SUNSTONE Orion 150s Series User manual

Orion™150s
Pulse Arc Welder Users Guide
20210728 • ITEM #1260

Orion™150sSeries Users Guide
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 07/2021 New Formatting
2
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PERMITTED UNDER APPLICABLE LAW.

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Contents
Chapter 1: Welder Setup & Assembly.........................1
What is in the Box.............................................................1
Microscope Arm Assembly Setup.............................1
Microscope Setup ...........................................................4
Welding Stylus Setup ....................................................4
Electrode Setup ..............................................................5
Adjusting The Microscope Focus ..............................6
Power Supply Setup - Back Panel..............................7
Electrode Care and Pressure .....................................8
Shield Gas Setup..............................................................9
Shielding Gas Tank and Regulator Setup............. 10
Microscope LCD Filter Shutter System................ 11
Become Familiar with the Microscope.................. 11
Chapter 2: How to Weld............................................... 13
Using the Tack Mode to Weld................................... 19
Chapter 3: Systems Settings...................................... 22
Interface Options.......................................................... 22
How to Change Language Preferences................ 22
How to Lock/Unlock the Welder.............................. 22
How to Adjust Volume ................................................. 24
How to Adjust Microscope Brightness ................. 24
How to Adjust Screen Brightness........................... 24
Gas Options .................................................................... 24
How to Adjust Pre-Flow Delay.................................. 25
How to Adjust Post-Flow Delay................................ 25
How to Purge Gas ......................................................... 25
How to Calibrate Gas ................................................... 26
Timing Options............................................................... 26
How to Adjust Pre-Weld Delay ................................. 27
How to Adjust Lift O Delay...................................... 27
How to Adjust Post-Weld Shutter Delay............... 28
How to Adjust the Time Between Welds .............. 28
How to Adjust the Agitation Duty Cycle ............... 28
How to Adjust Agitation Percentage...................... 29
System Settings............................................................ 29
How to Restore All Defaults....................................... 30
How to Clear All Memory............................................ 30
How to Update the Software .................................... 30
How to Connect to a WiFi Connection.................. 30
How to Enter the Test Suite....................................... 31
How to View System Information............................ 31
Chapter 4: How to Save, Load and Delete Weld
Schedules ........................................................................ 32
How to Save a Weld Schedule.................................. 32
How to Load a Weld Schedule ................................. 33
How to Save Over an Existing Weld Schedule ... 33
How to Delete an Existing Weld Schedule........... 34
Chapter 5: How to View Media ................................... 35
How to Download the Latest Library ..................... 36
......................... 37
Appendix 2: General Weld Parameters.................... 38

Orion™150sSeries Users Guide

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Chapter 1: Welder Setup & Assembly
What is in the Box
BOX 1 CONTENTS:
(1) Sunstone 150s Series Power Supply (1) Foot Pedal
BOX 2 CONTENTS
(1) Sunstone Microscope Arm Assembly (1) Sunstone Safety Guide
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) (2) Alligator Grounding Clips
(1) Cross Lock Tweezers (1) Shielding Gas Hose
(1) Fiberglass Brush
(1) Electrode Vial (10x 1.0mm Electrodes and 1 Diamond Sharpening Disk)
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™150sUsers 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 2.4. Cover the clamp
mechanism D with the
plastic cable guide cover E.
Figure 2.3. Lift Arm Assembly
up and slide onto the table.

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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™150sUsers 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 back of the microscope (the bottom
of the microscope head). See Figure 4.2.
• 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
Figure 4.1. Adjust the tension of the Arm Assembly for
more loose or more tight movement.
Figure 4.3 After installing the rubber eyepiece covers,
use the Shutter Cable to connect the power supply to
the bottom of the microscope head.

