Controlling Gas Flows to Plasma Arc Torches and Related Systems and Methods

In some aspects, methods for controlling a pneumatic system in a plasma arc processing system can include: receiving, by a computing device, a command to begin a plasma processing operation; generating a valve command signal for a valve that includes an operational drive voltage of at least about 125% of a continuous duty cycle coil voltage rating of the valve to open the valve; and once open, adjusting the valve command signal to facilitate a steady state operation to: monitor a steady state operational duty cycle of the valve, the steady state operational duty cycle being determined by comparing the continuous duty cycle coil voltage rating of the valve to an actual operational drive voltage supplied to the valve, and control the operational drive voltage supplied to the valve to maintain a steady state operational duty cycle of the valve at less than about 60% during steady state operation.