Copyright 2010 Sunstone Engineering R&D Corp

Table of Contents
Quick Start Setup Guide_____________________________ 1
Foreword_________________________________________ 6
Manufacturers Contact Information________________________________ 6
Welding Safety Precautions_______________________________________ 6

Chapter 1: Welding Basics____________________________ 11

Chapter 2: Setup and Training_________________________ 16
Chapter 3: User Interface_____________________________ 17
Arc Screen Interface______________________________ 17
Tack Screen Interface_____________________________ 21
Advanced Screen Interface_________________________ 22
Chapter 4: Arc Welding______________________________ 24
Chapter 5: Tack Welding_____________________________ 25
Chapter 6: Maintenance______________________________ 26
Warranty and Contact Information_____________________ 28

LCD Touch
Screen

Orion Welder

Mounting Brackets

Table Mount
Stereo Microscope

Adjustment Arm
Eye Pieces

Extender Arm
Accessories Boxes

Foot Pedal

Power Cable &

Serial Cable

Regulator and Gas

Tubing

Assembly Kit
(screws, bolts,
wrenches)

Arc Welding
Stylus

Hand Attachments

1. Clamp the microscope

table mount using the included allen wrench.

2. Attach the extender arm

and secure it in place by
tightening the set screw.

3. Insert the microscope

adjustment arm into the extender arm.

4. Secure the microscope

adjustment arm by
tightening the set screw.

5. Remove the LCD screen

from its box and remove the
protective screen.

6. Mount the LCD screen onto

the extender arm with the
included screws.

7. Attach the mounting

brackets with the support
bar attachment on the left.

8. Insert the stylus holster

into the mounting brackets.

9. Slide the support bar into

place and tighten with the
included allen wrench.

10. Attach the serial cable to

the back of the LCD screen.

11. Remove the lens caps

from the microscope optics.

12. Insert the eyepiece optics

into the microscope.

13. Attach the microscope

cable to the back of the
Orion.

14. Attach the foot pedal

cable to the back of the
Orion.

15. Attach the monitor cable

to the back of the Orion.

16. Attach the power cable

to the back of the Orion and
plug into the wall.

17. Connect the argon

regulator to the tank.

18. Insert the gas tubing into

the back of the Orion.

19. Connect the desired hand

pieces into the front terminals on the Orion.

20. Connect the stylus to the

front of the welder and turn
until it becomes tight.

21. Firmly press the weld

stylus farther into the welder
threads.

22. Repeat steps 20-21 until

the stylus is firmly connected
to the welder.

23. Insert the stylus into the

holder mounted under the
microscope.

24. Turn on the Orion and

begin welding.

Foreword:
Thank You for Choosing Sunstone Engineering.
You are now the proud owner of an Orion Pulse 250i Welder. The Orion has pulse-arc, fine spot resistance, and tack welding capabilities. This manual was designed to have you welding safely within minutes
of unpacking your new welder. Please read and follow all safety precautions before proceeding with the
welding process.
At Sunstone 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.
Sunstone Engineering R&D Corp.
1693 American Way Suite #5
Payson, UT 84651
Voice: 801-658-0015
Fax: 866-701-1209

Welding Safety Precautions

READ BEFORE WELDING
The following safety advice is generalized advice for the arc-welding industry. These safety precautions
are not all inclusive. All users should exercise reasonable caution while using this device. The following
group of symbols are warning symbols:

CAUTION, ELECTRIC SHOCK HAZARD, EYE PROTECTION REQUIRED.

Consult these symbols and the related instructions listed next to the symbols for proper action when
dealing with these hazards.

READ INSTRUCTIONS

Read the owners manual before using the Orion.

Only personnel trained and certified by the manufacturer should service the unit.

Use only genuine replacement parts from the manufacturer.

SAFETY PRECAUTIONS FOR FIRE OR EXPLOSION

Sparks can fly off from the welding arc. The flying sparks, hot work piece, and hot 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.
Do not overload your buildings electrical wiring be sure the power distribution
system is properly sized, rated, and protected to handle this unit.
Remove all flammable materials from the welding area. If this is not possible, tightly
cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks can easily go through small cracks and openings to adjacent areas.
Watch for fire and keep a fire extinguisher nearby.
Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors.
Remove any combustibles, such as butane lighters or matches, from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks, glowing embers,
and flames.
Do not exceed the equipments rated capacity.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.

