Rambozo
I'll try your suggestions when I get home today. I also have a Millermatic 211 MIG and that one does the same thing, after welding if I touch the wire to the metal it sparks, sometimes enough to darken the helmet. Miller says it's residual voltage from the caps. I know it's a different machine with the transformer though.

Performance
I read an article from Miller talking about having to scratch the tungsten across the metal if it doesn't start. They blame it on either the tungsten or the material is contaminated. I've considered this too but if even happens with clean metal and tungsten.

Something I noticed last night while trying this was the HF was erratic. Even when it started, the time varied, it wasn't always the .5 setting on the preflow, Sometimes it was noticeably longer even when it did work

Thanks for all the help