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Stylus Shaft (A) Collet (B) Collet Cap (C) Electrode (D) Stylus Hull (E)
place.
• 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 i Series pulse arc welder comes standard
with a 1.0mm electrode collet and ten (10) 1.0mm
electrodes. The 1.0mm electrodes are a good multipur-
pose electrode for most welding applications. Available
separately, Sunstone oers 0.5mm electrodes, which
are more suited for very small applications (less than 5
Ws of energy).
HOW TO PLACE THE ELECTRODE INTO THE
WELDING STYLUS
See the Stylus Components Chart (Figure 5.4) to install
the tungsten electrode (D) and then carefully follow
these instructions:
Figure 5.2. Tubing and other cables can be routed up and
through the removable cable guide portion of the arm.
Figure 5.1. Mount the Welding Stylus to the holder below
the microscope.
Figure 5.3. When
looking through the
microscope, the stylus
should appear in the
center of your focus,
as shown here.
Stylus Components
Figure 5.4

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Orion™150sUsers Guide
• Remove the stylus hull (E) by pulling it away
from the stylus shaft (A). See Figure 6.1.
• 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
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.
Adjusting The Microscope Focus
• Twist the knob on the microscope forward and
backward to lower and raise the head. This
will allow you to focus the microscope on the
welding stylus. See Figure 6.4.
• Place your nger under the welding electrode
to help judge the correct focus location. Focus
the microscope until the texture on the skin of
your nger is clearly visible.
Figure 6.4. Turn
this knob to adjust
microscope focus.
You’ll nd one knob
on each side of the
microscope arm.
Figure 6.1. To install the electrode, rst remove the stylus
shaft (A) from the stylus hull (E) by pulling them apart.
Figure 6.2. Use the guide engraved on the side of the
stylus hull (E) 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).

Questions? Call or Text [phone] • 7
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Power Supply Setup - Back Panel
Reference Figure 7.1 and follow these instructions (all
required cables are found in the accessories box).
• Plug the female end of the included power
cable into the 90-250 VAC Power Port (F).
• Connect the male end of the power cable
into AC power (wall outlet). The Orion s series
can accept voltages ranging from 90VAC to
250VAC. (When plugged in for the rst time the
Power Button LED will blink a couple of times
and then turn o.)
• Insert the included 1/4” gas tube rmly into the
Shield Gas Port (C). The tube may feel loose
when connected but should not come out if
pulled.
• Plug the foot pedal cable into the Foot Pedal
Port (D).
• Insert the stylus connector into the Weld Stylus
Port (H) on the back panel of the power supply.
Ensure that the white circular indicator on the
stylus is lined up with the white indicator on the
Weld Stylus Port. The connector will snap into
place.
• When making welds using the stylus, an alli-
gator clip cable can be connected to the Pulse
Arc+ Port (G) on the back of the power supply
for grounding the work piece during the weld.
• When tack welding, plug one alligator clip cable
into the Tack+ Port (A) and one into the Tack-
Port (B). Be sure to attach each alligator clip to
each work piece before tacking the two pieces
together.
• As instructed previously on page 4, connect the
Shutter Cable to the Shutter Port (E).
Note: Connecting other display port compatible devic-
es to the Orion 150s’s Shutter Port may damage the
welder and/or the other devices.
Figure 7.1. Back panel of the Orion 150s.
A
B
C
G
H
D
E
F

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Orion™150sUsers Guide
Electrode Care and Pressure
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 cause the electrode to
become contaminated (work piece material on the elec-
trode). Sunstone recommends cleaning or changing the
electrode when it sticks to the work piece.
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:
• Remove the electrode from the stylus.
• Pinch the electrode between the thumb and
index and/or middle nger with the shaft going
perpendicular to the ngers. See Figure 8.1.
• 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 8.2. 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


Figure 8.1. A sharp electrode tip improves arc initiation
and results in a better overall weld.
Figure 8.2. Use a rotary tool to sharpen the electrode.
R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N

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• 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 work piece 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,
as shown in Figure 9.1.
• Follow the “When to Sharpen the Electrode”
instructions on the previous page.
• 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.
• 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.
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
Figure 9.1. When working with silver, copper, and other
highly conductive metals, a at or blunt electrode
provides better results.

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Orion™150sUsers Guide
PRESSURIZED GAS SAFETY
There are several important rules that should be fol-
lowed when using a compressed shielding gas such as
argon:

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 a projectile,
expelling 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.
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 (C) COUNTERCLOCK-
WISE (closed) until it is fully backed out,
meaning the dial becomes loose, to prevent
over-pressurization of the line. See Figure 10.1.
• 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 (E) into the gas port
on the back of the power supply. Tug gently on
the tube to verify a tight t. See Figure 10.2.
• Connect the other end of the gas tubing (E) to
the gas regulator port (D), as shown in Figure
10.2.
• Open the gas tank at the main valve (F) slowly
as shown in Figure 10.3. The dials attached
to the regulator should respond as the valve
Figure 10.1. 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 10.2. Connect the OD gas tube (E) from the power
supply to the gas regulator port (D).
E
Figure 10.3. 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

