Orion Welders 200i2 User Manual
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Orion Welders 200i2 User Manual

Pulse arc welders
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Orion Pulse Arc Welders User Manual
Orion 200i
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Angelito Marapao
March 18, 2025

On the screen, it says Unfortunately, the process.com.android.phone has stopped.

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1 comments:
Mr. Anderson
May 14, 2025

The message "Unfortunately, the process.com.android.phone has stopped" indicates a crash of the Android phone process on the Orion 200i2 system. This is likely related to the Android operating system used in its touchscreen interface and not the welding function itself. It suggests a software error within the Android system managing phone-related processes.

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Summary of Contents for Orion Welders 200i2

  • Page 1 Orion Pulse Arc Welders User Manual Orion 200i...

  • Page 2: Table Of Contents

    Orion 200i2 Welder Connection Setup . . . . . . . . . . . . . . . . . .

  • Page 3: Welding Safety Precautions

    . Please read and follow all safety precautions before proceeding with the welding process . Sunstone Engineering is the parent company of Orion Welders . At Sunstone & Orion we are committed to producing quality products and ensuring complete owner satisfaction . If you require assistance after reading this manual please contact us with the information provided below .
  • Page 4 200i User Manual equipment can cause fires and burns . Ensure that your work area is clean and safe for welding before starting any weld job . • Do not install or operate unit near combustible surfaces . • Do not install or operate unit near flammables . •...
  • Page 5 Also arc welding gives off infrared and UV rays that can burn the retinal tissues within the eyes and cause surface burns to exposed skin, similar to a sun burn . • The stereo microscope provides proper eye protection when pulse-arc welding . No additional protection is necessary .
  • Page 6 200i User Manual MAGNETIC FIELDS CAN AFFECT IMPLANTED MEDICAL DEVICES • Wearers of pacemakers and other implanted medical devices should keep away . • Implanted medical device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations .

  • Page 7: Chapter 1: Welder Setup And Assembly

    ch.1 CHAPTER 1: WELDER SETUP & ASSEMBLY What is in the Box See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series- resources/ Box within main box: The Orion 200i will arrive in 1 box . (1) Welder Power Cord (1) Stylus Hand Piece Main Box: (1) Pair Alligator Clips...
  • Page 8 ch.1 200i User Manual Mounting Option 2 - Bolt through table 1 . Using the provided allen wrench, unscrew the 10m x 1 . 5 allen bolt underneath the arm base . 2 . Drill a 3/8’ (10mm) hole through the tabletop .

  • Page 9: Orion 200I2 Welder Connection Setup

    ch.1 Orion 200i Welder Connection Setup CONNECT THE WELDING STYLUS TO THE BACK OF THE TOUCH SCREEN BOX See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series- resources/ The welding stylus requires the most attention during setup . Since argon gas will flow through the stylus, a tight fit between the power supply and the stylus is critical .

  • Page 10: External Power Supply Setup

    ch.1 200i User Manual External Power Supply Setup SET UP THE EXTERNAL POWER SUPPLY The Orion has an internal switching power supply that can accept 90VAC to 240VAC . See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series- resources/ 1 .

  • Page 11: Adjustments On The Microscope Arm

    ch.1 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 See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series- resources/ 1 .

  • Page 12: True Color Optical Lcd Shutter

    ch.1 200i User Manual 5 . Now securely tighten the stylus holder screws . ADJUST THE MICROSCOPE FOCUS See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series- resources/ 1 . Twist this knob above the 1x 2x knob to focus the microscope . When adjusting the microscope focus, place a finger under the welding electrode to help judge the correct focus location .

  • Page 13: Electrode Setup

    ch.1 1 . Rest your hands on the table and position the work piece close to the welding electrode before looking into the microscope . 2 . Make sure your focus is at the tip of the electrode . 3 . Use slow, controlled movements . 4 .
  • Page 14 ch.1 200i User Manual 5 . There should be between 0 . 6 - 0 . 7 in (1 . 5 – 2cm) of the electrode protruding from the stylus shaft . This will allow the electrode enough room to stick out from the stylus once the stylus hull is placed back on the stylus .
  • Page 15 ch.1 WHEN TO FLATTEN/BLUNT THE ELECTRODE When working with silver, copper, and other highly conductive metals in energy levels above 20ws, it is recommended to blunt the electrode instead of sharpening it . See video explanations of setup at http://www . o rionwelders . c om/resources/orion-i-series-resources/ 1 .

