SUNSTONE Orion i Series User manual

Orion i Series Welding System
User Manual
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i Series User Manual
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Table of Contents
Chapter 1: Welder Setup and Assembly ..................... p.3
What is in the Box ....................................... p.3
Mounting Options ....................................... p.3
Microscope Arm Setup ................................. p.3
Attach Screen Case To Microscope ..................... p.4
Arm Tension Adjustment ................................ p.5
Adjusting e Microscope Focus ........................ p.6
Power Supply Setup ..................................... p.6
Electrode Setup ......................................... p.8
Shielding Gas Setup .................................... p.10
Microscope LCD Shutter System ....................... p.11
Chapter 2: User Interface Overview ......................... p.12
Waveform Graphic Area ................................. p.12
Parameter Selection Area .............................. p.13
Header Buttons ......................................... p.13
Basic Control Layout .................................... p.13
Arc Control Layout ...................................... p.13
Tack Control Layout .................................... p.15
Footer Buttons ......................................... p.16
Mini Screen Area ......................................... p.16
Media Screen ............................................ p.17
Save/Load Screen ....................................... p.18
Interface Options ........................................ p.19
Agitation Options........................................ p.19
Gas Options.............................................. p.20
Timing Options .......................................... p.20
System Options.......................................... p.21
Lock Options............................................. p.22
Updating Welder Software .............................. p.22
Chapter 3: Make a Weld ...................................... p.23
Weld State Button ...................................... p.23
Make a Tack Weld ....................................... p.24
Finding e Right Settings .............................. p.25
“Aiming e Electrode ................................... p.25
Reading e Waveform Graph ........................... p.26
Ignition................................................... p.26
Weld Discharge Waveform .............................. p.26
Agitation Profile ......................................... p.26
Length ................................................... p.26
Energy ................................................... p.27
Chapter 4: Declaration of Conformity ........................ p.27
Orion Welders
1693 American Way, Unit 5
Payson, UT 84651 USA
+ 1-801-658-0015
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Chapter 1: Welder Setup & Assembly
What is in the Box
Microscope Arm Setup
BOX 1 CONTENTS:
(1) Orion i Series Power Supply
(1) Orion Screen Case
(1) Power Supply Mounting Brackets
BOX 2 CONTENTS
(1) Orion i Series Microscope Arm Assembly
(1) Orion Safety Manual & Quick Start/ Quick Setting Guide
BOX WITHIN BOX2  ACCESSORIES BOX:
(1) Welder Power Cord
(1) Welding Stylus Hand Piece
(1) Comm. Cable ( Display Port Ends)
(1) Shutter Cable ( RJ45 ends)
(2) Alligator Grounding Clips
(1) Foot Pedal
(1) Shielding Gas Hose
(1) Electrode Vile (5x 0.5mm -- 5x 1.0mm Electrodes – 1x
Diamond Dremel Disk – 1x 0.5mm Orion Collet)
(1) Fiberglass Brush
(1) Cross Lock Tweezers
(1) System Cover
(1) Brass Lined Pliers
(1) Microscope Arm Mounting Hardware
(1) Pair Microscope Eye Piece Shields
(1) Loop Closing Pliers
(1) Set Allen Wrenches
•Remove the microscope arm assembly from the box and place it on your table.
•ere 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.
MOUNTING OPTIONS
Mounting Option 1 - Clamp to table
Best used on tables with accessible edges and for mounting without drilling
holes in the table.
*If your table is thicker than 3-1/2” (9cm), follow mounting options 2 or 3.
Hardware required from box:
(1x) Angled bracket (letter C)
(1x) Clamp mechanism (letter D)
(5x) Flat head screws (letter G)
•Lay the arm assembly down on the tabletop.
•Attach the angled bracket (C) to the bottom of the arm using (3) of the
included flat head screws (G). (4mm Allen wrench)
•Attach the clamp mechanism (D) to the angled bracket using (2) of the
included flat head screws.
•Adjust the knob on the clamp mechanism until the gap is sufficient for the
thickness of your table top.
•Lift the arm assembly up and slide the arm onto the table.
•Lock it into place by turning the knob on the clamp mechanism until the
clamp is pressing firmly against the bottom of the table.
•A plastic cable guide cover can be clipped on over the angled bracket if
desired.
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Mounting Option 2 - Bolt through table
Best used for tables without accessible edges.
Hardware required from box:
(1x) Flat Mounting Plate (letter H)
(3x) Flat head screws (letter G)
(1x) Long Carriage Bolt (letter F)
(1x) Flat Pressure Plate (letter I)
(1x) Adjustment Knob (letter J)
•Using a 4mm (5/32) Allen wrench, unscrew the flat head screws (G)