Questions? Call or Text [phone] • 11
e Micro Welder Experts
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 (C) CLOCKWISE
until the dial on the left shows gas pressure
between 7-10 liters per second. See Figure.
10.1.
Microscope LCD Filter Shutter
System
The Microscope LCD Filter Shutter
System provides an unobstructed
working view before welding and
completely protects your eyes during
the welding process. The Orion 150s’s internal comput-
er 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.
BECOME FAMILIAR WITH THE MICROSCOPE
The Sunstone 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. This
is an easy challenge to overcome. To begin, follow the
suggested practices below while the welder is in Weld
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 150s!

12 • Questions? Call or Text [phone]
Orion™150sUsers Guide
O Mode. While the welder is in Weld O Mode, it will
not be able to make a weld when the work piece touch-
es the electrode.
• Rest your hands on the table and position the
work piece close to the welding electrode
before looking into the microscope.
• Make sure your focus is at the tip of the elec-
trode.
• Use slow, controlled movements.
• It is helpful to have your hands resting on the
table and to only use your ngers to move the
work piece up to the electrode. See Figure 12.1.
• Place the work piece surface perpendicular
to the point of the electrode. As discussed
in later chapters, the angle of the electrode
tip relative to the work piece surface is very
important and will take practice.
• Now practice making soft contact with the work
piece to the electrode.
• Once you feel comfortable, attach the alli-
gator clip to the work piece 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 work piece.
Figure 12.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., Then look
through the microscope.

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Chapter 2: How to Weld
At the front of the Orion 150s 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 150s delivers, how the power is delivered, make
adjustments to agitation, make system changes, view instructional videos, or save welds.
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. 13.1. Wait for
the welder’s software to load.
When the Power Button (A) is pressed and the welder
is turned on, the Power Button illuminates with a blue
light. Wait for the welder’s software to fully load before
continuing.
Attach the Alligator Clip
Insert the alligator clip ground (B) to the front of the
welder as shown in Figure 13.1.
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 150s you can use the welder in two ways:
Arc Mode. The normal welding mode is the Arc Mode.
In this mode you’ll manually set the energy level, agita-
tion, and ignition. When in Arc Mode, the words “Arc” will
appear below the main row of blue buttons at the top. Figure 13.1. To get started, press the Power
Button (A); wait for the software to load; insert
the alligator clip ground (B).
A
B

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Basic Mode. Basic Mode is variation of the Arc Mode.
The 150s can automatically determine the amount of
energy and the type of agitation required for a success-
ful weld based on the type of metal and application you
select. As a result, you need but basic understanding
of power, agitation, and ignition. Use the Basic Mode
to take advantage of this automation. When in Basic
Mode, the words “Basic” will appear below the main row
of blue buttons at the top of the screen.
Tack Mode. In Tack Mode, you won’t use the stylus;
instead 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 work piece
grounded, a weld will occur where the pieces contact.
When in Tack Mode, the words “Tack” will appear below
the main row of blue buttons at the top of the screen.
Welding in Arc Mode
Choose Arc Mode by pressing the Weld Mode Button
(A) and select Arc in the drop down menu. The Arc
Mode is the default weld mode.
1. Enter Energy Level
The amount of energy you wish to use in any weld is
measured in Joules (or watt seconds). Enter the energy
level by pressing the Energy radio button (B), as seen
in Figure 14.1, and the place your nger against the
white energy wheel (G) and moving your nger down to
increase energy, or up to decrease energy. See Figure
14.2. When you reach the desired energy level, remove
your nger. The energy level increases or decreases by
two-tenths of a Joule at a time.
2. Select Length
Select the length of time the energy will run through the
electrode by pressing the Length radio button (C) and
then using the white wheel (G) to decrease or increase
time length. The default is 100%. and recommended
for most welds. Length is measured as a percentage. A
100% time length means that energy was disperesed
throughout the entire weld. A 50% time length means
energy was dispersed through 50% of the entire weld.
A
B
C
D
E
FI
G
Figure 14.1. To weld in the Arc Mode, select the power
(B); select the length (C); select the rate of re (D); select
the desired agitation (E); select the desired ignition (F);
select the desired Trigger Mode (H); press the Weld O
Button (I) to toggle to the Weld On Mode; attach the
alligator clip to the workpiece and then trigger the weld
accordingly.
Figure 14.2. The white wheel is used
for adjusting energy, length, and rate
of re.
Move your nger counter-
clockwise to decrease.
Move your nger clockwise to
increase.
H

