Orion Welders 200i2 User manual

Orion Pulse Arc Welders User Manual
Orion 200i2

200i2User Manual
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Table of Contents
Forward .......................................................... p.3
Manufacturer’s Contact Information ........................... p.3
Welding safety Precautions .................................... p.3
Chapter 1: Welder Setup and Assembly ........................ p.7
What is in the Box .......................................... p.7
Microscope Arm Setup ..................................... p.7
Orion 200i2 Welder Connection Setup .................... p.9
External Power Supply Setup .............................. p.10
Shielding Gas Setup ........................................ p.10
Adjustments on the Microscope Arm ...................... p.11
True Color Optical LCD Shutter ............................ p.12
Become Familiar with the Microscope ..................... p.12
Electrode Setup ............................................ p.13
Chapter 2: Welder Interface Overview .......................... p.16
Header Area ................................................ p.16
Waveform Graph Area ..................................... p.16
Metals Tab - Controls Area ................................ p.17
Arc Tab - Controls Area .................................... p.17
Seam Mode- Controls Area ........................... p.20
Tack Tab - Controls Area .................................. p.23
Video Tab .................................................. p.23
Load Tab ................................................... p.24
Save Tab ................................................... p.24
Settings Tab ............................................... p.24
Chapter 3: Reading the Waveform Graph ....................... p.26
Ignition ..................................................... p.26
Waveforms ................................................. p.27
Weld Time .................................................. p.27
Waveform Graph Overview ................................. p.27
Chapter 4: Pulse Arc Welding ................................... p.30
Chapter 5: Tack/Resistance Welding ........................... p.34
Chapter 6: Tungsten Electrodes ................................ p.38
Chapter 7: Orion Techniques, Tips and Tricks ................... p.43
Chapter 8: Metals ............................................... p.48
Chapter 9: Troubleshooting/FAQ ............................... p.56
Warranty Information ........................................... p.59

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FOREWORD:
ank You for Choosing Orion Welders and congratulations on your purchase!
You are now the proud owner of an Orion 200i2Welder. is manual was designed to help you set
up the welder and begin welding. Please read and follow all safety precautions before proceeding
with the welding process.
Sunstone Engineering is the parent company of Orion Welders. At Sunstone & 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, a Subsidiary of
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Payson, UT 84651
Email: [e-mail]
Voice: 801-658-0015
Fax: [phone]
Welding Safety Precautions
READ BEFORE WELDING
e following safety advice is generalized advice for the arc-welding industry. ese safety
precautions are not all inclusive. All users should exercise reasonable caution while using this
device. e following group of symbols are warning symbols:
CAUTION, ELECTRIC SHOCK HAZARD, EYE PROTECTION REQUIRED.
Consult these symbols and the related instructions listed next to the symbols for proper action
when dealing with these hazards.
READ INSTRUCTIONS
• Read the owner’s manual before using the Orion.
• Only personnel trained and certified by the manufacturer should service the unit.
• Use only genuine replacement parts from the manufacturer.
SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION
Sparks can fly off from the welding arc. e flying sparks, hot work piece, and hot

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equipment can cause fires and burns. Ensure that your work area is clean and safe for
welding before starting any weld job.
• Do not install or operate unit near combustible surfaces.
• Do not install or operate unit near flammables.
• Do not overload your building’s electrical wiring – be sure the power distribution
system is properly sized, rated, and protected to handle this unit.
• Remove all flammable materials from the welding area. If this is not possible, tightly
cover them with approved covers.
• Do not weld where flying sparks can strike flammable material.
• Protect yourself and others from flying sparks and hot metal.
• Watch for fire and keep a fire extinguisher nearby.
• Do not weld where the atmosphere may contain flammable dust, gas, or liquid
vapors.
• Remove any combustibles, such as butane lighters or matches, from your person
before doing any welding.
• 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. e input power circuit and
the internal circuits of the Orion welder are live when the power switch is turned on. Additionally
the internal capacitors remain charged for a period of time after the Orion is turned off and/or
power is disconnected. Incorrectly installed or improperly grounded equipment is a hazard. is
device was designed to operate indoors only. Do not operate welder in a wet/damp environment.
