THC Voltage

No, 157 is correct for your setup. The ADC on the ESP32 is not perfectly linear and 32 is very close to the floor, it's not reading any voltage on the input which points towards a wiring issue of some sort. Double check that none of the connections came loose at the Strike Command board. Since you have the DIN mounted analog isolator, make sure everything is connected up well there and it's under power, usually they have a power indicator LED. If everything looks good, I would measure voltage the voltage in circuit on the output side of that first at it's exposed terminals. You should see around 2v on a pilot arc on your multi-meter in VDC. Let me know what you find and we'll go from there!

Ok, will check tommorrow.

Not getting any signal from the plasma cutter.

Might be a bit before I get anywhere with it, trying to decide if I should just upgrade to a Hypertherm 85.

Thanks, Matt. Since you’re not getting a voltage signal from the plasma cutter, this is upstream of JC3 and the 157 scale setting.

Before writing off the 45XP, measure directly at its CPC interface while briefly firing the torch in open air on the pilot arc: pin 6 is divided-voltage positive and pin 5 is negative. With the divider set to 50:1, I would expect roughly 2.2–2.6 VDC between those pins.

If you have that voltage at pins 5 and 6, the cutter’s divider is working and the problem is farther downstream in the cable, DIN-mounted isolator, or related wiring. If there is no voltage directly at those pins, the CPC connection or internal voltage-divider board is likely the problem.

I’ve personally seen the voltage-divider boards fail fairly often in Powermax45 XP units, although I haven’t seen that same pattern across other Hypertherm models. Measure only the divided CPC output—not raw arc voltage.

We’ll leave this closed for now. Whenever you decide whether to repair the 45XP or move to the Powermax85, comment here and we’ll reopen it and help you get everything configured.

No voltage right at the machine, I need a handheld unit around the shop so figure I might as well upgrade.