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
LIMITATION OF LIABILITY
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OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY
OR PUNITIVE DAMAGES, OF ANY NATURE WHATSOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGI-
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PERMITTED UNDER APPLICABLE LAW.

e Micro Welder Experts
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.

Questions? Call or Text [phone] • 5
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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

Questions? Call or Text [phone] • 7
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• Pinch the electrode between the thumb and
index and/or middle nger with the shaft going
perpendicular to the ngers. See Figure 7.1.
• Power on the rotary tool then hold it with the
opposite hand.
• Place the electrode tip on the diamond disc so
the grit of the disk is moving parallel with the
electrode shaft and moving towards the tip. See
Figure 7.2. Sharpening the electrode in a way
other than explained here will aect the quality
of the weld.
• Set the electrode on the diamond disk at a
10-degree angle and begin to spin the elec-
trode with the thumb and middle nger. Tip:
A helpful way to get a sharp electrode is to
push down on the electrode with your index


• Once the electrode is sharp and clean, turn o
the rotary tool and insert the electrode back
into the stylus as explained above.
Note: As a rule of thumb, Sunstone recommends a
sharpened electrode anytime a new workpiece is being
welded.

ELECTRODE
• When working with silver, copper, and other
highly conductive metals in energy levels above
20 Ws, it can be helpful to blunt the electrode
instead of sharpening it, as shown in Figure 7.3.
• Follow the “When to Sharpen the Electrode”
instructions noted earlier.
• Once the electrode is sharp and clean, turn
the electrode to a 90-degree angle and push
it against the diamond disk in order to place
a at/blunt tip on the electrode. Cleaning
the edge of a blunt tip electrode assists in
preventing the electrode from sticking to the
weld surface.
Figure 7.1. A sharp electrode tip improves arc initiation
and results in a better overall weld.
Figure 7.2. Use a rotary tool to sharpen the electrode.
R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
Figure 7.3.. When working with silver, copper, and other
highly conductive metals, a at or blunt electrode can
provide better results.

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Orion™100cUsers Guide
• Once the electrode has a at/blunt tip, turn o
the rotary tool and insert the electrode back
into the stylus as explained earlier.
Shield 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 oc-
curred the protective gas turns o.
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), to prevent these eects.
PRESSURIZED GAS SAFETY
There are several important rules that should be fol-
lowed when using a compressed shielding gas such as
argon:
Always secure the pressurized gas
(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 a projectile, ex-
pelling the high-pressure shielding gas as propellant.

This will help your shielding gas supply
last longer in case there is a small leak in the tubing.
This is also a good safety practice. If the tube becomes
dislodged shielding gas could ll the room and displace
oxygen, which can lead to suocation. Argon is heavier
than air and will ll the room from the bottom upward.
If you experience a large shielding gas leak, open all of
the doors and windows in the room.
Need argon gas? Sunstone will
ship a right-sized tank to your
doorstep. No more adventurous
trips to the gas store! Call
Sunstone for immediate
delivery: [phone] or
scan the QR code above.
Purchase premium argon gas from
Sunstone.
Call [phone]
visit www.sunstonewelders.com/gas.
• Delivered directly to your door!
• Right-sized tank ts almost anywhere!
• Premium argon gas for your Orion
100c pulse arc welder.

Questions? Call or Text [phone] • 9
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SHIELDING GAS TANK AND REGULATOR
SETUP
• Ensure that your shielding gas tank is securely
fastened to a stationary point near the welding
area.
• Turn the regulator dial COUNTERCLOCKWISE
(closed) until it is fully backed out, meaning the
dial becomes loose, to prevent over-pressuriza-
tion of the line. See Figure 9.1.
• Screw the gas regulator (A) onto the shielding
gas tank (B) and tighten fully using a wrench.
• If not already done, insert one end of the
included ¼” OD gas tubing into the gas port on
the back of the power supply. Tug gently on the
tube to verify a tight t.
• Connect the other end of the gas tubing (E) to
the gas regulator (D), as shown in Figure 9.2.
• Open the gas tank at the main valve slowly
(F) as shown in Figure 9.3. The dials attached
to the regulator should respond as the valve
is opened. The right dial should measure and
show pressure inside the tank; the dial on the
left, which measures pressure in the hose,
should remain at zero (when the regulator dial is
fully backed out).
• Slowly turn the regulator dial CLOCKWISE until
the dial on the left shows gas pressure between
7-10 liters per second.
Figure 9.1. First, turn the regulator dial (C) counterclockwise
to close the regulator valve. Screw the gas regulator (A) to the
top of the shielding gas tank (B).
A
B
C
Figure 9.2. Connect the OD gas tube (E) from the power
supply to the gas regulator port (D).
E
Figure 9.3. Open the shielding gas tank main valve (F) slowly
clockwise until the left dial on the regulator port indicates gas
pressure of 7-10 liters per second.
D
F

