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Table of Contents
Related Manuals for SUNSTONE Orion 200i
Summary of Contents for SUNSTONE Orion 200i
- Page 1 Orion 200i ™ Pulse Arc Welder Users Guide 20210608 • ITEM #1210...
- Page 2 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.
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Page 3: Table Of Contents
e Micro Welder Experts Contents Chapter 1: Welder Setup & Assembly ......1 ARC Mode ..............17 What is in the Box ............1 TACK Mode ............. 20 Microscope Arm Assembly Setup .....1 Footer Buttons ............21 Mounting Options ...........2 Mini-Screen Area ..........22 Attach Touchscreen to Microscope Arm ..4 Weld Parameters........... - Page 4 Orion 200i Series Users Guide ™...
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Page 5: Chapter 1: Welder Setup & Assembly
What is in the Box BOX 1 CONTENTS: (1) Sunstone Touchscreen (2) Alligator Grounding Clips (1) Sunstone 200i Series Power Supply (1) Shielding Gas Hose (1) Foot Pedal (1) Electrode Vial (10x 1.0mm Electrodes and 1 Diamond Sharpening Disk) BOX 2 CONTENTS... -
Page 6: Mounting Options
Hardware required from Box 2: Figure 2.1. Attach angled (1) Angled Bracket C bracket C to A (1) Sunstone Microscope Arm Assembly A (1) Clamp Mechanism D (5) Flat Head Hex Screws G • Lay the arm assembly down on the tabletop. - Page 7 e Micro Welder Experts (1) Flat Mounting Plate H (3) Flat Head Hex Screws G (1) Long Carriage Bolt F (1) Flat Pressure Plate I (1) Adjustment Knob J • As shown in Figure 3.1, using a 4mm (5/32”) Allen wrench, unscrew the flat head hex screws (G) holding the mounting plate (H) to the arm.
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Page 8: Attach Touchscreen To Microscope Arm
Note: Connecting other RJ45 compatible devices to the Figure 4.3 After installing the rubber eyepiece covers, use the Shutter Cable to connect the Touchscreen to Sunstone shutter RJ45 port may damage the welder the bottom of the microscope head. and/or the other devices. -
Page 9: Welding Stylus Setup
e Micro Welder Experts Welding Stylus • Remove the Welding Stylus from the accesso- ries box. • Insert the Welding Stylus into the holder at the bottom of the arm assembly as shown in Figure 5.1. • The tubing can be routed up and through the removable cable guide portion of the arm if desired. -
Page 10: Electrode Setup
1.0mm electrode collet and ten (10) 1.0mm electrodes. The 1.0mm electrodes are a good multipur- pose electrode for most welding applications. Available separately, Sunstone offers 0.5mm electrodes, which are more suited for very small applications (less than 5 Ws of energy). -
Page 11: Adjusting The Microscope Focus
Figure 7.2. Use two mounting brackets (not included) Optional Mounting Brackets (Not Included) to attach the Power Supply to wall or other vertical surface. Call Sunstone at +1 801-658-0015 to request To mount the power supply to a vertical wall, request the mounting brackets. -
Page 12: Power Supply Setup - Back Panel
Orion 200i Users Guide ™ Power Supply Setup - Back Panel Reference Figure 8.1 and follow these instructions (all required cables are found in the accessories box). • Plug the female end of the included power cable into the 90-250 VAC Power Port (B). •... -
Page 13: How To Turn On The Power Supply
Micro Welder Experts Note: Connecting other display port compatible de- vices to the Orion 200i’s Comm. Port may damage the welder and/or the other devices. How to Turn on the Power Supply On the front of the power supply, push the power but- ton to initiate the power up sequence. -
Page 14: When To Flatten/ Blunt The Electrode
Once the electrode is sharp and clean, turn off 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. -
Page 15: Shield Gas Setup
• Delivered directly to your door! • Right-sized tank fits almost anywhere! • Premium argon gas for your Orion 200i! PRESSURIZED GAS SAFETY There are several important rules that should be followed when using a compressed shielding gas such as... -
Page 16: Shielding Gas Tank And Regulator Setup
7-10 liters per second. The Orion 200i’s internal computer verifies the Micro- scope LCD Filter Shutter System has been closed be- fore allowing the weld to take place. Should the shutter not close, the microscope lens is equipped with >UV 16... -
Page 17: Become Familiar With The Microscope
Micro Welder Experts BECOME FAMILIAR WITH THE MICROSCOPE The Sunstone microscope has been designed to pro- vide maximum visual clarity, eye protection, and ease of use. One challenge using the microscope is getting used to bringing the workpiece to the welding electrode while looking through the microscope. -
Page 18: Chapter 2: How To Use The Welder Software
