SUNSTONE Orion 100c User manual

Orion™100c
Pulse Arc Welder Users Guide
20210728 • ITEM #1259

Orion™100cSeries Users Guide
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 08/2021 New Formatting; Software Refresh
2
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Contents
Chapter 1: Welder Setup & Assembly.....................1
What is in the Box.........................................................1
Microscope Arm Assembly Setup.........................1
Mounting Options .......................................................2
Welding Stylus Setup .................................................4
Electrode Setup ..........................................................5
Shield Gas Setup..........................................................8
Pressurized Gas Safety..............................................8
Shielding Gas Tank and Regulator Setup............9
Become Familiar with the Microscope.............. 10
Cable Connections................................................... 11
Chapter 2: How to Weld........................................... 12
Using the Arc Mode to Weld ................................. 12
Using the Tack Mode to Weld............................... 17
Chapter 3: Systems Settings.................................. 20
Interface Options...................................................... 20
Volume .................................................................. 20
Microscope Brightness .................................. 21
Screen Brightness............................................ 21
Language Preferences.................................... 21
Gas Options ................................................................ 21
How to Adjust Pre-Flow Delay...................... 22
How to Adjust Post-Flow Delay.................... 22
How to Purge Gas ............................................. 22
How to Calibrate Gas ....................................... 23
Timing Options........................................................... 23
How to Adjust Pre-Weld Delay ..................... 24
How to Adjust Post-Weld Shutter Delay... 24
How to Adjust Pre-Weld Delay ..................... 24
System Settings................................................................ 25
How to Restore All Defaults........................... 25
How to Clear All Memory................................ 26
How to Update the Software ........................ 26
How to Enter the Test Suite........................... 27
How to View System Information................ 27
Chapter 4: How to Save/Load Weld Schedules. 28
How to Save a Weld Schedule.............................. 28
How to Load a Weld Schedule ............................. 29
How to Save Over an Existing Weld Schedule29
..................... 31
Appendix 2: General Weld Parameters................ 31

Orion™100cSeries Users Guide

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Chapter 1: Welder Setup & Assembly
What is in the Box
BOX 1 CONTENTS:
(2) Alligator Grounding Clips (1) Orion 100c Power Supply
(1) Foot Pedal (1) Shielding Gas Hose
(1) Electrode Vial (5x 1.0 mm and 5x 0.5 mm Electrodes and 1 Diamond Sharpening Disk)
BOX 2 CONTENTS
(1) Fiberglass Brush (1) Sunstone Microscope Arm Assembly
(1) Cross Lock Tweezers (1) Sunstone Safety Guide
(1) System Cover (1) Flat Peaked Plier
ACCESSORIES BOX (Located in Box 2)
(1) Microscope Arm Mounting Hardware (1) Pair Microscope Eye Piece Shields
(1) Welder Power Cord (1) Loop Closing Pliers
(1) Welding Stylus Hand Piece (1) Set Allen Wrenches
(1) Shutter Cable (RJ45 ends)
Microscope Arm Assembly Setup
• Remove the Microscope Arm Assembly from the box and place it on your table.
• There are three available options for mounting the Arm Assembly to your table. Select one of the
following methods and use the required mounting hardware from the accessories box as outlined.

