SUNSTONE Orion mPulse Bedienungsanleitung

Orion™mPulse

Users Guide

Version 20220111 • Part #1227

ATTENTION: Read the Safety Guide before operating this welder!

Operator assumes all liability.

REVISION DATE VERSION NO. DESCRIPTION OF CHANGES

1 04/2021 20210407 Reformatting

2 01/2022 20220111 Minor Corrections and Revisions

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PERMITTED UNDER APPLICABLE LAW.

e Micro Welder Experts

Contents

Welder Setup & Assembly .................................................................................1

How to Connect All Cables..........................................................................1

Microscope Arm Mounting Options ........................................................2

How to Adjust Microscope Focus .............................................................5

How to Place the Welding Stylus ..............................................................5

Electrode Setup .............................................................................................6

Electrode Care ................................................................................................7

Shield Gas Setup .............................................................................................9

Microscope Tips ...........................................................................................10

Microscope LCD Filter Shutter System ...............................................11

How to Use the Touchscreen Interface .....................................................12

How to Make a Weld..........................................................................................14

Recommended Welder Settings & Welder Specications.................16

Questions? Call or Text +1-801-658-0015 • 1

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Welder Setup & Assembly

What is in the Box

(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 Vial (5 1.0 mm Electrodes)

(1) Fiberglass Brush

If You Purchased the Darkening Lens System:

(1) Darkening Lens System (lens and stand) with attached RJ45 Cable

If You Purchased the Microscope System:

(1) Orion Microscope Arm

(1) Microscope Arm Table Mount

(1) Microscope Arm Support Bar

How to Connect the Basic Cables

The Orion mPulse cable connections vary. If you purchased the darkening lens or the microscope, cabling

needs change slightly. The darkening lens or microscope will automatically darken when the weld takes place,

which allows the operator to have a view of the work piece and remain protected from the ash during the weld-

ing process. Reference Figure 2.1 on the next page and follow these instructions for easy setup:

• Remove the welder and Darkening Lens System from the box and place them on a at work space.

• Plug the female end of the power cable into the AC Power port (D) on the back of the power supply.

Then connect the male end into an AC power supply. The Orion mPulse has an internal switching

power supply that can accept both 120 and 240VAC.

2• Questions? Call or Text +1-801-658-0015

Orion™mPulse User Manual

• Insert the 1/4” gas tube rmly into the Gas port

(E) on the back of the welder. It may wiggle

when connected, but should not come out if

pulled on.

• Insert the RJ45 Darkening Lens cable (from the

back of the Darkening Lens System) into the

ACC port (F) on the back of the welder. If using

a microscope, see page 5 for instructions.

• Connect the alligator clip to the Grounding port

(B).

• Place the Welding Stylus (A), which is already

connected to the back of the welder, to the side

for now.

• Adjust the Darkening Lens Shade by turning the

Shade dial above the Darkening Lens Screen.

Turn clockwise for a lighter shade and count-

er-clockwise for darker shade.

• Power on the welder by ipping the Power

switch (C) on the back of the welder.

Microscope Arm Mounting Options

If you purchased the Orion mPulse with a microscope,

carefully follow these instructions.

Mounting Option 1 - Clamp to Table

This option is best for tables with accessible edges and

for mounting without drilling holes in the table.

Note: If your table is thicker than 3-1/2” (9cm), follow

mounting option instructions 2 or 3 on the next page.

Hardware required from Box 2:

(1) Angled Bracket (C)

(1) Sunstone Microscope Arm Assembly (A)

(1) Clamp Mechanism (D)

(5) Flat Head Hex Screws (G)

• Lay the arm assembly down on a at surface.

• As shown in Figure 2.2, attach the Angled

Bracket (C) to the bottom of the Microscope

Figure 2.2. Attach Angled

Bracket (C) to Microscope

Arm Assembly (A).

Figure 2.3. Attach Clamp

Mechanism (D) to Angled

Bracket (C).

Figure 2.1. The back panel of the Orion mPulse. (A) Stylus

Cable. (B) Grounding port. (C) Power switch. (D) AC Power

port. (E) Argon gas port. (F) Darkening Lens System port.

