SUNSTONE Orion 150s Series User Manual
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SUNSTONE Orion 150s Series User Manual

Pulse arc welder
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Orion
150s
™
Pulse Arc Welder Users Guide
20210728 • ITEM #1260

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Summary of Contents for SUNSTONE Orion 150s Series

  • Page 1 Orion 150s ™ Pulse Arc Welder Users Guide 20210728 • ITEM #1260...
  • 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 Calibrate Gas ........... 26 What is in the Box .............1 Timing Options ............... 26 Microscope Arm Assembly Setup ......1 How to Adjust Pre-Weld Delay ......... 27 Microscope Setup ............4 How to Adjust Lift Off Delay ........
  • Page 4 Orion 150s Series Users Guide ™...

  • Page 5: Chapter 1: Welder Setup & Assembly

    Micro Welder Experts Chapter 1: Welder Setup & Assembly What is in the Box BOX 1 CONTENTS: (1) Sunstone 150s Series Power Supply (1) Foot Pedal BOX 2 CONTENTS (1) Sunstone Microscope Arm Assembly (1) Sunstone Safety Guide ACCESSORIES BOX (Located in Box 2)
  • Page 6 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: Microscope 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

    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 Figure 5.2. Tubing and other cables can be routed up and Ws of energy).

  • Page 10: Adjusting The Microscope Focus

    Orion 150s Users Guide ™ • Remove the stylus hull (E) by pulling it away from the stylus shaft (A). See Figure 6.1. • Loosen the collet cap (C) by twisting it counter- clockwise. • The welder accommodates 0.5mm and 1.0mm Figure 6.1.

  • Page 11: Power Supply Setup - Back Panel

    e Micro Welder Experts Power Supply Setup - Back Panel Reference Figure 7.1 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 (F). •...

  • Page 12: Electrode Care And Pressure

    Too much pressure will cause the work piece to stick to the electrode and cause the electrode to become contaminated (work piece material on the elec- trode). Sunstone recommends cleaning or changing the electrode when it sticks to the work piece. When to Sharpen the Electrode Refer to Chapter 3 for more information on electrodes.

  • Page 13: Shield Gas Setup

    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 work piece is being welded.

  • Page 14: Shielding Gas Tank And Regulator Setup

    Orion 150s Users Guide ™ 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 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 propellant.

  • Page 15: Microscope Lcd Filter Shutter System

    >UV 16 and >IR 16 for maximum eye protection. BECOME FAMILIAR WITH THE MICROSCOPE The Sunstone 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.
  • Page 16 Orion 150s Users Guide ™ Off Mode. While the welder is in Weld Off Mode, it will not be able to make a weld when the work piece touch- es the electrode. • Rest your hands on the table and position the work piece close to the welding electrode before looking into the microscope.

  • Page 17: Chapter 2: How To Weld

    e Micro Welder Experts Chapter 2: How to Weld At the front of the Orion 150s 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 150s delivers, how the power is delivered, make adjustments to agitation, make system changes, view instructional videos, or save welds.
  • Page 18 Orion 150s Users Guide ™ Basic Mode. Basic Mode is variation of the Arc Mode. The 150s can automatically determine the amount of energy and the type of agitation required for a success- ful weld based on the type of metal and application you select.
  • Page 19 e Micro Welder Experts 3. Rate of Fire Select the rate of fire by pressing the Rate of Fire radio button (D) and then using the white wheel (G) to de- crease or increase the rate of fire. The maximum rate of fire is 3; the minimum is Single Fire. Rate of Fire is the number of times the welder will release energy in one second.
  • Page 20 Orion 150s Users Guide ™ • Touch Detect. The Touch Detect mode is the default mode. The welder will initiate a weld when the electrode touches the work piece. • Foot Pedal. If you attach a foot pedal to the back of the welder, a weld will only occur when you depress the pedal.
  • Page 21 e Micro Welder Experts Once you select the metal type, the 150s will automatically adjust all welding parameters to optimum levels for that particular metal. You can always manually adjust these settings later. 2. Select Application Type Select the Application Button (E) as shown in Figure 14.1 and choose the application the best fits the type of weld you wish to accomplish.
  • Page 22 Orion 150s Users Guide ™ • Standard. In the Standard ignition option, the energy discharge occurs at approximately the same time as the tip lifts off the work-piece surface. Standard ignition mode is perfect for metal types that do not require a pre-heat phase during the weld.

  • Page 23: Using The Tack Mode To Weld

    e Micro Welder Experts Move your finger counter- 7. Press Weld On Radio Button. clockwise to decrease. At this point, touch the Weld On ratio button (G) as shown in Figure 16.2. As an additional safety measure, the welder incorpo- rates a digital switch that must be in the on position Move your finger clockwise before energy will be released.
  • Page 24 Tack - (negative) terminal (B) as shown in Figure 20.2. In Tack Mode, the front ground is not operation- al. Call Sunstone if you need to purchase alligator clip grounds specifically designed for Tack Mode. Select Power Setting For convenience, the welder allows you to choose a Low, Medium, or High power setting.
  • Page 25 e Micro Welder Experts Press Weld On Radio Button. At this point, touch the Weld Off Button (H). 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 Button to avoid an unintentional discharge of energy.