  • Page 16: Header Area

    ch.2 200i User Manual CHAPTER 2: THE USER INTERFACE PART 1 Overview HEADER AREA Metals, Arc, Tack, and Videos Tabs These four tabs contain features and settings specific to each view . We will go over each tab in more detail throughout this chapter .

  • Page 17: Metals Tab - Controls Area

    ch.2 METALS TAB - CONTROL AREA This section was created to help users that are first learning to pulse arc weld, or not sure which weld parameter to use . Metals To begin, simply select the metal that will be welded . Each metal has been pre programed to load the best settings we have found for welding that particular metal .
  • Page 18 The waveform selections determine and control how energy is released when welds are made . Classic - The classic waveform is the default waveform for welding on all Orion welders . It has a high peak current, which is the peak of the energy level, followed by a curved discharge slope .
  • Page 19 ch.2 the work piece surface . While similar to the Standard option, Standard+ includes a “pre-heat” function before the main weld . During this time, a very low amount of energy flows through the electrode and work piece . This preheating of the tungsten electrode helps create a more efficient weld area in preparation to the main weld .
  • Page 20 ch.2 200i User Manual Detect or Foot Pedal . Touch Detect - In Touch Detect, the welder will initiate the weld process any time that a grounded work piece makes contact with the electrode . Foot Pedal - When Foot Pedal is selected, the welder will only initiate a weld on a grounded work piece when the Foot Pedal is pressed .
  • Page 21 ch.2 have better weld joint penetration, surface finish etc . SEAM MODE TIPS AND TRICKS a . Start small . Always start small and work up in power . Develop a “feel” for the power contained in your Seam mode setting by welding on a scrap piece of material . Once you have tested your setting move on to the final work-piece .
  • Page 22 ch.2 200i User Manual unsafe level (e . g . too bright) . Weld Length Slider In Seam mode, the weld length slider automatically changes its maximum value to insure each seam weld will take place at the selected power setting . For example; if the weld power for a square wave is set to 4 kW, and the welds per second is set to 25, the welder will only allow a weld time that allows the system to fully charge and provide for identical welds during the seam cycle .

  • Page 23: Tack Tab - Controls Area

    ch.2 TACK TAB - CONTROL AREA The Tack Screen controls the resistance welding aspect of the welder . Tack welding is typically used to temporarily hold pieces together . Users will generally utilize this type of welding to hold their work pieces together before soldering or performing a pulse arc weld .

  • Page 24: Load Tab

    ch.2 200i User Manual LOAD TAB Touch the Load Button to open previously saved weld parameters . This feature will allow users to select from their list of previously saved weld parameters by simply scrolling through and touching the desired previously saved weld parameter they would like to load to the welder .
  • Page 25 ch.2 tip to stick out further from the Stylus Hull opening than is normal . The pre-flow delay can be alternatively shortened for applications that have a short distance from the electrode tip to the Stylus Hull opening . *It is recommended to use the default settings for all other applications .

  • Page 26: Chapter 3: Reading The Waveform Graph

    ch.3 200i User Manual CHAPTER 3: READING THE WAVEFORM GRAPH IGNITION Standard Weld Ignition: In Standard weld ignition mode, the timing is arranged so the weld starts on the surface of the work-piece as the electrode is lifting off . Advantages: This is very useful for tight/difficult weld joints because it insures that the weld is located exactly where the electrode is touching .

  • Page 27: Waveforms

    ch.3 Disadvantages: Similar to Tip Saver mode, Tip Saver Plus mode is not recommended for awkward or tight geometry welding surfaces . Since the arc is generated after the electrode has left the work piece, the arc will take the path of least resistance and might not touch the exact point that was desired .

  • Page 28: Waveform Graph Overview

    ch.3 200i User Manual Triangle: This graph shows how the time adjustment changes the shape and area of the Triangle mode . A shorter time will contain less energy but will have the same initial “punch” as a longer weld time would at the same power level . Both welds will have a degree of weld smoothing, with the longer weld time achieving the smoothest results .
  • Page 29 ch.3 Triangle: In this example we see a Triangle Wave with Standard weld ignition, and no agitation . A . This image shows a representation of Standard Weld Ignition . In this mode, no pilot arc is used and weld ignition happens based purely on electrode retract timing .

