9OrionWelders.com
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
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.
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