SUNSTONE Orion mPulse User manual

Orion™mPulse
Users Guide
Version 20220111 • Part #1227

ATTENTION: Read the Safety Guide before operating this welder!
Operator assumes all liability.
REVISION DATE VERSION NO. DESCRIPTION OF CHANGES
1 04/2021 20210407 Reformatting
2 01/2022 20220111 Minor Corrections and Revisions
LIMITATION OF LIABILITY
IN NO EVENT, UNDER ANY CAUSE OF ACTION OF THEORY OF LIABILITY, SHALL SUNSTONE ENGINEERING LLC, ITS DISTRIBUTORS,
OR SUPPLIERS BE LIABLE TO YOU OR ANY THIRD PARTY FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, EXEMPLARY
OR PUNITIVE DAMAGES, OF ANY NATURE WHATSOEVER, ARISING OUT OF THE USE OF OR INABILITY TO USE ANY SUNSTONE ENGI-
NEERING LLC PRODUCT, INCLUDING, WITHOUT LIMITATION, PROPERTY DAMAGE, LOSS OF VALUE OF THE SUNSTONE ENGINEER-
ING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH THE SUNSTONE ENGINEERING LLC PRODUCT,
OR LOSS OF USE OF THE SUNSTONE ENGINEERING LLC PRODUCT OR ANY THIRD PARTY PRODUCTS THAT ARE USED IN OR WITH
THE SUNSTONE ENGINEERING LLC PRODUCT, EVEN IF SUNSTONE ENGINEERING LLC HAS BEEN ADVISED OF THE POSSIBILITY
OF SUCH DAMAGES. WITHOUT LIMITING THE FOREGOING, YOU UNDERSTAND AND AGREE THAT SUNSTONE ENGINEERING LLC
HAS NO LIABILITY FOR ANY DAMAGE OR DESTRUCTION TO ANY PROPERTY. NOTWITHSTANDING ANY DAMAGES THAT YOU MIGHT
INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMITATION, ALL DAMAGES REFERENCED HEREIN AND ALL DIRECT
OR GENERAL DAMAGES IN CONTRACT, TORT (INCLUDING NEGLIGENCE) OR OTHERWISE), THE ENTIRE AGGREGATE LIABILITY OF
SUNSTONE ENGINEERING LLC AND ANY OF ITS DISTRIBUTORS AND/OR SUPPLIERS SHALL BE LIMITED TO THE AMOUNT ACTUALLY
PAID BY YOU FOR THE SUNSTONE ENGINEERING LLC PRODUCT GIVING RISE TO LIABILITY. SOME STATES AND/OR JURISDICTIONS
DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR
EXCLUSIONS MAY NOT APPLY TO YOU. THE LIMITATIONS OF LIABILITY SET FORTH ABOVE SHALL APPLY TO THE MAXIMUM EXTENT
PERMITTED UNDER APPLICABLE LAW.

e Micro Welder Experts
Contents
Welder Setup & Assembly .................................................................................1
How to Connect All Cables..........................................................................1
Microscope Arm Mounting Options ........................................................2
How to Adjust Microscope Focus .............................................................5
How to Place the Welding Stylus ..............................................................5
Electrode Setup .............................................................................................6
Electrode Care ................................................................................................7
Shield Gas Setup .............................................................................................9
Microscope Tips ...........................................................................................10
Microscope LCD Filter Shutter System ...............................................11
How to Use the Touchscreen Interface .....................................................12
How to Make a Weld..........................................................................................14
Recommended Welder Settings & Welder Specications.................16