  • Page 30: Chapter 4: Pulse Arc Welding

    ch.4 200i User Manual CHAPTER 4: PULSE ARC WELDING Welding Basics The Orion is a pulse-arc welder and a capacitive discharge resistance welder in one . This combination of abilities allows for infinite creative possibilities . In its Tack Mode the Orion can be used to temporarily position parts before welding or soldering .
  • Page 31 ch.4 thumb you can expect the penetration of the weld spot to be approximately ¼ of the diameter of the weld spot . Factors like electrode shape and condition also effect the weld penetration and will be discussed in more detail later . PULSE ARC VS .
  • Page 32 ch.4 200i User Manual As you can see from this example the Orion’s Arc Mode offers a lot of energy . At higher energies, this mode is perfect for larger/thicker pieces, deeper weld penetration and for welding highly conductive metals like silver . Hands on: Try welding on a flat plate with 30, 50, 75, 100, and 200 Ws of energy .
  • Page 33 ch.4 Using a more technical description – during the welding process the weld spot becomes a liquid pool of metal . The impact of the welding plasma causes vibrations on the molten pool’s surface, much like a stone causes ripples on the surface of a still body of water . The Orion welder’s energy discharge has been designed to ramp down the weld energy for longer weld time .

  • Page 34: Chapter 5: Tack/Resistance Welding

    ch.5 200i User Manual CHAPTER 5: RESISTANCE WELDING What is Resistance Welding (Tack Welding)? Resistance welding, often called tack or fusion welding , takes place using a very different process from that of TIG welding . In resistance welding a large electrical current is passed through two work pieces to join them together .
  • Page 35 ch.5 A resistance welder uses the resistance to the flow of electricity to heat and melt the part via a large electrical current . This contact point is where the highest heat is generated . Light pressure between the parts means less contact between the two surfaces, more resistance, and hence more heating and melting .
  • Page 36 ch.5 200i User Manual 3 . Practice at different energies and pressures until you feel comfortable with the process and results . The pressure between the tool holding the part is also very important . If insufficient pressure is applied between the tool and the part the weld may take place between the tool and the part .

  • Page 37: Chapter 6: Tungsten Electrodes

    ch.6 CHAPTER 6: TUNGSTEN ELECTRODES THE SINGLE MOST IMPORTANT VARIABLE IN THE WELDING PROCESS IS THE ELECTRODE . The Orion welder comes standard with (5) 0 . 5 mm and (5) 1 . 0 mm electrodes . The 1 . 0 mm electrodes are a good all around electrode while the 0 .
  • Page 38 ch.6 200i User Manual generated by the electrons impacting Material Melting Point (deg C) the work piece than the atoms striking Zinc the electrode . Aluminum Silver Gold 1064 Copper 1083 Stainless 304 1450 Carbon Steel 1500 Titanium 1660 Platinum 1772 Niobium 2468...
  • Page 39 ch.6 HANDS ON: Grind your electrode so that grind marks run parallel to the electrode shaft . Verify by looking under the microscope . Try to produce a taper that is approximately 2 . 5 x the electrode diameter . ELECTRODE SHAPING EFFECTS There are two main electrode shape configurations that Orion users should consider when preparing for a new project .
  • Page 40 ch.6 200i User Manual CONSIDERATIONS FOR ELECTRODE SHAPE: 1 . When welding very small features, under about 1mm, the electrode should be sharp to help focus the weld energy . 2 . When welding with less than 20-30 Joules(Ws) the electrode will typically be sharp . 3 .
  • Page 41 ch.6 Symptom Possible Problem Possible Solution Trouble igniting the arc Contaminated electrode Re-grind the electrode to remove con- tamination Electrode shape not conducive to Shape the electrode to a very sharp tip ignition at low energy Broken electrode, jagged edges Re-grind electrode to desired shape Cratering of the weld spot Electrode contamination leading to a...
  • Page 42 ch.7 200i User Manual Electrode contamination can lead to small “explosions” that create craters in the work piece. All four welds were made at the same setting. Metal contamination on the electrode caused one weld to create a crater. It is recommended that the user pay close attention to the electrode condition (see additional discussion) .
  • Page 43 ch.7 Remember that for a larger fill wire the energy must be increased to completely melt the wire. If there is insufficient energy there may only be partial melting of the wire. However, in some situations this may be advantageous. HANDS ON: Try adding fill wire using the side placement method .
  • Page 44 ch.7 200i User Manual A top electrode placement can work if the wire diameter is small compared to the energy setting. In this case there is enough plasma pressure to force the molten wire onto the base material. Placement of the electrode directly on top of the fill wire can melt the wire into the base if the energy is sufficient, or the wire is very small.
  • Page 45 ch.7 tries to push the molten metal, while the surface tension tries to keep it in place . This means: 1 . Some metals with lower surface tension (e . g . silver) are easier to “push” around than metals with high surface tension (e .
  • Page 46 ch.7 200i User Manual In this example the vertical member is more heat sensitive or is thinner than the horizontal member. Material is pushed from the horizontal member onto the vertical member to prevent part damage. Pulse Arc Welding: Weld Cracking Some materials are prone to crack because of their metal properties .
  • Page 47 ch.7 weld joint is stressed by hammering etc . This means that welding over porosity in a Pd piece can be accomplished with the Orion (or laser) to help clean up a ring during the finishing process . However, welding more than one overlapping weld will inevitably lead to cracking (laser or Pulse Arc welder) .

