Getting zapped on High Frequency Start

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I am using a Miller DialArc HF. It works great for TIG welding mild steel tubing with 3/32 electrode (2%). However, when I try to use the high frequency start feature, I often get a mild zap. It happens often but not all the time. Question: Does anyone else have this problem? Is there a technique to avoid the tingle. Someone suggested using thin latex/rubber gloves under the welding gloves. My gloves and the work are dry. I am standing on a concrete floor and have on heavy rubber soled workboots.Should I be talking with Miller to see if there is a problem with the machine?Thanks for your help in advance.Gil B
Reply:Is the machine properly grounded?Sure, I can fix it... I got a welder!!!
Reply:There is probably a crack in the torch body somewhere. You may not even be able to see it without really close inspection.Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:I used to get that until I figured out there were cracks in the troch leads insulation. I layed the torch lead across the table and turned off the lights and sure enough it would HF through the cracks.May not be the case with yours but it did happen to me
Reply:FWALZ3: The machine is hard wired and appears to be properly grounded at the junction box. It may be hard to tell what is happening at the power panel. Can you give me any suggestions on how to determine if the ground is suspect? If I call maintenance they may want some kind of evidence that there is a suspicious connection.
Reply:snip> . . . crack in the torch body somewhere.Hmmmm! It is an old torch. I'll see if there is another torch in the tool crib and try that. Thanks.
Reply:snip> I layed the torch lead across the table and turned off the lightsThat's a good idea. What did you see? Blue sparks? a Halo? What if I held a fluorescent lamp near it .... would it glow?
Reply:Ya know what it looks like when the electrode is too far from the work to start an arc but you can see the HF arc? that came out of my torch lead onto the table when the crack was near the table (which was grounded of course)
Reply:Originally Posted by geebee509I am using a Miller DialArc HF. It works great for TIG welding mild steel tubing with 3/32 electrode (2%). However, when I try to use the high frequency start feature, I often get a mild zap. It happens often but not all the time. Question: Does anyone else have this problem? Is there a technique to avoid the tingle. Someone suggested using thin latex/rubber gloves under the welding gloves. My gloves and the work are dry. I am standing on a concrete floor and have on heavy rubber soled workboots.Should I be talking with Miller to see if there is a problem with the machine?Thanks for your help in advance.Gil B
Reply:Gil,     Miller recommends a separate ground to the frame of the machine in addition to the ground through the power cord. Has the machine worked properly in the past and this is a new problem? If so, I would agree with the others that the torch is more than likely the problem.   Here's a link to Miller Owner's Manuals. You can download a generic Dialarc manual or if you have the serial number handy you can get the manual specific to your year machine.http://www.millerwelds.com/service/ownersmanuals.phpGood luck!FredSure, I can fix it... I got a welder!!!
Reply:Fred, No one has complained of this in the past but the machine has been used mostly for SMAW. I'm off today but I'll check the torch out on Monday. I'll also ground the machine frame to the EMT conduit and see if it helps.Thanks for the reply and link.
Reply:I have also had this problem when using water for coolant, rather than the stuff that's made for the machines.  It sounds odd, but water will transfer the high frequency, and the coolant won't.  I have a scar on my hand where I had high frequency burn through a torch handle, through my glove and zapped my hand.  When I put in the Miller coolant, it stopped doing that to me.
Reply:I agree with everything below. I have the the exact same machine and had the exact same problem, it was a bad ground clamp issue. Replaced the ground clamp and the problem was cured. Remember that at the end of the day the current will take the easiest path to ground. If the current is choosing you as its easiest path (getting shocked would obviously be evidence of this), then start right at the ground clamp and work your way towards the welder and finally to the supply circuit itself if need be.   Originally Posted by dave powelson****Gil, all of the above posters are correct and I'd suspect either faulty equipment grounding and/or leaking torch leads---as they note.It is possible for one's arms and hands (especially if wet or sweaty!) to become part of the HF arc start circuit--on AC or DC, especially if the ground is clamped far from the weld area, or just clamped to the table.     Solution is to ground close to the weld area--with the grounding clamp and that area to be nice and spiffy-clean--to ensure a good ground. That makes all the difference in how the job runs.     'Your's Truly'---has zapped hisself really good, a few times. Once the HF fired off, and went thru the skin to the bone of a finger. Another time, I whacked my poor, sweaty, younger brother with DC HF, who was holding a part for me to tack. He still talks about that--17 years later.      When hot and sweaty with bare arms, etc. then insulate your arms to the work area with dry cloth, leathers, gloves, etc.--The last thing anybody needs is current going up one arm, across the chest (and your heart), then down the other arm. ****Another item to avoid---is not having any other weld machine's grounding clamp on the same table or part--as the TIG ground. Just remove the MIG or stick ground, before tiggin'. You don't want to chance-putting extraneous current into another machine.