Orion i, i2 User Manual
Orion i Series Welding System
User Manual
i Series User Manual
Table of Contents
Chapter 1: Welder Setup and Assembly ..................... p.3
What is in the Box ....................................... p.3
Mount the Microscope Arm ............................. p.3
Microscope Arm Setup ................................. p.4
Welder Connection Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p.4
External Power Supply Setup ........................... p.5
Shielding Gas Setup .................................... p.5
Adjustments on the Microscope Arm ................... p.6
True Color Optical LCD Shutter ......................... p.6
Become Familiar with the Microscope .................. p.7
Electrode Setup ......................................... p.7
Make a Weld ............................................. p.9
Chapter 2: User Interface Overview ......................... p.10
Header Area ............................................ p.10
Waveform Graph Area .................................. p.10
Metals Tab - Controls Area ............................. p.10
Arc Tab - Controls Area ................................. p.11
Additional Information on Seam Mode ................. p.14
Seam Mode Advanced Screen .......................... p.14
Tack Tab - Controls Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p.16
Video Tab ............................................... p.16
Load Tab ................................................ p.17
Save Tab ................................................ p.17
Settings Tab ............................................ p.17
Chapter 3: Reading the Waveform Graph .................... p.18
Ignition .................................................. p.18
Waveforms ............................................. p.19
Weld Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p.20
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Orion Welders
1693 American Way, Unit 5
Payson, UT 84651 USA
+ 1-801-658-0015
Chapter 1: Welder Setup & Assembly
What is in the Box
BOX
e Orion i2 Series System will arrive in 1 box.
MAIN BOX:
(1) User Manual & Getting Started/Quick Setting Guide
(1) Orion i2 Power Supply
(1) Orion i2 Microscope Arm
(1) Orion i2 Microscope Extender Arm
(1) Orion i2 Microscope Arm Table Mount
(1) Orion i2 Microscope Arm Support Bar
(1) Orion i2 Interface Box
(1) Orion i2 10 pin power cable
BOX WITHIN MAIN BOX:
(1) Welder Power Cord
(1) Stylus Hand Piece
(1) Pair Alligator Clips
(1) Foot Pedal
(1) Shielding Gas Hose
(1) Cross Lock Tweezers
(1) Electrode Vile (5x 0.5mm -- 5x 1.0mm Electrodes – 1x
Diamond Dremel Disk – 1x 0.5mm Orion Collet)
(1) Fiberglass Brush
(1) Stainless Steel Weld Sample Card
(1) 3 Allen Wrenches with green microscope protective cover
(1) Pair Microscope Eye Piece Shields
(1) Loop Closing Pliers
Mount the Microscope Arm
MOUNTING OPTION 1 CLAMP TO TABLE
• 1. Determine the height of the tabletop. *If it is thicker than 2-3/4’ (7cm), follow arm base mounting options 2 or 3.
• 2. Position the microscope arm clamp under the tabletop.
• 3. Place the included allen wrench in the opening at the bottom of the clamp
bolt. Turn the bolt clockwise until the clamp is very snug.
2¾”
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.
3. Place a washer on the 10m x 1.5 bolt (length will depend on tabletop thickness) and run it up through the tabletop into
the arm base.
4. Tighten the bolt until it is very snug.
MOUNTING OPTION 3 BOLT TO TABLE
1. Position the base against the table.
2. Trace drill holes with a pen or marker.
3. Drill 1/4’ holes in the tabletop.
4. Run screws through the base into the drilled holes.
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i Series User Manual
Microscope Arm Setup
1. Place the microscope extender arm into the arm base.
2. Place the microscope arm into the top of the extender arm.
3. Place the touch screen box into the slot on the microscope arm above
the microscope optics.
4. Loosen/tighten the allen on the top of the microscope extender arm
to adjust the spring pressure. Turn the allen counter clockwise if the
arm does not hold the microscope up. Turn the allen clockwise if the
arm does not allow the microscope to come down.
5. Ensure the RJ45 microscope cable is plugged into the RJ45 port on the
light ring (below the microscope optics).
6. Plug the other end of the microscope cable into the RJ45 “Shutter”
port on the back of the touch screen box. *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.
7. Install the rubber eyepiece covers onto the optics.
8. Loosen the bolt in front of the microscope mount to move the microscope head left and right.
*When adjusting the spring pressure as described in step 4, be sure the arm is parallel to the table as seen here.
3.
2.
4.
1.
6.
7.
5.
8.
Welder Connection Setup
CONNECT THE WELDING STYLUS TO THE BACK OF THE TOUCH SCREEN BOX
e 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. is will insure that no oxygen is entrained into the weld. To accomplish this,
follow the steps below.
1. Position the end of the stylus so that the notch is facing down.
2. Push the stylus into the stylus connector port on the back of the touch screen box.
3. Turn the outside layer of the stylus connector clockwise so it screws onto the stylus connector port.
4. Continue to turn the outside layer of the stylus connector clockwise until it stops.
5. Now push in on the stylus connector, (you will feel it move in a couple centimeters). en turn the outside layer of the
stylus connector clockwise until it stops.
6. Repeat steps 2-5 until you feel the stylus connector bottom out, and you can no longer screw the stylus connector
clockwise. is will insure that the stylus connector is firmly seated.
