I have had the same issue on and off. This time it is not going away. Today I upgraded to F/W ver 3.6.0.0. I also performed a factory reset after the F/W update. The “Vol Knob Controls” is set to "Multi". Nothing has helped. It seems the problem is in the Vol Knob Control setting. When I changes the setting I can hear a little blip in the sound as the setting changes. Both from the headphones and the 1/4" plugged into my amp. So its doing something. But no matter what the setting value is, turing the Volume knob has no effect. Regardless of patch. I have checked all the factory patches.
After installing F/W 3.6.0.0, I have restarted the Helix LT unit and the HXEdit multiple times. Everything else seems to work fine except the Vol Knob.
I am out of ideas. Anything else left to try?