Orion m Series Welding System
User Manual
Table of Contents
Chapter 1: Setup and Assembly .................. p.5
What is in the Box ............................ p.5
Darkening Lens & Power Supply Setup ...... p.5
Microscope Arm Setup ....................... p.6
Microscope LCD Filter Shutter ................ p.8
Become Familiar with the Microscope ....... p.9
Electrode Setup ............................... p.9
Shielding Gas Setup .......................... p.11
Chapter 2: Welder Interface Overview ........... p.15
mPulse Interface ............................. p.15
Troubleshooting ............................... p.15
Chapter 3: Make A Weld .......................... p.17
Make an Arc Weld ............................. p.17
Orion mPulse Pulse Arc Welder
Welder Type Pulse-Arc
Weld Modes 1
Pre-Programmed Metal Settings 0
Customizable Save Settings 0
Languages None
Display 4.4” Touch Screen
Energy (Ws) 3-30 Ws
Switching Power Supply 110/230VAC (Auto Detected)
Weld Spot Diameter 1 - 1.25mm
Footprint 5.5” x 5.25” x 3.625” (13.79 x 13.34 x 9.21cm)
Weight 2 lbs. 6 oz. (1.07 kg)
Pulse Frequency 1/3.5 Hrz
*Stereo Microscope Magnification 5x (> IR 16 / > UV 16)
*Darkening Shutter Visibility: Shade 3 to Shade 12
*Depending on the model of mPulse you have
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Chapter 1: Welder Setup & Assembly
What is in the Box
ALL ORION M SERIES SYSTEMS COME WITH:
(1) Orion mPulse Welder/Power Supply and
Stylus Hand Piece
(1) Orion mPulse Welder Power Cord (2 pieces)
(2) Alligator Clips
(1) Shielding Gas Hose
(1) Electrode Vile (5 – 0.5mm and 5 – 1.0mm
Electrodes)
(1) Fiberglass Brush
IF YOU PURCHASED THE DARKENING LENS SYSTEM:
(1) Darkening Lens Stand with attached RJ45 Cable
IF YOU PURCHASED THE MICROSCOPE ARM SYSTEM:
(1) Orion Microscope Arm
(1) Microscope Arm Table Mount
(1) Microscope Arm Support Bar
Darkening Lens & 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.
e darkening lens or microscope will automatically darken when the weld takes place. is allows the user to have a view of
the work-piece and protection from the flash during the welding process.
Remove the welder and Darkening Lens from the box and place
them on the table.
1. Plug the female end of the power cable into the AC Power
port on the back of the power supply. en connect the
male end into AC power.
2. Insert the 1/4” gas tube firmly into the “Gas” port on the
back of the welder. *It may wiggle when connected, but
should not come out if pulled on.
3. Insert the RJ45 Darkening Lens cable (from the back of
the darkening lens) into the ACC port on the back of the
welder.
4. Plug the alligator clip into the positive port. *Remember to
attach the alligator clip to the work-piece before welding.
1. 2.
4.
7.
3.
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5. Insert the Orion stylus (from the back of the welder) into the Stylus
6. Adjust the darkening lens shade by turning the shade dial above the
5.
7. Power on the welder.
6.
Holder on the Darkening Lens stand.
darkening lens screen. Turn clockwise for a lighter shade and counterclockwise for darker shade.
Microscope Arm System 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.
6
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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• Loosen/tighten the allen on the microscope arm to adjust the spring
pressure. Turn the allen clockwise if the arm does not hold the microscope
up. Turn the allen counter clockwise if the arm does not allow the
microscope to come down.
ADJUST WELDING STYLUS POSITION
• Loosen the screws on either side of the stylus holder.
• Adjust the welding stylus to a 45-degree angle then slightly tighten the
screws on the sides just enough to hold the stylus in place at a 45-degree
angle.
• While looking through the microscope, slide the welding stylus forward
and backward until the tip of the stylus is in the center of your focus.
• Now securely tighten the stylus holder by tightening the screw on the
bottom of the stylus holder.