holding the clamp to the arm.
•Run the included 8mm (5/16) carriage bolt (F) through the included
plate (H).
•Attach plate (H) to the bottom of the arm using (3x) flat head screws
•Drill a 3/8’ (9 .5mm) hole through the tabletop.
•Lower the arm so the bolt goes through the hole in the table top.
•Slide the tightening plate (letter I) onto the bolt and then tighten the twist knob (J) onto the bolt until it is very snug.
Mounting Option 3 - Screw to table (vertical surface)
Required Hardware:
(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 of the
included flat head screws (G).
•Lift and position the arm assembly onto the table in the desired location.
•Run screws through the bracket and into vertical surface of the table.
Attach Screen Case to Microscope Arm
Once the Arm Assembly has been firmly secured, the Screen Case can be attached.
•Remove the screen case from the foam in box 1.
•Line up the mount bracket on the back of the screen case with the slot in the
clip mechanism 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.
•Remove the screen protector film from the front of the screen.
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Arm Tension Adjustment
The spring tension is factory pre-set, but should changes be desired, the spring tension can
be adjusted by turning a hex screw located on the pictured arm joint. Use the included 6mm
Allen wrench to make adjustments.
•Turn the hex screw counter clockwise (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 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).
•Plug the other end of the Shutter cable into the “Shutter” port on the back of the
Screen Case.
*Connecting other RJ45 compatible devices to the Orion Shutter RJ45 port may damage the
welder and/or the other devices.
Welding Stylus
•Remove the welding stylus from the accessories box.
•Insert the stylus into the holder at the bottom of the arm assembly as pictured.
•The tubing can be routed up and through the removable cable guide portion of the arm
if desired.
•For now, position the stylus such that only the smaller diameter portion protrudes
from the holder and 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 pictured (the stylus should be angled down).
•Fine tune the position of the 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 stylus is in the center of your focus
•Now securely tighten the stylus in place by tightening the thumb screw on the bottom of the stylus holder.
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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.
•Place your finger under the welding electrode to help judge the correct focus loca-
tion. Focus the microscope until the texture on the skin of your finger is clearly visible.
Power Supply Setup
Power Supply Support Mount Brackets
The Orion i3 power supply can either be mounted to a flat vertical surface (such as a wall or the side of a desk) using
mounting brackets; or rest on a flat horizontal surface. Keep in mind that the Power Supply will need to be mounted in
proximity to the Adjustable Arm.
Mounting Brackets:
It is recommended to attach the brackets to a stud in the wall or other structurally sound
vertical supports.
•Mount a bracket to the wall in the orientation indicated using the two
provided screws with washers.
•Remove the power supply from its protective foam.
•Lower the power supply onto the pins protruding
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Power Supply Setup - Back Panel
The cables used below can be found in the accessories box.
•Plug the female end of the included power cable into the
“90-250 VAC” Power port.
•Connect the male end of the power cable into AC power
(wall outlet). The i3 can accept voltages ranging from 90VAC
to 250VAC. (When plugged in for the first time the power
button LED will blink a couple of times and then turn off.)
•Insert the included 1/4” gas tube firmly into the “Shield Gas”
port. *It may wiggle when connected, but should not come
out if pulled on.
•Plug the foot pedal into the “Foot Pedal” port.
•Insert the stylus connector into the “Weld Stylus” port on
the back panel of the power supply. Ensure that the white
circular indicator on the stylus lines up with the white indica-
tor on the stylus port. The connector will snap into place.
•When making welds using the stylus, an alligator clip cable
can be connected to the “Pulse Arc +” port on the back of
the power supply for grounding the work-piece during the
weld. (Alternatively, the port on the front of the unit can be
used if preferred).
•When Tack welding, plug one alligator clip cable into the
“Tack +” port and one into the “Tack -” port. *Remember to
attach each alligator clip to each work- piece before tack
welding them together.
•Plug the included Comm. Cable (long display port cable) into the “Comm.” port.
•Plug the other end of the Comm Cable into the “Comm.” Port on the back of the Screen Case (the cable can be routed
through the removable cable guides on the arm system if desired).
*Connecting other display port compatible devices to the Orion Comm. port may damage the welder and/or the other devices.
Power Supply Setup - Front Panel
•Plug an alligator clip cable into the “Pulse Arc +” port on the left side of the front panel.
