Ahp Alphatig 225xi User manual

OPERATOR’S MANUAL

SAFETY AND USE INSTRUCTIONS

alphaTIG 225Xi

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: 04/01/2020

Publication: AHP225XI-101

CONTENTS

Shipping Issues? 3

CA Proposition 65 Warning 4

Safety First Information 5

Safety Warning, Dangers, Cautions and Instructions 6

About the Alpha TIG 225Xi 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

Using AC Controls in TIG Welding 22

Using 2T/4T/Pedal Functions 23

Pulse Use and Operation 24

Starting the TIG Arc 25

Welding in Stick Mode 26

Useful TIG Settings 27

26 Series Air-Cooled TIG Torch Information 28

Pinout Connector Information 29

Trouble Shooting 30

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 welder after delivery. We’ll be glad to help.

SHIPPING ISSUES?

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.

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.

Safety Warnings, Dangers, Cautions and Instructions

NOTICE. This unit manual is intended for users with basic knowledge and skillset in welding. It is

your responsibility to make certain that the use of this welder 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 Everlast welding support at 1-877 755-9353 ext. 204 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 welder. 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 welding 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.

WARNING! When welding always use an approved welding helmet or shielding device equipped with

at least an equivalent of a shade 9 or greater. Increase the shade number rating as amperage in-

crease over 100 amps. Inspect helmet 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-

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.

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 ap-

proved 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 welders. 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.

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 welder and 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.

Specications and Need-to-Know Information

alphaTIG 225Xi

About the AlphaTIG 225Xi

The AlphaTIG 225Xi is the latest evolution of the long running Al-

phaTIG series. It utilizes the latest in digitally controlled IGBT invert-

er welding technology, while providing the user with a mostly manual

interface. This unit is great for users who tend to use a few different

settings and like to be able to see and determine their settings at a

glance, but who still desire the simplicity and reliability of a internal

digital design.

The unit comes standard with the following features:

• Dual Voltage 120/240V operation capability

• 225A AC and DC TIG output for welding all metals

• 185A AC and DC Stick output

• TIG AC Frequency adjustment

• TIG AC Balance adjustment

• 2T/4T Torch switch operation capability

• Foot Pedal operation

• HF or Lift Start Modes for TIG arc starting

• AC and DC Pulse in TIG mode

• 10 Amp DC minimum start

• 20 Amp AC minimum start

• Water Cooler Plug in the rear

The unit comes standard with the following accessories:

• Nova Long Life Foot Pedal (Low Profile)

• 26 Series Gas-Cooled TIG torch,12.5 ft cable, 35-70 DINSE style

adapter

• Basic consumable kit for TIG torch (Tungsten not included)

• Billet Brass Floating Ball type regulator

• Stick Electrode holder, 9 ft cable, 35-70 DINSE style adapter

• 2T/4T torch switch

• 250A Work Clamp, 6 ft cable, 35-70 DINSE style adapter

• 240V to 120V step down power cord pig-tail adapter

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, shall be warrantied to the original owner for a

period to extend for 3 years from date of purchase against breakage,

malfunction, or other unit failure resulting from manufacturing de-

fect. 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 support 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 covered under warranty. Torches,

foot pedals and spool guns are warrantied 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 failure 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 understand operator's manual, obey occupa-

tional 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 ex-

tends 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/

Specications and Need-to-Know Information

alphaTIG 225Xi

AlphaTIG 225Xi Specifications

Input Voltage Welding Process Operating Range OCV

120V (± 10%) DC TIG 10-150A, 10.4-16V 75V

120V (± 10%) AC TIG 20-150A, 10.8-16V 75V

240V (± 10%) DC TIG 10A-225A, 10.4-19V 75V

240V (± 10%) AC TIG 20A-225A, 10.8-19V 75V

120V (± 10%) DC Stick 10-125A, 20.4-25V 75V

120V (± 10%) AC Stick 20-125A, 20.8-25V 75V

240V (± 10%) DC Stick 10-185A, 20.4-27.4V 75V

240V (± 10%) AC Stick 20-185A, 20.8-27.4V 75V

Input/Output Operating Range

Duty Cycle Range

Input Voltage Welding Process 60% 100%35%

120V (± 10%) DC TIG 150A @ 16V 110A @ 14.4V-

120V (± 10%) AC TIG 150A @ 16V 110A @ 14.4V-

240V (± 10%) DC TIG 200A @ 18V 160A @ 16.4V225A @ 19V

240V (± 10%) AC TIG 200A @ 18V 160A @ 16.4V225A @ 19V

120V (± 10%) DC Stick 100A @ 24V 80A @ 23.2V125A @ 25V

120V (± 10%) AC Stick 100A @ 24V 80A @ 23.2V125A @ 25V

240V (± 10%) DC Stick 160A @ 26.4V 130A @ 25.2V185A @ 27.4V

240V (± 10%) AC Stick 160 @ 26.4V 130A @ 25.2V185A @ 27.4V

Input Demand Inrush / Rated Effective Current

Consult a local, licensed electrician before wiring your electrical connections.

Reference Article 630 of the NEC for correct welder wiring code information.

