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System:
Orion Pulse 1500s - Pulse arc and resistance welder
12awg weld cable on an industrial stylus (3/32" tungsten electrode)
6awg ground cable with alligator clamp and ¼" angled copper probe

Weld 1: Inductor
The Orion 1500s is configured with an industrial weld stylus with 12awg weld cable gauge and a 6awg ground cable gauge. The 3/32" tungsten electrode is tapered at the tip and blunted about half way up the taper. The ground cable has an alligator clamp at one end which holds an angled ¼" copper probe to allow access to each terminal during the welds.

The inductor wires are welded with the 1500s set at 550ws energy with a length of 200ms. The closer the tip of the wire is to the edge of the terminal, the easier the weld will be to perform. Additional welds can be made to increase the welded joint area if desired.

Weld 2: Capacitor
The capacitor wires are welded at 500ws energy and 60ms length. These welds are easy to perform, but would be more simple if the wires were clipped closer to the hole prior to welding.

Weld 3: Resistor
The resistor wire welds are performed at 500ws energy and 60ms length. The wire extends about the right amount for good closure of the hole and minimal wire loss during the weld.

Weld 4:
These lead wires are also welded at 500ws energy and 60ms length.

Summary:
These weld samples were very easy to accomplish using the Orion 1500S. Trimming component legs to a small height above the surface will improve weld effiency on the smaller components. The inductor welds work best when the inductor leg and the tab are at the same height before the weld takes place.

Let us know if you have any questions.
Call or Text: +1-801-658-0015
Email: sales@SunstoneWelders.com
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