  • Page 26: Chapter 3: Systems Settings

    Orion 150s Users Guide ™ Chapter 3: Systems Settings To adjust the Orion 150s’s interface, gas, timing, and other systems, press the Systems Settings Button (A) in the top row of blue menu buttons, as shown in Figure. 23.1. A drop down menu will appear with the following options: •...
  • Page 27 A blue window will open with three options. You can unlock the welder, create a PIN, or cancel. • Enter the PIN to unlock the welder. If you forgot the PIN, call Sunstone Customer Service at +1 801-658-0015. • After you enter the PIN, the welder will unlock.

  • Page 28: How To Adjust Volume

    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 10 to set the gas pressure.

  • Page 29: How To Adjust Pre-Flow Delay

    e Micro Welder Experts HOW TO ADJUST PRE-FLOW DELAY • Press the System Setting icon (A) as shown in Figure 25.1. • From the sub-menu, press the Gas Screen option. • In the Settings-Gas Screen as shown in Figure 25.2, press your finger to the Pre-Flow Delay slider bar (E).

  • Page 30: How To Calibrate Gas

    Orion 150s Users Guide ™ • In the Settings-Gas Screen as shown in Figure 25.1, press the Purge Gas Button (D). You’ll briefly hear gas exit the gas line. Subsequently, the line has been purged. • Press the Exit Button (G) to exit. HOW TO CALIBRATE GAS If the regulator valve and the digital gas dial (G) indicate different pressure readings, you’ll want to calibrate the digital gas dial.

  • Page 31: How To Adjust Pre-Weld Delay

    e Micro Welder Experts within a given time period. However, adjusting the time downward may result in the electrode sticking to the weld because not enough time has elapsed for the previous weld to cool. Advanced Agitation Options • Duty Cycle. Agitation spikes energy during a weld, either by adding energy in an positive spike or removing energy in a negative spike.

  • Page 32: How To Adjust Post-Weld Shutter Delay

    Orion 150s Users Guide ™ right to increase the delay that elapses between the weld trigger and the weld ignition, measured in milliseconds; move your finger to the left to decrease the delay. • Press the Exit Button (H) to exit. HOW TO ADJUST POST-WELD SHUTTER DELAY •...

  • Page 33: How To Adjust Agitation Percentage

    Use 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.

  • Page 34: How To Restore All Defaults

    Orion 150s Users Guide ™ • After all defaults are restored, the Arc screen will appear. HOW TO CLEAR ALL MEMORY • Press the System Setting icon (J) as shown in Figure 29.1. • From the sub-menu, press the System option. •...

  • Page 35: How To Enter The Test Suite

    In the Settings-System Screen as shown in Figure 29.1, press the Enter Test Suite Button (O). • A blue warning screen will appear asking you to enter a custom password only available from Sunstone. To receive your custom password, call Sunstone’s customer service team at +1 801-658-0015 and provide them with the password displayed on the welder.

  • Page 36: Schedules

    Orion 150s Users Guide ™ Chapter 4: How to Save, Load and Delete 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 37: How To Load A Weld Schedule

    e Micro Welder Experts How to Load a Weld Schedule • Press the Save/Load Button (E) as shown in Figure 33.1. The Save/Load Screen will appear. • In the list of saved schedules (F), touch to select the schedule you wish to load. When you select the schedule, the name and description will appear in the schedule name box (G) and schedule note box (H).

  • Page 38: How To Delete An Existing Weld Schedule

    Orion 150s Users Guide ™ How to Delete an Existing Weld Schedule • Press the Save/Load Button (E) as shown in Figure 33.1. The Save/Load Screen will appear. • In the list of saved schedules (F), touch to select the schedule you wish to delete. •...

  • Page 39: Chapter 5: How To View Media

    e Micro Welder Experts Chapter 5: How to View Media The Orion 150s carries an on-board library of documents and videos in a number of different categories. Sun- stone periodically updates the library which you can access using a WiFi connection. To view the library follow these instructions: •...

  • Page 40: How To Download The Latest Library

    Orion 150s Users Guide ™ Figure 36.1.When you open a category, a list of Figure 36.2.To play a video, press the Play Button (H). To available documents and/or videos will appear rewind by 30 seconds, press the Rewind 30 Button (F). To with an accompanying thumbnail image.

  • Page 41: Appendix 1: Product Specifications

    e Micro Welder Experts Appendix 1: Product Specifications Pre-Programmed Metal Settings Customizable Save Settings 1,000 Languages 20 + (Ask us if we have your language) Display 8” Capacitive 10 point Touch Screen Energy (Ws) 1-150 Ws Switching Power Supply 110/240VAC (Auto Detected) Estimated Weld Spot Diameter Range 0.5 - 3.5 mm Footprint (L x W x H)

  • Page 42: Appendix 2: General Weld Parameters

    Orion 150s 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 43 e Micro Welder Experts Questions? Call or Text +1-801-658-0015 • 39...
  • Page 44 Orion 150s 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 ©2021 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 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 wwww.sunstonewelders.com PART #1260 ©2021 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20210728 •...

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