Voltage I1Max / I1Eff (Inrush/Rated)

120V 42A / 25A

240V 35A / 24A

Feature Range

Start Type HF and Lift Start (Lift is initiated with switch or pedal only)

Process AC/DC TIG and Stick

Amp Control 2T/4T Switch Control Sequencer or Pedal Control

AC Frequency 20-200 Hz

AC Balance 10-90% of Electrode Positive

Start Amps 10(20) to 225 Amps

End Amps 10(20) to 225 Amps

Pre-Flow 0-10 Seconds

Post-Flow 0-25 Seconds (2T/4T Use only)

Down Slope 0-25Seconds (2T/4T Use only)

Pulse Frequency .5-200 Hz

Pulse Time On 5-95%

Pulse Amp Ratio 5-95%

TIG Amp Range DC: 10-225A AC: 20-225A

Stick Amp Range DC: 10-185A AC: 20-185A

Stick Electrodes E6013, E6011, E7014, E7018, 309L and others.

NOTICE: Not for use with E6010

Feature and Range

Weight / Dimensions / Other

50 lbs. / 18” H X 10” W X 25” 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 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 welder wiring code information. The code is dif-

ferent for wiring a welder circuit than for household circuits.

CAUTION: Use only with extension cords 50 feet

long or less, rated for 240V welder 50A use, or

damage may result. For 120 operation, use only

with 30A rated cords, less than 25 feet in length.

Specications and Need-to-Know Information

alphaTIG 225Xi

Generator Operation Information

This unit may be used with any clean power rated 240V

generator with a 9000 Surge Watt rating. Clean Power is

defined as 5% or less Total Harmonic Distortion (THD).

This means the generator produces a clean sine wave simi-

lar to what is produced by power companies. Due to the po-

tential high inrush Amp demand (42A) while operating on 120V, op-

eration with 120V only generators is not recommended.

NOTICE: Operation on generators not rated by its manufacturer as a

“clean power” source is prohibited and will void the warranty. Many

manufacturers produce a version or series of their generators that

produce clean power. This is usually stated up front. If not, consult

the manufacturer of the generators to confirm THD. Clean power

generators are made in both inverter types and conventional types of

generators. Do not assume all inverter type generators produce

clean power unless the manufacturer states it. Clean power is need-

ed for most electronic equipment to prevent damage.

Duty Cycle Performance

The Duty Cycle of this machine has been established at 35%

@ 225A (40 C) while operating on 240V. While operating on

120V, the duty cycle has been established at 35% @ 125A

(40 C).

Duty Cycle is the amount of time, out of a solid 10 minute block of

time that the unit may operate at the rated setting. For the example

of 35% @ 225A, this means the unit may be operated up to 3.5

minutes continuously, or intermittently out of 10 minutes of time

before overheating. The balance of time remaining in the 10 minutes

(6.5 minutes in this example) should be while the unit is left to rest,

while continuing to run. As Amps are lowered, or as the ambient

temperature decreases below the 40 C testing benchmark, duty cycle

will increase.

It is not necessary to try to keep up with the duty cycle exactly by

timing it or recording it. The unit is equipped with a thermal sensor

which will trigger an interruption of operation if the temperature has

been exceeded. Keep in mind this is not a timed feature. A duty cycle

statement is based on time welding at a particular amperage, but

because so many variables exist, and ultimately the unit’s tempera-

ture is the regulating concern, duty cycle is determined by a preset

operating temperature threshold, rather than a timed one.

If you have triggered the duty cycle interrupt on this machine, allow

the unit to cool for a full 15 minutes. The unit should automatically

reset during this time, but allow a few more minutes so the machine

can cool sufficiently so as not to overheat quickly. If it does not reset

during this time, turn the machine off and back on to reset it.

Even though this unit is equipped with a duty cycle safety feature,

intentionally and repeatedly surpassing the duty cycle will shorten

the lifespan of the unit. Routine overheating damage will usually

leave signs that can be determined during warranty repair. Damage

caused by intentional abuse of the duty cycle will not be covered un-

der warranty.

If you find that you are constantly running into duty cycle issues, it is

likely you will need a bigger machine, or need to adjust your welding

strategies to comply with the duty cycle limits of this machine.

To assure maximum lifespan of the unit, never block the cooling vents

in the rear, sides, or front. Keep the unit 16” away, on all sides, from

any obstacle to free air flow such as a wall or partition.

Required Routine Maintenance

Most places where a welder is in operation floating and

flying debris is a factor. Dust, dirt and sparks are often

present in the air. The machine will draw these contami-

nants in during operation and they can be deposited inside

the machine onto critical components. These particles can

conduct electricity and create new circuit paths, not only causing poor

operation, unit lock up, but it can also cause long term damage. For

this reason, the machine should be opened up and cleaned with dry,

compressed air on a regular basis, once every month in heavy use,

and ever 3 to 6 months under light use. If the unit remains stored

most of the time, dust still will accumulate, and this should be done

at least every 6 months. When not in use, keep the machine covered.

Failure to do so constitutes neglect and may void the warranty.

To clean and service this welder:

1. Unplug the welder. Wait 10 minutes for the capacitors to dis-

charge. (To prevent electrical shock or electrocution.)

2. Put on a pair of safety glasses to prevent debris from blowing

into your eyes during this operation.

