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AHP alphaCUT 825i User manual

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OPERATOR’S MANUAL
SAFETY AND USE INSTRUCTIONS
alphaCUT 825i
Serial Number
Purchase Date (Attach Receipt to Cover For Proof of Purchase)
Need Information?
Contact:
[email protected]
925-391-3599
Technical Issues?
Contact:
[email protected]
925-391-3599 (Ext. 102)
Issue Date: 04/12/2023
Publication: AHP825i-103
© Ahp Welding Systems 380 Swift Ave. #11 South San Francisco, CA 94080
2
CONTENTS
Shipping Issues? 3
CA Proposition 65 Warning 4
Safety First Information 5
Safety Warning, Dangers, Cautions and Instructions 6
About the Alpha TIG 203Xi 9
Warranty Statement 9
Specifications 10
Generator Operation Information 11
Duty Cycle Performance 11
Routine Required Maintenance 11
HF Point Gap Maintenance 12
TIG Shielding Gas Information 13
TIG Polarity and Tungsten Type 14
Tungsten Preparation 15
Stick Polarity and Electrode Types 15
Front Panel Features 17
Rear Panel Features 17
Control Panel Features 19
LCD Screen Features 21
Using AC Controls in TIG Welding 23
Using 2T/4T/Pedal Functions 24
Pulse Use and Operation 25
Starting the TIG Arc 26
Welding in Stick Mode 27
Useful TIG Settings 28
26 Series Air-Cooled TIG Torch Information 29
Pinout Connector Information 29
Trouble Shooting 30
3
IMPORTANT! This unit has been thoroughly tested and inspected for function at the factory. However, you should be prepared to inspect
and test this unit completely within 72 hours after receipt. Please do not delay in doing this. Ahp needs to know if there is any damage
caused in shipping as soon as possible. Damage caused by shipping and discovered after 30 days due to lack of inspection will not be
covered under the free 30 day shipping policy.
Please contact us immediately should you have any questions or concerns about the plasma cutter after delivery. We’ll be glad to help.
SHIPPING ISSUES?
4
WARNING!
California Proposition 65 Warning:
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, can-
cer. (California Health & Safety Code § 25249.5 et seq.)
Warning: Cancer and/or Reproductive Harm
www.P65warnings.ca.gov
NOTICE:
Due to our constant effort to improve our products, specica-
tions are subject to change without notice or revision to this
manual. In addition, minor changes in product cosmetics,
accessory type and quantity may change without notice.
These do not constitute a major change in function or opera-
tion.
Ahp Welding Systems makes no warranty for merchantability
or tness for a particular purpose or application. Any claims
of such are expressly denied by Ahp Welding Systems. Fur-
thermore, Ahp Welding Systems does not accept liability for
injury or damages, consequential or incidental, resulting
from the use of this product or resulting from the content
found in this document or accept claims by a third party of
such liability.
5
SAFETY FIRST!
Ahp Welding Systems takes safety seriously. You should as well. Please read
this entire manual before using. Keep a copy of this manual available for all
employees or potential users of this machine to read and thoroughly review
before use.
No matter how detailed may be nothing can substitute for careful planning
and common sense required to operate and safe work environment.
Welding is an inherently dangerous activity. Failure to follow safety protocols
while welding may result in severe burns, blindness, severe shock, or death
from electrocution.
BE AWARE OF YOUR WORK AREA AND THE WHO OR WHAT IS IN IT!
AS THE USER OF THIS PRODUCT YOU ARE RESPONSIBLE FOR YOUR OWN
PERSONAL SAFETY AND FOR THE SAFETY AND SECURITY OF THE PEOPLE
AND ITEMS AROUND YOU!
If you feel you do not have the resources to provide a safe work environment,
or do not have the skills or (for whatever reason) the capability to safely oper-
ate this unit, do not use this unit until you seek professional instruction in safe
operation and care of this unit.
NOTICE:
Welding and cutting operations may generate undesira-
ble High Frequency (HF) and EMF energy. This can in-
terfere with surrounding electronic equipment such as
computers, routers, CNC equipment, televisions, radios,
uorescent lighting etc. If disturbance in surrounding
electrical and electronic equipment is noted, consult a
licensed electrician to help properly ground surrounding
equipment to limit the interference. This machine may
cause GCFI and ground fault outlets to malfunction.
This unit is designed to be operated on a dedicated,
properly grounded circuit.
6
Safety Warnings, Dangers, Cautions and Instructions
NOTICE: This unit manual is intended for users with basic knowledge and skillset in welding and
cutting operations. It is your responsibility to make certain that the use of this cutter is restricted to
persons who have read, understand and follow the warnings and instructions in this manual. If you
or the operator needs further instruction, contact AHP welding support or seek qualified professional
advice and training.