Holding the hand pieces connected to the front of the welder is okay and will not generate an
electrical shock.
• Remove personal jewelry before welding (i.e. rings, watches, bracelets, etc).
• Do not touch live electrical parts.
• Wear dry, hole-free insulating gloves and body protection.
• Properly install and ground this equipment according to this manual and national,
state, and local codes.
• 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.
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. Often sparks fly off from the weld joint area; therefore,
take the necessary precautions to avoid trapping a spark within your own clothing.

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Also arc welding gives off infrared and UV rays that can burn the retinal tissues within
the eyes and cause surface burns to exposed skin, similar to a sun burn.
• e stereo microscope provides proper eye protection when pulse-arc welding. No
additional protection is necessary.
• 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 tack welding or
when observing others performing pulse-arc and tack welds.
• Use a sunscreen of SPF 30 or high if welding for extended periods of time.
SAFETY PRECAUTIONS FOR HOT METAL
• Welding material that has a high thermal conductivity will cause metal to heat rapidly.
• Repetitive welds in the same location can cause metal to become hot.
• Do not touch hot weld areas bare-handed.
• Allow sufficient cooling time before handling welded pieces.
SAFETY PRECAUTIONS FOR FUMES AND GASES
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your
health. e Orion produces minimal fumes and gases when compared to large-scale arc welders.
ough not required, some form of ventilation is recommended.
• Keep your head out of the fumes. Do not breathe the fumes.
• Ventilate the area and/or use local forced ventilation at the arc to remove welding
fumes and gases.
• If ventilation is poor, wear an approved air-supplied respirator.
• Read and understand the Material Safety Data Sheets (MSDS) and the manufacturer’s
instructions for metals, consumables, coatings, cleaners, and degreasers.
• Welding in confined spaces requires good ventilation or an air-supplied respirator.
Always have a trained watch person nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
• Do not weld in locations near degreasing, cleaning, or spraying operations. e heat
and rays of the arc 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 area is well ventilated, and
while wearing an air-supplied respirator. e 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.
SAFETY PRECAUTIONS FOR HIGH FREQUENCY PITCH AND VOLUME
• Welding with high frequency pulse agitation can produce loud, high pitched sounds. It
is recommended to use hearing protection when welding with agitation turned on.

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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.
OBSERVE ALL NECESSARY PRECAUTIONS ASSOCIATED WITH COMPRESSED GASES
• Use only compressed gas cylinders containing the correct shielding gas for the
process used.
• Always keep cylinders in an upright position and secured to a fixed support.
• Cylinders should be located:
- Away from areas where they may be struck or subjected to physical damage.
- A safe distance from arc welding or cutting operations and any other source of
heat, sparks, or flame.
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, 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: [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: [phone], website: www.ansi.org).
CE TESTED AND CERTIFIED
Welder tested for electrostatic discharge immunity up to 2kV for CE compliance

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CHAPTER 1: WELDER SETUP & ASSEMBLY
What is in the Box
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
Microscope Arm Setup
MICROSCOPE ARM SET UP - BASE MOUNTING OPTIONS
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
Mounting Option 1 - Clamp to table
1. Determine the height of the tabletop. *If it is
thicker than 2-3/4’ (7cm), follow arm base
mounting options 2 or 3.
2. Position the microscope arm clamp under the
tabletop.
3. Place the included allen wrench in the opening
at the bottom of the clamp bolt. Turn the bolt
clockwise until the clamp is very snug.
ch.1
BOX
e Orion 200i2will arrive in 1 box.
Main Box:
(1) User Manual & Getting Started/Quick
Setting Guide
(1) Orion 200i2Power Supply
(1) Orion 200i2Microscope Arm
(1) Orion 200i2Microscope Extender Arm
(1) Orion 200i2 Microscope Arm Table Mount
(1) Orion 200i2 Microscope Arm Support Bar
(1) Orion 200i2Interface Box
(1) Orion 200i210 pin power cable
Box within main box:
(1) Welder Power Cord
(1) Stylus Hand Piece
(1) Pair Alligator Clips
(1) Foot Pedal
(1) Shielding Gas Hose
(1) Cross Lock Tweezers
(1) Electrode Vile (5x 0.5mm -- 5x 1.0mm
Electrodes – 1x Diamond Dremel Disk – 1x
0.5mm Orion Collet)
(1) Fiberglass Brush
(1) Stainless Steel Weld Sample Card
(1) 3 Allen Wrenches with green microscope
protective cover
(1) Pair Microscope Eye Piece Shields
(1) Loop Closing Pliers
2¾”

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Mounting Option 2 - Bolt through table
1. Using the provided allen wrench,
unscrew the 10m x 1.5 allen bolt
underneath the arm base.
