Ok, I think I finally figured out the root of the problem.
Shortening the pierce delay didn’t fix things, but with some manual testing I realized that my torch just won’t successfully create an arc if the air is flowing. It works at the first start since it seems like the air starts simultaneously, but not on subsequent cuts. Manual piercing tests with the air flowing and not confirmed this.
As a workaround, I manually added delays of a few seconds after every cut in the G-code so the plasma cutter had enough time to shut off the air flow before starting the next pierce. After making this change, the part cuts successfully. It doesn’t sound like this should normally be necessary.
@langmuir-daniel I’ll also check with Razorweld, but is this definitely indicative of a problem with the torch, or could this be a problem with the plasma cutter itself?