3. Remove the rear cover screws. Keep in mind there are 3 screws

on the bottom of the unit that hold the cover on as well. Do not

remove any other screws on the bottom.

4. Remove the rear cover and top handle.

5. Remove the steel cover screws.

6. Pull the rear cover up and to the rear while carefully watching

for wires that may catch on the louvered vents of the cover.

7. Check all wires and connections to make sure they are seated

and/or tight.

8. Use dry compressed air (or “canned” air) to blow the air off con-

nections, boards, and fittings. If the unit is particularly dirty,

unseat the affected connectors themselves, and blow out the

connections as well.

9. Reassemble the unit. Do not forget the handle!

NOTICE:

Opening the unit to clean and check connections will not

void the warranty. In fact it is required to maintain your in-warranty

status during the duration of your warranty. However, under no cir-

Specications and Need-to-Know Information

alphaTIG 225Xi

cumstances should you attempt to modify or make unauthorized

changes to the welder or its programming. To do so will void the war-

ranty.

HF Point Gap Maintenance

This unit is equipped with adjustable high frequency points

that generate the High Frequency Voltage to create the

touchless HF start of the unit. Occasionally, adjustment

may be needed, particularly in the first few months of oper-

ation, and periodically thereafter. This is a simple adjustment after

you’ve done it once or twice. The point gap should be set between

0.029” to .040” for best operation. The target point gap should be

between .030” and .035”. A point gap that is too small may cause

weak starts. A point gap that is too wide may cause electrical inter-

ference with surrounding equipment and electronic items.

The location of the points can be identified by quickly pressing the

torch switch/foot pedal while looking up through the front vents of

the welder. The points should arc briefly. If they do not, they may

only need adjustment or cleaning. (But if after adjustment they do

not fire, contact Ahp technical support at the number listed on the

front of this manual.) If you do not see the arc location, look up and

to the left of the unit. There will be a small board with a brass and

black plastic holder along with carbon contacts in them. They will be

located on a small square board with a couple rows of small capaci-

tors and a coil/transformer on the same board.

To gain access to the points and adjust them, follow steps 1– 6 on

the previous page. You will need a small jeweler’s or mechanic’s

screwdriver, and small ignition wrench and a feeler gauge to set the

points. Do not overtighten the jam nut securing the adjustment

screw. Hold the screwdriver in place on the screw while tightening

the jam nut with an ignition wrench. See the image below.

The board in the image below is shown inverted for demonstration

purposes and is removed from the unit. Removal is not necessary. The

points will be in the “hanging” position and can be adjusted through

the left side of the machine. (Whole board is not pictured.)

For more detailed written and illustrated directions on how to locate

and adjust the point gap, contact Ahp technical support.

NOTICE:

Point Gap adjustment is a part of regular maintenance and

is a normal responsibility of the customer. Point gap adjustment and

normal cleaning/maintenance does not fall under the warranty terms

for this welder. If you have any issues or questions concerning point

gap adjustment, call or contact Ahp tech support before attempting

the adjustment. The HF system used in this unit is only used for

starting the arc. They do not stay on while welding in DC or in AC.

They have no effect other than arc starting efficiency. Inverters

switch so quickly in AC that HF is not needed to maintain a stable arc.

IMPORTANT:

Do not needlessly adjust the point gap in order to try to

resolve operational issues not related directly to arc starting. Arc

starting is the only purpose of the HF points inside this unit. Before

assuming you have an HF starting issue, check the work clamp, the

work clamp cable and connections under the rubber boot on the

DINSE connector to make sure the connections are tight, and corro-

sion free. Connect the work clamp directly to a freshly ground spot

on the work piece and attempt to weld before assuming you have an

HF point gap issue. Also make sure polarity is correct. Most com-

monly, a poor connection to the work piece, corrosion or wrong polar-

ity is the cause of poor arc starting rather than a point gap issue.

Other items that may also cause poor arc starting:

• Wrong shielding gas, or not enough flow.

• Too much gas flow creating turbulence.

• Welder is too close to the weld area and fans are blowing gas

coverage off weld. Move to 6-8 feet away.

• Dirty or contaminated metal Preclean aluminum with Stainless

brush or special aluminum grinding wheel. Decontaminate with

acetone or aluminum cleaner made specifically for welding Alu-

minum. Grind steel with hard stone on grinder. Refrain from

using flap disks which often polish the mill scale rather than

remove it.

• Too long of an arc gap between tungsten and metal.

• Too much stick-out of the Tungsten, not enough shielding gas

flowing around Tungsten.

• No Pre-Flow. Set to .3 to .5 Seconds.

• Wrong Tungsten. Use Lanthanated or Ceriated Tungsten for all

processes. Do not use pure, zirconiated. Use caution when try-

ing new or proprietary “blends”. Often these have poor quality

control.

• Work Clamp is not connected directly to what is being welded.

• Work clamp, cable, or connector is corroded or bad. Check all

connections, including where the cable attaches to the DINSE

type connector. (You must pull rubber boot back).

• Dirty Tungsten. This is often indicated by a green flare or spit-

ting while starting the arc or while welding.

