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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 . The 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 .
