SUNSTONE Orion 200i User manual

Orion™200i
Pulse Arc Welder Users Guide
20210608 • ITEM #1210

Orion™200iSeries Users Guide
ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 06/2021 New Formatting
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
Attach Touchscreen to Microscope Arm ........4
Microscope Setup ...................................................4
Welding Stylus Setup ............................................5
Electrode Setup .....................................................6
Adjusting the Microscope Focus .......................7
Power Supply Setup ...............................................7
Power Supply Support Mount Brackets ..........7
Power Supply Setup - Back Panel......................8
How to Turn on the Power Supply .....................9
Electrode Care ........................................................9
Workpiece Electrode Pressure...........................9
When to Sharpen the Electrode.........................9
When to Flatten/ Blunt the Electrode ............ 10
Shield Gas Setup...................................................11
Pressurized Gas Safety ......................................11
Shielding Gas Tank and Regulator Setup.....12
Microscope LCD Filter Shutter System........12
Become Familiar with the Microscope..........13
Chapter 2: How to Use the Welder Software.......14
Home Screen..........................................................14
Waveform Graphic Area .....................................15
Parameter Selection Area .................................16
ARC Mode................................................................17
TACK Mode ............................................................. 20
Footer Buttons....................................................... 21
Mini-Screen Area .................................................. 22
Weld Parameters...................................................22
Help and Accessibility ........................................23
Media Screen .........................................................23
Save/Load Screen................................................24
How to Save a Weld .............................................24
How to Load a Weld .............................................25
How to Delete a Weld ..........................................25
Settings Screen..................................................... 26
Interface System Options .................................26
Agitation System Options .................................27
Gas Options............................................................ 28
Timing Options ......................................................28
System Options.....................................................30
Lock Options..........................................................31
Chapter 3: How to Weld.................................................33
How to Make a Basic Weld.................................33
How to Make a Tack Weld .................................. 34
How to Find the Right Settings ........................ 35
Welding Tips and Tricks .....................................36
How to Aim the Electrode..................................36
How to Read the Waveform Graph .................37
Declaration of Conformity ............................................39

Orion™200iSeries Users Guide

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e Micro Welder Experts
Chapter 1: Welder Setup & Assembly
What is in the Box
BOX 1 CONTENTS:
(1) Sunstone Touchscreen (2) Alligator Grounding Clips
(1) Sunstone 200i Series Power Supply (1) Shielding Gas Hose
(1) Foot Pedal
(1) Electrode Vial (10x 1.0mm 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) Communications Cable (Display Port Ends) (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™200iUsers 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. 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 (C)
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
(3) Flat Head Screws
(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 5.1.
• 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™200iUsers Guide
Attach Touchscreen to Microscope
Arm Assembly
Once the Microscope Arm Assembly has been rmly
secured, the Touchscreen can be attached.
• Remove the Touchscreen from the foam in box
1.
• Line up the mount bracket on the back of the
Touchscreen with the slot in the clip mecha-
nism on top of the arm and lower it into the slot
until the clip clicks into place. It can be helpful
to pull the clip back while sliding down. See
Figure 4.1.
• Remove the screen protector lm from the front
of the Touchscreen.
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
4.2. 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 back of the Touchscreen.
Note: Connecting other RJ45 compatible devices to the
Sunstone shutter RJ45 port may damage the welder
and/or the other devices.
Figure 4.1. Attach the Touchscreen to the Microscope
Arm Assembly. Remove the screen protector lm.
Figure 4.2. 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 Touchscreen to
the bottom of the microscope head.

Questions? Call or Text [phone] • 5
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Stylus Shaft (A) Collet (B) Collet Cap (C) Electrode (D) Stylus Hull (E)
Welding Stylus
• Remove the Welding Stylus from the accesso-
ries box.
• Insert the Welding Stylus into the holder at the
bottom of the arm assembly as shown in Figure
5.1.
• The tubing can be routed up and through the
removable cable guide portion of the arm if
desired. See Figure 5.2.
• 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.
• Rotate the stylus holder to approximately a
45-degree angle as shown in Figure 5.1 (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 5.3.
• 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 5.1.
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™200iUsers Guide
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).
INSTALL THE TUNGSTEN ELECTRODE ONTO
THE WELDING STYLUS
See the Stylus Components Chart (Figure 5.4) on previ-
ous page to install the tungsten electrode (D).
• 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 engraved guide 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 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.
Figure 6.1. To install the electrode, rst remove the stylus
shaft (A) from the stylus hull (E) by pulling them apart.
Figure 6.3. The electrode should protrude past the
stylus hull (E) 1/8 to 1/4 inch (3.175 to 6.35mm).
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.