SAFETY PRECAUTIONS FOR ELECTRICAL SHOCK

Touching live electrical parts can cause fatal shocks or severe burns. The input power
circuit and the Orions internal circuits are live when the power is on. Additionally the
internal capacitors remain charged for a period of time after the Orion is turned off or
power is disconnected. Incorrectly installed or improperly grounded equipment is a
hazard. This device was designed to operate indoors only. Do not operate welder in a
wet/damp environment.
Remove personal jewelry before welding (i.e. rings, watches, bracelets, etc).
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Properly install and ground this equipment according to this manual and national,
state, and local codes.
Do not weld with wet hands or wet clothing.
Always verify the supply ground check and be sure that the input power cord
ground wire is properly connected to a ground terminal in the disconnect box
or that the input power cord plug is connected to a properly grounded receptacle
outlet. Do not remove or bypass the ground prong.
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
Frequently inspect the input power cord and ground conductor for damage or bare
wiring replace immediately if damaged bare wiring can kill. Check ground
conductor for continuity.
Turn off all equipment when not in use.
Use only well-maintained equipment and repair or replace damaged parts at once.
PERSONAL PROTECTIVE EQUIPMENT RECOMMENDATIONS
FOR FLYING SPARKS AND ARC RAYS
It is essential for every person in the immediate work area to wear/utilize proper Personal Protection Equipment. 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. Very often sparks fly off from the weld joint area; therefore, take the necessary precautions to avoid trapping a spark within your own clothing.
Wear protective garments such as oil-free, flame-resistant leather gloves, heavy shirt,
cuff-less trousers, high shoes, and a cap.
Avoid synthetic fibers as they melt easily, wool is recommended.
Use an approved face shield or safety goggles with side shields.
Protect others in nearby areas by using approved flame-resistant or noncombustible
fire curtains or shields. Have all nearby persons wear safety glasses with side shields.

SAFETY PRECAUTIONS FOR HOT METAL

Welding material that has a high thermal conductivity will cause metal to heat rapidly.
Repetitive welds in the same location can cause metal to become hot.
Do not touch hot weld areas bare-handed.
Allow sufficient cooling time before handling welded pieces.

SAFETY PRECAUTIONS FOR FUMES AND GASES

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous
to your health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the area and/or use local forced ventilation at the arc to remove welding
fumes and gases.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturers
instructions for metals, consumables, coatings, cleaners, and degreasers.
Welding in confined spaces requires good ventilation or an air-supplied respirator. Always have a trained watch person nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat
and rays of the arc can react with vapors to form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while
wearing an air-supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
SAFETY PRECAUTIONS FOR FALLING EQUIPMENT
Use a working surface of adequate physical strength to support the welding unit during
operation or storage.
Secure welding unit during transport so that it cannot tip or fall.

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.

OVERUSE CAN CAUSE OVERHEATING

Allow a cooling period between strenuous welding schedules; follow rated duty cycle.
If overheating occurs often, reduce duty cycle before starting to weld again.

OBSERVE ALL NECESSARY PRECAUTIONS ASSOCIATED WITH COMPRESSED GASES

Use only compressed gas cylinders containing the correct shielding gas for the process
used.
Always keep cylinders in an upright position and secured to a fixed support.
Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage.
A safe distance from arc welding or cutting operations and any other source of heat,
sparks, or flame.
Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877413-5184, website:www.global.ihs.com).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part
1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box
371954, Pittsburgh, PA 5250-7954
(phone: 1-866-512-1800) (there are 10 Regional Officesphone for Region 5, Chicago, is 312-353-2220, website: www.osha.
gov).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 022699101 (phone: 617-770-3000, website: www.nfpa.org and www.sparky.org).
Canadian Electrical Code Part 1, CSA Standard C22.1, from Canadian Standards Association, Standards Sales, 5060 Mississauga, Ontario,
Canada L4W 5NS (phone: 800-463-6727 or in Toronto 416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National
Standards Institute, 25 West 43rd Street, New York, NY 100368002 (phone: 212-642-4900, website: www.ansi.org).

10

Chapter 1: 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. The Orion can be used as a tack welder to temporarily
position parts before welding or soldering. By increasing the power output it can also be used as a permanent fusion welder (resistance welder, spot welder). In its Pulse Arc Mode, the Orion can be used to
perform permanent welds, add metal, and do a variety of other amazing and time saving applications.