Questions? Call or Text [phone] • 1
e Micro Welder Experts
Welder Setup & Assembly
What is in the Box
(1) Orion mPulse Welder/Power Supply and Stylus Hand Piece
(1) Orion mPulse Welder Power Cord (2 pieces)
(2) Alligator Clips
(1) Shielding Gas Hose
(1) Electrode Vial (5 1.0 mm Electrodes)
(1) Fiberglass Brush
If You Purchased the Darkening Lens System:
(1) Darkening Lens System (lens and stand) with attached RJ45 Cable
If You Purchased the Microscope System:
(1) Orion Microscope Arm
(1) Microscope Arm Table Mount
(1) Microscope Arm Support Bar
How to Connect the Basic Cables
The Orion mPulse cable connections vary. If you purchased the darkening lens or the microscope, cabling
needs change slightly. The darkening lens or microscope will automatically darken when the weld takes place,
which allows the operator to have a view of the work piece and remain protected from the ash during the weld-
ing process. Reference Figure 2.1 on the next page and follow these instructions for easy setup:
• Remove the welder and Darkening Lens System from the box and place them on a at work space.
• Plug the female end of the power cable into the AC Power port (D) on the back of the power supply.
Then connect the male end into an AC power supply. The Orion mPulse has an internal switching
power supply that can accept both 120 and 240VAC.

2• Questions? Call or Text [phone]
Orion™mPulse User Manual
• Insert the 1/4” gas tube rmly into the Gas port
(E) on the back of the welder. It may wiggle
when connected, but should not come out if
pulled on.
• Insert the RJ45 Darkening Lens cable (from the
back of the Darkening Lens System) into the
ACC port (F) on the back of the welder. If using
a microscope, see page 5 for instructions.
• Connect the alligator clip to the Grounding port
(B).
• Place the Welding Stylus (A), which is already
connected to the back of the welder, to the side
for now.
• Adjust the Darkening Lens Shade by turning the
Shade dial above the Darkening Lens Screen.
Turn clockwise for a lighter shade and count-
er-clockwise for darker shade.
• Power on the welder by ipping the Power
switch (C) on the back of the welder.
Microscope Arm Mounting Options
If you purchased the Orion mPulse with a microscope,
carefully follow these instructions.
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
mounting option instructions 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 a at surface.
• As shown in Figure 2.2, attach the Angled
Bracket (C) to the bottom of the Microscope
Figure 2.2. Attach Angled
Bracket (C) to Microscope
Arm Assembly (A).
Figure 2.3. Attach Clamp
Mechanism (D) to Angled
Bracket (C).
Figure 2.1. The back panel of the Orion mPulse. (A) Stylus
Cable. (B) Grounding port. (C) Power switch. (D) AC Power
port. (E) Argon gas port. (F) Darkening Lens System port.
A B C
D E F

Questions? Call or Text [phone] • 3
e Micro Welder Experts
Figure 3.1. Attach Clamp
Mechanism (D) to angled
bracket (C).
Figure 3.2. Cover the Clamp
Mechanism (D) with the
plastic cable guide cover (E).
Arm Assembly 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 2.3. For thicker tables,
attach the clamp mechanism (D) to the two
lower holes in the Angled Bracket (C).
• Adjust the knob on the Clamp Mechanism (D)
until the gap is sucient for the thickness of
your tabletop.
• Lock the arm into place by turning the knob
on the Clamp Mechanism (D) until the clamp is
pressing rmly against the bottom of the table.
• Lift the Microscope Arm Assembly (A) up, slide
the arm onto the table as shown in Figure 3.1.
• A plastic cable guide cover (E) can be clipped
on over the angled bracket if desired. See
Figure 3.2.
Mounting Option 2 - Bolt through Table
Mounting Option 2 is best for tables without accessible
edges. Hardware required from Box 2:
(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 3.3, using a 4mm (5/32”)
Allen wrench, unscrew the at head hex screws
(G) holding the Flat Mounting Plate (H) to the
arm.
• Run the included 8mm (5/16”) Long Carriage
Bolt (F) through the included Flat Mounting
Plate (H).
• Attach Flat 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.
Figure 3.3. Remove the
plate from the arm, run
the carriage bolt (F)
through the mounting
plate (H), then re-attach
the mounting plate to
the arm.
Figure 3.4. Lower the
arm so the bolt goes
through the hole in the
table.

