Tig setup for ally.

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First off hello to everyoneMy company has just baught a new Esab caddy 2200i Tig welder its a good bit of kit and i used the same one in the last company i worked for.Only problem is ive set it up the best i can at the minuit and it works perfect on flat butt welds but if i try and weld an inside corner at 90degrees it tends to throw the filler back out of the weld pool Iv tryed lowering the gass wich hasn't helped as it makes it more difficult to arc up and get started. Also tryed lowering power but then i cant get the penitration i need.Its quite embarasing really as iv been welding for years as part of my job but i haven't had alot to do with the setup of new welders.Im still wondering if there is a function on the welder that im using that i haven't setup corectly?Any help would be grately appreciated.
Reply:I Don't have any hood time with this certain machine but i hope this helps...Polarity - Ac high freqAc balance - 65%Pulse - up to youHertz - up to you Have you welded much aluminium before?make sure you have correct stick out big factor on a aluminium filletAlso if you can post the settings you are currently runningCigweld Transmig 265seBoc 140amp StickBoss 200amp AC/DC TIGLincoln Electric Invertec V260-S
Reply:Thanks for the reply.Ye iv done quite a bit of tig welding but the tigs iv used have always been setup before use so iv never really had the chance to learn how to do it.Not sure what setting i hadIt was 4mm ally angle i used a 2mm white tip tungsten and had it set to 140amps with the gas on about 7.So as i havet checked the balance yet or frequency theres a good chance thas what it will be?
Reply:You don't have a pedal for it? That can help, you can always do one bead at a time with a pedal. I don't know what a white tip tungsten is. You are welding aluminum I take it, you did not actually say aluminum yourself but it seems like you might be welding aluminum.        Sincerely,             William McCormick
Reply:Apologys i should of said im welding alluminium.No no pedal just trigger.We have white tiped tugstens for use with ally and red tiped for steel/stainless.The thing is iv used the exact same welder in the past and welded every type of joint succesfully without problems. im using the same welder now but because i have to set it up myself im not sure on what i need to be looking at?Im quite embaressed to be welding for as many years as i have without knowing the ins and outs of tig welders.Should i be looking at balance and frequency?
Reply:Are you talking about your filler wire balling up at the end and not being able to add it? Sounds like a torch angle issue. Square up with your work piece a little more to focus the heat on that and not the filler. Then you should be adding filler to the puddle so make sure you have one established before trying. Doing inside corners gets tricky sometimes. Good luckUA Local 598
Reply:Originally Posted by BURT150Apologys i should of said im welding alluminium.No no pedal just trigger.We have white tiped tugstens for use with ally and red tiped for steel/stainless.The thing is iv used the exact same welder in the past and welded every type of joint succesfully without problems. im using the same welder now but because i have to set it up myself im not sure on what i need to be looking at?Im quite embaressed to be welding for as many years as i have without knowing the ins and outs of tig welders.Should i be looking at balance and frequency?
Reply:I can't imagine tig welding aluminum without a pedal or at least a hand amptrol.   Aluminum heats up so much during the weld, you need a way to reduce the current to keep the weld penetration and bead width and profile equal over the length of the weld.  Otherwise, you'll start out high and tight and end up wide and flat and maybe burning through.  Plus, you need to be able to back the heat down slowly and dip the filler to end the weld without a crater.  Good luck accomplishing all this without some kind of variable amptrol (aka foot pedal).   You can get away without a pedal on steel or stainless but not with aluminum, in my experience anyways.Basic settings for aluminum tig-AC weld outputHigh frequency onBalance at 20-35% cleaning, 65-80% penetrationFrequency at 60-150 Hz, higher frequency focuses the arc more, lower frequency widens the arcSlope offPulse offHot start onCurrent set at minimum one amp per 1/1000th inch of plate thickness (1/8" metal = 125 amps), though setting to higher current and controlling with foot pedal is better for me.  This allows hitting it hard to start the puddle quicker without overheating the part and then backing off for the rest of the weld.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op