A B C

D E F

Questions? Call or Text +1-801-658-0015 • 3

e Micro Welder Experts

Figure 3.1. Attach Clamp

Mechanism (D) to angled

bracket (C).

Figure 3.2. Cover the Clamp

Mechanism (D) with the

plastic cable guide cover (E).

Arm Assembly using three (3) of the included

at head hex screws (G) using a 4mm (5/16”)

Allen wrench (L).

• Attach the Clamp Mechanism (D) to the Angled

Bracket using two (2) of the included at head

hex screws. See Figure 2.3. For thicker tables,

attach the clamp mechanism (D) to the two

lower holes in the Angled Bracket (C).

• Adjust the knob on the Clamp Mechanism (D)

until the gap is sucient for the thickness of

your tabletop.

• Lock the arm into place by turning the knob

on the Clamp Mechanism (D) until the clamp is

pressing rmly against the bottom of the table.

• Lift the Microscope Arm Assembly (A) up, slide

the arm onto the table as shown in Figure 3.1.

• A plastic cable guide cover (E) can be clipped

on over the angled bracket if desired. See

Figure 3.2.

Mounting Option 2 - Bolt through Table

Mounting Option 2 is best for tables without accessible

edges. Hardware required from Box 2:

(1) Flat Mounting Plate (H)

(3) Flat Head Hex Screws (G)

(1) Long Carriage Bolt (F)

(1) Flat Pressure Plate (I)

(1) Adjustment Knob (J)

• As shown in Figure 3.3, using a 4mm (5/32”)

Allen wrench, unscrew the at head hex screws

(G) holding the Flat Mounting Plate (H) to the

arm.

• Run the included 8mm (5/16”) Long Carriage

Bolt (F) through the included Flat Mounting

Plate (H).

• Attach Flat Mounting Plate (H) to the bottom of

the arm using (3) at head hex screws (G).

• Drill a 3/8” (9.5mm) hole through the tabletop.

Figure 3.3. Remove the

plate from the arm, run

the carriage bolt (F)

through the mounting

plate (H), then re-attach

the mounting plate to

the arm.

Figure 3.4. Lower the

arm so the bolt goes

through the hole in the

table.

4• Questions? Call or Text +1-801-658-0015

Orion™mPulse User Manual

• Lower the arm so the Long Carriage Bolt (F)

goes through the hole in the tabletop. See

Figure 3.4.

• Slide the Flat Pressure Plate (I) onto the bolt.

Turn the Adjustment knob (J) clockwise to

tighten the plate to the underside of the table.

See Figure 4.1.

Mounting Option 3 - Screw to Table (vertical

surface)

Required hardware from Box 2:

(1) Angled Mount Bracket

(3) Flat Head Screws

(2) Wood Screws (not included)

• Attach the Angled Bracket (A) to the bottom of

the Microscope Arm Assembly (B) using three

(3) of the included at head hex screws (G) as

shown in Figure 2.2.

• Lift and position the arm assembly onto the

table in the desired location.

• Run wood screws through the Mounting

Bracket (A) and into a vertical surface of the

table, as shown in Figure 4.2.

ARM TENSION ADJUSTMENT

The spring tension is factory pre-set, but should chang-

es be desired, the tension can be adjusted by turning a

hex screw located on the arm joint, as shown in Figure

4.4. Use the included 6mm Allen wrench to make ad-

justments.

• Turn the hex screw counterclockwise (in the

direction of the “+” symbol on the arm) if the

arm does not hold the microscope up.

• Turn the hex screw clockwise (in the direction

of the “-“ symbol) if the arm does not allow the

microscope to be lowered easily.

For cable management, tubes and cables can be routed

through a removable guide as shown in Figure 4.5.

Figure 4.4. Adjust the tension of the Microscope Arm

Assembly for more loose or more tight movement.

Figure 4.5. Tubing and other cables can be routed up and

through the removable cable guide portion of the arm.

Figure 4.1. Turn the Adjustment knob (J)

clockwise to tighten the plate to the table.