WARNING! High Frequency (HF) energy can interfere with the operation of pacemakers and can dam-
age pacemakers. Consult with your physician and pacemaker manufacturer before entering an area
where welding and cutting equipment is in operation and before using this cutter. Some pacemak-
ers have limited shielding. Alert any users or customers of this potential problem.
WARNING! Use approved safety glasses with wrap around shields and sides while cutting and work-
ing in the weld area or serious eye damage or loss of vision may result. Use a grinding shield in
addition to the safety glasses during chipping and grinding operations. Have other workers in the
area use at least a shade 5 for indirect viewing of cutting work.
WARNING! When always use an approved welding helmet or shielding device equipped with at least
an equivalent of a shade 8 or greater when directly viewing the cutting arc. Increase the shade
number rating as amperage increases to 80 amps. Inspect helmet or shielding device for cracks in
lenses and in the helmet. Keep lens covers in good condition and replace as necessary.
WARNING! Welding/cutting operations carry inherent risks which include but not limited to possible
cuts burns, electrical shocks, lung damage, eye damage and even death. Take all appropriate
measures to use proper Personal Protective Equipment (PPE). Always use leather welding gloves,
closed toe (preferably reinforced or steel toe leather shoes, and long-sleeved flame resistant clothing
(i.e. denim). Do not wear Poly/Nylon blend materials.
DANGER! Welding/cutting poses shock and electrocution risks. Keep this welding equipment dry. Do
not weld in the rain or where moisture accumulates. Use dry, rubber soled shoes, gloves and cloth-
ing when welding. Do not rest or contact work clamp (ground) when welding. Keep all parts of the
body insulated from the part being welded when possible. Do not touch terminals or connections
while the unit is on. Consider all parts to be “live” at all times even if no live work is being per-
formed. Do not use frayed welding cables.
CAUTION! Fires are possible but also preventable while welding. Always remove flammable rags,
papers, and other materials from the weld area. Keep rags stored in an approved flame proof canis-
ter. Keep a fully charged fire extinguisher at hand. Remove any fuels, oils, paint, pressurized spray
cans, and chemicals from the weld area. Make sure any smoke/fire detectors are function properly.
Do not weld on tanks, drums or barrels, especially if pressurized or sealed. Do not weld on any con-
tainer that previously held fuel or chemicals. Make sure the weld area is clear of flammable materi-
als such as grass or wood shavings solvents and fuels. Do not wear frayed or loose clothing. Visual-
ly inspect and recheck the work area after welding looking for smoldering debris or flames.
WARNING! Welding gas cylinders are under high pressure. Keep all gas cylinders upright and
chained to a cart or held safely in a safety holding pen. Never transport gas cylinders in an enclosed
car van or other vehicle. Transport gas cylinders securely. Keep all cylinders capped while not in use
or during transport. Replace the cap on the cylinder when it is going to be more than 24 hours be-
fore use. Do not use or attempt to repair faulty regulators. Never weld on gas cylinders. Keep gas
cylinders away from direct sparks.
7
Safety Warnings, Dangers, Cautions and Instructions
DANGER! Welding and cutting operations pose serious inhalation hazards. Some of these hazards
are immediate while others are cumulative in their effect. Do not weld in enclosed spaces or in
areas without adequate ventilation. Fumes and gases released in the welding and cutting opera-
tions can be toxic. Use fans or respiration equipment to insure adequate ventilation if you are
welding in a shop or garage area. Do not weld on galvanized metal under any circumstance. You
may develop metal fume fever. Symptoms are similar to lu-like symptoms. Seek medical advice and
treatment if you are exposed to galvanized welding fumes.
If you experience any eye burning, nose or throat irritation while welding, these are signs that you
need more ventilation.
If you feel these symptoms:
• Stop work immediately and relocate work area with better ventilation.
• Wash and clean your face and hands.
• Stop work completely and seek medical help if irritation persists
DANGER! Never use brake cleaner or any chlorinated solvent to clean or degrease metal scheduled
to be welded or other related equipment in the area being welded. The heating of this cleaner and
its residue will create highly toxic phosgene gas. Small amounts of this vapor are harmful and can
lead to organ failure and death. If degreasing of a part is necessary, use Acetone or an approved
pre-weld cleaner. Use the proper personal protective equipment (PPE) when handling any cleaners/
solvents.