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Orion™100cUsers Guide
MOUNTING OPTIONS
Mounting Option 1 - Clamp to Table
This option is best for tables with accessible edges and
for mounting without drilling holes in the table.
Note: If your table is thicker than 3-1/2” (9cm), follow
the instructions for mounting options 2 or 3 on the next
page.
Hardware required from Box 2:
(1) Angled Bracket (C)
(1) Sunstone Microscope Arm Assembly (A)
(1) Clamp Mechanism (D)
(5) Flat Head Hex Screws (G)
• Lay the arm assembly down on the tabletop.
• As shown in Figure 2.1, attach the angled
bracket (C) to the bottom of the arm using three
(3) of the included at head hex screws (G)
using a 4mm (5/16”) Allen wrench (L).
• Attach the clamp mechanism (D) to the angled
bracket using two (2) of the included at head
hex screws (G). See Figure 2.2. For thicker
tables, attach the clamp mechanism D to the
two lower holes in the angled bracket C.
• Adjust the knob on the clamp mechanism (D)
until the gap is sucient for the thickness of
your tabletop.
• Lock the arm into place by turning the knob
on the clamp mechanism until the clamp is
pressing rmly against the bottom of the table.
• Lift the Arm Assembly up and slide the arm
onto the table as shown in Figure 2.3.
• A plastic cable guide cover (E) can be clipped
on over the angled bracket if desired. See
Figure 2.4
Mounting Option 2 - Bolt through Table
Mounting Option 2 is best for tables without accessible
edges. Hardware required from Box 2:
Figure 2.1. Attach angled
bracket (C) to (A).
Figure 2.2. Attach clamp
mechanism (D) to angled
bracket (C).
Figure 2.3. Lift Arm Assembly
up and slide onto the table.
Figure 2.4. Cover the clamp
mechanism (D) with the
plastic cable guide cover (E).

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(1) Flat Mounting Plate (H)
(3) Flat Head Hex Screws (G)
(1) Long Carriage Bolt (F)
(1) Flat Pressure Plate (I)
(1) Adjustment Knob (J)
• As shown in Figure 3.1, using a 4mm (5/32”)
Allen wrench, unscrew the at head hex screws
(G) holding the mounting plate (H) to the arm.
• Run the included 8mm (5/16”) carriage bolt (F)
through the included mounting plate (H).
• Attach mounting plate (H) to the bottom of the
arm using (3) at head hex screws (G).
• Drill a 3/8” (9.5mm) hole through the tabletop.
• Lower the arm so the bolt goes through the
hole in the tabletop. See Figure 3.2.
• Slide the at pressure plate (I) onto the bolt.
Turn the adjustment knob (J) clockwise to
tighten the plate to the underside of the table.
Mounting Option 3 - Screw to Table (vertical
surface)
Required hardware from Box 2:
(1) Angled Mount Bracket (A)
(3) Flat Head Screws (G)
(2) Wood Screws (not included)
• Attach the angled bracket (A) to the bottom
of the arm assembly using three (3) of the
included at head hex screws (G) as shown in
Figure 2.1.
• Lift and position the arm assembly onto the
table in the desired location.
• Run wood screws through the bracket (A) and
into vertical surface of the table, as shown in
Figure 3.3.
Figure 3.1. Remove the plate from the arm,
run the carriage bolt through the plate, then
re-attach the plate to the arm.
Figure 3.2. Lower the arm so the bolt goes
through the hole in the table. Turn the twist
knob clockwise to tighten the plate to the
table.
Figure 3.3. Use wood screws (not included)
to attach the angled bracket (A) to the table.

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Orion™100cUsers Guide
Arm Tension Adjustment
The spring tension is factory pre-set, but should chang-
es be desired, the tension can be adjusted by turning a
hex screw located on the arm joint, as shown in Figure
4.1. Use the included 6mm Allen wrench to make ad-
justments.
• Turn the hex screw counterclockwise (in the
direction of the “+” symbol on the arm) if the
arm does not hold the microscope up.
• Turn the hex screw clockwise (in the direction
of the “-“ symbol) if the arm does not allow the
microscope to be lowered easily.
Microscope Setup
• Install the rubber eyepiece covers onto the
microscope lenses.
• Plug the included Shutter Cable into the RJ45
port on the microscope (the bottom of the
microscope head). See Figure 4.3.
• Plug the other end of the Shutter Cable into the
Shutter Port on the welder’s back panel.
Note: Connecting other RJ45 compatible devices to the
Sunstone shutter RJ45 port may damage the welder
and/or the other devices.
Welding Stylus Setup
• Remove the Welding Stylus from the accesso-
ries box.
• Insert the Welding Stylus into the holder at the
bottom of the arm assembly. See Figure 4.3.
• The tubing can be routed up and through the
removable cable guide portion of the arm if
desired. See Figure 5.1.
• For now, position the Welding Stylus such that
only the smaller diameter portion protrudes
from the holder. Then, tighten the thumb screw
on the bottom of the stylus holder to hold it in
place.
Figure 4.1. Adjust the tension of the Arm Assembly for
more loose or more tight movement.
Figure 4.2 After installing the rubber eyepiece covers,
use the Shutter Cable to connect the welder to the
bottom of the microscope head.
Figure 4.3. Mount the Welding Stylus to the holder below
the microscope.