What is a Pulse-Arc Welder?

A pulse-arc welder is a special case of a Tungsten Inert Gas (TIG) welder. In TIG welding a sharpened
tungsten electrode is used in combination with electrical power to start and sustain an high temperature
plasma stream - an arc. This plasma arc is used as a heat source to melt the work piece metal. Filler metal
can also be added to build up joints and create strong and reliable weld beads, or weld seams.
TIG welders can use AC (alternating current) or DC (direct current) energy to initiate the plasma arc.
Sunstone Engineering has chosen to build on our extensive experience with DC welding technology. The
Orion uses industrial capacitive discharge technology to produce the pulse-arc weld. AC wall voltage can
vary up to 20% during the day. Capacitive welders have the advantage, over AC technologies, of precisely
storing energy before the welding process. This means that the Orion will produce a repeatable weld
independent of AC power fluctuations.
The Orion pulse-arc welder is a micro TIG welder and allows extremely fine control over all welding
parameters.

What is Resistance Welding (also called tack, fusion and spot welding)?

Resistance 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. At the contact point
between the two materials there is a resistance to the flow of the electrical current. As electrical current is
passed through this contact point resistive heating takes place. When enough current passes through the
work pieces the temperature (especially at the interface between the two pieces) can become hot enough
to melt the metal in a spot. The terms resistance welder and spot welder are descriptive of this process.
If you limit the amount of power and electrical current going into the weld you can create a temporary
or weak weld called a tack weld. Tack welding can be very useful depending on the task. It provides the
ability to temporarily position a part before permanent welding. This ability opens a multitude of creative
possibilities. It also helps eliminate the need for complicated binding or clamping of parts before permanent welding or soldering.

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11

Why is Protective Welding Gas Necessary for Arc Welding?

During the pulse-arc welding process high temperature plasma quickly melts metal into a molten pool at
the weld location. If room air is allowed to come into contact with the molten metal, oxygen from the air
will quickly react with the hot metal. The result is a metal oxide that is brittle, porous and burnt looking.
If we use a protective weld gas, such as pure Argon (99.9% pure, Argon 4.6) we can prevent these effects.
The argon is used to displace any oxygen at the weld location. As the arc is performed, the protective gas
acts as a barrier to prevent oxygen from entering the weld zone. After the weld has cooled the protective
gas is turned off.

Using the Orion Pulse-Arc Welding Stylus

The Orion pulse-arc welding stylus has been designed for ease of use. In Automatic Trigger Mode, when
the stylus electrode gently and lightly touches the weld surface, the Orion will start the welding process
for the user by pre-flowing protective gas (argon). Just before the Orion is about to make a weld it will
sound an audible beep alert. Removing the electrode from the work piece before or during this beep will
abort the welding process. If the weld is allowed to continue the arc will be initiated. During the welding process the stylus electrode is automatically retracted to prevent electrode contamination of the work
piece.
Most users can become proficient on the Orion pulse-arc welding stylus after a few minutes of practice.
We recommend performing a series of practice welds on some stainless steel or titanium material (or
whatever is available). These welds will help the new user learn the tip pressure requirements, the use of
gas flow, and a range of power settings available. In the Orion Master Jeweler Plus the user can select a tip
retract preference to better match contact pressure preference.
During welding your hands should be kept steady. Shaky hands may distort the finish of your weld. Rest
your hands on a surface to steady them. We highly recommend a pulse-arc welding stylus stand or the
use of the stereo-microscope to help overcome shaky hands.

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Practical Considerations before Welding

To help make your welding project successful we recommend that you consider and follow these steps:
1. Consider the physical properties of the materials to be welded
2. Practice welding on parts with similar size and composition to your final project (until you feel
comfortable)
3. Consider the joint and part to be welded

1. Consider Physical Properties

Different metals and alloys can respond quite differently during the welding process. To help determine
the correct starting parameters it is helpful to understand some physical properties associated with the
metal. For example does this material conduct heat away quickly (high thermal conductivity). If so you
may need to start with more energy to get the same spot size as a less conductive material. Does the material have a low melting temperature? If so you may need to turn down the power but extend the time of
the weld. Adding too much weld current (directly related to the power setting) to a low melting temperature metal may cause it to vaporize.
The Orion comes preloaded with MyWeldTM settings that can be used in many different situations. Obviously every single welding situation cant be planned for, so these included settings are there to point the
user in the right direction. After a short time welding on a variety of metals the user will gain an intuition
about selecting proper weld settings. It is always advisable when welding a new material to start with very
low power and work upward as needed.