2. Drill a 3/8’ (10mm) hole through the
tabletop.
3. Place a washer on the 10m x 1.5
bolt (length will depend on tabletop
thickness) and run it up through the tabletop into the arm base.
4. Tighten the bolt until it is very snug.
Mounting Option 3 - Bolt to table
1. Position the base against the
table.
2. Trace drill holes with a pen or
marker.
3. Drill 1/4’ holes in the tabletop.
4. Run screws through the base into
the drilled holes.
MICROSCOPE ARM SETUP - UPPER HALF
See video explanations of setup at http://www.orionwelders.com/
resources/orion-i-series-resources/
1. Place the microscope extender arm into the arm base.
2. Place the microscope arm into the top of the extender arm.
3. Place the touch screen box into the slot on the microscope arm
above the microscope optics.
4. Loosen/tighten the allen on the top of the microscope extender
arm to adjust the spring pressure. Turn the allen counter clockwise
if the arm does not hold the microscope up. Turn the allen
clockwise if the arm does not allow the microscope to come down.
5. Ensure the RJ45 microscope cable is plugged into the RJ45 port on
the light ring (below the microscope optics).
6. Plug the other end of the microscope cable into the RJ45 “Shutter”
port on the back of the touch screen box. *Orion RJ45 ports are not
compatible with any other RJ45 ports. Connecting them to other
devices may damage the welder and/or the other devices.
7. Install the rubber eyepiece covers onto the optics.
8. Loosen the bolt in front of the microscope mount to move the
microscope head left and right.
ch.1
8.
5.
4.
7.
6.
*When adjusting the spring pressure as
described in step 4, be sure the arm is
parallel to the table as seen here.
1.
2.
3.

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Orion 200i2Welder Connection Setup
CONNECT THE WELDING STYLUS TO THE BACK OF THE TOUCH SCREEN BOX
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
e welding stylus requires the most attention during setup. Since argon gas will flow through the
stylus, a tight fit between the power supply and the stylus is critical. is will insure that no oxygen
is entrained into the weld. To accomplish this, follow the steps below.
1. Position the end of the stylus so that the notch is facing down.
2. Push the stylus into the stylus connector port on the back of the touch screen box.
3. Turn the outside layer of the stylus connector clockwise so it screws onto the stylus
connector port.
4. Continue to turn the outside layer of the stylus connector clockwise until it stops.
5. Now push in on the stylus connector, (you will feel it move in a couple centimeters). en turn
the outside layer of the stylus connector clockwise until it stops.
6. Repeat steps 2-5 until you feel the stylus connector bottom out, and you can no longer screw
the stylus connector clockwise. is will insure that the stylus connector is firmly seated.
CONNECT THE REMAINING CABLES TO THE BACK OF THE TOUCH SCREEN BOX
1. Place an alligator clip into the positive port on the back of the touch screen box. *Remember
to attach the alligator clip to the work piece before welding.
2. Plug the foot pedal into the “trigger” port on the back of the touch screen box.
3. Verify that the RJ45 cable is securely fastened in the RJ45 port.
4. Insert the 1/4” gas tube firmly into the “Gas” port. *It may wiggle when connected, but should
not come out if pulled on.
CONNECTOR PORTS ON THE BACK OF THE INTERFACE BOX
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
1. Foot Pedal Connection Port.
2. Shutter/Darkening Lens Connection Port.
3. Stylus Connection Port
4. Power Supply Connection Port
5. External Device Port
6. Positive Grounding Port (Use for Arc Welding)
7. Negative Grounding Port (Use with Positive when Tack
Welding)
8. Inert Gas Connection Port
ch.1

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External Power Supply Setup
SET UP THE EXTERNAL POWER SUPPLY
e Orion has an internal switching power supply that can accept 90VAC to 240VAC.