4• Questions? Call or Text [phone]
Orion™mPulse User Manual
• Lower the arm so the Long Carriage Bolt (F)
goes through the hole in the tabletop. See
Figure 3.4.
• Slide the Flat Pressure Plate (I) onto the bolt.
Turn the Adjustment knob (J) clockwise to
tighten the plate to the underside of the table.
See Figure 4.1.
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 Microscope Arm Assembly (B) using three
(3) of the included at head hex screws (G) as
shown in Figure 2.2.
• Lift and position the arm assembly onto the
table in the desired location.
• Run wood screws through the Mounting
Bracket (A) and into a vertical surface of the
table, as shown in Figure 4.2.
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
4.4. 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.
For cable management, tubes and cables can be routed
through a removable guide as shown in Figure 4.5.
Figure 4.4. Adjust the tension of the Microscope Arm
Assembly for more loose or more tight movement.
Figure 4.5. Tubing and other cables can be routed up and
through the removable cable guide portion of the arm.
Figure 4.1. Turn the Adjustment knob (J)
clockwise to tighten the plate to the table.
Figure 4.2. Use wood screws (not
included) to attach the Angled
Mount Bracket (A) to the table.

Questions? Call or Text [phone] • 5
e Micro Welder Experts
Figure 5.1 After installing the rubber eyepiece covers, use the
RJ45 Shutter Cable to connect the welder to the back and
bottom of the microscope head.
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 5.1.
• Plug the other end of the Shutter Cable into the
shutter port on the back of the welder.
Note: Connecting other RJ45 compatible devices to
the Orion mPulse shutter RJ45 port may damage the
welder and/or the other devices.
How to Adjust 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 5.2.
• 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.
How to Place the Welding Stylus
• If using a microscope with the Orion mPulse,
insert the Welding Stylus into the holder at the
bottom of the Microscope Arm Assembly as
shown in Figure 5.3 (Left).
• If using the Lens Darkening System, insert the
Welding Stylus into the holder located behind
the screen. See Figure 5.3 (Right).
• The tubing can be routed up and through the
removable cable guide portion of the Micro-
scope Arm Assembly if desired. See Figure 4.5.
• For now, position the Welding Stylus such that
only the smaller diameter portion protrudes
from the holder, as shown in Figure 5.4. Then,
tighten the thumb screw on the bottom of the
stylus holder to hold it in place. See page 6 for
detailed electrode setup.
Figure 5.3. Styling mounting for microscope (Left) and for the
Darkening Lens System (Right).
Figure 5.2. Turn this knob
to adjust microscope
focus. You’ll nd one
knob on each side of the
microscope arm.
Figure 5.4. Only a small portion
of the electrode should extrude
from the holder.

6• Questions? Call or Text [phone]
Orion™mPulse User Manual
• Rotate the stylus holder to approximately a 45-degree angle as shown in Figure 5.3 (the stylus should
be angled down).
• Fine tune the position of the Welding Stylus while looking through the microscope: Loosen the thumb
screw on the bottom side of the stylus holder and slide the Welding Stylus forward and backward until
the tip of the Welding Stylus is in the center of your focus. See the example in Figure 5.4.
• Now securely tighten the Welding Stylus in place by tightening the thumb screw on the bottom of the
stylus holder.
Figure 6.2. To install the electrode, rst remove the Stylus
Shaft (A) from the Stylus Hull (E) by pulling them apart.
Figure 6.3. Use the guide engraved on the side of the Stylus
Hull (E) for proper Electrode (D) positioning.
Stylus Shaft A Collet B Collet Cap C Electrode D Stylus Hull E
Stylus Components
Figure 6.1
Electrode Setup
The Orion mPulse comes standard with a 1.0mm elec-
trode collet and ten (10) 1.0mm electrodes. The 1.0mm
electrodes are a good multipurpose electrode for most
welding applications. Available separately, Sunstone of-
fers 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
Refer to the Stylus Components Chart (Figure 6.1) to
install the tungsten electrode (D).
• Remove the stylus hull (E) by pulling it away
from the Stylus Shaft (A). See Figure 6.2.
• Loosen the Collet Cap (C) by twisting it counter-
clockwise.
The welder accommodates 0.5mm and 1.0mm elec-
trodes. The electrode stylus will be shipped with the
1.0mm electrode collet (B) installed.
• Insert a 1.0mm electrode (D) into the Collet (B).
Helpful Tip: There is a engraved guide on the