10 • Questions? Call or Text [phone]
Orion™100cUsers Guide
Become Familiar with the Microscope
The Sunstone microscope has been designed to pro-
vide maximum visual clarity, eye protection, and ease
of use. One challenge using the microscope is getting
used to bringing the workpiece to the welding electrode
while looking through the microscope. This is an easy
challenge to overcome.
To begin, follow the suggested practices below while
the welder is in Weld O Mode. While the welder is in
Weld O Mode, it will not be able to make a weld when
the workpiece touches the electrode.
• Rest your hands on the table and position
the workpiece close to the welding electrode
before looking into the microscope, as shown in
Figure 10.1.
• To adjust focus, turn the adjustment knob
located behind and slightly below the eyepiece.
See Figure 10.2. Make sure your focus is at the
tip of the electrode.
• Use slow, controlled movements.
• It is helpful to have your hands resting on the
table and to only use your ngers to move the
workpiece up to the electrode. See Figure 10.1.
• Place the workpiece surface perpendicular
to the point of the electrode. As discussed
in later chapters, the angle of the electrode
tip relative to the workpiece surface is very
important and will take practice.
• Now practice making soft contact with the
workpiece to the electrode.
• Once you feel comfortable, attach the alli-
gator clip to the workpiece and enable welds
(switching the unit to Weld On Mode) to begin
welding. Be mindful of your energy setting:
Too much power may damage the workpiece.
Microscope LCD Filter Shutter System
The Microscope LCD Filter Shutter System provides an
unobstructed working view before welding and com-
Figure 10.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., then look
through the microscope.
Figure 10.2. Turn
this knob to adjust
microscope focus.
You’ll nd one knob
on each side of the
microscope arm.

Questions? Call or Text [phone] • 11
e Micro Welder Experts
pletely protects your eyes during the welding process.
The Orion 100c veries the Microscope LCD Filter
Shutter System has been closed before allowing the
weld to take place. Should the shutter not close, the
microscope lens is equipped with >UV 16 and >IR 16
for maximum eye protection.
Cable Connections
Attach all cables as follows and as indicated in Figure
11.1:
Power Cable. Plug the female end of the power cable
into the 90-240 VAC port (G) and the male end to a 90-
240 VAC power outlet.
Shield Gas. Insert the 1/4” gas tube rmly into the
Shield Gas Port (C). To remove the tube, push in the
white quick release and them pull back on the tube at
the same time.
Foot Pedal. Connect the foot pedal cable to the Foot
Pedal port (F)
Microscope Cable. Connect the RJ45 cable coming
from the microscope or ADL to the Shutter Port (E).
Weld Stylus. Connect the stylus cable coming from the
stylus into the Weld Stylus Port (F). Be sure the white
indicator on the stylus cable lines up with the white
indicator on the stylus port before connecting. When
removing the stylus cable, only pull back on the black
section of the connector where the white dot is located.
Pulse Arc and Tack +. For tack welding, attach one
ground to the Tack + terminal (A). See page 17 for tack
welding instructions.
Tack -. For tack welding, attach another ground to the
Tack - terminal (B). See page 17 for tack welding in-
structions.
A
B
C
D
E
F
G
Figure 11.1. Cable connection guide for the Orion 100c.
Power Cable (G); Shield Gas (C); Foot Pedal (F); Microscope
Cable (E); Weld Stylus (F); Pulse Arc and Tack + (A); Tack - (B).