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
1. Plug the female end of the power cable into the “AC Power” port on the side of the external
power supply.
2. Connect the male end of the power cable into AC power.
3. Plug the 10 pin “external power supply to touch screen box“ cable
into the 10 pin port on the external power supply.
4. Run the cable from step 3 to the microscope extender arm.
Remove the plastic piece on the underside of the microscope
extender arm by squeezing the plastic piece on both ends with
your thumb and index fingers.
5. Place the cable in the plactic piece.
6. Connect the plastic piece back to the extender arm.
7. Plug the end of the cable into the 10 pin port on the back of the
touch screen box.
8. e red LED indicates that the power supply has AC power applied
and is ready to use.
Shielding Gas Setup
During the pulse-arc welding process high temperature plasma quickly melts metal into a
molten pool. As the weld is performed, a small amount of shielding gas is released through the
weld stylus to prevent oxygen from entering the molten pool. After the weld has occurred the
protective gas turns off.
If oxygen from the air enters this molten pool, the result is a metal oxide that is brittle, porous
and burnt-looking. Protective shielding gas is used, such as 99.996% pure Argon (Argon 4.6)
or higher, to prevent these effects. Shielding gas is necessary to produce clean and repeatable
pulse-arc welds. We recommend high purity argon. is can be purchased at your local welding
supply shop.
PRESSURIZED GAS SAFETY
ere are several important rules that should be followed when using a compressed shielding gas
such as argon.
1. Always secure the pressurized gas tank to a fixed location (such as a sturdy table leg). If the
pressurized gas cylinder were to tip and become damaged there is possibility that the tank
could become rocket-like, expelling the high pressure shielding gas as propellant.
2. ALWAYS TURN OFF THE SHIELDING GAS AT THE MAIN VALVE WHEN FINISHED. is will help
your shielding gas supply last longer in case there is a small leak in the tubing. is is also
a good safety practice. If the tube becomes dislodged, shielding gas could fill the room
displacing needed breathing oxygen. Argon is heavier than air and will fill the room from
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11OrionWelders.com
the bottom upward. If you experience a large shielding gas leak, open all of the doors and
windows in the room.
SHIELDING GAS TANK AND REGULATOR SETUP
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
1. Ensure that your shielding gas tank is securely fastened to a stationary point near the welding
area.
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 back of the power supply. 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.)
ADJUSTMENTS ON THE MICROSCOPE ARM
ADJUST WELDING STYLUS POSITION
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
1. Insert the welding stylus into the stylus holder under the
microscope head then tighten the stylus holder knob.
2. Loosen the screws on either side of the stylus holder.
3. Adjust the welding stylus to a 45-degree angle then slightly
tighten the screws just enough to hold the stylus in place at a
45-degree angle
4. While looking through the microscope, slide the welding stylus
holder forward/backward until the tip of the stylus is in the
center of your focus.
ch.1
1.
2. 45°
Regulator Dial
4.

200i2User Manual
12
5. Now securely tighten the stylus holder screws.
ADJUST THE MICROSCOPE FOCUS
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
1. Twist this knob above the 1x 2x knob to focus the microscope.
When adjusting the microscope focus, place a finger under the
welding electrode to help judge the correct focus location. Focus the
microscope till the texture on the skin of the finger is clearly visible.
True Color Optical LCD Shutter
Sunstone Engineering has developed a truly revolutionary optical LCD welding filter. e True
Color TM Optical LCD shutter system allows Orion users an unimpeded full color view of the
welding work piece before welding. During a weld the Orion pre-darkens the shutter to provide
complete eye protection. Even when a weld is not taking place the user’s eyes are always
protected from harmful UV and IR radiation to levels exceeding typical safety requirements.
e True Color TM Optical LCD shutter system has been specifically design for the Orion 200i2
seam mode. In seam mode the Orion 200i2automatically adjust the filter darkness according to
weld intensity to provide a comfortable and safe view of the welding process. e operator can
then see the molten weld puddle flow as the welding process takes place. is visibility allows the
user to adjust electrode position during the welding process to perform the best weld seam every
time.