Chapter 2: How to Use the Welder Software The Orion 200i interface consists of four main “screens” that can be accessed at any time by touching the icons located along the top of the screen in the header area. The four main screens are: •... -
Page 19: Waveform Graphic Area
e Micro Welder Experts Figure 15.1. The Waveform Graphic. The vertical axis represents the total weld energy available (A). The horizontal axis represents time in milliseconds. An approximation of the weld spot size (B) is also displayed. Current settings (C) are displayed along the bottom of the graph. -
Page 20: Parameter Selection Area
The Basic layout allows you to simply select the metal being welded and the type of weld being performed. Based upon the material selected, the Orion 200i will automatically choose the best settings that will deliver an optimum weld. See Figure 16.1. -
Page 21: Arc Mode
e Micro Welder Experts Figure 17.1. The Parameter Selection Area with the Arc layout selected. The Arc layout, as shown in Figure 17.1, consists of controls for Waveform (A), Ignition (B), Agitation (C), Energy (D), Length (E), and Weld Speed (F). With these controls, you can make adjustments that will allow you to suc- cessfully weld many different types of metals in different applications. - Page 22 Orion 200i Users Guide ™ 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. Ignition 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.
- Page 23 e Micro Welder Experts 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 for- mation, but yields additional penetration and enhanced weld strength.
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Page 24: Tack Mode
TACK The Orion 200i is capable of performing resistance tack welds. See “Make a Tack Weld” section in Chapter 3 for more information. Press the Tack button to see controls related to making tack welds, as shown in Figure 20.1. -
Page 25: Footer Buttons
Weld ON/OFF Pressing Weld ON/OFF icon (F) toggles the Orion 200i between an active and inactive state. If the icon shows “WELD ON”, the weld sequence can be initiated and welds can take place. When the icon shows “WELD OFF”, welds can not be initiated. -
Page 26: Mini-Screen Area
Orion 200i Users Guide ™ Figure 22.1. The Mini-Screen Area (A) displays additional information. You can customize what information you wish to view. Touch the down-arrow button to view a list of available information widgets. Mini- Screen Area The Mini-Screen Area, (A) in Figure 22.1, allows you to customize what additional information you wish to see in the Home Screen. -
Page 27: Help And Accessibility
Media Screen The Orion 200i provides a media library that can be viewed from the Media Screen for help and information regarding welding. See Figure 23.1. The user manual can also be found here. To access the Media Screen press the Media Screen icon (A) in the main toolbar at the top of the screen. -
Page 28: Save/Load Screen
Save/ Load Screen The Orion 200i can save and load weld settings for future use. For example, if you find a set of weld parameters that are particularly successful for a particular application, you can save all parameters under a custom name. -
Page 29: How To Load A Weld
e Micro Welder Experts • Click on the field below the graph (E) to enter a name for the saved weld settings, i.e. “1 mm jump rings”. When you click in the name field, a keyboard will automatically appear. • Enter any notes regarding the weld process if desired in the notes field (F). -
Page 30: Settings Screen
Press the Delete Media button (G) to clear all media from memory. Press the Download Latest Media button (H) to connect to Sunstone’s media library and download all new content. A Wi-Fi connection to the Internet is required. If a new file or an updated file exists on the server it will be downloaded. -
Page 31: Agitation System Options
To make changes to the Orion 200i’s agitation settings, press the Agitation button (A) within the Settings Screen. See Figure 27.1. As noted earlier, with the Orion 200i you can choose to use one of four different agita- tion profiles while welding: None, Negative, Sloped, and Sustained. See page 18 for a description of each. -
Page 32: Gas Options
To calibrate the gauge, close the main valve on the shielding gas tank, disconnect the gas line from the back of the Orion 200i power supply, and press the Calibrate Gas button (D). Then reconnect the gas line on the back of the power supply and open the main valve on the shielding gas tank. - Page 33 e Micro Welder Experts Figure 29.1. Choose the Timing button (A) within the Settings Screen to access and make changes to weld timing.. Pre-Weld Delay. You can modify the delay time between weld initiation (touch detect or foot pedal press) and the actual arc formation.
