Orion c, 100c2, 100c User Manual
Orion c Series Welding System
User Manual
c Series User Manual
Table of Contents
Chapter 1: Setup and Assembly .................. p.5
What is in the Box ............................ p.5
Power Supply Setup .......................... p.5
Microscope Arm Setup ....................... p.6
Microscope LCD Filter Shutter ................ p.8
Become Familiar with the Microscope ....... p.8
Darkening Lens Setup ........................ p.9
Electrode Setup ............................... p.9
Shielding Gas Setup .......................... p.11
Chapter 2: Welder Interface Overview ........... p.12
Basic Screen .................................. p.12
Arc Screen .................................... p.13
Tack Screen .................................. p.14
Save/Load Screen ............................ p.14
Settings Tab .................................. p.15
Media Screen ................................. p.17
Chapter 3: Make A Weld .......................... p.18
Gray Waveform ............................... p.18
Make an Arc Weld ............................. p.18
Make a Tack Weld ............................ p.18
Orion 100c Pulse Arc and Resistance Welder
Weld Modes 3 (micro 1, micro 2, tack)
Pre-Programmed Metal Settings 11
Customizable Save Settings 30 (15 Arc & 15 Tack)
Languages 20 + (Ask rep if we have your language)
Display 5” Capacitive Multi Touch Screen
Energy (Ws) 3 - 100 Ws
Switching Power Supply 110/240VAC (Auto Detected)
Weld Spot Diameter 0.5 - 2.5mm
Footprint (L x W x H) 11.5” x 6” x 6.75” (29 x 15 x 17cm)
Weight 20 lbs (9 kg)
Stereo Microscope Magnification 5x
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c Series User Manual
Chapter 1: Welder Setup & Assembly
What is in the Box
ALL ORION C SERIES SYSTEMS COME WITH:
(1) Safety Manual & Quick Start/Quick Settings Guide
(1) Orion c Series Power Supply
(1) Welder Power Cord
(1) Stylus Hand Piece
(2) Alligator Clips
(1) Foot Pedal
(1) Shielding Gas Hose
(1) Electrode Vial (5 – 0.5mm and 5 – 1.0mm Electrodes)
(2) Microscope Eye Piece Shields
(1) Fiberglass Brush
(1) Cross Lock Tweezers
(1) System Cover
(1) Brass Lined Pliers
IF YOU PURCHASED THE MICROSCOPE ARM SYSTEM:
(1) Orion Microscope Arm
(1) Microscope Arm Table Mount
(1) Microscope Arm Support Bar
(1) Set of Allen Wrenches
IF YOU PURCHASED THE DARKENING LENS
SYSTEM:
(1) Base Plate and Phillips Screw
(1) Base Plate Stand and Cap
(1) Darkening Lens
(1) Darkening Lens Arm
(1) RJ45 Darkening Lens to Welder Cable
Power Supply Setup
SET UP THE BACK SIDE OF THE POWER SUPPLY
e Orion has an internal switching power supply that can accept both 120 and 240VAC.
• Plug the female end of the power cable into the “90-240 VAC” Power port.
• Connect the male end of the power cable into AC power.
• Insert the 1/4” gas tube firmly into the “Shield Gas” port. *It may wiggle when
connected, but should not come out if pulled on.
• Plug the foot pedal into the “foot pedal” port.
• Plug the RJ45 microscope cable into the “Shutter” port on the back of the power
supply.
• Push the stylus into the stylus connector port on the back panel of the power
supply. Ensure that the white circular indicator on the stylus lines up with the
white indicator on the stylus port. e connector will snap into place.
• When pulse arc welding with the weld stylus, connect an alligator clip to the
“Pulse Arc and Tack +” port on the back of the welder. (If you do not use this port,
use the one on the front of the welder). *Remember to attach the alligator clip to
the work piece before pulse arc welding.
• When Tack welding, plug one alligator clip into the “Pulse Arc and Tack +” port and
one into the “Tack -” port. *Remember to attach each alligator clip to each work
piece before Tack welding them together.
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SET UP THE FRONT SIDE OF THE POWER SUPPLY
Look to the front on the Orion to power on the welder and control the touch screen.
• Plug the pulse arc welding alligator clip in the port at the bottom right of the welder.
Alternatively, you may use the “Pulse Arc and Tack +” port on the back of the welder.
• Push in the power button on the bottom left to start the welder.
• Touch the play button on the user interface to begin welding.
Microscope Arm Setup
MICROSCOPE ARM MOUNTING OPTIONS
• Remove the microscope arm from the box and place it on your
table.
• Follow the desired mounting method below.
Mounting Option 1 - Clamp to table
• Determine the height of the tabletop. *If it is thicker than 3-1/2’
(9cm), follow mounting options 2 or 3.
• Position the microscope arm clamp under the tabletop.
• Turn the clamp knob clockwise until the clamp is very snug.
Mounting Option 2 - Bolt through table
• Using a 4mm (5/32) allen wrench, unscrew the allen bolts
holding the clamp to the arm.
• Run the included 8mm (5/16) bolt (F) through the included
plate (H).
• Attach plate (H) to the bottom of the arm using the same
allen bolts from step 1.
• Drill a 3/8’ (9.5mm) hole through the tabletop.
• Lower the arm so the bolt goes through the hole in the table
top.
• Slide the tightening plate onto the bolt and then tighten the
twist knob onto the bolt until it is very snug.
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c Series User Manual
Mounting Option 3 - Bolt to table
• Remove the clamp and position the base against the table.
• Trace drill holes with a pen or marker.
• Drill 1/4’ holes in the tabletop.
• Run screws through the base into the drilled holes.
MICROSCOPE SETUP
• Remove the microscope from the box and place it into the round clamp
at the top of the arm.
• Tighten the screw on the round clamp to secure the microscope to the
arm.
• Install the rubber eyepiece covers onto the microscope lenses.
• Insert the welding stylus into the stylus holder under the microscope
then tighten the stylus holder knob.
• Ensure the microscope cable is plugged into the RJ45 port on the
microscope (the bottom of the microscope head).
• Ensure the microscope cable is plugged into the “Shutter” port on the
back of the power supply.
*Orion RJ45 ports are not compatible with any other RJ45 ports. Connecting
them to other devices may damage the welder and/or the other devices.
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