Is your plasma cutter not arcing, even though the machine powers on or air flows through the torch? This guide explains seven common causes of plasma arc failure, including incorrect air pressure, worn consumables, improper torch assembly, poor work clamp contact, damaged trigger cables, power supply protection, and pilot arc circuit faults. Learn how to identify symptoms, troubleshoot safely, and distinguish a failed pilot arc from an arc that will not transfer to the workpiece. Practical maintenance tips also help improve cutting reliability and reduce unexpected downtime.
INWELT WELDING’s China National Day Holiday Notice 2026: Our company will be closed from October 1st to October 7th, 2026, and resume normal business on October 8th. To ensure smooth production and timely delivery, customers are encouraged to place orders in advance. As a professional welding torch manufacturer and supplier, INWELT provides MIG welding torches, TIG welding torches, plasma cutting torches, welding consumables and OEM/ODM solutions. Our sales team will remain available online during the holiday to support customer inquiries and urgent requests.
MIG torch wire jamming is usually caused by excessive wire-feed resistance or unstable drive force. The most common causes include incorrect drive-roll pressure, the wrong drive roll, a dirty or incorrectly sized liner, tight cable bends, contact-tip blockage, excessive spool tension, contaminated wire, and poor feeder alignment. To fix a MIG wire jam, locate the restriction first, then inspect the contact tip, straighten the cable, check drive rolls and spool tension, and clean or replace the liner. Proper wire-path setup prevents birdnesting, unstable feeding, and production downtime.