Alternatively, you may use the “Pulse Arc +” port on the back of the welder.
•Push in the “Power” button to initiate power up sequence.
•The LED on the power button should light up. The touch screen and the microscope light
should power on as well.
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Electrode Setup
The Orion welder comes standard with a 0 .5mm electrode collet and (5) 0 .5mm electrodes; and a 1 .0mm
electrode collet and (5) 1 .0mm electrodes. The 1 .0mm electrodes are a good multipurpose electrode while
the 0 .5mm electrode is more suited for very small applications (less than 5ws of energy).
Stylus Components:
1.) Stylus Shaft 2.) Collet 3.) Collet Cap 4.) Electrode 5.) Stylus Hull
Install The Tungsten Electrode Onto The Welding Stylus
Follow these steps to properly install the tungsten electrode.
•Remove the stylus hull by pulling it away from the stylus shaft.
•Loosen the collet cap by twisting it counter-clockwise.
•The welder comes with 2 electrode collets. One that fits 0 .5mm
electrodes and one that fits 1 .0mm electrodes. The electrode stylus
will be shipped with the 1 .0mm electrode collet installed.
•Insert a 1 .0mm electrode into the collet. Helpful Tip: There is a groove
cut around the stylus hull that will help measure the electrode length.
Place the end of the stylus hull up against the collet cap, then make
sure the electrode tip falls between grooves. There is a silkscreen of
the electrode to help with this.
•There should be between 0 .6 - 0 .7in (1 .5 – 2cm) of the electrode
protruding from the stylus shaft. This will allow the electrode enough
room to stick out from the stylus once the stylus hull is placed back
on the stylus.
•Lock the electrode into place by hand tightening the collet cap in a
clockwise direction.
•Replace the stylus hull by pushing it in until you feel it snap back into place (the electrode should stick out between 1/8
– 1/4in (3.175 – 6.35mm) after the stylus hull is snapped back into place).
Work-Piece Electrode 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 in turn cause the electrode to be contaminated (work-piece material on the electrode). We recommend cleaning or
changing the electrode any time it gets stuck to the work-piece.
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When To Sharpen e Electrode
*Refer to Chapter 3 of the Orion Workbook for more information on electrodes.
e majority of applications are best welded using a sharpened electrode tip. A sharp tip improves arc initiation and helps
focus the arc properly. It is recommended that the user 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. e diamond disk can be
attached to a flex shaft or Dremel 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
finger with the shaft going perpendicular to the fingers.
• Power on the Dremel or flex shaft then hold it with the opposite hand.
• Place the electrode tip on the diamond disc in such a way that the
grit of the disk is moving parallel with the electrode shaft and moving
towards the tip. View image on the right for help with placement.
• This will affect the quality of the weld if not done as explained above.
• Set the electrode on the diamond disk at a 10-degree angle and begin to spin
the electrode with the thumb and middle finger. *A helpful way to get a sharp
electrode is to push down on the electrode with your index finger while twisting
the electrode with the thumb and middle finger.
• Once the electrode is sharp and clean, turn the Dremel off and insert the elec-
trode back into the stylus as explained above.
*As a general rule of thumb we recommend a freshly sharpened electrode anytime a
new work-piece is being welded.
When To Flatten/ Blunt e Electrode
• When working with silver, copper, and other highly conductive metals in energy levels above 20ws, it is recommended
to blunt the electrode instead of sharpening it.
• Completely remove the electrode from the stylus.
• Pinch the electrode between the thumb and middle finger with the point facing inward.
• Turn the Dremel or flex shaft on then hold it with the opposite hand. *Place the electrode tip in the diamond disc in such
a way that the grit of the disk is moving parallel with the electrode shaft and moving towards the tip.
• This will affect the quality of the weld if not done as explained above.
• Set the electrode on the diamond disk at a 10-degree angle and begin to spin the electrode with the thumb and middle
finger. *A helpful way to get a sharp electrode is to push down on the electrode with your index finger while twisting the
electrode with the thumb and middle finger.
• Once the electrode is sharp and clean, turn the electrode to a 90-de-
gree angle and push it against the Dremel in order to place a flat/blunt
tip on the electrode.
• Once the electrode has a flat/blunt tip, turn the Dremel off and insert
the electrode back into the stylus as explained above.
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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 occurred the protective gas turns off.
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) or higher, to prevent these effects. Shielding gas is
necessary to produce clean and repeatable pulse-arc welds. We recommend high purity argon. This can be purchased at