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• Rotate the stylus holder to approximately a
45-degree angle as shown in Figure 4.3 (the
stylus should be angled down).
• Fine tune the position of the Welding Stylus
while looking through the microscope: Loosen
the thumb screw on the bottom side of the
stylus holder and slide the Welding Stylus
forward and backward until the tip of the
Welding Stylus is in the center of your focus.
See the example in Figure 5.2.
• Now securely tighten the Welding Stylus in
place by tightening the thumb screw on the
bottom of the stylus holder, which you can see
in Figure 4.3.
Electrode Setup
The Orion 100c pulse arc welder comes standard with a
1.0mm electrode collet and ve (5) 1.0 mm electrodes.
The 1.0 mm electrodes are a good multipurpose elec-
trode for most welding applications. Also incuded are
ve (5) 0.5 mm electrodes, which are more suited for
very small applications (less than 5 Ws of energy).
INSTALL THE TUNGSTEN ELECTRODE ONTO
THE WELDING STYLUS
See the Stylus Components Chart (Figure 6.4) to install
the tungsten electrode (D).
• Remove the stylus hull (E) by pulling it away
from the stylus shaft (A). See Figure 5.3.
• Loosen the collet cap (C) by twisting it counter-
clockwise.
• The welder accommodates 0.5mm and 1.0mm
electrodes. The electrode stylus will be shipped
with the 1.0mm electrode collet (B) installed.
• Insert a 1.0mm electrode (D) into the collet.
Helpful Tip: There is a goove on the side of
the stylus hull (E) that helps measure the
electrode length. Place the end of the stylus
Figure 5.1. Tubing and other cables can be routed up and
through the removable cable guide portion of the arm.
Figure 5.2. Only a small portion of the electrode should
extrude from the holder.
Figure 5.3. To install the electrode, rst remove the stylus
shaft (A) from the stylus hull (E) by pulling them apart.
AE

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Orion™100cUsers Guide
hull (E) against the collet cap, then make sure
the electrode extends to the groove as indi-
cated. See Figure 6.2.
• There should be between 0.6 - 0.7 inch (1.5 –
2cm) of the electrode (D) protruding from the
stylus shaft (A). This will allow the electrode
enough room to stick out from the stylus once
the stylus hull (E) is placed back on the stylus.
• Lock the electrode (D) into place by hand tight-
ening the collet cap (C) in a clockwise direction.
• Replace the stylus hull (E) by pushing it in until
you feel it snap back into place. The electrode
(D) should stick out between 1/8 – 1/4 inch
(3.175 – 6.35mm after the stylus hull is snapped
back into place). See Figure 6.3.
When to Sharpen the Electrode
Refer to Chapter 3 for more information on electrodes.
The majority of applications are best accomplished
using a sharp electrode tip. A sharp tip improves arc
initiation and helps focus the arc properly. It is recom-
mended that you 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 ignition of the weld
arc. When this occurs, simply sharpen the electrode
with the included diamond disk. The diamond disk can
be attached to a rotary tool. Follow these steps for
sharpening the electrode:
• Completely remove the electrode from the
stylus.
Figure 6.2. Use the grooves engraved on the side of
the stylus hull (E), marked in red in this image, for proper
electrode (D) positioning.
Figure 6.3. The electrode should protrude past the
stylus hull (E) 1/8 to 1/4 inch (3.175 to 6.35mm).
Stylus Shaft (A) Collet (B) Collet Cap (C) Electrode (D) Stylus Hull (E)
Stylus Components
Figure 6.4