  • Page 48: Chapter 8: Metals

    ch.7 200i User Manual To do this, start with lower Energy settings . This will minimize the initial warping as you stabilize the work piece . Always alternate sides during the welding process – several welds in a row on one side can exaggerate the warping, while alternating welds will pull the part back and forth eliminating most warping .
  • Page 49 ch.8 Melting Point 1064 1083 1200 1300 1450 1500 1660 1772 2468 3410 Boiling Point 2467 2212 3080 2567 3100 2800 3000 3000 3287 3827 4742 5660 Specific Heat Electrical Resistivity 2 . 7 1 . 6 2 . 2 10 .
  • Page 50 ch.8 200i User Manual This measure of weldability comes from properties of the metal like melting point, thermal conductivity, density etc., and is intended as a relative reference between the different metals. It can be thought of as how much spot size and penetration a given amount of weld energy will have on the metal.
  • Page 51 ch.8 Titanium and Niobium metals will oxidize readily at elevated temperatures and voltages. The charts show (Ti) and (Nb) “painting” with electricity (showing the voltage at which the color will appear). However, similar colors will appear due to heat if welding without sufficient shield gas. These colors during welding need to be avoided.
  • Page 52 ch.8 200i User Manual removed via glass brush or clean rag . Yellow gold physical properties and composition (one possible): 58-75% gold, 12-27% silver, 9-15% copper and some zinc White Gold: White gold is also a relatively simple metal to work with . There are two main types of white golds –...
  • Page 53 ch.8 Palladium can be welded using the Orion welder, however, cracking can occur . Palladium cracking is an especially difficult phenomenon to overcome with laser or pulse arc welding . If only one weld spot is made, cracking will typically not occur unless the weld joint is stressed by hammering, etc .
  • Page 54 ch.8 200i User Manual silver parts may require a weld projection or “bump” to focus the weld current . This welding strategy is discussed in detail in Chapter 4 - Tack Welding . Aluminum (Al) Aluminum behaves very much like silver during the pulse arc welding process . Aluminum has a very low melting temperature (660 deg C) and is very mobile when in a liquid phase .
  • Page 55 ch.8 High Carbon Steels (Spring Steel / Tool Steel) High carbon steel welds easily but may become brittle after the welding process . To avoid weld failure the part must be heat treated after the welding process . Cobalt Chrome Alloys Cobalt Chrome is very sensitive to oxygen contamination .
  • Page 56 ch.9 200i User Manual CHAPTER 9: FAQ / TROUBLESHOOTING / GLOSSARY Frequently Asked Questions CAN I USE ANY ATTACHMENT WHILE IN TACK MODE? NO . The pulse-arc welding stylus should never be used while the Orion is in Tack Mode . However, any other attachment can be used .
  • Page 57 ch.9 HOW DO I DETERMINE THE BEST ENERGY SETTINGS FOR MY APPLICATION? In Arc Mode, metals will weld according to thermal conductivity and melting point . For example, a metal with lower thermal conductivity (e . g . stainless steel, titanium, cobalt alloys) will weld easily because the weld heat stays concentrated in the spot .
  • Page 58 ch.9 200i User Manual added to the joint . For joints were the Orion can penetrate approximately ½ to 3/4 of the way through the material an “I” seam may be appropriate . The weld location should be cleared of solder as this will reduce weld quality . ARE THERE SPECIAL JOINT PREPARATIONS NEEDED WITH TACK/FUSION WELDING? Just as in pulse-arc welding, all solder should be removed if a strong metal to metal tack/fusion weld is desired .
  • Page 59 In this manual, workpiece refers to anything being welded or worked on . WARRANTY AND CONTACT INFORMATION All Orion products come with a 2-year limited repair warranty . Orion Welders will repair all defects in craftsmanship without charge during this time period (excluding the cost of shipping) . This warranty does not cover damage caused by improper use of Orion Welder products .
  • Page 60 Orion 200i User Manual Go to http://www . o rionwelders . c om/resources/orion-i-series-resources/ for full video tutorials . Orion Welders 1693 American Way, Unit 5 Payson, UT 84651 USA + 1-801-658-0015 OrionWelders.com...

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