HF Point Gap Location

Locking Nut

Adjustment Screw

Specications and Need-to-Know Information

alphaTIG 225Xi

TIG Shielding Gas Information

Pure Argon is recommended for use in your Ahp TIG welder. This

is the best, most tried and true shielding gas for TIG. An Argon/

Helium mix may be used to increase the range of the unit. The

addition of Helium has the effect of making the arc “hotter”.

However, when using Helium blends, do not exceed 25% for best

arc starting and stability. The addition of Helium makes high

frequency starting harder as well as the arc more unstable. Addition-

ally , even small amounts of Helium will greatly increase the price of

the shielding gas over Argon. There are additional shielding gas

blends being offered by various welding supply stores, that include

other gases, with Argon being the base. These blends are often pro-

prietary, and are not recommended for every day use.

NOTICE: Under no circumstance should you ever use MIG gas such as

75/25 Ar/CO2 (C25) as a shielding gas for TIG welding. The addition

of CO2 to the TIG weld will rapidly consume the tungsten, leave po-

rosity in the weld, and make the weld brittle. MIG gas has never

been used to weld with TIG. When purchasing your shielding gas, be

sure to remind the store that you desire TIG shielding gas, or 100%

pure argon. One of the most common mistakes is the use of the

wrong shielding gas. If your supply store insists on Ar/CO2 for TIG,

refuse the gas, and insist on pure Argon, or find another store willing

to sell 100% pure argon. (Medical grade purity is not necessary).

The regulator is a floating ball type. This means that when gas is

flowing the ball in the clear cylinder will float, indicating not only that

gas is actively flowing, but also the amount of gas flowing through

the regulator. This type is more accurate in general than the gauge

type, and is easier to read at a distance. When installing the regula-

tor and making it ready for use, be sure to snug all fittings using two

wrenches. One will hold the stationary fitting, the other will be used

to turn the rotating fitting. If you do not hold the stationary fitting,

either on the regulator, or on the back of the unit, you can crack or

damage the fitting. Once installed, and all fittings have been tight-

ened, test all fittings for leaks with a spray of warm soapy water (or

leak detector) to check for leaks. If bubbles are present, retighten.

Do not use thread sealant, locking compound, anti-seize or tape to

seal the threads. If the threads do not seal, remove and check the

connections for debris or pieces of metal on the sealing surfaces.

When you open the cylinder valve, do so slowly and stand to the oppo-

site side of the regulator. Do not stand in front or behind it, incase

something were to malfunction or the regulator has been damaged.

Open the cylinder slowly, but open the cylinder valve completely.

Cylinder valves may leak if they are not fully open or fully closed.

Gas flow rates will vary by cup size and type. For standard cup sizes,

use at approximately 2.5 to 3 times the gas flow rate than the cup

number. For example a 7 cup would be 17.5 CFH to 21 CFH, in a

good work environment. This is just a general rule, but more or less

gas may be used, depending upon the circumstances.

NOTICE: Place the unit at least 6 feet away from the weld area. The

cooling fan(s) is/are powerful enough to blow the shielding gas off

the weld. Do not weld with the welder sitting next to you on the table

top or cart. If the welder cannot be removed from the immediate

area, then lower the height of the welder by placing the welder near

the floor level, or well under the work piece level. Porosity, rapid

tungsten consumption, and dirty, smudgy welds may result if the

welder is too close to the weld area.

NOTICE: Only use 100% Argon, or an Argon/Helium Blend. Do not

exceed 25% Helium content. Never use a MIG gas/ Argon/CO2 mix!

Argon Connection

Specications and Need-to-Know Information

alphaTIG 225Xi

TIG Polarity and Tungsten Type

Selecting the correct TIG polarity of the connections is

critical for correct operation. Incorrect polarity can lead to

rapid Tungsten consumption, bad arc stability, and refusal to

start. The TIG torch will always be connected to the negative

(-) terminal. This is called Direct Current, Electrode Negative

(DCEN -) or as “Straight Polarity”. (Polarity always refers to the con-

nection of the torch, not the work clamp. ) The work clamp will al-

ways be connected to the positive (+) terminal.

NOTICE:

The work clamp is often referred to as a “ground” since

negative ( - ) polarity is often viewed being connected directly to

earth. However this is technically incorrect and a cause of confusion

since the negative polarity only completes the circuit, rather than

being grounded directly to Earth. A common issue is that people still

refer to this as “ground” and mistakenly connect the work clamp the

negative terminal as a result. Don’t forget that while TIG welding,

the work clamp will always remain in the positive terminal ( + )

regardless of whether it is being used in DC or AC mode.

Ahp recommends Lanthanated 2% (blue band) Tungsten for all TIG

welding, whether welding in DC or AC modes. 1.5% Lanthanated

(gold band) is also a good choice. Alternatively, 2% Ceriated (gray or

orange band) also exhibits good performance, but does not have

quite the resistance to erosion/consumption at higher amperages

that are found in Lanthanated. Overall, however, Ceriated is a suitable

Tungsten type for most inverter welder general applications.

Never

use pure tungsten (green band) or Zirconiated ( usually brown

band).

These are designed and intended for transformer use only.

