Hey man,

You need to add some sort of dryer to the system.

As I have read in the past moisture in your air can destroy consumables in minutes.

Think of it this way, whatever the humidity level is in your ambient air it is increased in the compressed air. With your small compressor running all the time the air doesn't even have a chance to sit in the tank and cool down.

I'm not an expert on the science of a plasma system .... but I know moisture is conductive and having it in the air cannot do anything but hinder the system.

I have what I consider to be the MINIMUM drying system ... a Motor Guard filter.

Read what MILLER says about Plasma Air Supply
Q: What are the necessary air requirements?

A: Compressed air is the most popular gas used for plasma cutting. You can use an air compressor or a bottle of compressed air. The CFM (Cubic Foot per Minute) is important because that is the amount of air that will be distributed per minute and will keep your Plasma machine running consistently. The PSI (Pounds per Square Inch) is the actual air pressure required to operate the machine. All machines need different PSI and CFM. For instance the Miller Spectrum 375 requires 4.5 CFM at 60 PSI to achieve a 3/8-inch rated cut, while the Spectrum 375 X-TREME requires 5 CFM at 90 PSI.

The other gas used is nitrogen, but the only advantages to using it are when cutting stainless steel. You will get a cleaner cut but the cut thickness will be diminished a little. With some exotic metals a gas mixture may be needed.

You will also want to have dry air when operating a plasma cutter. Miller offers a couple of Dryer/Filters that are designed to keep the air dry and clean. Dry air is important because if there is moisture in the line it will travel with the air and exit the end of the torch. This is not necessarily dangerous but will shorten the life of your consumables because the arc will follow the moisture in all directions and erode the tip prematurely.

READ THE LAST LINE --- Do you remember complaining about " the arc going sideways " It followed the moist air.