2. Practice on Similar Sized Material

Work piece size can play a large role on weld properties. Practice on a test piece of similar size and geometry to help find the exact settings desired. During your practice welds phase, hold the work piece with a
welding attachment and not directly with your fingers. This will help you get a feel for the final temperature of the part. The temperature of the work piece will depend of material properties - especially the size
of the work piece vs. the amount of weld energy. If the piece is large its overall temperature will likely
stay low, regardless of the weld energy. If the work piece is small and the energy input is small (e.g. micro
mode) its temperature will also stay low.

3. Consider the Joint and Part to be Welded

Remember that some materials, such as solder, perform poorly when welded with the pulse-arc setting. If
your joint contains solder you should remove it prior to welding. If your joint has cracked you may consider adding filler material out past the cracked area to restore metal strength. Consider the type of joint
(I, X, V, Y etc.) and plan to use an appropriately sized filler wire if needed.

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13

Determining the Best Power Settings for a Particular Weld Application

In Pulse 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. Therefore, less power is required to weld one of these metals
than other metals of the same thickness that have a higher thermal conductivity.
Metals with higher thermal conductivity (e.g. copper, silver, gold) will require more power to create the
same spot because much of the heat is conducted away quickly.
The melting temperature of the metal is also very important when determining the necessary power
setting for a weld. Knowing the approximate or relative melting temperature of your working metal will
enable you to estimate the amount of energy required to create a spot. High melting temperature translates to a large amount of energy required. Low melting temperature translates into a smaller amount of
energy required to make the weld.
In Tack Mode, power is important but there are two other important factors that need to be remembered.
These factors are electrical conductivity and contact pressure. In Tack Mode the Orion is an industrial
resistance welder. This means that the Orion uses a metals electrical resistance to create the welding heat.
Metals that conduct electricity well (e.g. copper) are more difficult to weld in Tack Mode and require
special Tack attachments to obtain a proper weld. The second important factor when in Tack Mode is the
weld contact pressure. The weld contact pressure can be controlled by how much force you apply to the
two pieces that are being welded together. The harder you push the pieces together, the lower you make
the electrical contact resistance between them and the lower the created heat. Conversely, light pressure
will result in high contact resistance and high heat.
For all welds, the size and thickness of the metal will play a significant role in the power settings that you
choose. Sunstone Engineering recommends that users start at a low power and work upwards until an
appropriate power setting is found.

The Welding Electrode

The Orion pulse-arc welding stylus can accept two electrode diameters, 0.5 and 1.0 mm. Weld current is
related to the diameter of the welding electrode. For small, low power welds, especially in Micro Mode,
the 0.5mm electrodes can be used. The 1.0mm electrodes are preferred for large, high power welds, but
can be used for low power welds as well.

14

Power vs. Time Adjustment

The Orion allows the user a great deal of flexibility to control the penetration and size of the pulse-arc
weld spot. The power adjustment control can be generally thought of as a control of spot size while the
time adjustment can be thought of as weld penetration. Additionally, power can be considered a measure
of welding current and heat. The time can be considered the time that welding current or heat is applied.
Because the Orion is based on a capacitive discharge resistance welder, the welding output pulse will have
a smooth welding current decay. The pulse will start with a peak current which will decay to a final weld
current value. The curve will look very similar to a triangle. If the weld pulse is allowed to decay fully to
its low state the actual weld will look smooth. This decay behavior allows the weld pool to solidify more
slowly and provides an extremely fine, smooth finish. If the weld pulse (and time) are short the pulse will
approximate a square shape. The weld current will rise quickly and stay relatively constant and then stop.
This type of square pulse behavior is an excellent choice when the weld electrode must be placed at a
shallow angle. The square pulse (short weld time) provides a stable arc as the weld electrode is retracted.