Arc instability and overballing will result. 2% Thoriated Tungsten

(red band) may be used with DC, and is excellent for DC and can work

for AC, but the tungsten is subject to forming nodules, splitting, and

other forms of tip deformation at higher amp ranges in AC. As an

alpha particle emitter, Thoriated tungsten is a slightly radioactive

emitter. Some areas of the world have banned Thoriated Tungsten

for this. But in general, Thoriated is still the standard for DC welding

and has excellent arc properties. It’s been in use in the industry for

many years. The main risk is inhalation while grinding. Research

Thoriated Tungsten before you make your mind up one way or the

other. Be informed.

There are other types and colors of tungsten rapidly becoming availa-

ble that are being promoted as 3-in-ones, tri blends, rare earth

blends, special treatments, etc. Keep in mind for general welding

purposes, these are still considered “novelty” products and most have

very little research to support their claims of superiority for or suita-

bility for particular applications Some include Zirconium, which has

little or no value to inverter welders. Additionally, quality control is

typically very poor. The amount included of the “special” blend of

each rare earth metal oxides is often miniscule and are allowed to

vary by as much as 40%. Again, research and make your own decision

concerning this. In particular, be sure to read the Safety Data Sheets

regarding the Tungsten that should be available on these products to

assist you in comparing apples to apples. Standard coloring is being

changed arbitrarily by some manufacturer’s to confuse the buyer, or

to try to promote and differentiate their own “special” product. Read-

ing the SDS can help clear up confusion and give you an indication of

formulation and quality control standards.

You must choose between the torch switch operation (2T/4T) or the foot

pedal operation. Both cannot be connected to the control connection or

used at the same time.

Argon Argon Gas Line

TIG Torch

Work Clamp

Foot Pedal (To Control)

All Power Adapters are DINSE 35 Series Type (1/2” nominal pin diameter). These

will be listed as either 35/70mm2 or 35/50mm2.

TIG 2T/4T Torch switch

Control Line

NOTICE: Tungsten electrodes are often identified and referenced by

the painted color band on the end of the electrode only. Each color

represents a different type (or formulation) of Tungsten. Most Tung-

sten electrodes are a rare earth or special metal oxide blended with

the elemental metal Tungsten. Whether it is to improve arc starting,

to improve amp handling characteristics, or to reduce Tungsten tip

erosion, etc., each elemental addition is claimed to serve a purpose.

Tungsten varies in both metal type and content of each metal oxide.

We recommend use with Lanthanted Tungsten in AC and DC. The

content of the Lanthanum is roughly between 1.5 to 2%. The color

band is blue for 2% Lanthanated Tungsten. For 1..5% Lanthanated

Tungsten, it is a Gold band. The slight change in percent is said to

impart different durability and performance characteristics. Re-

search and test on your own to determine the best one for you.

Specications and Need-to-Know Information

alphaTIG 225Xi

Tungsten Preparation

Proper Tungsten electrode preparation is important to arc stability

and cone shape. It even has a significant effect on penetration.

Different angles should be experiemented with. Usually in AC

mode, the grind will be shallower, and more not as steep for maxi-

mum penetration. In DC, the grind will be steeper, and longer.

The way you grind is as important as the angle that you grind as well.

Always grind the tungsten so that the grind marks line up with the

length of the Tungsten. Grinding radially will cause arc instability.

NOTICE:

On an inverter, you should never ball your Tungsten elec-

trode to weld AC. On older transformer types this was done. But if

you ball your Tungsten, arc stability will be reduced and it will affect

penetration and cleaning negatively.

Use the guide below to help you get the best performance out of your

Tungsten electrodes.

Low cost, economical purpose-built Diamond coated Tungsten grind-

ers have revolutionized the industry. These will usually have pre-

drilled holes/slots to guide you to quickly and safely grinding the

correct angle.

However, if you do not have one, you may use a bench grinder with a

fine grit stone that is dedicated to grinding Tungsten only.

CAUTION:

Grip your Tungsten firmly so the Tungsten is not snatched

from your hands. Use safety glasses, and gloves when grinding.

See below for proper and improper grinding examples.

Stick Polarity and Electrode Types

Stick welding is usually performed in DC with the electrode

positive (DCEP+), or “ Reverse Polarity”. However, certain

electrodes (also referred to as welding rods) also allow

operation in AC or in DC, electrode negative (DCEN—). For

example, the E6011 may be operated either in DCEP, DCEN, or in AC.

Some people mistake it for an AC only rod, because of its ability to be

used with old style transformer “buzz box” welders that only produce

AC current, but in reality it will operate just as well, if not better on

DCEP. Even if a welding rod allows operation in AC or in DCEN it will

typically perform better in DCEP in most applications. Only a few

specialty rods, like some hard facing may require AC operation only.

Some manufacturers may state that some welding rods such as 7018

may be run on AC. But in general, hard starting and sticking may be

experienced. To combat this, some manufacturers simply produce an

AC version of 7018 for AC only welders. The use of AC usually is not

needed, since DCEP is smoother, quieter, and in general offers better

Correct length-wise grind.

Smooth starts, stable arc.

Incorrect radial grind.

Hard starting, Arc starts

up in Cup, Unstable arc.

DC <50 A

2.5 – 3 X Ø (DIAMETER)

Pointed for low

Amp DC use.