12 • Questions? Call or Text [phone]
Orion™100cUsers Guide
Chapter 2: How to Weld
At the front of the Orion 100c pulse arc welder is a digital touchscreen display. You’ll use the software interface
that appears on the display to control how much power the 100c delivers, how the power is delivered, make
adjustments to agitation, among others.
Before you begin welding, make sure you have carefully reviewed Chapter 1 and all installation steps have been
completed. Also carefully review the Safety Guide that accompanied this users guide.
Follow these instructions to weld:
Power On the Welder
On the front of the welder, in the lower left corner, press the Power Button (A) as shown in Figure. 12.1. Wait for
the welder’s software to load.
When the Power Button (A) is pressed and the welder is turned on, the Power Button lights up, as shown in Fig-
ure 12.2.
Wait for the welder’s software to fully load before continuing.
A
Figure 12.1. Turn the power on by
pressing the Power Button (A).
Figure 12.2. The Power Button lights
up wihen the welder is on. Wait for
the software to load, as shown here.
Figure 12.3. Insert the alligator clip
to the front of the welder, as shown
here.

Questions? Call or Text [phone] • 13
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Attach the Alligator Clip
Insert the alligator clip, which acts as a ground, to the
front of the welder as shown in Figure 12.3.
Choose a Welding Mode: Arc vs Tack
With the welder on and the software loaded you should
see the Arc Mode screen, as shown in Figure 13.1. With
the 100c you can use the welder in two ways:
Arc Mode. The normal welding mode is the Arc Mode.
In the Arc Mode, you’ll use the electrode to place a weld
where the electrode makes contact with the workpiece.
Tack Mode. In Tack Mode, you’ll connect an additional
ground (whether as an alligator clip, plier, or other type
of ground) to the back of the welder. With two pieces
of the workpiece grounded, a weld will occur where the
two pieces make contact. In Tack Mode, you won’t use
the electrode.
To choose Arc Mode, press the Weld Mode icon (B) and
select Arc in the drop down menu. The Arc Mode is the
default weld mode.
To choose Tack Mode, press the Weld Mode icon (B)
and select Tack in the drop down menu. Make sure you
attach a secondary ground to the rear of the welder
before continuing.
Note: The selected Weld Mode, whether Arc or Tack, is
displayed above the white power selection wheel.

Continue if you wish to weld in Arc Mode.
Select Metal Type
Press the Metal Button (C) as shown in Figure 13.2 and
choose the type of metal you’re working with. If the
metal you see is not listed, for now, choose the most
similar or choose Generic. Metal types are listed by
name and the element symbol, such as Ag for silver.
Once you select the metal type, the 100c will automat-
ically adjust all welding parameters to optimum levels
for that particular metal. You can always manually adjust
these settings later.
B
Figure 13.1. To get started, choose the Weld Mode icon
(A) and choose Arc or Tack from the drop down menu. The
selected weld mode is displayed above the whie power
selection wheel.
Figure 13.2. Press the Metal Button (C) and choose the type
of metal you’re working with, or choose the most similiar.
C

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Orion™100cUsers Guide
Select Application Type
Select the Application Button (A) as shown in Figure
14.1 and choose the application the best ts the type
of weld you wish to accomplish.
You can choose from the following:
• Large. Select this Application Type if you have
a large gap to ll or working with a thick mate-
rial.
• Small. Select this Application Type for smaller
gaps or for thinner materials.
• Joint. Select this application Type when joining
two pieces together in a 90º or less angle.
• Wire. Select this Application Type when adding
ller wire to a workpiece.
• Prong. Select this Application Type when
extending or repairing a prong.
If you don’t see an applicable Application Type, choose
the one most similar to your needs. You can always
make adjustments to all weld settings later.
Select Agitation
Note: The welder will automatically adjust the Agitation
based on the metal and application types selected. You
can choose to accept the welder’s recommendations
for agitation or make manual adjustments.
Agitation denes how the weld pool is allowed to cool.
By agitating the power as it is delivered to the weld, you
can aect how the weld may appear.
You can select from three dierent agitation types:
• None. With no agitation, the energy dissipates
evenly, leaving a smooth weld nugget.
• Sloped. With sloped or sustained agitation,
high levels of agitation improve weld spot
strength in some metals. The high levels
of agitation energy will aect 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
Figure 14.1. Press the Application Button (A) and choose
the application the best ts the type of weld you wish to
accomplish.
A
Figure 14.2. To adjust the agitation, press the Agitation
Button (B) and choose the desired agitation type.
B

