Breakaway error

Without seeing your breakaway design, it's hard to say. Post some pictures of what you've got going on.

Is it possible that the pressure from the torch is causing your switch to become un-tripped?

Is your Breakaway LED lit before you start cutting?

You could do a halplot, but I'm sure it will show that the breakaway switch is tripped some time after the torch fires.

Have you tried wiring the breakaway switch out the equation?

Again, not sure how helpful we can be without seeing anything.

That is from EMI interference, so will need shielded wiring and shielding around the switches.
BTW, this is the 5 or 6 topic you started regarding the same machine, and this one is after you have been told to keep everything in one topic! You are making a mess for you and for us who are trying to help as some issues are related and you are presenting them as separate, hence the answers will be messed up.

I guess I missed the other posts. But one thing I do wonder is why you wired them normally open. Industry practice is to wire these sort of safety switches normally closed, so if a wire ever breaks, becomes disconnected, smashed, etc. the machine will fault out and prevent you from further issue....

No worries, it just makes it really hard for us to follow and keep track of what we already did answer and what not.
First check the grounding, that is the main thing for proper operation of a plasma cutter, then use shielded cable and attach the shielding to ONLY the electronics side or the control box, always do grounding from a single point namely from the main power cord and go from there to other parts of the machine, use a shield for each cable and attach all of them to that single point in the box. No daisy chaining.

Kale wrote:

I wired it normally closed. It works this way. I think this helps with the EMI noise a little too.

Good, glad to hear! And it’s a wee bit safer too!