KICKS welding amplifier: how to improve weld quality and arc stability

Welding is a process where every little detail affects the result. Even experienced craftsmen encounter problems: unstable arc, metal burns, poor seam formation. This is often due to insufficient welding current at critical moments. This is where it comes to the rescue amplifier KICKS (or "kicker"), which briefly increases the current when striking an arc or during welding. This device is especially relevant for inverters and semi-automatic devices that work with thin metal or under unstable voltage conditions.

But how to choose the right model among dozens of offers on the market? How to connect the amplifier correctly so as not to burn the welding machine? And what settings will help you achieve the perfect seam? In this article we will analyze KICKS-1000, KICKS-2000 Pro and other popular models, and also give step-by-step instructions for installation and operation. We will pay special attention to typical errors that shorten the service life of equipment.

What is a KICKS amplifier and why is it needed?

Amplifier KICKS (from English. kick - "push") is an electronic device that briefly increases the welding current at the moment arc ignition or when critical loads. Its main task is to compensate for voltage dips that arise due to:

• 🔌 Long welding cables (more than 10 meters)
• 🔋 Weak network (for example, generator or household outlet)
• 🔥 Work with refractory electrodes (for example, UONI 13/55)
• ⚡ Welding thin metal (0.8–2 mm), where precise current control is required

Without an amplifier, the welding machine may “suffocate” - the arc will be interrupted, and the seam will turn out to be porous. KICKS solves this problem by adding up to 20–50% additional current at the right time. For example, when welding aluminum or stainless steel, where high arc stability is required, a kicker becomes a mandatory accessory.

It is important to understand that an amplifier is not a replacement for a powerful welding machine, but addition to him. It will not increase the maximum current of the inverter, but will make its operation more stable in difficult conditions. This is especially noticeable when using budget Chinese devices, which often suffer from voltage sags.

Top 5 KICKS amplifier models: comparison of characteristics

There are dozens of amplifier models on the market, but not all of them are equally effective. We have selected the 5 most popular devices, which are time-tested and recommended by professional welders. Main selection criteria - maximum current, response time And compatibility with device types.

Model	Max. current (A)	Response time (ms)	Type of devices	Features
KICKS-1000	200	10–15	Inverters, MMA	Budget model, suitable for home use
KICKS-2000 Pro	300	5–8	Semi-automatic, TIG	Overheat protection, digital display
KICKS-3000 Turbo	400	3–5	Industrial devices	Adjusting the push force, working with aluminum
KICKS-Mini	150	20–30	Household inverters	Compact size, easy connection
KICKS-Digital	250	1–2	Any devices	Programmable modes, USB port for setup

Sufficient for most household tasks KICKS-1000 or KICKS-Mini. If you work with a semi-automatic machine or weld aluminum, it is better to choose KICKS-2000 Pro or KICKS-3000 Turbo. The latest models are equipped with overload protection and allow you to more precisely configure the response parameters.

⚠️ Attention: Amplifiers with a response time of more than 20 ms may not have time to respond to sudden changes in the arc. This is critical when welding thin metal, where even a split second makes a difference.

Connection diagrams for the KICKS amplifier to the welding machine

Incorrect connection of the amplifier may result in damage to the welding machine or even fire. There are three main connection schemes, the choice of which depends on the type of equipment you have:

1. Serial connection (the most common option). The amplifier is connected to the gap between the welding machine and the electrode holder. Suitable for most inverters and semi-automatic machines.
2. Parallel connection. Used for devices with a separate output for arc control (for example, TIG welding). Requires precise polarity adjustment.
3. Integrated Connectivity. The amplifier is built into the welding machine (relevant for industrial models). Requires knowledge of electrical engineering.

Let's take a closer look serial circuit, since it is the most universal:

1. Unplug the welding machine

2. Connect the cable from the amplifier to the “+” terminal of the device

3. Connect the amplifier output to the electrode holder

4. Connect the ground of the amplifier to the ground of the device

5. Check the polarity before turning on-->

For clarity, here is a typical connection diagram for an inverter:

[Сварочный аппарат] —(+)→ [Усилитель KICKS] —(+)→ [Держатель электрода]
—(-)→ [Масса] —(-)→ [Заготовка]

If your device supports TIG welding, an additional control unit may be required. In this case it is better to use KICKS-Digital, which allows you to program response parameters for different modes.

Setting up the KICKS amplifier: step-by-step instructions

Even the most expensive amplifier will not produce results if it is not configured correctly. The main parameters that need to be adjusted:

• 🔧 "Push" force (usually 10–50% of main current)
• ⏱️ Pulse duration (0.1 to 1 second)
• 🔄 Trigger sensitivity (low/medium/high)

Setting algorithm:

1. Install on welding machine base current, which you usually work with.
2. On the amplifier KICKS set the push strength to 20% from the base current.
3. Light the arc and observe its stability. If the arc goes out, increase the push force by 5–10%.
4. If the metal begins to burn through, reduce the pulse duration.
5. When welding aluminum or stainless steel, sensitivity may be required at "High".

Example of setting for welding thin steel (1.5 mm) with an electrode 2.5 mm:

• Base current of the device: 80 A
• KICKS push strength: 16 A (20%)
• Pulse duration: 0.3 s
• Sensitivity: "Average"

⚠️ Attention: When welding at maximum currents (more than 200 A), it is not recommended to set the push force above 30%. This can lead to overheating of the welding transformer windings.