Questions? Call or Text [phone] • 15
e Micro Welder Experts
weld energy slightly to maintain the same melt
spot size.
• Negative. A negative agitation pulses the
energy in the opposite direction of sustained
agitation, but the peaks of energy are removed
rather than added. This works in reverse of
other agitation options in that it makes a
smaller spot, and de-focuses the weld arc.
As noted, the welder will automatically adjust the agita-
tion based on the type of metal and application chosen.
You can choose to accept the recommendations or
make manual adjustments.
To adjust the agitation, press the Agitation Button (B)
(see Figure 14.2) and choose the desired agitation type.
Select Ignition
Note: The welder will automatically adjust the Ignition
based on the metal and application types selected. You
can choose to accept the welder’s recommendations
for ignition or make manual adjustments.
Ignition denes how the weld is started. You can select
two dierent types of ignition types;
Standard. The weld is ignited when the electrode is
stil in contact with the workpiece using the Standard
Ignition Mode. The Standard Mode is ideal if you are
welding in a groove or channel as it helps prevent the
arc from igniting on the sides of the workpiece rather
than the bottom, as desired.
Standard Plus. The weld is ignited after the electrode
contacts the workpiece. In the Standard Plus Ignition
Mode or S+, you may nd it easier to weld. Electrode life
is also prolonged in this mode. Standard Plus is recom-
meded for most applications.
As noted, the welder will automatically adjust the igni-
tion based on the type of metal and application chosen.
You can choose to accept the recommendations or
make manual adjustments.
To adjust the ignition, press the Ignition Button (C) as
shown in Figure 15.1 and choose the desired ignition
type.
Figure 15.1. To adjust the agitation, press the Agitation
Button (B) and choose the desired agitation type.
C

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Orion™100cUsers Guide
Select Foot Pedal or Touch Detect
You can choose for the welder to initiate the weld in two
ways:
Foot Pedal. In Foot Pdeal Mode a weld will only occur
when you depress the pedal. Place the pedal on a oor
that is at, devoid of debris, and away from trac areas.
In this mode, you place the electrode against the work-
piece in the desired location and then depress the foot
pedal to initiate the weld.
Touch Detect. The Touch Detect mode is the default
mode. The welder will initiate a weld when the electrode
touches a grounded workpiece.
To choose a mode, touch the radio button (A) next to
the mode you wish to use. See Figure. 16.1.
Adjust Energy as Needed
The amount of energy to be delivered is displayed in the
center of the white Energy Wheel (B) as shown in Figure
16.2. You can adjust the energy amount as needed.
As noted earlier, the welder will automatically adjust the
energy for optimum results given the metal and appli-
cation already selected. However, you can make manual
adjustments.
To manually adjust the energy level, touch the small
white circle in the curved slider bar (C) and move your
nger counter-clockwise to reduce energy or clock-
wise to increase energy. As you move your nger, the
amount of energy selected will change in one-tenths of
a watt second (Ws).
Once you remove your nger, the energy level dis-
played in the Energy Wheel is the amount of energy to
be delivered.
Press Weld On Radio Button.
At this point, touch the Weld On radio button (D) as
shown in Figure 16.3.
As an additional safety measure, the welder incorpo-
rates a digital switch that must be in the on position
before energy will be released. When the welder is not
Figure 16.1. To choose one mode over the other, touch the
radio button (A) next to the mode you wish to use.
A
B
Figure 16.2. The Energy
Wheel.
Move your nger counter-
clockwise to decrease energy.
Move your nger clockwise to
increase energy.
C
Figure 16.3. Touch the Weld On radio button to begin welding.
Touch the Weld O radio button to avoid an unintentional
discharge of energy.
D