Become Familiar with the Microscope
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
e Orion Microscope has been designed to provide maximum visual clarity, eye protection and
ease of use. One challenge using the microscope is getting used to bringing the work piece to the
welding electrode while looking through the microscope. is is an easy challenge to overcome.
To begin, follow these steps with the welder on pause. *While the welder is on pause it will not
weld when the work piece touches the electrode.
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13OrionWelders.com
1. Rest your hands on the table and position the
work piece close to the welding electrode before
looking into the microscope.
2. Make sure your focus is at the tip of the electrode.
3. Use slow, controlled movements.
4. It is helpful to have your hands resting and to only
use your fingers to move the work piece up to the
electrode.
5. Place the work piece surface perpendicular to
the point of the electrode. *As will be discussed,
the angle of the electrode tip relative to the work piece surface is very important and will take
practice.
6. Now practice making light contact with the work piece to the electrode.
*Remember to follow these steps once the welder is completely set up ready to begin welding.
Electrode Setup
e Orion welder comes standard with a 0.5mm electrode collet and (5)
0.5mm electrodes; and a 1.0mm electrode collet and (5) 1.0mm electrodes.
e 1.0mm electrodes are a good all around electrode while the 0.5mm
electrode is excellent for very small projects (less than 5ws of energy).
Stylus components:
1. Stylus Shaft 2. Collet 3. Collet Cap 4. Electrode 5. Stylus Hull
INSTALL THE TUNGSTEN ELECTRODE ONTO THE WELDING STYLUS
Follow these steps to properly install the tungsten electrode. See video explanations of setup at
http://www.orionwelders.com/resources/orion-i-series-resources/
1. Remove the stylus hull by pulling it away from the stylus.
2. Loosen the collet cap by twisting it counter-clockwise.
3. e welder comes with 2 electrode collets. One that fits 0.5mm electrodes and one that
fits 1.0mm electrodes. e electrode stylus will be shipped with the 1.0mm electrode collet
installed.
4. Insert the 1.0mm electrode into the collet.
a. ere is a groove around the Stylus Hull that
will help measure the electrode length.
b. Place the end of the stylus hull up against the
collet cap
c. Make sure the electrode tip falls between groove. (ere should be between 0.6 - 0.7in
(1.5 – 2cm) of the electrode protruding from the stylus shaft. is will allow the electrode
enough room to stick out from the stylus once the stylus hull is placed back on the stylus.)
ch.1

200i2User Manual
14
5. ere should be between 0.6 - 0.7in (1.5 – 2cm) of the electrode
protruding from the stylus shaft. is will allow the electrode
enough room to stick out from the stylus once the stylus hull is
placed back on the stylus.)
6. Lock the electrode into place by hand tightening the collet cap in a clockwise direction.
7. Replace the stylus hull by pushing it snuggly until you feel it snap back
into place (the electrode should stick out between 1/8 – 1/4in (3.75 –
6.75mm) after the stylus hull is snapped back into place).
WORK PIECE TO ELECTRODE PRESSURE
See video explanations of setup at http://www.orionwelders.com/resources/orion-i-series-
resources/
Touch the work piece to the electrode with very light pressure. Too much pressure will cause
the work piece to stick to the electrode and in turn cause the electrode to be contaminated
(work piece material on the electrode). is will shorten the amount of time you can weld before
re-sharpening or replacing the electrode. *As a general rule of thumb we recommend a freshly
sharpened electrode anytime a new work piece is being welded.
WHEN TO SHARPEN THE ELECTRODE
It is recommended that the user pay close attention to the electrode condition. An electrode that
appears to be dark colored or covered with material from previous welds can lead to inconsistent
welding and poor igniting of the weld. When this occurs, simply sharpen the electrode with the
included diamond disk. e diamond disk can be attached to a flex shaft or Dremel tool. Follow
these steps for sharpening the electrode. See video explanations of setup at http://www.
orionwelders.com/resources/orion-i-series-resources/
1. Completely remove the electrode from the stylus.
2. Pinch the electrode between the thumb and
middle finger with the point facing inward.