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15

Chapter 2: Basic Setup and Training

The Orion Pulse 250i is a powerful and easy to use multi function welding device. Unlike a conventional
TIG welder the Orions computer does most of the work for the operator. Some important skills and
techniques are needed to become proficient with the Orion Pulse 250i. To help get started, follow these
simple setup instructions. A photographic walkthrough can be found on pages 1-5.
The Orion has an internal switching power supply that can accept both 120 and 240VAC - simply plug
the power cable into the back of the unit and connect the other the wall outlet. Next, plug your 1/4
gas tube firmly into the back of the welder until it stops fully. The stereo microscope shutter or the auto
darkening lens can be plugged into the optical unit port. The serial chord can be connected to the serial
port and tightened into place. If desired plug the foot pedal into the foot switch port.
The pulse arc welding stylus requires the most attention during setup. Since the argon gas will flow
through the hand piece, a tight fit between the power supply and the hand piece is necessary. To accomplish this, push the connector onto the Orions front panel and screw it down. Next, push in the connector again and continue to screw it down. Finally, push in the connector unit you feel it bottom out then
screw the connector in unit it is firmly seated. Other welding attachments are quickly attached positive
and negative. connections.
Next, mount the microscope arm clamp to your workbench using the provided allen wrench. Insert the
height extender into the clamp and tighten the set screw. Next, insert the entire 3d microscope arm with
the microscope into the height extender and tighten the set screw. With the arm assembly mounted and
secured, remove the LCD screen and screw it in place above the microscope. Finally, connect the serial
chord to the back of the screen.
The final step involves connecting the argon gas. Any argon gas regulator will work with the Orion. A
tube adapter may be require to attach the 1/4 tubing to the regulator. For step by step instructions on
connecting the regular to the tank, see our argon gas video. Only low pressure is required to provide
shielding gas for the work piece. Start at very low gauge flow rate values and work up as needed. Always
turn the gas tank off when the welder is not in use. Protective shielding gas should be used for all pulse
arc welds.

16

Chapter 3: User Interface

The Orion Pulse offers a simplified and streamlined interface for ease of use and one touch access to every welding parameter. To help get started and familiarized with the new interface, here is a brief explanation of all the various buttons and options found on the screens.

Arc Screen

MyWeld Management Software

17

The new MyWeldTM Management software is a great

starting point. By clicking here, user can simply select
the metal or application and the Orion will automatically
make the appropriate adjustments based on the selection. Once this is selected, users simply need to adjust
the weld energy and begin welding. To help with power
selection, a spot size approximation is displayed on the
screen.

17

Energy Selection

There are a few different ways to select

weld energy. One option is to use the
power selection bar. This bar is divided
into three sections - nano mode for
0.1-5 joules, micro for 5-30 joules, and ultra for 30-250 joules. Sliding from one section to the other will
automatically change the mode. A second option for energy selection is to use the power up and down
buttons to the right of the bar. This will jump the energy up or down.

Save/Load Settings

Once a particular metal and energy setting if found, to save this setting for future use,
click on the save disc icon and inter a name and notes for this setting. To recall or load
a previously save setting, click the load icon and select your setting.

Pulse Waveform Display

For some special metals, adjusting the pulse shape waveform may provide
superior weld results. Users can adjust pulse length, agitation and ignition - each will have a different effect on the weld formation. These will
each be discussed individually.

Weld Initiation

The right column of the screen offers weld initiation options. Trigger will toggle between touch detect and foot pedal. In touch detect, the unit will automatically fire once the work piece is touched
to the electrode tip. In foot pedal mode, initiation occurs only when
the pedal is pressed. Rate can be toggled between single and rapid.
Single is best for slower and more detailed welding, while rapid will
allow for quick seam welding.

Play/Pause/Sleep

The lower right corner has three buttons - play, pause, and sleep. In
order to weld, the play button must be pushed. When the welder
will not be in use for a short period of time the pause button can be
pushed. This will keep the unit powered on, but welding functions
will be disabled. The sleep button is a power saving option that will
power down the unit. To awake from sleep mode, simply touch the screen twice.

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Agitation Options

High Frequency Pulse Agitation can be an extremely valuable option - especially when welding the more
difficult to weld metals. The agitation can improve weld formation and strength. The various agitation
options will be discussed here:

None:

Sloped:

Sustained:

This is the standard weld discharge curve with a smooth slope. This good is for
most simple metals and will give maximum control over spot size formation.

The Sloped agitation offers low levels of agitation and has a minimal impact
on spot size formation and accuracy. This is ideal for metals that require some
agitation.

This offers high levels of agitation for improved weld spot strength. However,
the high levels of agitation energy will also affect the spot size due to the added
extra energy. It is recommended to lower the overall weld energy slightly to
compensate for the additional agitation energy.

