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Summary of Contents for SUNSTONE Orion mPulse
- Page 1 Orion mPulse ™ Users Guide Version 20220111 • Part #1227...
- 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 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 ................... -
Page 5: Welder Setup & Assembly
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. -
Page 6: Microscope Arm Mounting Options
Place the Welding Stylus (A), which is already connected to the back of the welder, to the side for now. Figure 2.1. The back panel of the Orion mPulse. (A) Stylus Cable. (B) Grounding port. (C) Power switch. (D) AC Power •... - Page 7 e Micro Welder Experts Arm Assembly using three (3) of the included flat 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 flat head hex screws.
- Page 8 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.
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Page 9: How To Adjust Microscope Focus
Figure 5.1 After installing the rubber eyepiece covers, use the Note: Connecting other RJ45 compatible devices to RJ45 Shutter Cable to connect the welder to the back and the Orion mPulse shutter RJ45 port may damage the bottom of the microscope head. welder and/or the other devices. -
Page 10: Electrode Setup
Collet Cap C Electrode D Stylus Hull E 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... -
Page 11: Electrode Care
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. Electrode Shaping... - Page 12 Figure 8.2. Use a rotary tool to sharpen the electrode. into the stylus as explained above. Note: As a rule of thumb, Sunstone recommends a sharpened electrode anytime a new workpiece is being welded.
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Page 13: Shield Gas Setup
Delivered directly to your door! • Right-sized tank fits almost anywhere! • Premium argon gas for your Orion mPulse! 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). -
Page 14: Microscope Tips
SHIELDING GAS TANK AND REGULATOR SETUP The following instructions are specific for a Sunstone argon regulator. Other regulators may operate differently. 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. -
Page 15: Microscope Lcd Filter Shutter System
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 fingers to move the workpiece up to the electrode. -
Page 16: 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 fingernail or the tip of the alligator clip works best when touching the screen. - Page 17 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.
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Page 18: How To Make A Weld
How to Make a Weld If you’ve never used the Orion mPulse or other Orion pulse arc welder, you should practice first on the provided welding plate. After careful setup and familiarization of how the welder operates, follow these instructions using the welding plate. - Page 19 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.
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Page 20: Recommended Welder Settings & Welder Specifications
Orion mPulse User Manual ™ Recommended Welder Settings & Welder Specifications Refer to these general setting recommendations to get started. Preferred settings will be found by adjusting energy settings up and down. Electrode Placement Types Add Metal Weld Add Metal Weld Butt Weld T-Joint Weld Add Metal Weld... - Page 21 Sharp 20 ws Titanium Sharp 10 ws Brass Sharp 17 ws Brass Sharp 10 ws Orion mPulse Welder Specifications Weld Technology Type Pulse Arc Weld Modes Pre-Programmed Metal Settings Customizable Save Setting Languages Not Applicable Display 4.4” Touchscreen Energy 3-30 Ws Weld Spot Diameter 1.0-1.25mm...
- Page 22 100c! 3-30 Joules 3-100 Joules 1.0-1.5 mm Spot Size 0.75-2.5 mm Spot Size 1 weld every 2 seconds 1 weld every 0.7 seconds ©2022 Sunstone Engineering LLC. Sunstone and Orion are trademarks of Sunstone Engineering LLC. All rights reserved.
- Page 23 e Micro Welder Experts Pulse Arc Welders Orion 100s Orion 200i The world’s bestselling pulse arc welder! For large shops who value production Most of the features and power you’ll need. efficiencies—or for the master welders who deserve it all! 1-150 Joules 0.2-200 Joules 0.5-3.5 mm Spot Size...
- Page 24 1693 American Way Ste 5 • Payson UT 84651 USA Tel. +1-801-658-0015 wwww.sunstonewelders.com PART #1227 ©2022 Sunstone Engineering LLC. Safety information subject to change. Sunstone and Orion are trademarks of Sunstone Engineering LLC. 20220111 •...
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