ADJUST THE MICROSCOPE FOCUS
• Twist the knob on the microscope forward and backward to raise and
lower the head. is will allow you to focus the microscope on the welding
stylus.
• Place your finger under the welding electrode to help judge the correct
focus location. Focus the microscope until the texture on the skin of your
finger is clearly visible.
Microscope LCD Filter Shutter
e microscope LCD filter shutter allows an unobstructed working view before welding and completely protects the user’s
eyes during the welding process. e Orion’s internal computer verifies the microscope LCD filter shutter has been closed
before allowing the weld to take place. In the case that the shutter does not close, the microscope lens is equipped with >UV
16 and >IR 16 for maximum eye protection.
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Become Familiar with the Microscope
e Orion Microscope has been designed to provide maximum visual clarity, eye protection and ease of use. One challenge
using the microscope is getting used to bringing the work piece to the welding electrode while looking through the
microscope. is is an easy challenge to overcome. To begin, follow these steps with the welder on pause. *While the welder
is on pause, it will not be able to make a weld when the work piece touches the electrode.
• Rest your hands on the table and position
the work piece close to the welding electrode
before looking into the microscope.
• Make sure your focus is at the tip of the
electrode.
• Use slow, controlled movements.
• It is helpful to have your hands resting and to
only use your fingers to move the work piece up
to the electrode.
• Place the work piece surface perpendicular to
the point of the electrode. *As discussed in later
chapters, the angle of the electrode tip relative
to the work piece surface is very important and
will take practice.
• Now practice making soft contact with the work
piece to the electrode.
• *Once you feel comfortable, attach the alligator
clip to the work piece and touch the play button
to begin performing real welds.
Electrode Setup
e Orion welder comes standard with a 0.5mm electrode collet and (5) 0.5mm
electrodes; and a 1.0mm electrode collet and (5) 1.0mm electrodes. e 1.0mm
electrodes are a good all around electrode while the 0.5mm electrode is more for
very small applications (less than 5ws of energy).
STYLUS COMPONENTS:
1. Stylus Shaft 2. Collet 3. Collet Cap 4. Electrode 5. Stylus Hull
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INSTALL THE TUNGSTEN ELECTRODE ONTO THE WELDING STYLUS
Follow these steps to properly install the tungsten electrode.
• Remove the stylus hull by pulling it away from the stylus shaft.
• Loosen the collet cap by twisting it counter-clockwise.
• e welder comes with 2 electrode collets. One that fits 0.5mm
electrodes and one that fits 1.0mm electrodes. e electrode stylus will
be shipped with the 1.0mm electrode collet installed.
• Insert a 1.0mm electrode into the collet. Helpful Tip: ere is a groove cut
around the stylus hull that will help measure the electrode length. Place
the end of the stylus hull up against the collet cap, then make sure the
electrode tip falls between groove.
• ere should be between 0.6 - 0.7in (1.5 – 2cm) of the electrode
protruding from the stylus shaft. is will allow the electrode enough
room to stick out from the stylus once the stylus hull is placed back on
the stylus.)
• Lock the electrode into place by hand tightening the collet cap in a
clockwise direction.
• Replace the stylus hull by pushing it in until you feel it snap back into
place (the electrode should stick out between 1/8 – 1/4in (3.75 –
6.75mm) after the stylus hull is snapped back into place).
WORK PIECE TO ELECTRODE PRESSURE
Touch the work piece to the electrode with very light pressure. Too much pressure will cause the work piece to stick to
the electrode and in turn cause the electrode to be contaminated (work piece material on the electrode). We recommend
cleaning or changing the electrode any time it gets stuck to the work piece
WHEN TO SHARPEN THE ELECTRODE
It is recommended that the user pay close attention to the electrode condition. An
electrode that appears to be dark colored or covered with material from previous
welds can lead to inconsistent welding and poor igniting of the weld. When this occurs,
simply sharpen the electrode with the included diamond disk. e diamond disk can
be attached to a flex shaft or Dremel tool. Follow these steps for sharpening the
electrode.