Ignition Options

Standard: This ignition option provides precise and accurate welds. The energy discharge occurs very quickly in relation to the electrode retraction. The electrode is close to the work
piece when the weld is formed and thus, precise placement is achievable. This is the normal
micro pulsed TIG ignition process.
Tip Saver: This ignition option delays the energy discharge in relation to the electrode tip retraction. Because the electrode is able to retract away from the work piece before welds are
formed, the electrode is significantly less susceptible to contamination and sticking. This
will significantly extend the life of the electrode, but is slightly less accurate due to the space
that the weld energy must jump to form the weld. This is not recommended when welding
gaps or tight areas.
Focused This option utilizes the Tip Saver function combined with a weld focusing technology.
The focused option provides the electrode preservation of the Tip Saver with the precision
and accuracy of the Standard ignition. This is great for all metals. It is recommended to
lower the overall weld energy slightly to compensate for the additional agitation energy.

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19

Options and Preferences

The left button in the upper right corner will give access to adjust the User Options and
Preferences. Available options include Visual, Audio, Messages, Memory Status, and System
parameters.

Help Menu

Finally, the right button in the upper right corner provides access to screen help menus.
These help screens offer an explanation of all the various items displayed on each specific
screen.

20

Tack Screen

The Tack Screen controls the resistance welding aspect of the welder.

Weld Initiation

The right column of the screen offers weld initiation options. Trigger will toggle between touch detect
and foot pedal. In touch detect, the unit will automatically fire once the work piece is touched to the
electrode tip. In foot pedal mode, initiation occurs only when the pedal is pressed.

Pulse - ON/OFF

This button will turn the resistance welding capabilities on or off

Energy Bar

This controls the overall energy that will be discharged during the welding process.

Length Bar

This controls the total time that the weld energy is discharged during the welding process.

Trigger to Weld Delay

This controls the delay time from the moment the weld is initiated (either by compressing the foot pedal
or touching the positive and negative pieces together) to the moment the energy is released and the weld
is created.

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21

Advanced Screen

The Advanced Screen gives complete control to the user. Users can adjust and manipulate every weld parameter to achieve any combination of custom weld settings. As a note, changes made on the Advanced
screen will adjust any settings already configured on the Arc screen.

Primary Weld Tab

Energy Bank Selection - Turns on/off the various energy banks (Nano, Micro, Ultra).
Primary Voltage Bar - Adjusting this bar translates into energy selection based on the primary
banks selected. Turning all three banks with maximum voltage translates into approximately 250 Joules of weld energy. Using only the nano bank at a minimum voltages translates into as little as 0.01 Joules of weld energy.
Length Bar - This adjusts the amount of time that the energy is discharged from the welder. A
longer discharge time will lead to smoother weld surfaces and less internal stresses within
the weld spot.

Agitation Tab

High Frequency Bank Selection - Similar to the primary bank selection, these buttons allow the
use of special agitation banks that are used for high-frequency pulse agitation welding.
Note that the + Boost button utilizes the primary micro energy bank as an added agitation booster. Therefore, only one can be used to weld at a time - either the micro primary
bank, or the + Boost bank on the agitation screen.

22

HF Voltage Selection - Adjusting this bar adjusts the total agitation energy that will be used during
the welding process.
Duty Cycle - The duty cycle controls the width of each agitation spike, or the amount of agitation
energy that each spike delivers.
HF Frequency - The frequency bar adjusts the total number of spikes that will occur during the
welding process.

Ignition Tab

Type - This allows for selection of either Foot Pedal or Touch Detect weld initiation.
Rate - This will toggle between rapid fire or single fire settings.
Low Current Ignition - The Low Current Ignition offers a pre-weld pre-heat option that can be
helpful during the welding process. Similar the Tip Saver option on the Arc screen.
w/ Focus - The Orions focusing technology works with the Low Current Ignition to help refocus
the welding arc to allow for a tighter weld energy beam and to improve weld accuracy.
Pre-heat Length Bar - This is only visible if the Low Current Ignition is turned on. This bar controls the length of time that the electrode pre-heats before welding.
Trigger to Retract Delay - This is only visible if the Low Current Ignition is turned off. This bar
controls the length of time between the initiation (via foot pedal or touch) and the electrode
tip retraction.
Lift-off to Weld Delay - This controls the length of time between when the electrode retracts from
the work piece and when weld energy is released from the welder.
Tip Return Delay - This controls the length of time that the electrode stay retracted after the weld
has been performed.