Questions? Call or Text [phone] • 7
e Micro Welder Experts
Figure 7.1. Electrodes should protrude past the stylus hull 1/8
to 1/4 inch (3.175 to 6.35mm).
side of the Stylus Hull (E) that helps measure
the electrode length. Place the end of the
Stylus Hull (E) against the Collet Cap (C), then
make sure the Electrode (D) extends as indi-
cated. See Figure 6.3.
• 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 Shaft
once the Stylus Hull (E) is placed back on the
Stylus Shaft.
• 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 protrude from the Stylus Hull (E) by
1/8 – 1/4 inch (3.175 – 6.35mm after the Stylus
Hull is snapped back into place). See Figure 7.1.
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
The majority of applications are best accomplished
using a sharp electrode tip. See Figure 7.2. A sharp tip
improves arc initiation and helps focus the arc properly.
It is recommended 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 igni-
tion 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:
Stylus Cone
Example of a Sharp
Electrode Tip
Example of a Flat
Electrode Tip
Electrode Shaping
Figure 7.2.
Stylus Hull

8• Questions? Call or Text [phone]
Orion™mPulse User Manual
• 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 8.1.
• Power on the rotary tool then hold it with the
opposite hand.
• Place the electrode tip on the diamond disc so
the grit of the disk is moving parallel with the
electrode shaft and moving towards the tip. See
Figure 8.2. Sharpening the electrode in a way
other than explained here will aect the quality
of the weld.
• Set the electrode on the diamond disk at a
10-degree angle and begin to spin the elec-
trode with the thumb and middle nger. Tip:
A helpful way to get a sharp electrode is to
push down on the electrode with your index
nger while twisting the electrode with the
thumb and middle nger. See Figure 8.2
• 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 is recommended to blunt the
electrode instead of sharpening it. 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
Figure 8.1. A sharp electrode tip improves arc initiation and
results in a better overall weld.
Figure 8.2. Use a rotary tool to sharpen the electrode.
R
O
T
A
T
I
O
N
R
O
T
A
T
I
O
N

Questions? Call or Text [phone] • 9
e Micro Welder Experts
the edge of a blunt tip electrode assists in
preventing the electrode from sticking to the
weld surface.
• Once the electrode has a at/blunt tip, turn o
the rotary tool and insert the electrode back
into the stylus as explained earlier.
Shield Gas Setup
During the pulse arc welding process high temperature
plasma quickly melts metal into a molten pool. As the
weld is performed, a small amount of shielding gas is
released through the weld stylus to prevent oxygen
from entering the molten pool. After the weld has oc-
curred the protective gas turns o.
If oxygen from the air enters this molten pool, the result
is a metal oxide that is brittle, porous, and burnt-looking.
Protective shielding gas is used, such as 99.996% pure
argon (Argon 4.6), to prevent these eects.
PRESSURIZED GAS SAFETY
There are several important rules that should be fol-
lowed 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
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 mPulse!

10 • Questions? Call or Text [phone]
Orion™mPulse User Manual
last longer in case there is a small leak in the tubing. This is also a good safety practice. If the tube becomes
dislodged shielding gas could ll the room and displace oxygen, which can lead to suocation. Argon is heavier
than air and will ll the room from the bottom upward. If you experience a large shielding gas leak, open all of the
doors and windows in the room.
SHIELDING GAS TANK AND REGULATOR SETUP
The following instructions are specic for a Sunstone argon regulator. Other regulators
may operate dierently. Consult instructions that may have come with other regulators.
•Ensure that your shielding gas tank is securely fastened to a stationary point near the
welding area.
•Turn the argon regulator dial (not to be confused with the main argon tank valve) COUN-
TERCLOCKWISE (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 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 to the gas regulator.
• Open the gas tank at the main valve slowly. 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 Tips
The Orion mPulse 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 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 paused. While the welder is in paused, it
will not make a weld when the workpiece touches the
electrode.
• Rest your hands on the table and position
the workpiece close to the welding electrode
before looking into the microscope.
Figure 10.1. Rest your hands on the table and position the
workpiece close to, but not touching the electrode., Then
look through the microscope.

