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Had this same problem with a Yamaha sub. Unfortunately it's the amp section in the sub. If they can't fix it in the shop (problem is they don't leave it on long enough for the problem to return), the only option is replacement. I buy exclusively on AmEx cards, because they cover this kind of stuff - an additional 1 year warranty on anything you buy.
The settings you have will not break anything and may sound OK.
But they may not be optimum for getting the best bass from your system. The SubSonic setting filters out frequencies below the threshold of hearing allowing the amp to put more power into the frequencies that can be heard. So, it should be set to about the same frequency that your enclosure is tuned for or just a little lower. If your enclosure is tuned for 35Hz, then the subsonic should be close to maximum.
Similarily, the low pass sends all frequencies below the setting to the subs, (other than those blocked by the subsonic filter) and is commonly referred to as the "crossover" frequency. Typical crossover frequencies for subwoofers are 60Hz, 80Hz and 100Hz. For a ported enclosure, lower is probably better.
The phase shift should be set to the position that best synchronizes the bass with the music. Because of the additional wiring required for the subs, the signal to them is sometimes slightly delayed causing the bass to be "out-of-sync" with the rest of the music. The thump of the bass comes just a little sooner or later than expected. If the bass sounds out of phase, turn the phase shift on, otherwise leave it off.
The "gain" or level control allows you to match the amps input to your head units subwoofer output. The best setting is usually as high as possible without distortion. Set it by turning up the head unit volume to about 3/4 maximum and then advance the amp gain until your subs just begin to distort. Then back it off slightly.
These settings should allow your amp to put the most power into the frequencies that your subwoofers are designed for and hence produce the loudest and lowest bass.
Subsonic refers to frequencies too low for the human ear to hear. Generally humans can hear frequencies in the range of 20 to 20000 hertz (cycles per second), but we hear best in the range of 1000 to 4000 hertz. High amplitude subsonic frequencies can cause damage to your speakers so many amplifiers have an electronic filter in them to reduce the amplitude of these very low frequency signals.
The subsonic filter is to help your system's overall performance by blocking frequencies that your subwoofer cannot effectively produce. For example, if you have a single 10 inch sub, it's not likely to be able to produce sound much lower than 60-80Hz with any respectable volume. If you have the subsonic filter on and set to 60Hz, it will prevent a 40Hz tone from being delivered to the sub. If the subsonic filter is turned off, your sub will get everything, and it will try to produce every sound. If it gets a 40Hz tone, it will make the sub work extra hard without any audible noise. It'll just degrade the overall so the answer to "shoud the subsonic filter stay off" would be "it depends on your system" but in most cases, you should keep it on, and set it to the low end of your subwoofer or woofer range. This also applies to filters on mids and highs.
The subsonic filter is used to filter out the bass that is too low for the human ear to detect or hear--remember the lower the frequency or bass note that you try to play the harder the amp has to try to reproduce it-so by filtering out the bass that you cant hear it saves life on your amp and subs and your not missing anything anyways cuz ya couldnt hear it to begin with.
The phase is used to match the phase of the sub, highs amps. If you don't know how to determine if there's a phasing problem between the two amps and you can hear no difference, leave it set to 0.
Many people use the subsonic to prevent over driving speakers in a ported enclosure. If you're using a sealed enclosure, leave it set to the lowest frequency. If you have a ported enclosure, set it just below the resonant frequency of the port in your enclosure.
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