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Page 34: System Options
Once this function is completed it can not be undone. Update Welder. Periodically, Sunstone will update the software for the Orion 200i and send the update file to you via email, or it may be available for download on Sunstone’s website. Keeping your welder’s software up to date will ensure the very best welding results. -
Page 35: Lock Options
Enter Test Suite. To assist Sunstone in diagnosing and repairing potential problems, your Sunstone customer service rep will place the welder in a test suite. Only access the test suite while working a Sunstone customer service representative. When you press the Enter Test Suite button (E), the welder will ask for a password. Your Sunstone customer service representative will provide that password to you. - Page 36 Orion 200i Users Guide ™ Figure 32.1. To lock or unlock the welder, press the Lock button (A) in the Settings Screen then press the Toggle Lock Mode button (B). To lock/ unlock the welder, you will need to create or enter a 4-digit PIN.
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Page 37: Chapter 3: How To Weld
Chapter 3: How to Weld with the Orion 200i Before you begin to weld, Sunstone highly recommends you carefully review the Safety Guide & Pulse Arc Weld- ing Workbook. Make sure you are in compliance with all safety precautions. Sunstone also recommends you practice welding on the included stainless steel weld plate. -
Page 38: How To Make A Tack Weld
Orion 200i Users Guide ™ • Slide the Energy bar (D) to desired value (between 10 and 20 is a good place to start. • Press the Touch button (F) to enable touch detect. • Press the Weld State button (E) to toggle the welder to “WELD ON”. -
Page 39: How To Find The Right Settings
e Micro Welder Experts Warning: Do NOT use the Pulse Arc + terminals for Tack Welds. Do NOT use the stylus in Tack Mode. Refer to Figure 35.1 and carefully follow these instruc- tions to weld in Tack Mode: • From the Home Screen, press the TACK button (A) to display the tack controls. -
Page 40: Welding Tips And Tricks
Orion 200i has to offer. Although it can be intimidating to experiment with new technology, “playing”... -
Page 41: How To Read The Waveform Graph
e Micro Welder Experts HOW TO READ THE WAVEFORM GRAPH The Waveform Graph is a helpful tool for understanding the things taking place during a weld. One quick look can provide information such as which ignition mode is being used, which waveform has been selected, which agitation profile is being used, and the length of the energy discharge. - Page 42 Orion 200i Users Guide ™ Square mode can also be adjusted independently, but the peak remains constant for the duration of the dis- charge, as shown in Figure 37.2. As a result, twice the energy will be released into the weld site compared to Triangle mode if the peak and lengths were set to the same values.
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Page 43: Declaration Of Conformity
L VD Standard EN 60974-6:2016 Arc Welding Equipment-Safety Requirements The Technical File required by both directives above is maintained at the headquarters of Sunstone Engineering LLC, 1693 American Way #5, Payson, UT 84651, U.S.A. CE Year 2020 �o� May 19, 2020... - Page 44 Orion 200i Users Guide ™ 40 • Questions? Call or Text +1-801-658-0015...
- Page 45 e Micro Welder Experts Questions? Call or Text +1-801-658-0015 • 41...
- Page 46 ©2020 Sunstone Engineering LLC. Sunstone and Sunstone Circle are trademarks of Sunstone Engineering LLC. Conditions and restrictions apply. Ask for details or visit www.sunstonewelders.com/sunstonecircle for complete terms of service. Sunstone Engineering LLC reserves the right to change, alter, modify, or cancel this program at any time.
- Page 47 Expedited Customer More Valuable Upgrades Shipping Service Member Benefits! When your welder is Should your Sunstone At Sunstone every You’ll receive snazzy powered by the latest welder ever need repair, customer is a VIP, but when Sunstone swag, a software improvements we’ll cover the shipping...
- Page 48 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 www.sunstonewelders.com PART #1210 ©2021 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20210217 •...
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