Okay, my hum is back with a vengeance all of a sudden. I seem to have blown an output cap on the supply board. The output has even more hum than before (when not attached to the boards; the caps on the actual audio boards seem to reduce this to a negligible level when measured from there). I have no idea if this is related, though. I'm starting to think the power supply fixes were mostly red herrings.
That said, I have confirmed that the hum appears to be entirely induced. I hooked cables up between two units, and even with a very limited ability to move (due to short cables), I was able to eliminate almost every trace of the hum through reorientation of the unit whose power supply I was using. I'm confident that if I had cables about three inches longer, I could completely get rid of it, but I'm not going to make custom miniature Molex cables just to prove a point.
I don't know why we're getting the amount of induction we're getting, nor do I know where it is entering the audio path. The two things that I'm pretty sure about are A. that the power supply in these units sucks in a very fundamental way, and B. that the hum is being induced into some part of the circuit due to being in close physical proximity with that massive EM field generator that the manufacturer calls a transformer....
A quick measurement of the current drain from this device (a brief inrush spike notwithstanding) shows the total load at around 10 or 12 W, according to my UPS. Given that most of this is roughly a 30V circuit, we're talking 300-350mA total. I can't imagine why they designed the supply the way they did.
I'm thinking that perhaps I should scrap the entire power supply circuit and start over. Use the 30VAC secondary to provide 48VDC with this circuit:
http://sound.westhost.com/project96.htm
and also use it to provide 24VDC through a regulator circuit (one side of the current supply circuit). Use the center tap to provide a ground reference for +/- 15VAC going into caps followed by +/-12VAC regulators.
With such a change, that huge toroidal transformer gets replaced by a single tapped 30VAC secondary. Digikey has standard transformers as cheap as $14 that would do the job.
http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=237-1005-ND
Now doesn't that look a whole lot more inviting than a toroidal monster the size of your fist?
