Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Related Manuals for SUNSTONE Orion 100c
Summary of Contents for SUNSTONE Orion 100c
- Page 1 Orion 100c ™ Pulse Arc Welder Users Guide 20210728 • ITEM #1259...
- 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.
-
Page 3: Table Of Contents
e Micro Welder Experts Contents Chapter 1: Welder Setup & Assembly .....1 How to Adjust Pre-Flow Delay ...... 22 What is in the Box ............1 How to Adjust Post-Flow Delay ....22 Microscope Arm Assembly Setup ......1 How to Purge Gas ..........22 Mounting Options ............2 How to Calibrate Gas ........ - Page 4 Orion 100c Series Users Guide ™...
-
Page 5: Chapter 1: Welder Setup & Assembly
What is in the Box BOX 1 CONTENTS: (2) Alligator Grounding Clips (1) Orion 100c Power Supply (1) Foot Pedal (1) Shielding Gas Hose (1) Electrode Vial (5x 1.0 mm and 5x 0.5 mm Electrodes and 1 Diamond Sharpening Disk) -
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.
-
Page 8: Welding Stylus Setup
Plug the other end of the Shutter Cable into the Shutter Port on the welder’s back panel. Note: Connecting other RJ45 compatible devices to the Sunstone shutter RJ45 port may damage the welder and/or the other devices. Welding Stylus Setup •... -
Page 9: Electrode Setup
Figure 4.3. Electrode Setup The Orion 100c pulse arc welder comes standard with a 1.0mm electrode collet and five (5) 1.0 mm electrodes. The 1.0 mm electrodes are a good multipurpose elec- trode for most welding applications. - Page 10 Orion 100c Users Guide ™ Stylus Components Figure 6.4 Stylus Shaft (A) Collet (B) Collet Cap (C) Electrode (D) Stylus Hull (E) hull (E) against the collet cap, then make sure the electrode extends to the groove as indi- cated. See Figure 6.2. •...
- Page 11 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 Electrode Shaping Figure 7.2. Use a rotary tool to sharpen the electrode.
-
Page 12: Shield Gas Setup
If you experience a large shielding gas leak, open all of the doors and windows in the room. Need argon gas? Sunstone will ship a right-sized tank to your doorstep. No more adventurous... -
Page 13: Shielding Gas Tank And Regulator Setup
e Micro Welder Experts 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 COUNTERCLOCKWISE (closed) until it is fully backed out, meaning the dial becomes loose, to prevent over-pressuriza- Figure 9.1. -
Page 14: Become Familiar With The Microscope
100c Users Guide ™ 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 15: Cable Connections
Microscope Cable. Connect the RJ45 cable coming from the microscope or ADL to the Shutter Port (E). Figure 11.1. Cable connection guide for the Orion 100c. Weld Stylus. Connect the stylus cable coming from the Power Cable (G); Shield Gas (C); Foot Pedal (F); Microscope stylus into the Weld Stylus Port (F). -
Page 16: Chapter 2: How To Weld
Chapter 2: How to Weld At the front of the Orion 100c pulse arc welder is a digital touchscreen display. You’ll use the software interface that appears on the display to control how much power the 100c delivers, how the power is delivered, make adjustments to agitation, among others. - Page 17 e Micro Welder Experts Attach the Alligator Clip Insert the alligator clip, which acts as a ground, to the front of the welder as shown in Figure 12.3. Choose a Welding Mode: Arc vs Tack With the welder on and the software loaded you should see the Arc Mode screen, as shown in Figure 13.1.
- Page 18 Orion 100c Users Guide ™ Select Application Type Select the Application Button (A) as shown in Figure 14.1 and choose the application the best fits the type of weld you wish to accomplish. You can choose from the following: • Large.
- Page 19 e Micro Welder Experts weld energy slightly to maintain the same melt spot size. • Negative. A negative agitation pulses the energy in the opposite direction of sustained agitation, but the peaks of energy are removed rather than added. This works in reverse of other agitation options in that it makes a smaller spot, and de-focuses the weld arc.
- Page 20 Orion 100c Users Guide ™ Select Foot Pedal or Touch Detect You can choose for the welder to initiate the weld in two ways: Foot Pedal. In Foot Pdeal Mode a weld will only occur when you depress the pedal. Place the pedal on a floor that is flat, devoid of debris, and away from traffic areas.
-
Page 21: Using The Tack Mode To Weld
e Micro Welder Experts being used, you should press the Weld Off radio button to avoid an unintentional discharge of energy. Attach the Alligator Ground to the Workpiece Attach the alligator clip ground to the workpiece at a spot that ensures the best contact between ground and workpiece. - Page 22 Orion 100c Users Guide ™ Select Power Setting For convenience, the welder allows you to choose a Low, Medium, or High power setting. Select the desired energy level (start with a lower energy level and work up) by pressing the Low, Medium, or High Quick Power Setting buttons (A) as shown in Figure 18.1 To manually adjust the energy level, touch the small white circle in the curved slider bar (B) and move your...
