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Well it has finally been warm enough in the shop to continue working on the PoLabs THC error problem.  I was using an oscilloscope to observe the divided voltage signal coming out of the Hypertherm.  I have to say it is really ugly.  I started to experiment with conventional RC low pass filters but was having little success.  I got a suggestion from a guy that worked in the oil industry doing siesmic testing.  He thought using a transformer as a very large series inductor might work.  I had a step down torriodal transformer that when from 110 or 220V down to 24V.  I used the 110V windings and it seems to work like a charm.  I have not yet looked at the signal with the O-scope, but the OP Labs PlasmaSensOut is happy (meaning no error being displayed) and the voltage being displayed is very stable and quiet.  Now it is time to tune the torch height control speed.  I will update  progress on making the system work.  

Vexing is an understatement . My problem initially was happening with no cables attached except for power.  If I had the unit installed in the same side of the building as my table it would error out.  Changing the grounds in the control panel to a common buss bar,  and adding some ferrite chokes, and another ground rod  seemed to have resolved that issue. Next I did the DC, and added more ferrite chokes.  Now I will try changing out some of the wiring to rs-485 shielded twisted pair.  I will also be trying to eliminate the relays that I have attached to Torch up, torch down, and arc ok lines.  I am going to use the 5.6k ohm resistors as described in the Masso manual.  Hopefully that will eliminate the rest of the error.  Nothing at this point has resolved the issue entirely.  

Wayne- Have you tried to isolate which of the cables connected to the PlamaSens system is causing your issue?  For instance, have you disconnected everything except power and optical link and still see the error?  I'm not trying to be a back seat driver, but if we make our debugging information public, everyone can benefit.  Grounding and shielding can be particularly vexing.

My problem is noise in the system too.  I have not even addresses the hypertherm hookup yet.  I recently redesigned my DC power circuits along with isolation from all of the AC lines (physical location in the cabinet), I ran shielded twisted pair wiring. I also installed several ferrite chokes on the different lines.   That seemed to help. Now My E-1 error is intermittent and not constant.  As soon as I start any drive motion, it seems to get worse.  My next step is going to be replacing the Servo drive -Masso control wires.  Currently they are Shielded twisted pair, but they are a low grade security system wire.  I am upgrading all of the comm wires to RS-485 cable.  It is a bit pricey, but because of the higher twist rate and 100% shielding, I hope to reduce the remaining noise.  I am already using this style cable from the Hypertherm, so I hope I won't experience the same issue as Curtis is.   Time will tell.  I'll post any success or failures as they happen.  Good luck to all, and Thank you to Arturo and his team for the advice and help.

My PoLabs THC controller started having E-1 communication errors as well.  It seems to work for about 1-2 seconds after the torch starts and then the error is generated.  Sometimes it will start to work again during the same torch event, but not reliably.  It is not related to the Ready Delay time.  I have tired multiple cables and also cleaning the optical I/O ports.  I have opened a ticket with PoLabs, but have not gotten a response yet.  It shouldn't be a ground related problem on the sensor side as that is the point of the optical isolation.  On the SenseOut side, everything is a common ground at the BOB.  Has anyone made progress with this problem?

More Information:

If the Hypertherm Divided Torch Voltage is disconnected and an external variable power supply is used to simulate the torch voltage, the E-1 error does not occur.  The torch is on and the servo are moving; everything is as if the system is running, but the height control voltage is coming from an external power supply.  

Is noise on the torch voltage lines causing the problem?  This at least points to the problem being on the transmit side of the optical link and not the receive side and eliminates the actual optical cable and connectors as not being the problem.  

I have started communicating with PoLabs.  They asked me to provide pictures of where the PlasmaSens and PlasmaSensOut are installed and well as wiring details. 

I have been working with Arturo at CNC4PC,  an also the techs at PoLabs.  Both have been very helpful.  My unit is hooked up in a sinking fashion.  So the torch up/ down functions go to common ground when activated.  I am using solid state relays to carry the load.  The noise issue is not completely resolved yet. The THC is VERY sensitive to electrical noise.  So far I have re-wired all of my grounds, and installed ferrite chokes. The most significant solution has been the install of shielded twisted pair wires on the ac and DC sides.  I am still experiencing some intermittant comm errors.  I am waiting for some new DC terminal blocks, and I will be changing all of my DC wires to sheilded twisted pair.  The shields will terminate on one end only (to control panel earth ground.) I hope this should resolve the remaining noise issue. If not, the only thing left may be a filter /reactor on the mains.  Let me know how things turn out, and I will post any significant progress.

I am having the same issue. It did it right after I uncapped the cable and unplugged the ports, so I know it's not dirty. Mine is intermittent. However, that's not the only thing wrong with mine. When running in the test function, I'm not getting any voltage to the torch on, torch up, or the torch down terminals. Yesterday, when I first put power to it, I was getting about 8.9V coming from them with 19V DC going in. This morning I only got ~4V, now there is nothing. 

Did you find a solution yet?

I recently purchased the PoLabs THC package.  I have it installed (without the plasma attatched yet).  I am getting an E-1 error.  I thought that it might be a damaged fiber so I replace it with a new one.  Now I am getting an E-1 error alternating with a -----.  I have a trouble ticket in with Polabs, but their only response so far was to wiggle the fiber and check for dust, (It has not helped).  As far as the unit operation, I am able to run an up/down test from the menu and that appears to work fine.  Do you have any sugestions?