Questions? Call or Text [phone] • 11
e Micro Welder Experts
• Make sure your focus is at the tip of the electrode.
• 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 10.1.
• Place the workpiece surface perpendicular to the point of the electrode. As discussed in later chap-
ters, 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 alligator clip to the workpiece and enable welds (by touching the
Play button) to begin welding.
Note: Be mindful of your energy setting: Too much power may damage the workpiece.
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 PA250i’s internal computer veries the Microscope
LCD Filter Shutter System has been closed before allowing the weld to take place. Should the shutter not close,
the microscope lens is equipped with >UV 16 and >IR 16 for maximum eye protection.
Warning: Avoid direct view of the welding area without protective lenses.

12 • Questions? Call or Text [phone]
Orion™mPulse User Manual
How to Use the Touchscreen Interface
The Orion touch screen interface is very user friendly. Users have access to every welding parameter with one
touch. Below is an explanation of the various buttons and options found on the Orion mPulse interface. *Orion
touch screens are resistive touch screens. This means they respond best to a little bit of pressure. The end of
your ngernail or the tip of the alligator clip works best when touching the screen.
C D E
A
B
Weld Energy Level. This number
represents the amount weld energy
level, in Joules, ready to be released
through the electrode.
Energy Bar. Use a nger and slide
horizontally to adjust the weld energy
level, in Joules. The Current Energy
Level (A) will change as a nger is
moved across the Energy Bar.
Minus Button. Tap this
button to reduce the weld
energy level by 1 Joule.
The Weld Energy Level (A)
will change as this button
is tapped.
Play/Pause Button. This
button alternates between
Play and Pause as it is
tapped. The welder will
operate when in the Play
mode; the welder will not
operate in the Pause mode.
Plus Button. Tap this
button to increase the
weld energy level by 1
Joule. The Weld Energy
Level (A) will change as
this button is tapped.

Questions? Call or Text [phone] • 13
e Micro Welder Experts
Weld Energy Level
The Orion mPulse has weld energy range of 3 to 30 Joules (or Ws). The larger the number the more energy
released through the electrode and, generally speaking, the larger the weld spot. The current weld energy level
is displayed in the top right corner of the mPulse touchscreen interface, called the Weld Energy Level (A), as
shown on the previous page.
Energy Bar
The Energy Bar (B) is used to adjust the Weld Energy Level up or down. Use a nger and slide horizontally to
rapidly adjust the Weld Energy Level.
Play/Pause Button
When the Orion mPulse is initially powered on, the Play/Pause button (D) will be in the Pause mode. The welder
will not operate while in Pause mode.
To operate the welder, tap once on the Play/Pause button to switch to the Play mode. Once in the Play mode, the
Orion mPulse will operate.
Minus Button
While the Energy Bar allows rapid change of the Weld Energy Level, the Minus button (C) will alter the Weld Ener-
gy Level by one Joule per tap. This button is used for precision adjustment of the Weld Energy Level.
Plus Button
Like the Minus button, the Plus button (E) will alter the Weld Energy Level by one Joule per tap. For precision
adjustment of the Weld Energy Level, the Plus and Minus buttons are more useful than the Energy Bar.

14 • Questions? Call or Text [phone]
Orion™mPulse User Manual
How to Make a Weld
If you’ve never used the Orion mPulse or other Orion pulse arc welder, you should practice rst on the provided
welding plate. After careful setup and familiarization of how the welder operates, follow these instructions using
the welding plate.
• On the touch screen select 7 Ws on the Energy
Bar. Use a nger to slide horizontally across
the Energy Bar until the Weld Energy Level is 7
Use the Plus or Minus buttons for more precise
selection. See Figure 14.1.
• Tap the Play button. The button changes to a
green triangle. See Figure 14.1. With the welder
in Play mode the welder will release energy, but
only when the electrode touches the welding
plate AND the alligator clip is attached to the
welding plate (or any workpiece). Don’t worry
about the alligator clip yet.
• Make sure your eyes are protected by properly
using the darkening lens or microscope. Never
operate the welder without eye protection.
• Attach the alligator clip to the welding plate.
• Rest your arms on the table or workbench,
holding the metal plate with both hands.
• Make sure you have a clear view of the metal
plate through the darkening lens or micro-
scope.
• On the metal plate you will see a number of
dierent boxes. For this exercise, lightly touch
the welding plate (or workpiece) to the elec-
Figure 14.1 Set the Weld Energy Level to 7 ws and then tap
the Pause button so the button displays a green triangle.
Figure 14.2 Attach the alligator clip to the welding plate. With
proper eye protection, hold the welding plate with both hands
and lightly touch the electrode to the welding plate. When the
electrode contacts the welding plate, the welder will release
energy and create a weld.

