Plasma Sputtering. Regulator issue?

[Newman180]

I was having an issue with my 250i yesterday with plasma cutting. It would not hold a consistent arc and would pop a lot. After calling longevity they told me to back it down to 55 psi instead of the 75 psi stated in the manual. That seemed to work and I was cutting fine.
Today, I cut 3 1-1/2 " holes in a 1/2" thick plate. Starting the 4th hole I ran into the sputtering issue again. I had to lower the pressure all the way down to 30 psi, and even after that it was popping on and off. If I go any lower, either the machine overrides the arc, or the consumable melts almost instantly.

What is going on? Do I have a bad regulator? The compressor seems to be fine and is holding 125 psi in the tank consistently.

For the 1/2" plate, I'm running it at max power which seems to be 51 amps.

Thanks,
Austin

[rustycase]

Could be moisture in the air supply???
rc

[Gadget]

Moisture or other contaminants in the air supply would be my guess.

[Newman180]

Thanks guys. I actually thought it could be moisture, and right after I posted I drained the tank, which had a decent amount of water in it. I was able to start cutting again but my pressure is still way low. I think I'm going to add another air filter at the compressor end.

[Gadget]

I put an HF desiccant dryer on my line and it works like a charm. Put it as far from the compressor as possible like right next to the cutter for best results. The air has time to cool and the moisture time to condense that way.
Desiccant Air Dryer

[rustycase]

Newman, try a google on 'franzinator'.

It's a closed tube, (exhaust pipe?), with an air inlet midway, aimed down the tube when it's in a vertical position. Tap air direct from the compressor cylinder to feed it.
Bottom has a drain cock on it to dump condensation.
Flow is out the top, to the compressor tank.

Seems they work very well.

Good luck
rc

[Newman180]

I put an HF desiccant dryer on my line and it works like a charm. Put it as far from the compressor as possible like right next to the cutter for best results. The air has time to cool and the moisture time to condense that way.
Desiccant Air Dryer

Thanks. I have an extra standard air/water sepeartor which I was going to try. If that doesn't help, I'll try this.

Newman, try a google on 'franzinator'.

It's a closed tube, (exhaust pipe?), with an air inlet midway, aimed down the tube when it's in a vertical position. Tap air direct from the compressor cylinder to feed it.
Bottom has a drain cock on it to dump condensation.
Flow is out the top, to the compressor tank.

Seems they work very well.

Thanks, but that seems like overkill for me

[rustycase]

Well, all depends on how much and what quality cuttin yah gotta do... and the humidity in yer shop...
LoL I only drain about a gallon out... when I remember to do it! LoL
rc

[LONGEVITY-Support]

I would make sure to run it at 45 psi and also check the contaminants from your air supply as the other forum members suggested.

[Newman180]

I ordered a small desiccant dryer to put inline with the compressor. We'll see how that helps. Florida tends to be very humid, so who knows...