Typical mistakes when using the KICKS amplifier

Even experienced welders sometimes make mistakes that negate all the benefits of the amplifier. Here are the most common of them:

• ⚡ Wrong polarity. If you confuse “+” and “-” when connecting, the amplifier will not only not work, but may even fail.
• 🔥 Overcurrent. Setting the push force to more than 50% of the base current leads to burnouts and damage to the welding machine.
• ⏳ Ignoring response time. Slow amplifiers (more than 20 ms) are useless for welding thin metal.
• 🔌 Connecting to a weak network. If the socket cannot withstand the total power of the device and the amplifier, this may cause the circuit breakers to trip.

One of the most dangerous mistakes is Using the amplifier with an incompatible welding machine. For example, KICKS-3000 Turbo Not suitable for household inverters with power less than 5 kW. At best, it simply won’t work, at worst, it will burn out the power part of the device.

What happens if you connect KICKS to a device with less power?

The amplifier will try to "pull" a current that the inverter is not designed for. This will lead to overheating of the transistors, tripping of the protection or breakdown. In some cases, the cable insulation may even melt.

Another common problem is Incorrect sensitivity setting. If the sensitivity is set too high, the amplifier will respond to any interference, resulting in an unstable arc. If the sensitivity is too low, it will not respond to real voltage dips.

KICKS amplifier for semi-automatic welding (MIG/MAG)

When welding with semi-automatic welding, the KICKS amplifier plays a special role. Here it is needed not only to stabilize the arc, but also for:

• 🔄 Wire feed control (prevents sticking)
• ⚡ Arc ignition improvements (especially important for aluminum)
• 🛠️ Reduce splashing (due to more stable combustion)

For semi-automatic machines, it is recommended to use models with adjustable response time, such as KICKS-2000 Pro or KICKS-Digital. They allow you to adjust to the wire feed speed and gas type.

Typical settings for a semi-automatic machine:

• Steel + CO₂: pushing force 15–25%, duration 0.2–0.4 s
• Aluminum + Argon: pushing force 30–40%, duration 0.5–0.8 s
• Stainless steel + gas mixture: pushing force 20–30%, duration 0.3–0.5 s

When welding aluminum, the amplifier should work fasterthan when working with steel, since aluminum has a higher thermal conductivity and requires more energy to melt. If your amplifier cannot cope, check the sensitivity settings or try a model with a shorter response time (for example, KICKS-Digital from 1–2 ms).

KICKS amplifier maintenance and repair

Like any electronic device, the KICKS amplifier requires periodic maintenance. Basic procedures:

• 🧹 Dust removal (especially important for models with ventilation holes)
• 🔧 Checking contacts (oxidation may cause loss of power)
• 🌡️ Temperature control (overheating shortens service life)

If the amplifier stops working, first check:

1. Reliability of cable connections (especially ground).
2. Presence of voltage at the input (with a multimeter).
3. State of the fuse (if the model has one).

The most common malfunction is breakdown of power transistor. This happens due to:

• Work at maximum currents for a long time
• Short circuit in the welding circuit
• Wrong polarity connection

If you do not understand electrical engineering, it is better to entrust the repair to a specialist. However, some problems can be fixed on your own. For example, if the amplifier does not turn on, but the fuse is intact, check diode bridge (often fails during power surges).

⚠️ Attention: When disassembling the KICKS amplifier, be sure to discharge the capacitors! They can retain dangerous voltage even after being unplugged.

FAQ: Frequently asked questions about KICKS amplifiers

Is it possible to use the KICKS amplifier with a Chinese inverter?

Yes, but there are two things to consider:

1. The maximum current of the amplifier should not exceed the rated current of the inverter.
2. Chinese devices often have unstable output voltage, so it is better to choose an amplifier model with overload protection (for example, KICKS-2000 Pro).

Which KICKS amplifier is best for aluminum welding?

For aluminum, models with a response time of no more than 5 ms and the ability to adjust the push force up to 40% are suitable. Optimal options:

• KICKS-3000 Turbo (for industrial devices)
• KICKS-Digital (for semi-automatic machines with programmable modes)

Be sure to use argon as a shielding gas!

Why does the KICKS amplifier not work when the arc is struck?

There may be several reasons:

• The control cable is not connected correctly (for models with a separate input).
• Sensitivity setting is too low.
• The current sensor inside the amplifier is faulty.

Try increasing the sensitivity by 1–2 notches or check the connection according to the diagram.

Is it possible to make a KICKS amplifier with your own hands?

Theoretically yes, but this requires deep knowledge of electrical engineering. Homemade amplifiers often suffer from:

• Unstable operation (due to low-quality components).
• Lack of overload protection.
• Poor repeatability of results.

If you still decide to assemble the amplifier yourself, use circuits based on IRFP250 or IRFP460 with the obligatory inclusion of a fuse and a diode bridge.

How to check if the KICKS amplifier is working?

The easiest way is to connect an ammeter to the welding circuit and observe the current surges at the moment the arc is ignited. If the amplifier is running, you will see a short-term increase in current of 10-50% of the base value.

You can also check the voltage at the amplifier output with a multimeter (with the load disconnected). It must correspond to the model's passport data.