your local welding supply shop.
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 fixed 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 propel-
lant.
• Always turn off the shielding gas at the main valve when finished. 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 fill the room and displace oxygen, which can lead to suffocation. Argon is heavier than air and will fill 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 COUNTER CLOCKWISE (closed) until it is fully backed out.
Meaning the dial becomes loose to prevent over-pressurization of the line.
• Screw the gas regulator onto the shielding gas tank.
• 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 fit.
• Connect the other end of the gas tubing to the gas regulator.
• Open the gas tank slowly. The dial on the right should pressurize and the dial
on the left should remain at zero (when the regulator dial is fully backed out or
the dial becomes loose).
• Slowly turn the regulator dial CLOCKWISE until the gas pressure reads between
7-10 psi. (This will adjust the dial on the left side of the regulator.)
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Microscope LCD Shutter System
e microscope LCD filter shutter allows an unobstructed working view before welding and completely protects the user’s
eyes during the welding process. e Orion’s internal computer verifies the microscope LCD filter shutter has been closed
before allowing the weld to take place. In the case that the shutter does not close, the microscope lens is equipped with >UV
16 and >IR 16 for maximum eye protection.
Become Familiar With e Microscope
e Orion 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. is is an easy challenge to overcome. To begin, follow these steps with the welder disabled. (While the
welder is in “Weld Off”, it will not be able to make a weld when the work-piece touches the electrode.)
• Rest your hands on the table and position the work-piece close to the welding electrode before looking into the micro-
scope.
• Make sure your focus is at the tip of the electrode.
• Use slow, controlled movements.
• It is helpful to have your hands resting and to only use your fingers to move the work-piece
up to the electrode.
• 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 alligator clip to the work-piece and enable welds (Weld On) to begin performing
real welds.
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Chapter 2: User Interface Overview
The i3 interface consists of four main “screens” that can be accessed at any time using the icons located along the top of the
screen in the header area: HOME SCREEN, MEDIA SCREEN, SAVE/LOAD SCREEN, and SETTINGS SCREEN.
HOME SCREEN
The home screen is comprised of three separate Areas: The Waveform Graphic Area (1), The Parameter Selection Area (2),
and the Mini-Screen Area (3).
WAVEFORM GRAPHIC AREA
This area displays a graphic representation of what will take place during each weld and provides a quick reference for
various settings. The waveform displayed will change based on the control settings selected by the user (see Chapter 4:
Reading the Graph for more information).
• Along the left side of the graph, the vertical axis represents the total weld energy available. 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 is shown based on the current settings and
represents a full discharge of the total weld energy available. This provides a visual reference of changes in spot size as
settings are adjusted.
• Current settings are displayed along the bottom of
the graph. Ignition, Agitation, Length, and Weld Speed
values are shown.
• As length decreases, the amount of energy dis-
charged will decrease as represented in text just be-
low the graph. The represented spot size displayed
will not decrease, but the actual weld spot size will
decrease as length is adjusted down.
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PARAMETER SELECTION AREA
This area displays the buttons and sliders that can be used to control the parameters that will affect the weld.
HEADER BUTTONS
The three buttons at the top of the Parameter Selection Area are used to switch between control layouts and are always
displayed. Pressing a button will change the controls that are displayed in the area.
BASIC CONTROL LAYOUT
The Basic Control Layout allows users to simply select the metal being welded and the type of weld being performed. The Orion
i3 will then adjust settings automatically for that application.
• Select Metal
The buttons scroll from left to right or right to left. Select the metal type being welded and the Orion will automatically
choose weld parameters for that metal.
• Select Application
Select the type of weld being made by pressing the representative icon and the Orion will modify settings accordingly.
• Energy Slider
This slider adjusts the amount of energy that is being applied in the weld to achieve desired results for your application. If
you need more precision press the Keypad Icon to open the keypad mode.
ARC CONTROL LAYOUT
The Arc Layout consists of controls for Waveform, Ignition, Agitation, Energy, Length, and Weld
Speed. This allows for adjustments that will allow welding many different types of metals/ap-
plications.