• Completely remove the electrode from the stylus.
• Pinch the electrode between the thumb and index and/or middle finger with the
shaft going perpendicular to the fingers.
• Power on the Dremel or flex shaft then hold it with the opposite hand. *Place the
electrode tip in the diamond disc in such a way that the grit of the disk is moving
parallel with the electrode shaft and moving towards the tip.
• is will affect the quality of the weld if not done as explained above.
• Set the electrode on the diamond disk at a 10-degree angle and begin to spin
the electrode with the thumb and middle finger. *A helpful way to get a sharp
10
electrode is to push down on the electrode with your index finger while twisting the electrode with the thumb and
middle finger.
• Once the electrode is sharp and clean, turn the Dremel off and insert the electrode back into the stylus as explained
above.
*As a general rule of thumb we recommend a freshly sharpened electrode anytime a new work piece is being welded.
*See Chapter 5 for additional information on the Tungsten Electrodes
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.
• Completely remove the electrode from the stylus.
• Pinch the electrode between the thumb and middle finger with the point facing inward.
• Turn the Dremel or flex shaft on then hold it with the opposite hand. *Place the electrode tip in the diamond
disc in such a way that the grit of the disk is moving parallel with the electrode shaft and moving towards the
tip.
• is will affect the quality of the weld if not done as explained above.
• Set the electrode on the diamond disk at a 10-degree angle and begin to spin the electrode with the thumb
and middle finger. *A helpful way to get a sharp electrode is to push down on the electrode with your index
finger while twisting the electrode with the thumb and middle finger.
• Once the electrode is sharp and clean, turn the electrode to a 90-degree angle and push it against the
dremel in order to place a flat/blunt tip on the electrode.
• Once the electrode has a flat/blunt tip, turn the Dremel off and insert the electrode back into the stylus as
explained above.
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
ere are several important rules that should be followed when using a compressed shielding gas such as argon.
• 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.
• 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 and displace oxygen, which can lead to suffocation. 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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SHIELDING GAS TANK AND REGULATOR SETUP
• Ensure that your shielding gas tank is securely fastened to a stationary point near
the welding area.
• Turn the regulator dial COUNTER CLOCKWISE (closed) until it is fully backed out.
meaning the dial become loose, to prevent over-pressurization of the line.
• Screw the gas regulator onto the shielding gas tank.
• Connect one end of the gas tubing to the gas regulator.
• 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.
Regulator Dial
• Open the gas tank slowly. e dial on the right should pressurize and the dial on
the left should remain at zero (when the regulator dial is fully backed out or the
dial becomes loose).
• 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.)
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Chapter 2: The Touch Screen Interface
e Orion touch screen interface is very user friendly. Users have access to every welding parameter with one touch. Below
is an explanation of the various buttons and options found on the Orion mPulse interface. *Orion touch screens are resistive
touch screens. is means they respond best to a little bit of pressure. e end of your fingernail or the tip of the alligator
clip works best when touching the screen.
mPulse Interface
PLAY/PAUSE BUTTONS
Play - In order to weld, the play/pause button must show the green triangle “play“ symbol.
Pause - If the welder is not going to be in use for a period of time, users can push the play/pause button (a pause symbol will
appear). is will keep the unit powered on, but welding functions will be disabled.
ENERGY BAR
e energy bar ranges from 3.0Ws (Watt-Seconds or Joules) to 30Ws. Users can slide their finger anywhere along the bar to
move the energy up or down.
PLUS/MINUS BUTTONS
Another option for moving the energy up or down is to use the + and - buttons to the right of the energy bar.
Troubleshooting
Welder is not welding.
1. Is it on play?
2. Is the alligator clip attached?
3. Is the electrode clean?
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Chapter 3: Make a Weld
Make An Arc Weld (using the provided weld plate)
1. On the touch screen select 7.5 Ws on the Energy bar and then hit Play.
*Remember to verify the gas pressure and microscope connection.
2. Lightly touch the electrode in
the box on the provided weld plate.
Maintain contact & keep hands steady
by resting them on the table.