Gas Control Tab

Purge Time - This controls the amount of purge time the Orion will have. The purge time is beneficial to help clear the gas lines of any atmospheric gases that may have entered. This will
help ensure that the first weld is well shielded.
Maintained Flow Rate - This controls the flow rate of the argon gas once the purge time is over.
By adjusting the flow rate, users can achieve optimal coverage - free from gas turbulence while significantly reducing the consumption of argon gas.
Pre-Weld Flow Time - This controls the amount of time that the gas flows before the weld is initiated.
Pre-Weld Flow Time - This controls the amount of time that the gas flows after the entire welding
process has occurred.

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Chapter 4: Arc Welding

Basic Operation

Arc Welding creates a small welding arc using the stylus. The high energy capacitors inside the Orion can
be charged to contain from 0.1 Joules up to 250 Joules. However, this doesnt necessarily mean that the
full amount of energy will be put into the weld. The other important factor, weld time, determines the
actual amount of discharge energy. This can be set between ms to 30ms. The higher the weld time, the
greater the percentage of maximum energy discharged in the weld.
With these two parameters, weld power and weld time, the user can finely tune the type of weld to be
made. A general rule is that weld power controls the diameter or size of the resulting weld, and weld time
controls the penetration or depth of the resulting weld.
Use extra caution whenever the weld power is set with in the Ultra range. On thin materials, this can
actually vaporize the metal around the arc. Higher power is useful in larger or thicker metal applications.
Generally, when pulse-arc welding, the shielding gas should be at 10 liters per minute or higher. For
larger welds, extra gas flow helps cover more surface area for a longer period of time.

Arc Mode Welding Tips

To reduce the discoloration that can appear after a weld, use more shielding gas, use a sharpened
electrode, or try shortening the length of exposed electrode.
If the electrode sticks to the weld, its probably time for electrode sharpening. Lighter holding pressure and higher power will also aid in avoiding sticks.
Thoroughly clean the weld area to avoid black soot after a weld.
Instead of a few larger welds, try making a number of smaller welds.
Typically, when the electrode is at a 90 angle to the work piece, the resulting weld is more perfectly symmetrical and attractive.
When welding close to areas that are heat sensitive, allow a few seconds to pass between successive
welds so that more heat is dissipated from the work piece.
If accuracy is difficult to achieve while in Auto Trigger Mode, consider switching over to Foot
Pedal Triggering.

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Chapter 5: Tack Welding

Basic Operation

Tack Welding is fundamentally different from Arc Welding. Arc welding generates welding heat by forming an electric arc using the stylus. Tack Mode generates welding heat by nature of the resistive properties
between the positive and negative terminals. This type of weld is also commonly called a resistance or fusion weld. By their very nature, lower powered tack welds can be temporary. Instead of using a complex
binding to hold two pieces flush while theyre welded, they can be temporarily fused with a tack weld,
then permanently joined with an arc weld or a high powered tack weld.

When using Tack Mode keep in mind these major functional differences:

There is NO shielding gas.

There is NO tip retraction, and thus the stylus should never be used.
Sparking is possible, but can be significantly reduced with more pressure between the pieces to be
joined. The darkening lens or microscope are not required for eye protection but can still be
used if desired.
There is NO aborting a weld once it has been triggered. For this reason it is recommended that
Foot Triggering be used for more precision. Also, with Foot Pedal Triggering, the weld is immediate after a foot press. This allows a higher degree of accuracy and efficiency due to the lack
of beeps before the weld.

Tack Mode Welding Tips

Using the stylus in Tack Mode will only serve to stick the electrode to the work piece. Experiment
with using the different tack hand attachments.
Auto Trigger Mode may be useful in certain situations but Foot Pedal Triggering is generally recommended for Tack Mode.
Tack welds are not necessarily permanent. In many cases, pieces that have been tacked can be broken apart with your hands. As such, anytime a low power tack weld is made be sure to follow it
up with a more permanent solution.
Unlike the stylus, when tacking, hold everything firmly- both the hand attachments and the work
pieces. This will virtually eliminate any chance for sparking, and create higher quality welds.
Successive tack welds not only generate heat in the work piece, but also in the hand attachments
and the cabling. As everything heats up it becomes less efficient electrically. To overcome these
losses, change out the hand attachments or allow them to cool periodically.