The waveform selections determine and control how energy is released when welds are made.
• Classic - The classic waveform is the default waveform for welding on all Orion welders. It has a high initial peak current,
followed by a capacitive discharge slope. One key advantage of the classic waveform is its ability to create large weld
spots with shallow surface penetration, which helps keep the overall work-piece cooler. The capacitive dis-
charge slope allows the weld spots to cool with less internal stress, and without surface ripples. Classic welds
will typically have a smoother surface than other waveforms.
• Triangle - The Triangle waveform is similar to the classic waveform’s ability to make smooth and uniform weld results.
One key advantage of the triangle waveform is the ability to set the peak current lower and still be able to dis-
charge the full amount of energy over a longer period of time. Welds performed in Triangle Mode will typically
get deeper into the weld surface than with Classic. Triangle also gives users more control over the total energy
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being discharged than is possible with Classic.
• Square - Similar to the triangle waveform, a square waveform allows users to utilize the full amount of
energy over a longer period of time. The difference of this waveform compared to Classic and Triangle is
the abruptness of power at the start and end of each weld. The square waveform closely mimics the weld
output of a typical laser welder.

The ignition options control the timing of released energy in relation to the position of the electrode.
• Standard - In the Standard ignition option, the energy discharge occurs at approximately the same time
as the tip lifts off the work-piece surface. This 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 electrode may dull more
quickly. Standard ignition mode is typically used for welding very fine applications that would be damaged
by high energy levels since there is no pre-ignition arc.
• Standard+ - In Standard+ ignition mode, the energy discharge occurs well after the electrode tip lifts off the
work-piece surface. While similar to the Standard option, Standard+ includes a “pre-heat” function 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. This 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.
• Adaptive - In adaptive ignition mode, the arc can be maintained for longer periods of time in order to adapt
to variations in work-piece positioning techniques from user to user. This mode is more forgiving of move-
ment of the work-piece during arc formation. Initially, however, more energy is released into the work-
piece than in the other modes and can be detrimental for smaller weld applications or heat sensitive metals.
It is recommended to perform a few welds on a test piece, to allow this mode to adapt, before performing
actual welds on a work-piece. Welds on a test piece will need to be done every time the unit is powered
down.

During the weld, a high frequency agitation feature can be used to improve weld formation and strength in certain
applications. Positive agitation is added energy to the weld in the form of micro energy bursts. Negative agitation is
subtracted energy from the weld in the form of micro energy pockets. These energy bursts occur at a rate of up to 10,000
times per second. Using agitation can produce an audible, high-pitched “ping” noise. Additional Agitation settings can be
found in the Settings Screen or using the Mini Screen.
None - With “None” selected, no agitation is added to the weld. This is the standard weld discharge curve with a
smooth slope.
Negative – Negative agitation decreases the overall energy of the weld and has the same peak voltage of the weld
without agitation. This can be useful to minimize porosity of the weld.
Sloped - The Sloped agitation option offers low levels of agitation. It has minimal impact on spot size forma-
tion, but yields additional penetration and enhanced weld strength. This agitation is available up to 233Ws of en-
ergy.
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Sustained - The Sustained option offers high levels of agitation for improved weld spot strength in some metals.
The high levels of agitation energy will affect the spot size because of the extra energy used in this option. To com-
pensate 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 133Ws of energy.
/  
This slider adjusts the amount of weld energy or weld power that will be discharged depending on the waveform selected.
• Users can touch or drag along the slider to adjust the value.
• Pressing on the calculator icon will bring up a keypad for entering exact values. On the keypad, type in the desired value
and press enter. The value on the slider will change and the keypad will disappear.
• As the setting increases it will lead to more forceful welds, more heat at the weld site, deeper penetration, and larger
spot sizes.
• It can be helpful to start at lower values and gradually increase to higher values to fine tune the weld results without
damaging the work-piece.
 
