Humans have much better perception of temporal differences than frequency difference, it’s been shown that we can perceive as little as a 6ms difference, personally I find a temporally inaccurate system more objectionable than a linearly inaccurate system. I have always found that full range speakers sound better than sub sat systems, Ideally I’d have RP-280ms for all 5 floor speakers, considering they have an f3 of 34hz, a sub would only be necessary for LFE, since the main channels in movies are mixed with full range cinema systems (f3 of ~40hz) in mind, there would be very little content below this point. I just don’t have the funds for that unfortunately.
What I don’t understand is why it disappears at lower crossover points. It sounds fine crossed over at 60hz or below, and this has actually been a near universal experience with different speakers and subs in different rooms.
Also, why would not using a crossover at all make a difference? I haven’t tried it this way, because I don’t see any point in wasting power and increasing IM distortion by sending content below the tuning frequency to my speakers.
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Well we are in controversial territory here. I believe timing matters and can not be shrugged off.
Now as I have often pointed out time and phase difference are the same thing. However it is much better to think in terms of time rather than phase.
Lets take two sounds that are 360 degrees in phase apart. Loose talkers say that the sounds are in phase, and look like it on a response graph. However they are actually 360 degrees out of phase. If you use time instead of phase in your thinking, the error is immediately apparent, as the sounds a one whole wavelength in time apart. This way of looking at it points out the error and the trespass created right away.
So if you run your mains full range there should not be a timing error on that end. Now the sub filter will be fourth order and so there will be a 180 degree phase lag, which in time is half wave length late.
Now if we use the crossover on both mains and sub the mains have a second order crossover, and so lead by 90 degrees, which is one quarter of a wavelength in time. So the mains lead the sub by 3/4 of a wavelength in time. Now the sub phasing knob does not correct time. If it were labelled in time and not phase, the faulty thinking would be revealed.
Take a look at the impulse of my lower level system and you can see the time difference of the subs and mains. This is a two channel system. The main speakers are run full range.
Here is a frequency plot and impulse response at one of the listening position and you can see the time smear. The time smear is mainly due to the time path. The electrical phase lag of the woofers is only 1/3 of a wavelength in time.
Here is the impulse response of the studio system which is an integrated full range speaker system designed with an eye to minimal time smear.
On your last point I suspect the reason is that your mains are probably starting to roll off and below 50 Hz you are getting into the low sensitivity area of human perception.
Some would say this does not matter, but I'm certain it does. From recent comments of experienced engineers here, I'm certain does.