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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