Approx. 60 .

DC >50 A

Pointed but tip is

slightly truncated

for high Amp DC

use. Approx. 60

AC Pointed but tip

grind is shallower

for focused arc in

AC use. Approx.

Incorrect use. Do not ball

Tungsten. Hard starting,

Unstable, wandering arc.

Start with a slight upward

angle. Turn Tungsten at a

slow, steady rate while

grinding evenly.

Gradually increase angle

and continue to twist

until point is created.

NOTICE: Never grind sideways as

shown. This will create a radial

grind pattern and cause arc insta-

bility and hard starting.

Specications and Need-to-Know Information

alphaTIG 225Xi

penetration. However, in certain conditions, if the work piece be-

comes magnetized, or some part of the welding table does, then the

arc may become highly unstable while welding in DCEP. High

amounts of spatter and a wild, uncontrollable arc may be experi-

enced. This usually will occur while welding in corners. In this case,

this is referred to as “Arc Blow”. When Arc Blow happens, AC will

usually straighten up the arc, and force it where it needs to go. Keep

in mind that this is a very rare occurrence. And when AC isn’t availa-

ble, or practical, Arc Blow in DCEP can be combatted by changing the

location of the work clamp, or by wrapping the work clamp cable,

several times around the welding table leg, or item being welded.

The illustration below depicts the standard connection for most weld-

ing rods. Always consult your welding rod manufacturer’s recommen-

dation as an ultimate source of information. Usually the box or can

will have polarity recommendations along with Amp range recom-

mendations on it if you are in doubt about settings or polarity.

This welder is designed to weld with a variety of welding rods, includ-

ing E6011, E7014, E6013, E7018, E7024, and even stainless rods like

E309L. However, this unit is not designed to weld with E6010 and

should not be attempted. Performance with E6011 may be brand

dependent. You may need to experiment with different brands to find

the best one for your use. This is of course true for all welding rods,

but especially for E6011 with this machine. For general purpose fab-

rication, and practical use, consider using E7014. This is considered a

“fabrication rod”. With this rod, high-quality, rapid, self-releasing

welds can be made, without having to have a hot box that is required

to maintain low-hydrogen type rods such as E7018, which has similar

tensile strength. E7014 rods are particularly easy to use, and leave a

smooth, high quality appearance, even in the hands of novice users.

The E7014 can be easily drug along the work piece while maintaining

an arc. The slag is medium heavy and will self release if the amp

range and technique is correct.

IMPORTANT: Whenever welding, this unit performs best when a tight,

close arc is held. Long arc lengths will create arc outages.

This welder has a maximum output of 185 Amps while operating on

240V. This is sufficient to weld with most 5/32” welding rods. Run-

ning larger rods may be difficult and may make the duty cycle inter-

rupt or over current interrupt engage. When operating on 120V, use

a 3/32” or smaller welding rod. Operation at higher than 85A while

on 120V may trip a 20A circuit breaker,

Work Clamp

NOTICE: In AC mode, the electrode holder should remain in the positive (+)

terminal. Only change/swap torch/work clamp position for DCEN (-) when need-

ed. Use in DCEN is very rare and should only be changed for applications requir-

ing its use.

Electrode Holder

Front Panel Features

When setting up your unit (especially forthe first time), it is important

to pay attention to the polarity and the connections of your machine.

Otherwise you may experience issues with operation. Usually setup

issues are the leading cause of “emergency panic calls” to technical

support. Refer to the illustration below to identify the components and

properly set up your unit.

1. Protective Cover. The protective cover offers protection from flying

debris, dust, and damage to the front panel screen. The cover

should always remain down except when adjusting the unit.

2. Negative Terminal. The negative terminal is a 35/50mm2 and

35/70mm2 DINSE type compatible connector. In TIG mode this is

the location of the TIG torch. In Stick mode this is the

usual

location for the work clamp. In some instances the stick electrode

holder will be connected here in cases where DCEN (Straight Po-

larity) Polarity is required. Otherwise, in AC and in DCEP (Reverse

Polarity) the work clamp will be located here.

3. Control.

The control is used for TIG welding only. This is where

either the torch switch, or the foot pedal is connected while TIG

welding. It allows you to start and stop the arc (torch switch and

foot pedal), and/or control the amperage ( foot pedal) remotely. A

torch switch or foot pedal must be connected to this terminal to

energize and maintain the arc. This unit does not have a live lift/

scratch start function where the Tungsten remains live. This is a

safety feature to prevent accidental arc starting and flashing of

the eyes. Unplug this connection while Stick welding.

4. Positive Terminal. The positive terminal is a 35/50mm2 and

35/70mm2 DINSE Type compatible connector. In Stick mode, this

is the usual location (except of applications requiring DCEN) of the

electrode holder. The stick torch should remain in the positive

while welding in AC as well. In TIG mode this is always the loca-

tion of the work clamp.

5. Gas Connector. The gas connector supplies gas to the torch. This

is a quick coupler type connector. The unit is supplied with a gas

-cooled torch (also referred to as air cooled) 26 series. The line

that comes from the DINSE type connector of the torch is con-

nected directly here. For Water-cooled torches (optional) the gas

line will run separately. The DINSE Type connector line with the

quick coupling then becomes a water line. Do not confuse the

two when installing a water cooled torch on this unit or water will

pour from the torch head.

