100c
User Manual
16
ch
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1
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 . A video explanation
of the steps below can be found at
http://www .orionwelders .com/resources/orion-c-series-
resources/
1 . Completely remove the electrode from the stylus .
2 . Pinch the electrode between the thumb and middle finger with the point facing inward .
3 . Turn the Dremel or flex shaft on then hold it with the opposite hand . *If the Dremel is in the
left hand, then sharpen the electrode on the side of the diamond disk furthest
from the body . If the Dremel is in the right hand, then sharpen the electrode on
the side of the diamond disk closest to the body . The reason for this is to keep the
striations on the electrode moving towards the electrode point, not away . This will
effect the quality of the weld if not done as explained above .
4 . 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 .
5 . 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 .
6 . Once the electrode has a flat/blunt tip, turn the Dremel off and insert the
electrode back into the stylus as explained above .
See the Orion Workbook for additional details about the Tungsten Electrodes .
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 . This can be purchased at your local welding
supply shop .
PRESSURIZED GAS SAFETY
There are several important rules that should be followed when using a compressed shielding gas
such as argon .
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 . This will help
your shielding gas supply last longer in case there is a small leak in the tubing . This is also
