Orion 250i2 EV CNC User Manual Download Page 1

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Orion Welder User Manual

250i2 EV CNC

Summary of Contents for 250i2 EV CNC

Page 1: ...Orion Welder User Manual 250i2 EV CNC...

Page 2: ...er 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 Ti...

Page 3: ...roducing 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...

Page 4: ...second option does not involve the use of the microscope or hand held stylus This option is best when only using the welder to make automated welds on the CNC table OPTION 1 MOUNT THE WELDER NEXT TO T...

Page 5: ...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 Then push the stylus into the port...

Page 6: ...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 ou...

Page 7: ...ify 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 g...

Page 8: ...mi 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 o...

Page 9: ...The 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 t...

Page 10: ...ctrode 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...

Page 11: ...selecting lower level settings This 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...

Page 12: ...he square waveform closely mimics the weld output of a typical laser welder IGNITION The ignition options control the electrode tips position at the moment the energy is released STANDARD In the Stand...

Page 13: ...ease 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 t...

Page 14: ...es contact with the electrode When paused White Play icon users are unable to weld UNDO The Undo icon allows the user to go back through the 5 previous screen taps This is helpful when a change is acc...

Page 15: ...ill 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 L...

Page 16: ...d 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 GENERAL SETTINGS Application T...

Page 17: ...not illuminated press the MODE button then use the cursor arrows to highlight Teaching Mode Once highlighted press the ENTR button Step 5 2 The next few steps will focus on setting up the welding para...

Page 18: ...nce 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 Se...

Page 19: ...en 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 This will be saved as Point 1 Step 11 After pressing ENTR the scree...

Page 20: ...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...

Page 21: ...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...

Page 22: ...the GO button CAUTION This will move the robot back to the home position so don t be in the way of the robot arm Step 24 The robot should look something like this back at home position It is now poss...

Page 23: ...utputs 2 The I 0 1 IN line has 8 spaces and the 3rd from the left should display 1 This indicates that the welder is ready to weld the play button is pressed and the welder is ready to weld Repeatably...

Page 24: ...ion 250i2 screen the PLC weld ready and weld good signals are displayed for your convenience These two dots will display the same information we just looked at on the I O Test screen on the pendant St...

Page 25: ...ndant 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 swit...

Page 26: ...nly 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 The Weld Ready indicator dot will turn green Ste...

Page 27: ...oftware 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 The Robot Na...

Page 28: ...ating 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 pro...

Page 29: ...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 This will pull up a JOG wi...

Page 30: ...ter 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...

Page 31: ...indow 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...

Page 32: ...ings 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 Ch...

Page 33: ...w 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 The robot will mov...

Page 34: ...eady and Weld Good should be red ON if the weld was good and the welder is ready to weld again This will be what normally happens If I O 1 IN pin 08 is gray OFF after welding then the previous weld wa...

Page 35: ...itch 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 Ope...

Page 36: ...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 axi...

Page 37: ...le 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 sect...

Page 38: ...ake electrode maintenance part of the SOP for the weld process TIP SHAPE The geometric shape of the electrode can have an effect on weld penetration and quality depending on the metals being welded an...

Page 39: ...rical 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 ca...

Page 40: ...the top layer but the bottom layer remains unaffected The 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 f...

Page 41: ...ting in conjunction with Length controls how much energy will be released as the weld is discharged The higher the power the more heat will be put into the weld This typically leads to larger weld spo...

Page 42: ...in 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 o...

Page 43: ...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 an...

Page 44: ...t 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 ins...

Page 45: ...t 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 th...

Page 46: ...apidly 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 area...

Page 47: ...nsport 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 sh...

Page 48: ...mportant not to place hands or body extremities directly below the Gas Cone or inside the travel envelope of the XYZ Table The weld head makes sudden movements and could pinch smash impact hands or ot...

Page 49: ...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...

Page 50: ...lugged 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 firml...

Page 51: ...netrate 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...

Page 52: ...ORION WELDERS 1693 American Way Suite 5 Payson UT 84651 1 877 786 9353 toll free 1 801 658 0015 international OrionWelders com...

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Orion 250i2 EV CNC, User Manual

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Summary of Contents for 250i2 EV CNC

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