DANGER! People with pacemakers should consult a physician and pacemaker manufacturer before
welding. There is a potential for damage or serious malfunction resulting in death. High Frequen-
cy energy (HF)/Electromagnetic Fields generated during welding can interfere with pacemaker sig-
nals, even permanently damaging it. Some pacemakers offer some shielding, but restrictions re-
garding amperage and HF starting of TIG arcs may be placed upon the individual. Warn all poten-
tial bystanders that they should exit the work area if they have a pacemaker or similar medical
equipment before welding. Severe electrical shock leading to injury or death may occur while using
the plasma cutter if the user becomes part of the circuit path. While the Amp output of the plasma
cutter is limited, the unit may produce an OCV of 300V or greater. Consult with a Physician if a
pacemaker is expected to be implanted.
DANGER! Never defeat or modify any safety guards or shields. Keep all safety covers and shields
in place.
Never place your fingers in or near a fan shroud or insert any object into the fan(s).
CAUTION! Trip Hazards exist around welding and cutting operations. Cords, cables, welding leads
and hoses pose a trip hazard. Be aware of their location and inform others of their location. Tape
and secure them so they will stay out of high traffic areas.
8
Safety Warnings, Dangers, Cautions and Instructions
CAUTION! Welded metal can stay hot long after welding is completed. Burns may occur. Always
wear gloves or use tongs/pliers when handling welded or cut metal. Remember the heat from the
metal may catch other material on fire. Always have a fire-proof area ready to place welded compo-
nents until they fully cool. Use soap stone or a metal marking marker to label the metal as “HOT”
to serve as a reminder to all present in the area.
CAUTION! Welding and cutting operations generate high levels of ultraviolet (UV) radiation which
can burn and damage skin and eyes. The intensity is so high that exposed skin and eyes can burn
in a few minutes of exposure. Minimize direct skin and eye exposure to this intense form of radia-
tion by using proper PPE and sun screen where appropriate.
CAUTION! Do not allow untrained, unqualified bystanders to observe welding. Do not allow others
without proper Personal Protection Equipment (PPE) suitable for welding to stand in the welding
area or to observe welding and welding related activities. If protection is not readily available, use
a welding screen to separate the welding area from the rest of the area. If no protection or screen
is available, physically exclude them from the welding area by a wall or other solid divider. Keep all
pets and young children away from the welding area.
CAUTION! Electromagnetic Fields can be generated by this plasma cutter and can radiate into the
work place. The effect of EMF is not fully known. Exercise caution when welding by: NOT draping
welding leads (guns/cables) over your shoulders or arms, NOT coiling them around your body, NOT
inserting yourself directly between the cables, and by NOT contacting the unit while welding. DO
keep the work clamp connected as close as possible to the area of the weld and directly to the
object being welded whenever possible.
DANGER! Never touch connectors or fittings while this machine is turned on. Keep all safety covers
in place when not in use.
9
Specications and Need-to-Know Information
alphaCUT 825i
AlphaCut 825i Specifications
Input Voltage Operating Range OCV
120V (± 10%) 20-30A, 88-92V 300V
240V (± 10%) 20-60A, 88-104V 300V
Input/Output Operating Range
Duty Cycle Range
Input Voltage 35% 60% 100%
120V (± 10%) 30A/92V 25A/90V 20A/88V
240V (± 10%) 60A/104V 50A/100V 40A/96V
Input Demand Inrush / Rated Effective Current
Consult a local, licensed electrician before wiring your electrical connections.
Reference Article 630 of the NEC for correct wiring code information.
Voltage I1Max / I1Eff (Inrush/Rated)
120V 36A / 22A
240V 41A / 25A
Feature Range
Start Type Blow-Back Style (Contactless, Non HF)
Torch Type Innotec iPT 60
Process Plasma Cutting (A-PAC)
Amp Control Manual Knob
Post-Flow Adjustable 0-60 Seconds
Pilot Arc Auto Restart and 3 Second Tip Saver
Air Pressure (while actively cutting) 65-72 psi
Supply Pressure From Compressor No more than 95 psi
Air Compressor Requirement 5.3 CFM @ 90 PSI with 25 Gallon tank capacity
3/8” hose minimum up to 25 ft.
For distances longer than 25 ft. use 1/2” hose.
Feature and Range
Weight / Dimensions / Other
50 lbs. / 18” H X 9.5” W X 17” L / Ingress Rating IP21S
Use between 14 F and 104 F
Store between 0 F and 120 F
.
NEMA 6-50P
This unit uses a NEMA 6-50P for 240V use. This is the standard welder
and plasma cutter plug for 240V 1 phase use in North America.
This unit is supplied with a 240V to 120V pigtail adapter. No internal
adjustment or change is required to use it on 120V. Simply install the
adapter. The unit will adjust automatically.
IMPORTANT: Be responsible. Consult a local, licensed electrician
before wiring your electrical connections.
Reference Article 630 of
the NEC for correct wiring code information. The code is different for
wiring a welder/plasma cutter circuit than for household circuits.