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3. Rate of Fire
Select the rate of re by pressing the Rate of Fire radio button (D) and then using the white wheel (G) to de-
crease or increase the rate of re. The maximum rate of re is 3; the minimum is Single Fire.
Rate of Fire is the number of times the welder will release energy in one second. If you are seam welding, a fast-
er rate of re may make more ecient use of time. If you are tacking, a single re rate may be applicable.
4. Select Agitation
Select the desired agitation by pressing the icon (E) of the type agitation you wish to use. You can choose from
one of four dierent types of agitation:
• None. With no agitation, the energy dissipates evenly, leaving a smooth weld nugget.
• Negative. Negative agitation decreases the overall energy of the weld and has the same peak voltage
of the weld without agitation. Negative agitation can be useful to minimize porosity of the weld.
• Sloped. The Sloped agitation option oers low levels of agitation. It has minimal impact on spot size
formation, but yields additional penetration and enhanced weld strength. This agitation is available up to
233 Ws of energy.
• Sustained. The Sustained option oers high levels of agitation for improved 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, users may need to slightly lower the
overall weld energy when using this option. This agitation is available up to 133 Ws of energy.
5. Select Ignition
Select the type of ignition you wish to use by pressing the Ignition icon (F). By pressing the Ignition icon you’ll
toggle between two types of ignition:
• Standard. In the Standard ignition option, the energy discharge occurs at approximately the same time
as the tip lifts o the work-piece surface. Standard ignition 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 elec-
trode may dull more quickly. Standard ignition mode is typically used for welding very ne applications
that would be damaged by high energy levels since there is no pre-ignition arc. Standard may also be
suitable when welding a tight joint.
• Standard Plus. In Standard+ ignition mode, the energy discharge occurs well after the electrode tip lifts
o the work-piece surface. While similar to the Standard option, Standard+ includes a “pre-heat” func-
tion know as a Focus Arc before the main weld. As the electrode begins to pull away from the surface,
a small amount of energy is discharged prior to the main weld discharge. The additional energy helps
preheat the weld area and helps establish an arc when the electrode is further away from the surface.
The Standard+ ignition helps provide better weld consistency by allowing more variation in contact
pressure before the weld takes place. You may also see this ignition mode preserve the electrode tip
and accumulate less contamination.
6. Select Trigger Mode
Select how you want the weld to be triggered by pressing the Touch Detect Button or Foot Pedal Button. See (H)
in Figure 14.1. Choose one of the following trigger types:

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Orion™150sUsers Guide
• Touch Detect. The Touch Detect mode is the
default mode. The welder will initiate a weld
when the electrode touches the work piece.
• Foot Pedal. If you attach a foot pedal to the
back of the welder, 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.
7. Select Weld On Mode
At this point, touch the Weld On ratio button (I) as
shown in Figure 14.1.
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
being used, you should toggle this button to the Weld
O mode to avoid an unintentional discharge of energy.
8. Attach Alligator Clip to Work piece
Attach the alligator clip ground to the work piece as
close to the intended weld spot. See Figure 16.1.
Welding in Basic Mode
The 150s can automatically determine the amount of
energy and the type of agitation required for a success-
ful weld based on the type of metal and application you
select.
After you choose the metal and application type, the
150s will set the energy level, the best agitation type,
and the best ignition type.
To begin, choose Basic Mode by pressing the Weld
Mode Button (A) and select Basic in the drop down
menu, as shown in Figure 16.2.
1. Select Metal Type
Press the Metal Button (B) as shown in Figure 16.2 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.
Figure 16.1. Attach the alligator clip ground to the workpiece
at a spot that ensure the best contact between ground and
workpiece.
A
Figure 16.2. To weld in Basic Mode, press the Weld
Mode Button (A) and choose Basic; press the Metal
Button (B) to select a metal; press the Application Button
(E) to select an application type; press the Agitation
Button (C) to select the desired type of agitation; press
the Ignition Button (F) to select the desired type of
ignition; select a Trigger Mode (D); press the Weld O
Button (G) to toggle to the Weld On Mode.
B
C
E
F
G
D