yes

Weld Head

Collets 1.0 mm

Pressure Range 30-90psi (120psi max)

Height Adjustment 0-7” (17.8 cm)

Force Weight 1-12 lbf (4.5-54N)

Preferred Working Distance 1/8-1/2”

Actual Working Distance See chart at right

Weld Cycle Rate 30 welds per minute

Weight 28 lbs. (12.7 Kg)

Shipping Weight 36 lbs. (16.33 Kg)

SYSTEM SPECIFICATIONS

Force (lbF)

*Preferred Working Distance

2 7/8”4 3/4”6 5/8”8 1/2”10 3/8”12 1/4”14 1/8”

Distance

CE TESTED AND CERTIFIEDWelder tested for electrostatic discharge immunity up to 2kV for CE compliance

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

SAFETY PRECAUTIONS FOR FIRE OR EXPLOSIONThere 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.

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• 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 SHOCKTouching 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.

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PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS FOR FLYING SPARKS AND ARC RAYSIt is essential for every person in the immediate work area to wear/utilize proper personal protection equipment. There 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 CABLESWelding 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 GASESWelding 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. Though 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

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instructions 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: 1-877-413-5184, website:www.global.ihs.com).OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal

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Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 5250-7954 (phone: 1-866-512-1800) (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: 617-770-3000, 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: 800-463-6727 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: 212-642-4900, website: www.osha.gov).

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SUNSTONE ENGINEERING R&D CORPORATION1693 American Way Suite #5

Payson, UT 846511.877.786.9353 (toll free)

+1-801-658-0015 (international)SunstoneWelders.com