Questions? Call or Text [phone] • 7
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Figure 7.2. Use two mounting brackets (not included)
to attach the Power Supply to wall or other vertical
surface. Call Sunstone at [phone] to request
the mounting brackets.
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 7.1.
• 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.
Power Supply Setup
POWER SUPPLY SUPPORT MOUNT
BRACKETS
The Orion i Series power supply can either be mounted
to a at vertical surface (such as a wall or the side of a
desk) using mounting brackets, or rest on a at hori-
zontal surface. Keep in mind that the power supply will
need to be mounted in proximity to the microscope arm
assembly.
Optional Mounting Brackets (Not Included)
To mount the power supply to a vertical wall, request
mounting brackets from Sunstone. Call +1 801-658-
0015. Attach the mounting brackets only to a struc-
turally sound vertical support. One mounting bracket
should attach to the top of the power supply and one to
the bottom.
Attach the lower mounting bracket to the wall rst
(using wood screws or other appropriate hardware,
not included) and attach the power supply to the lower
mounting bracket using the two provided screws. Next,
attach the upper mounting bracket to the power supply,
then attach the upper mounting bracket to the wall. See
Figure 7.2.
Figure 7.1. Turn
this knob to adjust
microscope focus.
You’ll nd one knob
on each side of the
microscope arm.

8• Questions? Call or Text [phone]
Orion™200iUsers Guide
Power Supply Setup - Back Panel
Reference Figure 8.1 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 (B).
• Connect the male end of the power cable
into AC power (wall outlet). The Orion i 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 (F). The tube may feel loose
when connected but should not come out if
pulled.
• Plug the foot pedal cable into the Foot Pedal
Port (G).
• 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 (E) on the back of the power supply
for grounding the workpiece during the weld.
• When tack welding, plug one alligator clip cable
into the Tack+ Port (A) and one into the Tack-
Port (D). Be sure to attach each alligator clip to
each workpiece before tacking the two pieces
together.
• Plug the included communications cable (long
display port cable) into the Comm. Port (C).
• Plug the other end of the communications
cable into the Comm. Port on the back of the
Touchscreen (the cable can be routed through
the removable cable guides on the Microscope
Assembly Arm).
Figure 8.1. Power supply setup - Back Panel
A
B
C
D
E
F
G
H

Questions? Call or Text [phone] • 9
e Micro Welder Experts
Figure 9.1. A sharp electrode tip improves arc initiation
and results in a better overall weld.
Figure 9.2. Use a rotary tool to sharpen the electrode.
Note: Connecting other display port compatible de-
vices to the Orion 200i’s Comm. Port may damage the
welder and/or the other devices.
How to Turn on the Power Supply
On the front of the power supply, push the power but-
ton to initiate the power up sequence. The power button
will illuminate and the touchscreen and the microscope
light will begin to power on.
Electrode Care
WORKPIECE ELECTRODE PRESSURE
Touch the workpiece to the electrode with very light
pressure. Too much pressure will cause the workpiece
to stick to the electrode and cause the electrode to
become contaminated (workpiece material on the elec-
trode). Sunstone recommends cleaning or changing the
electrode when it sticks to the workpiece.
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.
• Pinch the electrode between the thumb and
index and/or middle nger with the shaft going
perpendicular to the ngers. See Figure 9.1.
• Power on the rotary tool then hold it with the
opposite hand.
R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N

10 • Questions? Call or Text [phone]
Orion™200iUsers Guide
• 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 9.2. 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
nger while twisting the electrode with the
thumb and middle nger. See Figure 9.2
• 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.
WHEN TO FLATTEN/ BLUNT THE
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 10.1.
• 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.
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
Figure 10.1. When working with silver, copper, and
other highly conductive metals, a at or blunt electrode
provides better results.

Questions? Call or Text [phone] • 11
e Micro Welder Experts
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 followed when using
a compressed shielding gas such as
argon:
Always secure the pressurized gas tank to a xed
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.
Always turn o the shielding gas at the main valve
when nished. 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 200i!