Rear Panel Features

The rear panel has a few features that may not be readily deciphered.

Pay attention to the illustration and explanation below to ensure your

unit is correctly installed.

1. Switch. This is the main power switch for the unit. There is no

other to turn the unit on or off. The switch also serves as an “air

breaker” and will trip if a short or overload occurs. If this switch

trips while in use, it will usually indicate a severe problem or fault.

If this trips, then the main circuit breaker in the panel box may

also trip. Examine the power supply for proper wiring and ground-

ing in the panel box. If this trips and an error code is displayed,

this usually indicates a severe internal fault has occured. If this

happens discontinue use and contact Ahp Technical support.

2. Power Input Cable and NEMA 6-50 plug (Plug not pictured). The

input cable is approximately 6 ft. long. This is sized appropriately

for the unit and includes the standard welder plug for North

America. The standard plug only uses three wires for 240V opera-

Component Identication and Explanation of Function

alphaTIG 225Xi

Component Identication and Explanation of Function

alphaTIG 225Xi

tion. There is no neutral in a welder circuit. Do not change, length-

en, or otherwise alter the input cable or plug. Doing so may void

your warranty.

3. Water-Cooler Outlet This outlet is designed for use with an op-

tional Ahp or similar 240V water cooler plug only. Although this

unit will supply 120V output while on 120V, the outlet should not

be used while operating on 120V, unless a dual voltage cooler is

being used. For safety, unplug the cooler and discontinue use

while operating on 120V. Use an air cooled torch on 120V. WARN-

ING! Do not use this outlet for anything other than powering an

approved water cooler. This is a low amp outlet and damage and

fire could result if this outlet is used for anything other than a low

amp (4A or less) water cooler is used with this unit.

4. 5/8” CGA Gas fitting. This connection is used to connect the TIG

shielding gas directly to the unit. This is a standard inert gas

fitting used by all major welding manufacturers in North America.

Use one wrench to hold the fitting while using another wrench to

tighten the fitting from the regulator tubing.

5. HF Ground Bolt. The HF ground bolt is used to help dissipate HF

energy and possible electrical interference generated by this ma-

chine. If an electrical disturbance is noted, connect a 12 gauge

wire to this bolt, and connect it directly to a separate ground rod

driven into moist ground outside of shop or structure. Also, con-

nect and ground all metal items, including plumbing and the

structure itself via wire and ground to a separate ground rod driv-

en in the ground at 10 foot intervals. This is not a recommenda-

tion unique to Ahp. It is a standard recommendation across most

manufacturers in order to prevent possible electrical interference

created by a welder, especially where supplied power does not

meet the resistance requirements needed for a proper, commer-

cial ground. If you experience any electrical interference, and

before resorting to using this HF ground bolt, consult with a li-

censed, local electrician to make sure this connection is wired and

grounded appropriately, and complies with local codes.

NOTICE:

This unit uses a reliable high output fan mounted in the rear

of the unit (not pictured). It pulls cooler air in from the rear and push-

es out spent air through the front vents and side vents of the unit. It is

designed to stay on continuously. This provides the unit with exception-

al duty cycle at maximum output when compared to most systems that

utilize a thermostatically controlled fan. The always-on design helps

the unit operate at a much lower average temperature than “as-

needed” fan designs, prolonging the life of the unit. Do not attempt to

modify this system in any way. Doing so will void the warranty. If the

fan does not come on when the unit is switched on, or seems to be

compromised in operation, contact Ahp tech support immediately.

Component Identication and Explanation of Function

alphaTIG 225Xi

Control Panel Features

The control panel layout has been arranged with convenience and

speed of adjustment in mind. The graphics on the panel have been

grouped and color coded (the brackets themselves) to remind the user

what value the controls are indexed in and/or what function the con-

trols are related to. The panel below should be referenced during set-

up to help users understand the basic controls of the unit.

67789

1011

Control Panel Features

1. Power Indicator and Warning Light. The LED Power Indicator will remain on while the switch is turned on, if power is being supplied. If the warning light

comes on during use, then check the error code provided to help determine whether it is an over current or duty cycle issue. If it is a duty cycle issue, allow the

unit to continue to run, without welding for 15 minutes. The unit will automatically reset. If the code is a over current issue, then switch theunit off and check

the cause. The unit may not clear the code when it is switched back on, or may instantly display again when welding is attempted. In this case, immediately

2. Display. The display is designed to display selected maximum welding amps while not welding while the torch switch is in use. While the foot pedal is in use,

it will display the minimum “sensed” amps of the foot pedal. However, while adjusting the Amps (#11) knob, the unit will read the maximum selected amperage

and will continue to display the selected amperage up to 3 seconds after adjustment has been completed. After 3 seconds, the display will revert back to read-

ing the relative position of the foot pedal amperage. While welding the display will read dynamically, and display actual Amp output. In the event of a duty

