Thanks for all your help with this. I really do appreciate it!
QUOTE(dakos @ Feb 16 2012, 05:24 PM)

A few suggestions and questions:
One thing I see you're doing a bit wrong is your HP filter setting, it should be set at the -3dB point of your speaker, not your -10dB. So set your HP filter to 44Hz with Butterworth 24db/Oct slope, this should draw less current from your amp that's being wasted as heat and not hurt the SQ. Note that this is the recomended initial setting, this is not an absolute number and it should be tweaked in accordance with your musical needs.
Cool. 35hz was an initial suggestion from the cab manufacturer. My sound is very full range, hence choosing a cab with a tweeter, but as I play live drum & bass, my core 'bass' tone is a little more sub than a typical live bass player. I guess I should start letting the club PA's do a little more work for me! I shall make this change when I'm at the studio over the weekend and see how it sounds.
QUOTE(dakos @ Feb 16 2012, 05:24 PM)

Also after looking at your speaker, I see you are running the amp bridged @4 ohm, this is an extreme load for any amp, especially on sub duty, especially when you further push it with the +3dB EQ setting @50Hz and those octave pedals. This type of load will put almost every amp into thermal especially budget amps.
I have since removed the output EQ boost (before the thermal clipping happened yesterday) due to the realisation that any DI taken at live shows is from the Preamp and that boosting at the power amp stage is only going to give me a sound in the studio/from the cab that is not reproduced through a venue PA. therefore that is no longer an issue (but was not adding to the cause of yesterdays issues). As for the bridge mono mode - the amp was bought to provide me that amount of headroom. As 'powerful' bass amps were being pushed to audible distortion at the output due to EQ'ing in lower bass frequencies. This allowed me more headroom for doing so. As you point out though - maybe its not the 'best' amp for the job.
QUOTE(dakos @ Feb 16 2012, 05:24 PM)

Sone things that would help us further figure out if there are additional problems that contribute to this thermal limiting... Do you have the amp inside a rack? Is there something blocking the air passage? Is your grid voltage stable?
Yes the amp is in a 3U Gator shallow rack. The amp is literally exactly the same depth as the rack so the back (and the fan) poke out just a bit, meaning the air flow goes straight out into the room behind it. It has the preamp above it in the rack, which runs constantly cold and doesn't add any additional heat to the racks airflow. Voltage wise, it's an oldish building in a city centre so I'd say it was far from stable. Most venues I've played recently have been far worse though (one even put some of my effects pedals into crazy shutdown). I don't experience any issues in terms of mains hum etc within our studio though.
QUOTE(dakos @ Feb 16 2012, 05:24 PM)

I was confused about the fan setting it exists on the newer XTIs (1002, 2002, 4002, 6002) and not the older ones (1000, 2000, 4000, 6000).
The thermal limiter will not hurt your speakers.
It sounds like your amp gain and preamp gain are set up properly, do you hear an upgrade in volume?
How you back off is of no consequence, on the pre, on the amp or on the octave pedal, all should get the job done.
Cool. The output gain will increase and decrease along with the XTi's attenuator though if I am correct? Whereas the input gain (seen in SA and is not clipping) will reduce with the output of the preamp before it?
Shep