Hi Ed,
Long time, no speak.
By way of comparison, my own test rig is capable of 1.943V RMS in -10dBV trim and 7.62V RMS in +4dBU trim via the Lynx 2B sound card. Havng tested more Velodyne subs than most, and using them in my own home system, I am all too aware of the potential for overloading them inadvertently.
The gain structure on the Velodyne DD subs is rather high, particularly when driven via the XLR inputs, and the overload threshold is not very generous. By my own measurements, a form of clipping sets in around 1.5V RMS. The odd thing is this distortion starts to creep in below 20Hz to start with. As you increase the drive level by a few dB, the distortion creeps up the frequency scale maintaining a very definite descending slope with increasing frequency. Which suggests to me this is not simple clipping but possibly some quirk in the DSP code at high amplitudes. I have a question about this open with Chris Hagen at Velodyne currently.
The upshot of this is that I am acutely aware of the potential for overload when testing these subs. The sloping nature of the distortion as it starts to appear makes it less easy to spot in swept sine tests as it simply becomes a contributing factor in the background. Spotting it with tone-burst testing would be even harder as it will typically just appear as rather high levels of odd-order distortion. Something for the reviewer/tester to beware of is all I am saying.
However, this issue can also impact on the general user. By their nature these subs will tend to end up in high-end systems, often partnered by equipment that generates signal levels more typical in the professional arena. For example, my own Theta Casablanca DACs are specified to deliver up to 20V RMS via XLR. If you connect a DD sub direct to this and match levels, you typically end up with the DD volume set to something like 3 to compensate for the very high signal level from the processor. In this scenario, it then becomes rather easy to clip the subwoofer on loud material, which is a pity after spending all that money! A higher overload margin and lower gain on these subs would be a good idea, particularly via the XLR inputs.
My advice to anyone using these subs in such a high end system would be to ensure you don't set the DD volume lower than 15 and match the speaker levels by dropping the level of the subwoofer output in the processor setup menus only. If you currently have the DD volume set in single figures, then this overload issue may be a problem for you that you may not even be aware of.