Anyone have any ideas?

Hypertherm Powermax 600 plasma cutter-
all new consumables- it will arc ONE time after you power on. You can cut as long as you want, but if you let go of the trigger, you have to power down and power it back on before you can cut again.

After that first time, when you press the trigger you don't even get a blast of air or anything- it's like the trigger button is dead. But- It is very consistent. 1st arc after reboot always strikes with no issue, so I would think it's not a torch/trigger problem.