SUNSTONE Orion 50p User manual

Orion 50p Welding System
User Manual

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Table of Contents
Chapter 1: Welder Setup .......................... p.5
What is in the Box ............................ p.5
Power Supply Setup .......................... p.6
Chapter 2: User Interface ........................ p.7
Overview ...................................... p.7
Chapter 3: Sample Project ....................... p.8
How to make your first weld .................. p.8
Chapter 4: Safety ................................ p.9
Overview ...................................... p.9
Chapter 5: FAQ ................................... p.12
Overview ...................................... p.12
Chapter 6: Specifications ........................ p.13
Specifications ................................ p.13

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Chapter 1: Welder Setup & Assembly
What is in the Box
ORION 50p:
(1) Orion 50p Power Supply
(1) Power Supply Power Cord
(2)Negative and Positive Cable
(1) Foot Pedal
(1) Post Weld Head

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Power Supply Setup
SETUP
1. Unbox the welder and weld head
2. Connect cables to the back of the welder:
a. Port 1 is an 8-din connector. Connect the cable from the weld head
into this port.
b. Port 2 is a 3-din connector. Connect the foot pedal or the double
hand trigger into this port.
c. Terminal 3 is the positive terminal. e positive cable should be
attached to the workpiece, or to the grounding foot if equipped.
d. Terminal 4 is the negative terminal. e negative cable should be
attached to the brass post holder on the weld head.
e. Port 5 is the power inlet port. Connect a power cable here, and
then connect to a wall outlet. e welder can be connected to 100-
240VAC. e connector has a 10A fuse.
f. Switch 6 is the power switch. Switch it up to turn the unit on, or
down to turn it off.
3. Weld Head Adjustments
a. e weld head height can be adjusted by loosening the two adjustment knobs on the right of the weld head.
b. To set the height, pull down on the block holding the brass post holder. With the post holder all the way down,
lower the weld head until the post holder makes contact with the weld surface. Next, lower the weld head
slightly more, until there is a gap of approximately 0.1” to 0.125” between the top of the block and the cotter pin.
c. If not already completed, connect the positive cable to the grounding block, the workpiece, or the grounding
foot if equipped.
d. If not already completed, connect the negative cable to the brass post holder.

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4. Turn the unit on using the power switch on the back of the welder.
a. If needed, the touchscreen can be recalibrated. To do so:
i. Turn the welder off
ii. Touch and maintain contact on the screen while turning the welder on
iii. Once the calibration menu appears, follow the on-screen instructions
iv. A series of red dots will appear on the screen. Touch each dot on the
screen.
v. Once this is done, there will be a test screen to draw on to verify the
calibration
vi. If the calibration is accurate, click the complete button. If not, you may
recalibrate and try again.
Chapter 2: User Interface
User Interface
OVERVIEW
1. Weld Screen
a. ere are two slider bars on the weld screen. ese
control the weld voltage and the speed of the weld
head. Higher voltages will result in bigger welds. Note
that too much energy can have a negative effect
on the weld. Also, excessive speed can also have a
negative effect on the weld. It is recommended to make
adjustments to only one slider at a time. As a starting
point, set the voltage to 105V and the speed to 39in/sec.
b. e Play/Pause button on the bottom of the screen
will turn the weld voltage on or off. In a pause state, the
welder will not weld because the voltage is turned off
and not allowed to discharge.
c. e lock icon on the screen will allow a user input
a PIN number to lock the current voltage and speed
settings. Changes will not be allowed until the welder is
unlocked using the original PIN number.

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2. Settings Screen
a. Audio Signals - Turn the audio signals on or off here.
b. Laser Targeting - e weld head has a laser pointer
mounted inside. is is to be used to align the post
above the workpiece. is button will turn the laser on
or off.
C. Erase Pin - Touch here to erase the set pin code.
Chapter 3: Demo Sample Project
Demo Sample Project
TO MAKE YOUR FIRST WELD, FOLLOW THESE STEPS:
1. Set the weld head height according to the instructions found in the setup section of the user manual.
2. Place the workpiece on the grounding block and make sure it has adequate contact with the positive terminal, clip,
or grounding foot if equipped.
3. Position and align the workpiece using the laser alignment in the weld head. If a red dot laser is not visible, ensure
that there is no post in the brass post holder, ensure that the laser is turned on by clicking to the settings screen on
the welder, and/or ensure that the brass post holder is properly aligned.
4. Once the workpiece is positioned under the weld head, insert a post into the brass post holder. e post will be
held in place by a ball bearing being held tight by a rubber o-ring. If the post seems loose, remove the post and push
inward on the ball bearing and rubber o-ring. en reinsert the post. Note that once the post is inserted, the laser
pointer will no longer be visible.
5. Next, set the weld parameters on the welder. Navigate to the weld screen, adjust the voltage to 100V and adjust
the speed to 39in/sec. Tap the Play/Pause icon to put the welder into the “Play” state.
6. Finally, make sure that all hands and objects are safely away from the weld head, and then initiate the weld either
by stepping on the foot pedal, or pressing both buttons on the double button trigger. e weld head should slam
down, make a weld, and then return to the starting position.