3. Power on the Dremel or flex shaft then hold it with
the opposite hand. *If the Dremel is in the left
hand, then sharpen the electrode on the side of the
diamond disk furthest from the body. If the Dremel
is in the right hand, then sharpen the electrode on
the side of the diamond disk closest to the body.
e reason for this is to keep the striations on the electrode moving towards the electrode tip,
not away. is will effect the quality of the weld if not done as explained above.
4. Set the electrode on the diamond disk at a 15-degree angle and begin to spin the electrode
with the thumb and middle finger. *A helpful way to get a sharp electrode is to push down on
the electrode with your index finger while twisting the electrode with the thumb and middle
finger. See the video on our website for additional instruction on this method.
5. Once the electrode is sharp and clean, turn the Dremel off and insert the electrode back into
the stylus as explained above.
*See Chapter 5 for additional information on the Tungsten Electrodes
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15OrionWelders.com
WHEN TO FLATTEN/BLUNT THE ELECTRODE
When working with silver, copper, and other highly conductive metals in energy levels above
20ws, it is recommended to blunt the electrode instead of sharpening it. See video explanations
of setup at http://www.orionwelders.com/resources/orion-i-series-resources/
1. Completely remove the electrode from the stylus.
2. Pinch the electrode between the thumb and middle finger with the point facing inward.
3. Turn the Dremel or flex shaft on then hold it with the opposite hand. *If the Dremel is
in the left hand, then sharpen the electrode on the side of the diamond disk furthest
from the body. If the Dremel is in the right hand, then sharpen the electrode on
the side of the diamond disk closest to the body. e reason for this is to keep the
striations on the electrode moving towards the electrode point, not away. is will
effect the quality of the weld if not done as explained above.
4. Set the electrode on the diamond disk at a 10-degree angle and begin to spin the
electrode with the thumb and middle finger. *A helpful way to get a sharp electrode is
to push down on the electrode with your index finger while twisting the electrode with
the thumb and middle finger.
5. Once the electrode is sharp and clean, turn the electrode to a 90-degree angle and
push it against the dremel in order to place a flat/blunt tip on the electrode.
6. Once the electrode has a flat/blunt tip, turn the Dremel off and insert the electrode
back into the stylus as explained above.
See chapter 6 and 7 for additional details about the Tungsten Electrodes.
MAKE AN ARC WELD
1. Select Clasic on Waveform, Standart + on Ignition, None on Agitation, 15 ms on Length, 25Ws
on the Energy dial, Single on Mode, Touch Detect on Trigger, and then hit play. *Verify Gas
Pressure is between 7 and 11 PSI.
2. Lightly touch the electrode in the 25 Ws box on the provided
weld plate. Maintain contact & keep hands steady by resting
them on the table.
3. Use the provided stainless steel weld plate as a guide to
try different settings. Make several welds on the weld plate
to get comfortable with the stylus and the different weld
parameters.
HOW TO MAKE A TACK WELD
1. Select low on quick power settings, short on pre weld delay,
Foot Pedal for the Trigger, and then touch the Play button.
2. Attach the negative alligator clip to one work piece and the
positive alligator clip to the other work piece.
3. Lightly touch the two work pieces together where you want to
tack them.
4. Step on the foot pedal.
5. If the work pieces stay together, proceed to the Arc screen to
perform a permanent weld using the Pulse Arc Welding Stylus. If
the pieces do not stay together, move to the medium settings and
repeat steps 2-4.
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CHAPTER 2: THE USER INTERFACE PART 1
Overview
HEADER AREA
Metals, Arc, Tack, and Videos Tabs
ese four tabs contain features and settings specific
to each view. We will go over each tab in more detail
throughout this chapter.
Save Icon
e save icon allows users to create a custom weld
parameter based on their current weld settings. Users can
create up to 1000 custom weld parameters.
Load Icon
e load icon allows users to select those pre-saved custom weld parameters and use them
again.
Settings Icon
e settings icon opens a window to adjust Interface, Gas, Timing, and System settings.
*We will go over the save, load and settings tabs in more detail at the end of this chapter.
WAVEFORM GRAPH AREA
In this area, the user has a full preview of the current weld settings and can see exactly what will
take place during each weld. e waveform displayed will change based on the control settings
the user selects.