The Length value dictates the duration of time for each weld energy discharge.
• When using the classic waveform mode, the length should typically be set to 100% for most weld applications. This al-
lows the weld puddle to cool at the proper rate and will result in smoother weld spots.
• In the Triangle and Square waveform modes, changing the length of the weld has a much bigger impact on weld results.
Longer length settings lead to more heat at the weld-site and generally result in bigger spot sizes/deeper welds.
• Experimentation with different lengths and power settings can help achieve the best results when using Triangle and
Square modes.
  
The Orion i3 is capable of performing resistance tack welds. See “Make a Tack Weld” section in
Chapter 3 for more information.
  
These buttons allow the user to quickly set the power to one of three common settings.
• Low: Tack energy is set to 30 Ws.
• Medium: Tack energy is set to half its maximum.
• High: Tack energy is set to maximum.
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- 
These buttons set the time between weld trigger and weld initiation.
• Short: Sets a quarter second delay before initiating the weld.
• Medium: Sets a half a second delay before initiating the weld.
• Long: Sets a one second delay before initiating the weld.
  
This slider adjusts the amount of weld energy that is being used. In order to precisely adjust the energy, click the keypad
icon to enter keypad mode.”
 
The buttons along the bottom of the Parameter Area are displayed at all times.
Weld ON/OFF - Pressing the icon toggles between Weld OFF and Weld ON. If the icon shows “WELD ON”, the weld sequence
can be initiated and welds can take place. When the icon shows “WELD OFF”, welds will not be able to initiated.
Undo - The Undo icon allows the user to go back through the 5 previous settings changed.
Redo - The Redo icon allows the user to cycle forward after pressing undo.
Reset - The Reset icon resets all the variables and parameters on the screen back to the factory
default settings.
Touch Detect - In Touch Detect, the welder will initiate the weld process any time that a grounded
work-piece makes contact with the electrode. When this button is selected, the “Pedal” button
will be greyed out.
Foot Pedal - When Foot Pedal is selected, the welder will only initiate when the Foot Pedal is
pressed. Move the grounded work-piece into contact with the electrode, hold still, and press the
foot pedal to initiate the weld. This can be useful for the ability to weld complex parts without
worrying about accidentally triggering a weld before getting into position. When this button is
selected, the “Touch” button will be greyed out.
MINI SCREEN AREA
The Mini-Screen Area allows users to customize the Home Screen by choosing from a list of modes that will be displayed
in the area for quick access to various weld control parameters, system settings, and information; all without leaving the
Home Screen. Push the drop-down arrow to bring up the list of viewable options. The current option will be highlighted in
blue. There are different options based on whether you are in Basic, Arc or Tack screen.
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 
• Agitation Options – adjust the agitation frequency, duty cycle, and weld per-
centage. (see Agitation section of Arc Control Layout).
• Gas Options – view gas pressure gauge and adjust gas flow timing. Tapping on
the gas gauge will cause a purge of the gas line. (see Gas section of Settings
Screen).
• Dynamic Energy Adjustment Mode – Enable or Disable the mode and adjust the desired percentage. When this mode
is active, operators may press the foot pedal to momentarily change the weld energy by the set percentage. Users can
choose to increase or decrease the weld energy by up to 50% while the foot pedal is pressed. This can be useful for
making energy adjustments without using hands or looking away from the
scope. Touch detect triggering is required and the only trigger mode avail-
able when using this mode.
• Save Load Mode – access to saving and loading settings (see the Save
Load Screen section). Help and Accessibility:
• Description Mode – a short description will appear for various buttons/
sliders when they are in use.
• Keypad Mode – the numbered keypad will stay visible when this mode is selected.
• Weld Counters – view and reset weld counters (see System section of Settings Screen)
Media Screen
e Orion i3 has preloaded media that can be viewed from the Media Screen for help and information regarding welding. e
user manual can also be found here.
• Press on the desired dropdown box on the left to expand the
lists of viewable content
• Press on one of the file names to bring up the media in the
viewing area
• Press the Play icon to begin viewing the file, Pause to stop, or
press the arrows to advance or rewind.
• Clicking on the video will also play and pause it.
• The volume can be adjusted using the slider or muted by tap-
ping the volume icon.
• The files can be viewed in full screen as well.
• “Load Recommended Weld Settings” button can be pressed if settings used in video are desired to be used on the
Orion i3.
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Save/ Load Screen
e Orion i3 can save and load your weld settings for future use.
 