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Chapter 6 Maintenance
Changing and Sharpening Electrodes

As electrodes wear, they will become dull and result in lower quality and less attractive welds. Sharpening
or changing them out periodically is important to maintain weld consistency.
The Orions electrodes are made of lanthanated tungsten and are double ended, meaning that either end
can be used for welding. The 1mm electrodes require the included collet with the small hole in the center.
This collet is pre-installed in the stylus when shipped. The 1mm electrodes cannot be used with the other
non-holed collet, and similarly the 0.5mm electrodes cannot be used in the holed collet. Inserting and
tightening electrodes into the wrong collet can damage the stylus.
When swapping electrodes, use caution when touching any part internal to the stylus. With extensive use,
the internal parts and especially the electrode WILL BE HOT. Allow them to cool before attempting to
change electrodes. As an added safety precaution, it is recommended to put the Orion in Stop Mode.
To change the electrode, first remove the stylus hull by gently pulling on it. Then loosen the collet cap by
twisting it counter-clockwise. Grasp the electrode and push it into the collet to free it, then pull it out to
remove it.
If changing electrode sizes, the collet must also be swapped out. To do this, remove the collet cap by
continuing to twist it counter-clockwise. The collet should be loose and will remain in the stylus shaft. If
it is not loose, gently tap it out with a screwdriver or other small tool. Replace the collet with the desired
one. Replace the collet cap, but do not tighten yet. Insert the fresh electrode into the collet and lock it into
place by hand tightening the collet cap in a clockwise direction. Finally, replace the stylus hull by pushing
it snuggly back into place. See below for an exploded view of the stylus.
When sharpening electrodes, be sure to remove them from the stylus first. Use the included diamond
wheel in a rotary tool to reshape the tips. Be sure to follow all safety instructions provided by the rotary
tool manufacturer. When grinding down the tips, attempt to create a 15 angle to the tip as shown below.
A sharp tip welds better in much the same way that a sharp pencil writes better. However, grinding a very
small flat surface on the tip of the electrode tip will improve the number of welds between tip sharpenings.

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Cleaning Guidelines
Work pieces: The included fiberglass brush can be used to clean off weld debris and discoloration
from weld areas. The bristles are extended and retracted by twisting the top.
General Cleaning Guidelines: Be sure to only perform cleaning on the Orion when it is switched
off and unplugged. Never use abrasive cleaning implements on any part of the Orion. Do not
blow compressed air into any part of the Orion as this may damage the internal components.
Never use any chemicals besides mild detergents on any part of the Orion. Always clean the
Orions parts indirectly by moistening or spraying a soft cloth first, and then use only the
cloth to perform the cleaning.
Stylus and Hand Attachments: If discoloration appears at the end of the stylus or hand attachment,
it can be wiped off using a moistened cloth.
Cables and Cords: Detach cables and cords from the Orion and wipe them off using a moistened
cloth.
Orions Case and LCD Screen: Wipe gently with a moistened cloth being careful not to let any
moisture into the air vents.

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Warranty and Contact Information

All Orion products come with a 2-year limited repair warranty. Sunstone Engineering 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 Sunstone products. This warranty does not
include consumable items, such as welding electrodes or hand piece attachments. Sunstone Engineering is dedicated to keeping our products operating at peak performance for years to come. Any repairs
needed after the 2-year warranty period are performed at cost, typically costing $50-100 USD.
Sunstone Engineering offers a 30-day money-back guarantee on all of our products. Before sending a
product back please contact Sunstone Engineering to receive an RMA number. The RMA number should
appear clearly on the outside of the package. Customer refunds are accomplished via check. Please note
that a 3% restocking fee will apply to all returns. Equipment damaged by improper use or insufficient
shipping precautions will be charged additional fees.
Sunstone Engineering is dedicated to providing quality products and support. Please feel free to call with
any questions before or after purchasing our products.
Phone 1-801-658-0015
Fax 1-866-701-1209
E-mail
Sales sales@SunstoneSpotWelders.com

Technical Support tech@SunstoneSpotWelders.com

Customer Service
custservice@SunstoneSpotWelders.com
Web www.SunstoneSpotWelders.com


Mail
Sunstone Engineering R&D Corporation

1693. American Way, Unit 5
Payson, UT 84651

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