Plasma Cutter Issues

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Hi folks,  I have a cebora plasma cutter that I have been using for years without any issues for light automotive bodywork.  It recently stopped working and I am unable to troubleshoot what could possibly be wrong with it.  It strikes a primary arc and the air pressure switch appears to be working but it does not seem to transition over to the secondary arc for cutting?  I replaced the electrode and nozzle but it still has same symptoms.  I also checked the air/water seperator and everything looks nice and dry. I know this is probably something stupid.  Any thoughts as to what it might be or what else I can check?Thanks,-Rich
Reply:I was going to say is your air pressure high enough? But it looks like you may have checked that if you checked the switch.Drivesector Hobart Handler 140Hobart Handler 180Ready Welder 2Hobart Air Force 400Airco Stinger 225Of all the things I've lost, I miss my mind the most."OZZY"
Reply:Oh check your ground wire, and wire to ground clamp. If it were me I would pull the cover off and tighten all connections and blow it out with compressed air also.Drivesector Hobart Handler 140Hobart Handler 180Ready Welder 2Hobart Air Force 400Airco Stinger 225Of all the things I've lost, I miss my mind the most."OZZY"
Reply:Thanks guys.  I double checked the airpressure and took the cover and blew out the dust inside.  All the connections look good to me.  Unfortunately, it still does the same thing.  Any other suggestions...I'm out of ideas.-Rich
Reply:This is just a shot in the dark, but the problem might be as simple as a bad relay or contactor.    I've not seen the innerds of a plasma unit, but there has to be some sort of device to connect the circuit for the cutting arc.    Search the circuit board for a relay or contactor and listen if it clicks when the cutting arc should start.There are no small projects
Reply:Rich,       Is this the first time you have replaced the electrode and nozzle? First time you have used this particular replacement part or manufacturer of the part?    I experienced this same problem with my Hypertherm Powermax 380 when my welding supplier sold me Miller replacement parts, swearing they were identical. Well they are not.     What happened with mine was that the Miller electrode was about .010" shorter than the Hypertherm part. When assembled into the torch, the electrode had enough free play between the nozzle and contact switch to not activate the switch completely. This would allow the air supply to start, an initial arc would strike and then almost immediately stop.  Check and make sure that the replacement parts you used are specific for your machine.  I chased this problem with mine for months, figuring my plasma had a serious issue...little did I know it was only a $6 electrode!!!- Paulhttp://all-a-cart.comWelding Cart Kits and accessories