To save your current weld parameters, press the SAVE ICON on the row of Header Buttons. e parameters will be repre-
sented in the graphic waveform window.
• Click on the field below the Graph to enter a
name for the saved weld settings. i.e. “ring tip-
ping”. The keypad will automatically pull up.
• Enter any notes regarding the weld process if
desired
• Click the “Save as New” button. This stores the
file for retrieval at a later date. The saved file
will appear in the column on the left.
• Click the “Save” to save the current settings
over another already saved weld setting.
 
Saved Weld Setting files can be loaded (the weld settings will all change to whatever had been saved).
• Look for the desired file in the column on the left side or search for the file name by entering it into the search box.
• Press “Alphabetical” to sort the list by starting letter or “Creation” to sort the list by order created. Pressing either but-
ton again will reverse the order listed, i.e. (a-z, z-a).
• Pressing on the file name will bring it up in the graph window.
• Press the “Load” button and the settings will be applied to the welder and return to the HOME SCREEN.
SETTINGS SCREEN
e settings screen provides access to various system settings and weld parameter settings. A row of buttons lists the
configurable features.
Clicking on any of the settings buttons (shown in image above) will bring up the available options in that category as de-
scribed below:
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 
• Volume Slider
This slider adjusts the volume
of system sounds.
• Microscope Brightness
Slider
This slider will increase or
decrease the brightness of the
LED lights on the bottom of the
microscope.
• Screen Brightness Slider
Adjust the brightness of the
screen as desired.
• Language Selection Drop-
down Box
The Orion i3 comes preloaded with several language settings. Press on the down arrow to bring up a list of languages. Se-
lect desired language for the interface.
• Theme Selection Dropdown Box
The Orion i3 has two different thematic color schemes. (Orion Blue or Sunstone Orange) Press on the desired color from
the drop-down box.
• Video Settings Buttons
Press the “Delete Media” button to clear all media from memory.
Press the “Download Latest Media” button (if Wi-Fi is available) to connect to the Orion website for the all related media
files. If a new file or an updated file exists on the server it will be downloaded.
 
Each Slider has + and – buttons that will appear for 5 seconds
after slider has been adjusted.
• Agitation Profile Buttons
Press the button for the desired agitation profile (see
Agitation section in Arc Control Layout). None, Negative,
Sloped, and Sustained.
• Percentage of Weld Slider
Allows the user to set the duration of the agitation
spikes in relation to the length of the weld. At 100%, the
agitation spikes will last for the entire discharge of weld
energy. At anything less than 100%, the percentage is
measured from the end of the weld. The above image has agitation that is set at 50% of the weld.
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• Frequency Slider
Allows the users to adjust the frequency (Hz) of the agitation spikes. Typically, values of around 2500Hz are ideal for good
weld results; but different metals may require different values. Higher frequencies will help break up crystalline structures
during cooling.
• Duty Cycle Slider
Higher duty cycle means more spikes will occur during the weld, and also means less time between spikes. Higher duty
cycles will add more energy to the weld than lower duty cycles.
• Graphic Display Window
Displays the changes that take place to the waveform as settings on the left are adjusted. The waveform is for reference
only and was achieved using a set system resistance.
 
Each Slider has + and – buttons that will appear for 5 seconds after slider
has been adjusted.
• Pre-Flow Delay Slider
Allows the user to set how long the gas will be on before the weld
initiates. The welder will automatically increase this time if a weld
hasn’t occurred for a given time in order to purge the line and de-
crease oxygen at the weld location.
• Post-Flow Delay Slider
Allows the user to set how long the gas will remain on after a weld has taken place. Longer delays are useful for metals that
oxidize quickly, such as titanium, where oxygen will cause cracks while the molten metal is cooling.
• Calibrate Gas Button
Allows the users to recalibrate the gas pressure to make sure the gas read out is accurate. To calibrate, turn off the gas
tank, disconnect the gas from the back of the Power Supply and press the button.
• PSI Gauge
Graphic representation of Shield Gas Pressure.
• Purge Gas Button
Allows the users to purge the line of air and or gas, useful for pressurization and to check gas flow.
 
Each Slider has + and – buttons that will appear for 5 seconds after slider has been adjusted.
• Pre-Weld Delay Slider
Modifies the delay time between weld initiation (touch detect or foot pedal press) and the actual arc formation. This can
provide operators extra time to ensure correct position of electrode.
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