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Chapter 4: Safety
Safety
EYE PROTECTION:
When operating this unit, use eye protection. Weld splash can occur, which can be harmful to eyes.
PINCH POINTS
ere are a few different pinch points on the weld head.
If equiped with a grounding foot, the above circled spot on
the unit can be adjusted vertically. When being adjusted, be
sure not to put your hand or other extremities underneath.
e brass post holder on the weld head will descend
automatically once a trigger from welder has been actuated.
Once triggered the portion of the head will come down
with great speed and force. Do not stick hand or other
extremeties underneath while operating. We suggest to
use our two hand switch system to avoid any pinching or
breaking of extremeties.
When manually adjusting height of weld head keep hands
and extremities away from the edges where slippage can
occur.

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Area between brass post holder block and the body of the weld
head will be exposed for short periods of time during a weld. e
post holder block will drop down and go back up very quickly, so
avoid putting hands and extremities near this area of equipment
when operating.
ELECTRIC SHOCK
ere is a potential between the positive and negative terminals
of the weld head of up to 170VDC during the welding process.
Note that unlike other similar welders, voltage is only live after
the trigger is initiated by either the foot pedal or double button.
We suggest using our double button switch system in order to
avoid any potential electrical shock. Never touch both of these
areas with exposed skin, while triggering a weld. If you want to be
able to hold the workpiece, we suggest using isolated gloves or
tools that are not conductive.
TIPPING OVER:
is unit may be top heavy and can tip over. In order to prevent
this we suggest that you mount it to a table or fixture.

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LASER SAFETY
is product uses a Class 3A laser. A Class 3A laser is low powered. It normally would not harm eyes during a
momentary exposure of less than ¼ second. is is within the aversion response, where a person turns away and/
or blinks to avoid bright light. Do not deliberately look or stare into the laser beam. Laser protective eye wear is
normally not necessary. A Class 3A laser is not a skin or materials burn hazard.
AVOID EXPOSURE. laser radiation is emitted from the APERTURE
LASER RADIATION-AVOID DIRECT EYE EXPOSURE
LASER DIODE, Wavelength: 630-680nm
Max. Output: 4mw, CLASS IIIA LASER PRODUCT
DANGER

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Chapter 5: Frequently Asked Questions
FAQ
WHY AM I GETTING POOR WELD QUALITY?
• Not the right size collet
• Bad ground connection
• Loose ground connection
• Dirty material
• Energy level too high or too low
• Check connection to welding unit
• e (+) and (-) terminal are not connected correctly. (Orientation matters)
WHAT SHOULD I MAINTAIN ON THIS UNIT?
• e shafts for moving collet system up and down could be lubed after every 1000 welds. is will help
produce better, more consistent welds.
• What if I trigger and nothing happens?
• e play button needs to be pushed
• Trigger pedal isn’t properly connected
• e unit isn’t charged and ready yet
WHAT IF THE UNIT COMES DOWN, BUT DOESN’T COME BACK UP?
• e collet is more than likely stuck to the workpiece.
• is can happen if the stud is incorrectly placed in collet or the collet that is used isn’t designed for the
size of stud that is being used.
WHAT IF I SEE A BIG SPARK?
• ere will be some sparks from the stud welding process, however if you see more than normal this could
mean that the workpiece holder has misaligned and is coming in contact with the collet.
WHAT IF MY LASER ALIGNMENT IS OFF?
• You can turn the collet until you find a more defined bright spot. e laser goes through a corridor of
reflective metal, so you will see a little splatter, but just look for the point that is brighter than the rest.
WHAT IF MY UNIT AUTOMATICALLY RESETS?
• ere is a built in shutdown sequence that will occur if the motor sees over current. is will happen if some
how the system is being bound.
• is usually will only happen if the collet is stuck to the workpiece and the motor was not able to return
the collet to its beginning position.
WHAT IS THE MAX OUTPUT VOLTAGE AND PEAK CURRENT?
• 170VDC and 5700A Peak

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50p Weld Head Specifications
Max throat depth 4”
Height adjustment from 0”- 3” (standard)
Exerted force on part from 1lbF (4.5N) – 15lbF (66.7N)
Weld Cycle Rate Accommodate up to 30 studs per minute
Weight 19lbs (27lbs with power supply)
Weld Cables 18awg x 16”
50p Welder Specifications
AC Power 90-230VAC Single Phase
Dimensions 9.25” X 5.75” X 6.5”
Display 4.3” Touch Screen
Save Settings Up to 5 Saved settings
Preset Settings 5 preset weld settings
Output Peak Current 5700A
Max Output Voltage 170VDC
Foot trigger yes
Supervisor lock pin yes
Laser sight for correct part placement yes
Chapter 6: Orion Earring Post Welder Specifications
Specifications

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