Orion Welders mPulse - User Manual

Follow these steps before welding. ese are also great
troubleshooting steps to follow if you feel like your welds are not
consistent or not looking the way you think they should.
STEP 1: Check the Gas Pressure
• Gas is at 8 - 12 psi
STEP 2: Shape the Electrode
• Hold the dremel in one hand (close to the body for support)
and the electrode in the other hand.
• Place the electrode on the diamond disk at a 45 degree angle
and spin it to sharpen.
• Make sure the striations in the electrode are horizontal.
STEP 3: Verify Electrode Length
• e electrode should stick out of the Stylus Cone 4 - 6 mm
(1/8 - 1/4”). Make sure the Stylus Cone is pushed in all the
way (you will feel it click into place and bottom-out).
STEP 4: Verify the Darkening Lens Setup
• Darkening Lens cable is securely connected to the welder.
• Electrode is centered in your field of view and in focus.
• Electrode is at a height where you can rest your hands on the
baseplate and lift your work piece up with your fingers.
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Orion Welders - mPulse Getting Started
STEP 5: Welder Settings and when to use the Reset Button
• Before beginning any weld, double check the energy level.
• Verify Energy and that the play button is showing before
beginning a weld. *Settings on p.2
STEP6: How to Touch the Electrode to the Work piece
• Clip the alligator clip to the workpiece.
• Rest your hands on the table under the darkening lens.
• Position the work piece so that it is right under the electrode
then look through the lens.
• Lightly lift your fingers up and touch the work piece to the
electrode (the electrode will retract after it is touched).
• Hold the work piece steady after touching the electrode - if
you pull the work piece away after touching the electrode, it
will not weld. If you follow the electrode with the work piece
while it is retracting, the electrode will stick to the work piece.
STEP7: How to Set up the Work pieces for Welding.
• When closing a jump ring, or welding two pieces together;
make sure the two sides are pushed together and flush
before welding.
• When adding material, touch the wire to the work piece at a
45-degree angle then enter the electrode in at a 90-degree
angle. Touch the electrode between the work piece and the
wire.

Orion Welders mPulse Specifications

General

TIG Lift Arc	Yes
Welding Type	Stick
Material Compatibility	Steel, Stainless Steel, Aluminum
Display	Digital
Output Current Range	5 - 200 A
Duty Cycle	60% at 200 A
Welding Processes	TIG, Stick

Summary

Core Welding Procedures

Check Gas Pressure

Verify gas pressure is set between 8-12 psi before welding.

Shape the Electrode

Sharpen the electrode to a 45-degree angle using a diamond disk, ensuring striations are horizontal.

Verify Electrode Length

Ensure the electrode extends 4-6 mm from the Stylus Cone, pushed fully in.

Verify Darkening Lens Setup

Confirm lens connection, electrode focus, and comfortable hand positioning for welding.

Set Welder Energy

Double-check energy level and ensure the play button is visible before welding.

Touch Electrode to Workpiece

Clip workpiece, position under electrode, and lightly touch to retract electrode.

Set Up Workpieces for Welding

Ensure pieces are flush. For adding material, use a 45-degree angle for wire and 90-degree for electrode.

General Settings for Metals and Applications

26 AWG Wire;Chain;Jump Ring Settings

Recommended energy settings for welding 26 AWG wire, chain, or jump rings with various metals.

Earring Post Settings

Specific energy settings for welding earring posts with different metals, often using a T joint.

0.5 mm Thick Ring Settings

Energy and tip shape recommendations for welding 0.5mm thick rings on various metals.

1 mm Thick Ring Settings

Energy and tip shape recommendations for welding 1mm thick rings on various metals.

2 mm Thick Ring Settings

Energy and tip shape recommendations for welding 2mm thick rings on various metals.

Add Material (24 AWG Wire) Settings

Settings for adding material with 24 AWG wire at a 45-degree angle to the workpiece.

Add Material (30 AWG Laser Wire) Settings

Settings for adding small amounts of metal using 30 AWG wire for precise material addition.

Retip Prong Settings

Energy and tip shape recommendations for retipping prongs on various metals.