CAUTION:
Do not use with 240V extension cords over 50 feet long or that are
rated for less than 40A use as damage may result. For 120 opera-
tion, use only with 40A rated cords, less than 25 feet in length.
NOTICE:
This unit uses a full time fan. It is not an “on demand” or thermostat-
ically controlled fan. However, noise level is moderate. To reduce
overall noise level while operating, mount the air compressor outside
of the work area, or use a queiter oil type compressor rather than an
oilless compressor.
10
Specications and Need-to-Know Information
alphaCUT 825i
About the AlphaCUT 825i
The AlphaCUT 825i is well-suited for day to day cutting tasks in the
small shop and home garage. The duty cycle of the machine (35% at
60A) offers more than enough duty cycle to handle regular, daily
cutting chores. The design is simple and intuitive, lending itself to
perform well in situations where there are multiple or beginning us-
ers.
The unit comes standard with the following features:
• Dual Voltage 120/240V operation capability
• 60A max output for cutting nearly all metals
• 2T/4T Torch switch operation capability
• Adjustable post-flow timer
• Auto restart pilot arc or Tip Saver Pilot Arc
• Gas purge function
• Modern Blow-back type arc starting
• 20 Amp minimum operation
• Air Pressure Gauge
The unit comes standard with the following accessories:
• Innotect iPT 60 Plasma Torch, 14 ft.
• Work clamp and cable, 9 ft.
• Combination air pressure regulator/water trap
• 240 to 120V pigtail adapter
• 60A consumable starter kit
Ahp Warranty Statement
WARRANTY ONLY APPLIES TO UNITS WITH PROOF OF PURCHASE
FROM AN AUTHORIZED DEALER. NO EXCEPTIONS. PLEASE FEEL FREE
TO REQUEST A LIST OF AUTHORIZED DEALERS.
All new AHP welders and plasma cutters, shall be warrantied to the
original owner for a period to extend for 3 years from date of pur-
chase against breakage, malfunction, or other unit failure resulting
from manufacturing defect. The faulty unit will either be repaired or
an exchange will be made for a new or factory reconditioned unit at
AHP Welds discretion. The customer must contact the technical sup-
port team to review unit failure so that the warranty claim can be
established. Items such as electrodes, contact tips, nozzles, cups,
shields, liners etc, considered to be consumable items, are NOT cov-
ered under warranty. Torches, foot pedals and spool guns are warran-
tied for a period of 6 months. Additionally, certain items such as
torches, foot pedals and easily serviced parts may be individually
exchanged without returning the entire unit assembly should a fail-
ure with these items occur, at AHP Welds discretion. AHP Welds will
not be responsible for time/contract loss from unit failure, damages
occurring from improper or unskilled operation, damages resulting
from improper maintenance, improper wiring, poor quality power
sources, abuse or neglect. Nor will AHP assume responsibility for the
customer's failure to heed/read safety instructions, to read and un-
derstand operator's manual, obey occupational laws or to ensure the
unit's safe operation complies with state or local laws, personal injury
arising from the inherent risks involved with welding, including
burns, electric shock or death. Warranty extends only to the machine,
its accessories and parts contained inside as stated above. No other
warranty is expressed or implied.
In the event of unit failure or malfunction, the customer must contact
AHP to obtain a location of a designated return/repair facility. The
replacement unit will then be returned to the customer. AHP will
cover the shipping charges both ways for domestic customers that
have units in need of warranty within the first 30 days from the pur-
chase date. After the 30 days from the purchase date, the customer
shall be responsible for all shipping and handling costs both ways of
non-functioning units for repair or replacement. Customers located
outside of the USA lower 48 states will have to pay shipping and han-
dling charges both ways from the purchase date. It is the customer's
responsibility to adequately insure the unit, as AHP is not responsible
for lost or damaged returns. Labor coverage only applies if the unit is
serviced at our facility or one of our authorized dealers. We will not
reimburse the labor if the customer decides to have a third-party or
unauthorized repair technicians work on the unit.
NOTICE:
Ahp’s TIG products are designed for use by individuals with
a professional knowledge base in TIG and Stick welding and is de-
signed with commercial operation in mind. Ahp cannot be held ac-
countable for instruction and training of inexperienced users or dam-
age or malfunctions that may result from use by inexperienced users
or improper installation. If you do not have the skill level or
knowledge base to properly operate and install this machine, do not
use this machine until proper training and instruction has been re-
ceived.
View full warranty, terms of sale and shipping details here:
https://ahpwelds.com/
NOTICE:
Output on 120V will be limited to 30A. This unit is supplied with 60A consuma-
bles. To operate on 120V, you’ll need to purchase 20 or 30A rated consumables.
With a 60A consumable installed while operating on 120V, arc operation will be
erratic and unstable.. See torch page for Amp ranges of consumables.