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No arc. Power and Air OK

I have a Miller Plazcut that stopped woking. At first it worked intermitently. Air pressure and power is OK. I opened up the torch head and found plasma in side the cup, cleaned it out, even tried new nozzzle and cup. At first I was getting air at the nozzle. Power lamp is on, but ready lamp wont stay on, when I toggle the ready Switch. At one point the head got hot (after I cleaned it). When I squeeze the trigger and then toggle the ready switch, I get sparking at the spark gap, but only when the HI/LO SWitch is in the HI position. But no matter what I do, before and now, It won't produce an arc at the tip. One other thing I did notice, is that I found a large cut (some wires still connected)in the high voltage wire. It was not arcing, but I did rejoin the wire and provided ample insulation to avoid any possible future arcing. Is there something special about the torch? There are two electrical connections on the torch which according to the wiring diagram are supposed to act as a loop (closed swich) Does the torch head contain some kind of fuse or fusible link that blows when there is trouble or internal arcing. I checked these two connections with an ohmeter, and it shows an open. Under what conditions do the 3 time delay modules (TD1 TD2 TD3) fail. As I tried to troubleshoot the problem, things progressively woorsened. I have two of these units with the same problem. Please help.

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  • kevin_max
    kevin_max Jan 20, 2010

    Is yours a Miller Plazcut. The plazcut model is the only unit I know of that has two trigger wires and two additional wires of the same size going to the gun, in addition to the high voltage lead. A total of 5 conductors plus gas hose.



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If the main power cable is cut that is your problem,unit uses high frequency.the two leads go to the gun trigger back to unit,no fuse or fuseable links in the gun.

Posted on Jun 28, 2009

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Did you ever resolve this problem as I have the same problem and would like to know what to check.

Posted on Jan 20, 2010


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