I am trying to repair a Miller Econotig tig welding machine which has lost its arc-start function. The arc start is a high-voltage current that allows for a 'jump' from the welding electrode to the workpiece so that the electrode doesn't need to be touched directly to the work. On this machine it is done with a small (approx. 1lb weight and 4"x1"x2") high voltage transformer. This transformer seems to have overheated and I had a broken connection in the secondary winding. The transformer is made by Cramer specially for Miller and only available from Miller and they want $400 for it! I'm trying to figure out a workaround as at the price the welder isn't worth repairing. This is new territory for me but when I dismantled the transformer it appeared fairly 'normal' with a ferrite core, a secondary winding of around 120 turns of 33awg and a primary of 10 turns of maybe 16awg. The 33awg wire has solid insulation which is maybe a little unusual? At any rate I have access to a second, working machine and I'm wondering if I can simply measure the input and output voltages off the working machine and look for an aftermarket replacement but I'm not sure if there are additional risks to myself and/or my multimeter from the high-voltage. Is this as simple as setting the multimeter to VAC and measuring off of the primary and secondary coils? I'm familiar and comfortable with measuring 110 and 220/240 vac circuits with my meter but I'm not sure what the voltage step up is to create the arc start. There is some more information on the welder and my issue on this welding forum where I started a thread: http://weldingweb.com/showthread.php?738471-Miller-Econotig-Issue-Weak-to-no-HF-startThanks!
