SUNSTONE Orion 50p User manual

Orion 50p Welding System

User Manual

3OrionWelders.com

Table of Contents

Chapter 1: Welder Setup .......................... p.5

What is in the Box ............................ p.5

Power Supply Setup .......................... p.6

Chapter 2: User Interface ........................ p.7

Overview ...................................... p.7

Chapter 3: Sample Project ....................... p.8

How to make your ﬁrst weld .................. p.8

Chapter 4: Safety ................................ p.9

Overview ...................................... p.9

Chapter 5: FAQ ................................... p.12

Overview ...................................... p.12

Chapter 6: Speciﬁcations ........................ p.13

Speciﬁcations ................................ p.13

50p User Manual

5OrionWelders.com

Chapter 1: Welder Setup & Assembly

What is in the Box

ORION 50p:

(1) Orion 50p Power Supply

(1) Power Supply Power Cord

(2)Negative and Positive Cable

(1) Foot Pedal

(1) Post Weld Head

50p User Manual

Power Supply Setup

SETUP

1. Unbox the welder and weld head

2. Connect cables to the back of the welder:

a. Port 1 is an 8-din connector. Connect the cable from the weld head

into this port.

b. Port 2 is a 3-din connector. Connect the foot pedal or the double

hand trigger into this port.

c. Terminal 3 is the positive terminal. e positive cable should be

attached to the workpiece, or to the grounding foot if equipped.

d. Terminal 4 is the negative terminal. e negative cable should be

attached to the brass post holder on the weld head.

e. Port 5 is the power inlet port. Connect a power cable here, and

then connect to a wall outlet. e welder can be connected to 100-

240VAC. e connector has a 10A fuse.

f. Switch 6 is the power switch. Switch it up to turn the unit on, or

down to turn it oﬀ.

3. Weld Head Adjustments

a. e weld head height can be adjusted by loosening the two adjustment knobs on the right of the weld head.

b. To set the height, pull down on the block holding the brass post holder. With the post holder all the way down,

lower the weld head until the post holder makes contact with the weld surface. Next, lower the weld head

slightly more, until there is a gap of approximately 0.1” to 0.125” between the top of the block and the cotter pin.

c. If not already completed, connect the positive cable to the grounding block, the workpiece, or the grounding

foot if equipped.

d. If not already completed, connect the negative cable to the brass post holder.

7OrionWelders.com

4. Turn the unit on using the power switch on the back of the welder.

a. If needed, the touchscreen can be recalibrated. To do so:

i. Turn the welder oﬀ

ii. Touch and maintain contact on the screen while turning the welder on

iii. Once the calibration menu appears, follow the on-screen instructions

iv. A series of red dots will appear on the screen. Touch each dot on the

screen.

v. Once this is done, there will be a test screen to draw on to verify the

calibration

vi. If the calibration is accurate, click the complete button. If not, you may

recalibrate and try again.

Chapter 2: User Interface

User Interface

OVERVIEW

1. Weld Screen

a. ere are two slider bars on the weld screen. ese

control the weld voltage and the speed of the weld

head. Higher voltages will result in bigger welds. Note

that too much energy can have a negative eﬀect

on the weld. Also, excessive speed can also have a

negative eﬀect on the weld. It is recommended to make

adjustments to only one slider at a time. As a starting

point, set the voltage to 105V and the speed to 39in/sec.

b. e Play/Pause button on the bottom of the screen

will turn the weld voltage on or oﬀ. In a pause state, the

welder will not weld because the voltage is turned oﬀ

and not allowed to discharge.

c. e lock icon on the screen will allow a user input

a PIN number to lock the current voltage and speed

settings. Changes will not be allowed until the welder is

unlocked using the original PIN number.

50p User Manual

2. Settings Screen

a. Audio Signals - Turn the audio signals on or oﬀ here.

b. Laser Targeting - e weld head has a laser pointer

mounted inside. is is to be used to align the post

above the workpiece. is button will turn the laser on

or oﬀ.

C. Erase Pin - Touch here to erase the set pin code.

Chapter 3: Demo Sample Project

Demo Sample Project

TO MAKE YOUR FIRST WELD, FOLLOW THESE STEPS:

1. Set the weld head height according to the instructions found in the setup section of the user manual.

2. Place the workpiece on the grounding block and make sure it has adequate contact with the positive terminal, clip,

or grounding foot if equipped.

3. Position and align the workpiece using the laser alignment in the weld head. If a red dot laser is not visible, ensure

that there is no post in the brass post holder, ensure that the laser is turned on by clicking to the settings screen on

the welder, and/or ensure that the brass post holder is properly aligned.

4. Once the workpiece is positioned under the weld head, insert a post into the brass post holder. e post will be

held in place by a ball bearing being held tight by a rubber o-ring. If the post seems loose, remove the post and push

inward on the ball bearing and rubber o-ring. en reinsert the post. Note that once the post is inserted, the laser

pointer will no longer be visible.

5. Next, set the weld parameters on the welder. Navigate to the weld screen, adjust the voltage to 100V and adjust

the speed to 39in/sec. Tap the Play/Pause icon to put the welder into the “Play” state.

6. Finally, make sure that all hands and objects are safely away from the weld head, and then initiate the weld either

by stepping on the foot pedal, or pressing both buttons on the double button trigger. e weld head should slam

down, make a weld, and then return to the starting position.

9OrionWelders.com

Chapter 4: Safety

Safety

EYE PROTECTION:

When operating this unit, use eye protection. Weld splash can occur, which can be harmful to eyes.

PINCH POINTS

ere are a few diﬀerent pinch points on the weld head.

If equiped with a grounding foot, the above circled spot on

the unit can be adjusted vertically. When being adjusted, be

sure not to put your hand or other extremities underneath.

e brass post holder on the weld head will descend

automatically once a trigger from welder has been actuated.

Once triggered the portion of the head will come down

with great speed and force. Do not stick hand or other

extremeties underneath while operating. We suggest to

use our two hand switch system to avoid any pinching or

breaking of extremeties.

When manually adjusting height of weld head keep hands

and extremities away from the edges where slippage can

occur.

50p User Manual

Area between brass post holder block and the body of the weld

head will be exposed for short periods of time during a weld. e

post holder block will drop down and go back up very quickly, so

avoid putting hands and extremities near this area of equipment

when operating.

ELECTRIC SHOCK

ere is a potential between the positive and negative terminals

of the weld head of up to 170VDC during the welding process.

Note that unlike other similar welders, voltage is only live after

the trigger is initiated by either the foot pedal or double button.

We suggest using our double button switch system in order to

avoid any potential electrical shock. Never touch both of these

areas with exposed skin, while triggering a weld. If you want to be

able to hold the workpiece, we suggest using isolated gloves or

tools that are not conductive.

TIPPING OVER:

is unit may be top heavy and can tip over. In order to prevent

this we suggest that you mount it to a table or ﬁxture.

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