- Page 23 e Micro Welder Experts As an additional safety measure, the welder incorpo- rates a digital switch that must be in the on position before energy will be released. When the welder is not being used, you should press the Weld Off radio button to avoid an unintentional discharge of energy.
-
Page 24: Chapter 3: Systems Settings
Chapter 3: Systems Settings To adjust the Orion 100c’s interface, gas, timing, and other systems, press the Systems Settings icon on the left side of the screen, as shown in Figure. 20.1. A drop down menu will appear with the following options: •... -
Page 25: Microscope Brightness
As explained on page 8, a shield gas is released during a weld to shield to prevent oxidation. Usually, argon is a suitable choice as a shield gas, which you can purchase directly from Sunstone at www.sunstonewelders.com/ gas. See page 9 to set the gas pressure. -
Page 26: How To Adjust Pre-Flow Delay
Orion 100c Users Guide ™ longer pre- and post-flow delays require more shielding gas, subsequently drawing more often on your supply. Note that delays extend the time required for a weld to be completed; therefore, the longer the delay the less number of welds you’ll be able to complete within a given time. -
Page 27: How To Calibrate Gas
e Micro Welder Experts ever changes you made to the regulator. To purge the gas line, follow these steps: • Press the System Setting icon (A) as shown in Figure 22.1. • From the sub-menu, press the Interface option (B). •... -
Page 28: How To Adjust Pre-Weld Delay
Orion 100c Users Guide ™ a shorter period of time. The Lift-Off Delay is a user preference setting; weld quality is not necessarily affected by the Lift-Off Delay. You may prefer a longer delay, which may provide you with a bit more time to make sure the elec- trode is placed exactly where you want it. -
Page 29: System Settings
Use the sub-menu. this button to begin that process. Note: Sunstone strongly recommends you only utilize these features when working closely with the Sunstone customer service team. Call or text +1 801-658-0015 to contact us. HOW TO RESTORE ALL DEFAULTS •... -
Page 30: How To Clear All Memory
Orion 100c Users Guide ™ • In the Settings-System Screen as shown in Figure 25.2, press the Restore All Defaults Button (H). • A blue warning screen will appear asking you to confirm. Press the Yes button to continue; press the No button to cancel and go back. -
Page 31: How To Enter The Test Suite
System Settings icon (B) and then choose System (C) from enter a custom password only available from the sub-menu. Sunstone. To receive your custom password, call Sunstone’s customer service team at +1 801-658-0015 and provide them with the pass- word displayed on the welder. •... -
Page 32: Chapter 4: How To Save/Load Weld Schedules
Orion 100c Users Guide ™ Chapter 4: How to Save and Load Weld Schedules The welder has the ability to save weld schedules, which you can then access and load later, saving you the time it may otherwise require to enter the desired weld parameters manually. A weld schedule is a set of weld parameters. -
Page 33: How To Load A Weld Schedule
e Micro Welder Experts That abbreviated name becomes the name of the weld schedule. • Press the Save Button (C) to save. • Press the Exit Button (D) to exit to the previous screen. How to Load a Weld Schedule •... - Page 34 Orion 100c Users Guide ™ example, F); you may need to scroll down the list of saved weld schedules by placing your finger at the bottom of the screen and sliding up. • Touch the weld schedule you wish to save over. The box will turn a lighter blue when selected. •...
-
Page 35: Appendix 1: Product Specifications
e Micro Welder Experts Appendix 1: Product Specifications Welder Type Pulse-Arc & Resistance Weld Modes Pre-Programmed Metal Settings Customizable Save Settings Languages Multiple Display 4” Touch Screen Energy (Ws) 3-100 Ws Switching Power Supply 110/240VAC (Auto Detected) Weld Spot Diameter 0.75 - 2.5mm Footprint 9.25”... -
Page 36: Appendix 2: General Weld Parameters
Orion 100c Users Guide ™ Appendix 2: General Weld Parameters The following charts are intended to help you determine appropriate energy settings for various applications and metal. Remember to start at a lower power and work up. 26 AWG wire/chain/jump ring Earring Post Metal Tip Shape... - Page 37 e Micro Welder Experts Questions? Call or Text +1-801-658-0015 • 33...
- Page 38 ©2020 Sunstone Engineering LLC. Sunstone and Sunstone Circle are trademarks of Sunstone Engineering LLC. Conditions and restrictions apply. Ask for details or visit www.suntonewelders.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 39 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 40 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 wwww.sunstonewelders.com PART #1259 ©2021 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20210728 •...
Need help?
Do you have a question about the Orion 100c and is the answer not in the manual?
Questions and answers