The gas does not settle if used within a normal time frame. I wouldn't say a year is a normal time frame.
You're using a bottle a year. That's your problem right there. The gas is settling out or going above the dew point.
Maybe you’ve got a bad bottle of gas, and you’ve been having the same problem for a year?
Have it back under warranty sounds dodgy to me
It’s your power supply thenIts not the welder, I sold a perfectly good R-Tech Mig 160 because of this fault and bought the Esab - the issue remained!
Different gas, different wire, different machine.
It’s your power supply then
You need to see if you’ve got a voltage drop. You’ve got the same issue on two welders the only thing that leaves is power supply. Maybe you get spikes?Its possible, but I would like to know how - I have a good grounding in electronics and power supply and fail to see how it could be that doing this, there is no light dimming, no interference on radio - the plasma cutter uses more power and that runs fine.
Baffling
You’ve had this problem follow suit with 2 independent welding machines for a number of years and you haven’t tried it on another supply to rule it out????Its possible,
You’ve had this problem follow suit with 2 independent welding machines for a number of years and you haven’t tried it on another supply to rule it out????
I still cannot believe it’s an issue after this length of time. Have you actually tried anything to resolve this or are you just hoping a snake falls out of the wire feeder one day and that’s problem sorted. No offence but if it’s not the actual machine then diagnosing the underlining issue could be very easily done in a matter of an hour with process of elimination. Ie supply, gas, torch, you.
Way Way back(2017?) you said it welded perfect even with reg set at 1 lm rather than the norm,6/8ltm, I suggested then(this might be with your old welder) that if thats the case your regulator is fuba, have you got a new reg since??