Along the left side of the graph, the numbered scale changes as the weld energy is increased
or decreased. You’ll also notice that the time of the weld is represented by the length
measurement shown at the bottom of the graph. ese settings show what’s happening during
the weld.
In the upper right hand corner, an approximation of the
weld size is shown based on the current settings. is helps
users have a visible reference when setting power and
other parameters.
Lastly, in the lower right portion of this section, all the
currently enabled Waveform, Ignition, Agitation, and Length
values are displayed.
CONTROL AREA
is section contains the different controls to customize the 200i2 ‘s settings for welding
output. We will go over each tab in more detail throughout this chapter.
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METALS TAB - CONTROL AREA
is section was created to help users that are first learning
to pulse arc weld, or not sure which weld parameter to use.
Metals
To begin, simply select the metal that will be welded. Each
metal has been pre programed to load the best settings we
have found for welding that particular metal.
* If welding two different metals, we suggest using the
welder factory default settings. Touch the “reset button” in
the control area of the “Arc Tab” to load these settings.
Power Control
is circular dial controls and selects the amount of weld energy or weld power. 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 that 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 Joules.
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.
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.
Trigger Options
Touch Detect - the welder will initiate the weld process any time that a grounded work piece
makes contact with the electrode.
Foot Pedal - e welder will only initiate a weld on a grounded work piece when the Foot Pedal
is pressed.
ARC TAB - CONTROL AREA
is section contains the different controls to customize the
200i2 ‘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.
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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 Joules.
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.
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 work piece, the electrode may dull
more quickly.
Standard+ - In Standard+, the energy discharge happens well after the electrode tip lifts off
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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.
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.
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.
Play/Pause, Undo, and Reset Options
e Play/Pause, Undo, and Reset are the functions of the option section.
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.
Trigger options
ese settings allow the user to select how the welds will engage. e options are: Touch
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Detect or Foot Pedal.
Touch Detect - In Touch Detect, the welder will initiate the weld process any time that a
grounded work piece makes contact with the electrode.
Foot Pedal - When Foot Pedal is selected, the welder will only initiate a weld on a grounded
work piece when the Foot Pedal is pressed.
Weld Speed
e 200i2has three options to choose from to control how fast the welds occur.
Single Fire Mode - In Single fire mode, the 200i2welder will go through the following steps
each time a weld is initiated:
1. e argon gas will pre-flow 2. e weld energy will be released
3. e shutter will close 4. e electrode will retract
5. e arc will form 6. A weld will be made
7. e energy will turn off 8. e shutter will open
9. e tip will return 10. And the gas will turn off
Making a second weld will repeat this process.
Rapid Fire Mode - In Rapid fire, the welder is able to speed up the weld rate by eliminating
some of the steps mentioned in the ‘single fire’ mode. Primarily, the gas will stay on for as
long as a subsequent weld is initiated. e electrode is able to retract, make a weld, and
return, and if it makes contact with the work piece, it immediately retracts again to make
another weld. Rapid Fire makes it possible to have between 1-4 welds per second. A slide bar
will appear above the Rapid Fire button, allowing users to select the weld speed.
Seam Mode - Seam Mode operates as a combination of a pulse arc welder and a micro TIG
welder. Once a weld has been initiated, the electrode retracts and produces a small pilot
arc that will stay lit during the entire seam welding process. While the pilot arc remains lit,
individual weld pulses are overlaid at speeds of up to 30 welds per second. e Seam mode
can also be used to pre-heat difficult to weld parts, as elevating the temperature of certain
metals will greatly improve weld properties.
is mode allows for continuous seam welds, and is effective in improving results for
geometries and metals that are prone to hot cracking. For best results users will need to
maintain a close, consistent distance between the work piece and the electrode. Please note
that in this mode the work piece will become hot! A leather glove is highly recommended to
prevent finger burns while welding.
SUGGESTED USES FOR SEAM MODE:
a. Anywhere that a continuous seam needs to be made.
b. In large parts where hot cracking is an issue.
c. Smoothing excess material in joints where filler material has been used.
d. To pre-heat weld parts; often metal that has been heated to higher temperatures will
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