CONNECT THE REMAINING CABLES TO THE BACK OF THE TOUCH SCREEN BOX
1. Place an alligator clip into the positive port on the back of the touch screen box. *Remember
to attach the alligator clip to the work-piece before welding.
2. Plug the foot pedal into the “trigger” port on the back of the touch screen box.
3. Verify that the RJ45 cable is securely fastened in the RJ45 port.
4. Insert the 1/4” gas tube firmly into the “Gas” port. *It may wiggle when connected, but
should not come out if pulled on.
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CONNECTOR PORTS ON THE BACK OF THE INTERFACE BOX
1. Foot Pedal Connection Port.
2. Shutter/Darkening Lens Connection Port.
3. Stylus Connection Port
4. Power Supply Connection Port
5. External Device Port
6. Positive Grounding Port (Use for Arc Welding)
7. Negative Grounding Port (Use with Positive when Tack Welding)
8. Inert Gas Connection Port
External Power Supply Setup
SET UP THE EXTERNAL POWER SUPPLY
e Orion has an internal switching power supply that can accept 90VAC to 240VAC.
1. Plug the female end of the power cable into the “AC Power” port on the side of the external
power supply.
2. Connect the male end of the power cable into AC power.
3. Plug the 10 pin “external power supply to touch screen box“ cable into the 10 pin port on the
external power supply.
4. Run the cable from step 3 to the microscope extender arm. Remove the plastic piece on the
underside of the microscope extender arm by squeezing the plastic piece on both ends with
your thumb and index fingers.
5. Place the cable in the plastic piece.
6. Connect the plastic piece back to the extender arm.
7. Plug the end of the cable into the 10 pin port on the back of the touch screen box.
8. e red LED indicates that the power supply has AC power applied and is ready to use.
Shielding Gas Setup
During the pulse-arc welding process high temperature plasma quickly melts metal into a molten pool. As the weld is
performed, a small amount of shielding gas is released through the weld stylus to prevent oxygen from entering the molten
pool. After the weld has occurred the protective gas turns off. If oxygen from the air enters this molten pool, the result is a
metal oxide that is brittle, porous and burnt-looking. Protective shielding gas is used, such as 99.996% pure Argon (Argon
4.6) or higher, to prevent these effects. Shielding gas is necessary to produce clean and repeatable pulse-arc welds. We
recommend high purity argon. is can be purchased at your local welding supply shop.
PRESSURIZED GAS SAFETY
1. 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 rocket-like, expelling the high pressure
shielding gas as propellant.
2. ALWAYS TURN OFF THE SHIELDING GAS AT THE MAIN VALVE WHEN FINISHED. is will help your shielding gas supply
last longer in case there is a small leak in the tubing. is is also a good safety practice. If the tube becomes dislodged,
shielding gas could fill the room displacing needed breathing oxygen. Argon is heavier than air and will fill the room from
the bottom upward. If you experience a large shielding gas leak, open all of the doors and windows in the room.
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i Series User Manual
SHIELDING GAS TANK AND REGULATOR SETUP
1. Ensure that your shielding gas tank is securely fastened to a stationary point near the welding
area.
2. Turn the regulator dial COUNTER CLOCKWISE (closed) until it is fully backed out to prevent
over-pressurization of the line.
3. Screw the gas regulator onto the shielding gas tank.
4. Connect one end of the gas tubing into the gas regulator. It will stop when it is fully
connected. Tug gently on the tube to verify a tight fit.
5. Insert the other end of the gas tubing into the gas port on the back of the power supply.
It will stop when it is fully connected. Tug gently on the tube to verify a tight fit.
6. Open the gas tank slowly. e dial on the right should pressurize and the dial on the
right should remain at zero (when the regulator dial is fully backed out – see step 2).
7. Slowly turn the regulator dial CLOCKWISE until the gas pressure reads between 7-10 psi.
(is will adjust the dial on the left side of the regulator.)
Adjustments on the Microscope Arm
ADJUST WELDING STYLUS POSITION
1. Insert the welding stylus into the stylus holder under the microscope head then tighten the
stylus holder knob.
2. Loosen the screws on either side of the stylus holder.
3. Adjust the welding stylus to a 45-degree angle then slightly tighten the screws just enough to
hold the stylus in place at a 45-degree angle
4. While looking through the microscope, slide the welding stylus holder forward/backward until
the tip of the stylus is in the center of your focus.
5. Now securely tighten the stylus holder screws.
4.
Regulator Dial
1.
2. 45°
ADJUST THE MICROSCOPE FOCUS
1. Twist the large dial on either side of the microscope to move the microscope up or down in
order to focus the lenses.
When adjusting the microscope focus, place a finger under the welding electrode to help judge
the correct focus location. Focus the microscope till the texture on the skin of the finger is clearly
visible.
True Color Optical LCD Shutter
Sunstone Engineering has developed a truly revolutionary optical LCD welding filter. e True Color TM Optical LCD shutter
system allows Orion users an unimpeded full color view of the welding work-piece before welding. During a weld the Orion
pre-darkens the shutter to provide complete eye protection. Even when a weld is not taking place the user’s eyes are
always protected from harmful UV and IR radiation to levels exceeding typical safety requirements.
e True Color TM Optical LCD shutter system has been specifically design for the Orion i2 seam mode. In seam mode the
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