Questions? Call or Text [phone] • 15
e Micro Welder Experts
trode in the box labeled “10”. When the electrode makes contact with the welding plate, the welder will
release energy and a weld will occur.
Tip: When the electrode touches the workpiece, don’t back away from electrode until after the weld is com-
pleted. The Orion mPulse will automatically retract the electrode away from the workpiece by a few millimeters
when the weld occurs. This retraction assists in forming a more desirable weld spot. If you move the workpiece
away from the electrode just before or during the weld, the weld will not occur.
• Next, adjust the Weld Energy Level to 20 ws using the Energy Bar and/or Plus and Minus buttons. Then
touch the electrode to the box labeled “20”. You will see a dierence between the 7 ws weld and the 20
ws weld. The spot size will be larger and the weld will be deeper.
• Use the provided stainless steel weld plate as a guide to try dierent settings. Make several welds on
the weld plate to get comfortable with the stylus and the dierent weld parameters.
• Disregard the higher numbers and agitation labels on the welding plate. Other Orion pulse arc welders
have higher energy levels and have agitation features which the mPulse does not. See your Sunstone
dealer to learn more about more advanced models and the features they provide.
Read the Safety Guide & Pulse Arc Welding Workbook
Prociency in using the Orion mPulse pulse arc welder can be achieved in two ways:
First, use the welder often and experiment with dierent power settings, dierent types of metal, and the angle
at which you touch the electrode to the workpiece.
Second, carefully read the Safety Guide & Pulse Arc Welding Workbook to more fully understand the science
behind the weld. The workbook also provides useful tips specic to dierent types of metals and how to use the
welder in dierent applications. The workbook can be found together with this user manual. If the workbook is
missing, call Sunstone for a complimentary replacement copy at [phone].

16 • Questions? Call or Text [phone]
Orion™mPulse User Manual
Recommended Welder Settings & Welder Specications
Refer to these general setting recommendations to get started. Preferred settings will be found by adjusting
energy settings up and down.
Electrode Placement Types
T-Joint Weld
Butt Weld Add Metal Weld Add Metal Weld Add Metal Weld
26 AWG Wire/Chain/Jump Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 10 ws Butt weld with 90º
electrode angle
Butt Weld
24k Gold Sharp 7 ws
Silver Sharp 10 ws
Platinum Sharp 10 ws
Stainless Steel Sharp 7 ws
Palladium Sharp 7 ws
Titanium Sharp 10 ws
Brass Sharp 10 ws
Earring Post
Metal Tip Shape Energy Notes
14k Gold Sharp 10 ws T-Joint weld with
45º electrode angle
T-Joint Weld
24k Gold Sharp 10 ws
Silver Sharp 12 ws
Platinum Sharp 12 ws
Stainless Steel Sharp 7 ws
Palladium Sharp 7 ws
Titanium Sharp 12.5 ws
Brass Sharp 10 ws
0.5mm Thick Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 12 ws Butt weld with 90º
electrode angle
Butt Weld
24k Gold Sharp 10 ws
Silver Sharp 17 ws
Platinum Sharp 15 ws
Stainless Steel Sharp 15 ws
Palladium Sharp 15 ws
Titanium Sharp 15 ws
Brass Sharp 15 ws
1.0mm Thick Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 22 ws Butt weld with 90º
electrode angle
Butt Weld
24k Gold Sharp 20 ws
Silver Semi Blunt 30 ws
Platinum Sharp 25 ws
Stainless Steel Sharp 22 ws
Palladium Sharp 20 ws
Titanium Sharp 25 ws
Brass Sharp 25 ws