Figure 4.2. Use wood screws (not

included) to attach the Angled

Mount Bracket (A) to the table.

Questions? Call or Text +1-801-658-0015 • 5

e Micro Welder Experts

Figure 5.1 After installing the rubber eyepiece covers, use the

RJ45 Shutter Cable to connect the welder to the back and

bottom of the microscope head.

MICROSCOPE SETUP

• Install the rubber eyepiece covers onto the

microscope lenses.

• Plug the included Shutter Cable into the RJ45

port on the microscope (the bottom of the

microscope head). See Figure 5.1.

• Plug the other end of the Shutter Cable into the

shutter port on the back of the welder.

Note: Connecting other RJ45 compatible devices to

the Orion mPulse shutter RJ45 port may damage the

welder and/or the other devices.

How to Adjust Microscope Focus

• Twist the knob on the microscope forward and

backward to lower and raise the head. This

will allow you to focus the microscope on the

welding stylus. See Figure 5.2.

• Place your nger under the welding electrode

to help judge the correct focus location. Focus

the microscope until the texture on the skin of

your nger is clearly visible.

How to Place the Welding Stylus

• If using a microscope with the Orion mPulse,

insert the Welding Stylus into the holder at the

bottom of the Microscope Arm Assembly as

shown in Figure 5.3 (Left).

• If using the Lens Darkening System, insert the

Welding Stylus into the holder located behind

the screen. See Figure 5.3 (Right).

• The tubing can be routed up and through the

removable cable guide portion of the Micro-

scope Arm Assembly if desired. See Figure 4.5.

• For now, position the Welding Stylus such that

only the smaller diameter portion protrudes

from the holder, as shown in Figure 5.4. Then,

tighten the thumb screw on the bottom of the

stylus holder to hold it in place. See page 6 for

detailed electrode setup.

Figure 5.3. Styling mounting for microscope (Left) and for the

Darkening Lens System (Right).

Figure 5.2. Turn this knob

to adjust microscope

focus. You’ll nd one

knob on each side of the

microscope arm.

Figure 5.4. Only a small portion

of the electrode should extrude

from the holder.

6• Questions? Call or Text +1-801-658-0015

Orion™mPulse User Manual

• Rotate the stylus holder to approximately a 45-degree angle as shown in Figure 5.3 (the stylus should

be angled down).

• Fine tune the position of the Welding Stylus while looking through the microscope: Loosen the thumb

screw on the bottom side of the stylus holder and slide the Welding Stylus forward and backward until

the tip of the Welding Stylus is in the center of your focus. See the example in Figure 5.4.

• Now securely tighten the Welding Stylus in place by tightening the thumb screw on the bottom of the

stylus holder.

Figure 6.2. To install the electrode, rst remove the Stylus

Shaft (A) from the Stylus Hull (E) by pulling them apart.

Figure 6.3. Use the guide engraved on the side of the Stylus

Hull (E) for proper Electrode (D) positioning.

Stylus Shaft A Collet B Collet Cap C Electrode D Stylus Hull E

Stylus Components

Figure 6.1

Electrode Setup

The Orion mPulse comes standard with a 1.0mm elec-

trode collet and ten (10) 1.0mm electrodes. The 1.0mm

electrodes are a good multipurpose electrode for most

welding applications. Available separately, Sunstone of-

fers 0.5mm electrodes, which are more suited for very

small applications (less than 5 Ws of energy).

INSTALL THE TUNGSTEN ELECTRODE ONTO

THE WELDING STYLUS

Refer to the Stylus Components Chart (Figure 6.1) to

install the tungsten electrode (D).

• Remove the stylus hull (E) by pulling it away

from the Stylus Shaft (A). See Figure 6.2.

• Loosen the Collet Cap (C) by twisting it counter-

clockwise.

The welder accommodates 0.5mm and 1.0mm elec-

trodes. The electrode stylus will be shipped with the

1.0mm electrode collet (B) installed.

• Insert a 1.0mm electrode (D) into the Collet (B).

Helpful Tip: There is a engraved guide on the

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