Orion S, 150s User Manual

Orion s Series Welding System

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

Grey Waveform ............................... p.18

Make an Arc Weld ............................. p.18

Make a Tack Weld ............................ p.18

Orion 150s Pulse Arc and Resistance Welder

Weld Modes 4 (nano, micro, ultra, tack)

Pre-Programmed Metal Settings 11

Customizable Save Settings 50 (25 Arc & 25 Tack)

Languages 20 + (Ask rep if we have your language)

Display 8” Capacitive 10 point Touch Screen

Energy (Ws) 1-150 Ws

Switching Power Supply 110/240VAC (Auto Detected)

Weld Spot Diameter 0.5 - 3.5mm
Footprint (L x W x H) 12” x 6” x 10” (30.5 x 15.2 x 25.4cm)

Weight 20 lbs (9 kg)

Stereo Microscope Magnification 5x

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150s User Manual

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Chapter 1: Welder Setup & Assembly

What is in the Box

ALL ORION S SERIES SYSTEMS COME WITH:

(1) Safety Manual & Quick Start/Quick Settings Guide
(1) Orion s 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 +” 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 “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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150s User Manual

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 +” 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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