3. Start Amps/End Amps (10-225 Amps). The Start and End Amp settings are used to control the starting Amperage and ending Amperage of the machine dur-

ing the weld cycle. If using with the torch switch, the Start and End Amps work in Conjunction with the 2T/4T function. It can be used to provide a “Hot Start”

in Aluminum to give the unit the punch to create an initial puddle, or a gentle low amp start to more slowly build up the heat in the weld. If using with the foot

pedal, normally Start and End Amps will be set to the minimum setting. However, when using a foot pedal, a higher amp start may be required with larger

diameter Tungsten ( 1/8” and over) so that the arc may start cleanly without wandering. With the foot pedal, a low End Amp setting is preferred so that a clean,

soft “tail out” of the amperage can be achieved, and a large crated will be avoided. A higher setting may also be used if preferred if the arc begins to wander

before the tail out is finished. A higher End Amp setting while using the foot pedal also works better with Tungsten 1/8” and over. NOTICE: In AC mode, mini-

mum Start Amps is changed to 20 Amps. In DC minimum Start Amps is 10 Amps.

4. Pre and Post Flow (Seconds). The Pre and Post Flow functions provide gas flow to the weld before weld start and after weld completion. A Pre-Flow of gas is

useful to provide an oxygen free environment to start the arc in order to protect the weld metal and the Tungsten during a start. Post-Flow protects the molten

puddle from oxidation as it cools. NOTICE: During start, a short burst of gas may be heard during start. This is normal as the regulator acts to stabilize the gas

flow as the solenoid opens. During welding, gas flow should be nearly undetectable. If the flow can be heard over the welding arc, too much gas is being used.

Component Identication and Explanation of Function

alphaTIG 225Xi

678910

1112

Control Panel Features

5. Down-Slope (Seconds, 0-10). The Down-Slope is used exclusively with the 2T/4T settings while the torch switch is in use. This provides a “crater fill” time

and gradually diminishes the welding amperage down to the End Amp setting. This provides the user time to properly fill the crater left at the end of the weld

pool. NOTICE: This feature is not used with the foot pedal. Make sure that the Down-Slope is turned to the minimum setting while the foot pedal is connected.

6. AC Frequency (Hertz, 20-200Hz). For welding Aluminum or Magnesium in AC mode. While welding in AC TIG mode, the AC frequency helps to control arc cone

width, and the directability of the arc by adjusting the number of times per second that the AC oscillates between Electrode Negative and Electrode Positive. A

higher AC frequency settings is desirable for welding on thin metals to give maximum control, by providing a narrow, easy to control bead. However, increasing

the frequency will also make the weld progress more slowly and reduce wet-in of the puddle and filler. It will make the weld feel “cooler”. Lowering the fre-

quency will tend to make a wider welding arc, with less directional control of the arc However, wet-in of the puddle will be increased, and it will make the weld

feel “hotter”. When welding on thicker materials a lower frequency is useful to maximize welding capacity. NOTICE: AC Frequency is irrelevant in DC TIG mode

and does not need to be set while welding in DC TIG.

7. AC Balance ( 10-90% of full Electrode Positive). For welding Aluminum or Magnesium in AC mode. While welding in AC TIG mode, the AC balance adjusts the

relative balance of time spent in the Electrode Positive and Electrode Negative portion of one AC cycle (Hertz). The Electrode positive portion of the AC cycle

provides cleaning action necessary to weld Aluminum by breaking up the oxide layer naturally found on Aluminum. The Electrode Negative portion of the AC

cycle provides penetration to the welding arc. The AC balance affects the cleaning action of the AC arc that is necessary to remove the Aluminum oxidation.

Increasing the AC balance increases the amount cleaning, but also begins to overheat the Tungsten as it edges above 40%. The cleaning lines (the etched area

on either side of the weld) normally present just on the outside edge of the weld will be increased. Decreasing AC balance reduces the cleaning action impart-

ed to the weld, increases penetration while also reducing the amount of heat placed on the Tungsten. Amounts as low as 10-15% on thoroughly pre-cleaned

metal can greatly increase penetration while welding in AC mode. NOTICE: AC Balance is irrelevant in DC TIG mode and does not need to be set while welding

in DC TIG.

8. Pedal, 2T, 4T Remote Control/Sequencer Selector. This button selects which method is desired for controlling the weld arc and timing. Select foot pedal for

use with the foot pedal or an Amp slider control mounted on the torch. Select 2T for simple On/Off operation with the torch switch. Select 4T for more ad-

vanced operation with the torch switch. See explanation found later in this manual on how to use 2T/4T control.

9. AC/DC, TIG/Stick Selector. This button selects which mode of operation the unit is in. NOTICE: If Stick mode is selected, two LED’s will be lit at the same time

to indicate the unit is in stick mode and whether it is in AC or DC mode. In TIG mode, only AC or DC will be lit. There is no separate TIG indicator.

10. Pulse Selector. Off/Low/High This button selects Pulse mode. In Low mode, the pulse only operates between .5 and 20 Hertz to allow maximum fine con-

trol of the pulse setting at lower Hertz. In High Pulse Mode, the pulse operates between 20 Hz and 200Hz, to allow a more course, rapid adjustment of the

pulse in the frequency ranges that aren’t as sensitive to minor changes in pulsing speed. Hertz=Pulses Per Second (PPS). NOTICE: The Pulse features (#11)

have no effect while the Pulse is off.

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