3. Use the provided stainless steel
weld plate as a guide to try different
settings. Make several welds on the
weld plate to get comfortable with
the stylus and the different weld
parameters.
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Chapter 4: Recommended Welder Settings
General Settings
• ese settings are to help users get started. Remember to adjust the power up and down as needed.
Electrode Shaping:
Stylus Cone
Stylus Cone
Sharp Electrode Tip
Electrode placement examples:
Butt Weld
T-Joint Weld
26 AWG wire/chain/jump ring
Metal Tip Shape Energy Notes
14k Gold Sharp 10 ws
24k Gold Sharp 7.5 ws
Silver Sharp 10 ws
Platinum Sharp 10 ws
Stainless Steel Sharp 7.5 ws
Palladium Sharp 7.5 ws
Titanium Sharp 10 ws
Brass Sharp 10 ws
0.5mm thick Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 12.5 ws
24k Gold Sharp 10 ws
Silver Sharp 17.5 ws
Platinum Sharp 15 ws
Stainless Steel Sharp 15 ws
Palladium Sharp 15 ws
Titanium Sharp 15 ws
Brass Sharp 15 ws
Add Metal Weld
Butt weld with 90
degree electrode
Butt weld with 90
degree electrode
Flat Electrode Tip
Add Metal Weld
angle
Butt Weld
angle
Add Metal Weld
Earring Post
Metal Tip Shape Energy Notes
14k Gold Sharp 10 ws
24k Gold Sharp 10 ws
Silver Sharp 12.5 ws
Platinum Sharp 12.5 ws
Stainless Steel Sharp 7.5 ws
Palladium Sharp 7.5 ws
Titanium Sharp 12.5 ws
Brass Sharp 10 ws
T joint with 45
degree electrode
angle
T-Joint Weld
1mm thick Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 22.5 ws
24k Gold Sharp 20 ws
Silver Semi Blunt 30 ws
Platinum Sharp 25 ws
Stainless Steel Sharp 22.5 ws
Palladium Sharp 20 ws
Titanium Sharp 25 ws
Brass Sharp 25 ws
Butt weld with 90
degree electrode
angle
Butt WeldButt Weld
18
2mm thick Ring
Metal Tip Shape Energy Notes
14k Gold Sharp 30 ws
24k Gold Sharp 30 ws
Silver Blunt 30 ws
Platinum Sharp 30 ws
Stainless Steel Sharp 30 ws
Palladium Sharp 30 ws
Titanium Sharp 30 ws
Brass Sharp 30 ws
Butt weld with 90
degree electrode
angle
Butt Weld
Add Material (30 AWG laser wire)
Metal Tip Shape Energy Notes
14k Gold Sharp 12.5 ws
24k Gold Sharp 12.5 ws
Silver Sharp 15 ws
Platinum Sharp 15 ws
Stainless Steel Sharp 10 ws
Palladium Sharp 10 ws
Titanium Sharp 15 ws
Brass Sharp 12.5 ws
Wire at 45 degree
angle.
Electrode touch-
ing work piece
next to wire.
T-Joint Weld
Add Material (24 AWG wire)
Metal Tip Shape Energy Notes
14k Gold Sharp 17.5 ws
24k Gold Sharp 15 ws
Silver Sharp 20 ws
Platinum Sharp 20 ws
Stainless Steel Sharp 15 ws
Palladium Sharp 15 ws
Titanium Sharp 20 ws
Brass Sharp 17.5 ws
Wire at 45 degree
angle.
Electrode touching
work piece next to
wire.
Add Metal Weld
Retip Prong (26 AWG wire)
Metal Tip Shape Energy Notes
14k Gold Sharp 10 ws
24k Gold Sharp 7.5 ws
Silver Sharp 10 ws
Platinum Sharp 10 ws
Stainless Steel Sharp 7.5 ws
Palladium Sharp 7.5 ws
Titanium Sharp 10 ws
Brass Sharp 10 ws
Butt weld with 90
degree electrode
angle
Add Metal Weld
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