12 • Questions? Call or Text [phone]
Orion™200iUsers Guide
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 12.1.
• 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 12.2.
• Open the gas tank at the main valve (F) slowly
as shown in Figure 12.3. 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.
Microscope LCD Filter Shutter
System
The Microscope LCD Filter Shutter System provides an
unobstructed working view before welding and com-
pletely protects your eyes during the welding process.
The Orion 200i’s internal computer veries the Micro-
scope LCD Filter Shutter System has been closed be-
fore 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.
Figure 12.1. 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).
Figure 12.2. Connect the OD gas tube from the power supply
to the gas regulator port.
Figure 12.3. Open the shielding gas tank main valve slowly
clockwise until the left dial on the regulator port indicates gas
pressure of 7-10 liters per second.
A
B
C
E
D
F

Questions? Call or Text [phone] • 13
e Micro Welder Experts
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 elec-
trode.
• Rest your hands on the table and position
the workpiece 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
workpiece up to the electrode. See Figure 13.1.
• 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.
Figure 13.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., Then look
through the microscope.

14 • Questions? Call or Text [phone]
Orion™200iUsers Guide
Chapter 2: How to Use the Welder Software
The Orion 200i interface consists of four main “screens” that can be accessed at any time by touching the icons
located along the top of the screen in the header area. The four main screens are:
• Home Screen
• Media Screen
• Save/Load Screen
• Settings Screen
Home Screen
The Home Screen is comprised of three areas: The Waveform Graphic Area (1), The Parameter Selection Area
(2), and the Mini-Screen Area (3) as shown in Figure 14.1.
Figure 14.1. The Home Screen is comprised
of three areas: The Waveform Graphic (!),
the Parameter Selection Area (2), and the
Mini-Screen Area (3).
1
2
3

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WAVEFORM GRAPHIC AREA
The Waveform Graphic Area displays a graphic representation of what will take place during each weld and pro-
vides a quick reference for various settings, as shown in Figure 15.1. The waveform displayed will change based
on the control settings selected by the operator (see Chapter 4: How to Read the Waveform for more informa-
tion).
Along the left side of the graph, the vertical axis represents the total weld energy available (A). The horizontal
axis represents time (ms). The actual values are displayed below the graph.
In the upper right-hand corner, an approximation of the weld spot size (B) is shown based on the current set-
tings and represents a full discharge of the total weld energy available. The spot provides a visual reference of
changes in spot size as settings are adjusted.
Current settings (C) are displayed along the bottom of the graph. Ignition, agitation, length, and weld speed
values are shown.
As length decreases, the amount of energy discharged will decrease as represented in text just below the
graph. The represented spot size displayed will not decrease, but the actual weld spot size will decrease as
length is adjusted down.
Figure 15.1. The Waveform Graphic. The vertical
axis represents the total weld energy available (A).
The horizontal axis represents time in milliseconds.
An approximation of the weld spot size (B) is also
displayed. Current settings (C) are displayed along the
bottom of the graph. Ignition, agitation, length, and
weld speed values are shown.
A
B
C

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Orion™200iUsers Guide
PARAMETER SELECTION AREA
The Parameters Selection Area displays the buttons and sliders used to control the parameters that will aect
the weld. The three buttons at the top of the Parameter Selection Area, Basic, Arc, and Tack, are used to switch
between dierent welding controls and are always displayed. Touching one of these buttons will change the
controls that are displayed in the Parameter Selection Area.
Basic
The Basic layout allows you to simply select the metal being welded and the type of weld being performed.
Based upon the material selected, the Orion 200i will automatically choose the best settings that will deliver an
optimum weld. See Figure 16.1.
Select Metal
At the top of the Basic layout are buttons labeled with dierent types of metals (A). The buttons scroll from left
to right or right to left. To scroll, touch and hold any one of the buttons and then drag left or right. Select the
metal type being welded and the Orion 200i will automatically choose weld parameters for that metal.
Select Application
Select the type of weld desired by pressing the representative icon (B). The welder will modify the settings ac-
cordingly. Choose from the following: Thick work-piece, Thin work-piece, Inside Joint, Adding Material, or Prong.
Energy Slider
The Energy Slider (C) adjusts the amount of energy to be used in the weld to achieve the desired results for your
application. You can adjust the energy by touching and sliding the bar left or right. If you need more precision
press the keypad Icon to open the keypad mode.
A
B
C
Figure 16.1. The Parameter Selection Area with the
Basic layout selected.