Dear Headfellows,
Just read this thread and decided to throw in my 2 cents
As tangent rightly noticed all potentiometers have a certain imbalance, especially at low volumes. Even the expensive Alps Blue Velvet is specified to be accurate within 2 dB only.
The tracking imbalance is one of the reasons that the overall (maximum) gain of the CORDA HA-1 is rather low. Thus people are forced to turn-up the potentiometer a little bit more than usual, thus operating in a region of optimal tracking. Another positive effect is an increased signal to noise ratio.
The overall gain of the PORTA CORDA is much higher. The reason is that in most cases the source will be a portable CD-player. These players have a much lower output level than home-units and therefore a higher gain is required to drive high impedance headphones to an adequate sound-level (for the headbangers among us).
As far as tracking is concerned, Joe's configuration is far from optimal. If I'm well informed his CD-player has a rather high output level and his headphones (EX70) are very sensitive. Thus he can't turn up volume to a (normal) level of improved tracking .
My suggestion to Joe was (and still is) to reduce the effective output of his CD-player by using an interconnect cable with a voltage divider integrated. Thus the potentiometer can be turned up much further and his problem will be solved.
Of course we can also reduce the gain factor of his amp but what happens if Joe wants to buy a very inefficient K501, using a low level output PCDP?! We would have to increase the gain factor again. With a different interconnect cable he will be more flexible for the future.
As for the quality of potentiometers.
The potentiometer inside the HA-1 indeed is the renowned ALPS BLUE VELVET. It's quite expensive and counts for approximately 10% of the total costs for the parts (housing included!). Nonetheless tracking is specified within 2dB only at lower volumes. Some time ago ALPS also produced an even more noble potentiometer with an accuracy of 1dB. It costed around $500,- !!!!
Stepped attenuators are very nice, but one such attenuators normally costs more than a complete HA-1.
The potentiometer inside the PORTA CORDA is also made by ALPS and actually, considering its size, is quite a good one. It is completely sealed and thereby insensitive to moisture and dust. Not unimportant for a portable. Within its size hardly anything better can be found.
However, everything that is to be made small also has higher tolerances in accuracy and this potentiometer is specified within 3dB tracking only. Anything better, if available at all, will be much more expensive
Joe told that his old CD-player has an analog potentiometer with better tracking, but my guess is that the maximum gain factor of this portable is such that the potentiometer has to be turned up much further to obtain the same sound level. It thus operates in the region of optimal tracking. With his 580 Joe probably can turn up his PCDP to maximum volume and it will be loud. If he turns up his PC to maximum he will be deaf. That's the difference!
(Of course Joe also could have been lucky and he simply obtained a pot with better than specified tolerances. There always is a certain production variance)
The digital potentiometer on his new CD-player indeed will have a much better tracking than any analog potentiometer. It's by design. However, digital volume controls do have a certain number of drawbacks not given by analog potis.
A very common method is to mathematically divide the digital signal. Thus the "input signal" of the DAC is reduced and therefore the output signal of the DAC is lowered. Although tracking imbalance is not affected, at low volumes the signal resolution is strongly impaired. (much lower than 16bit)
Another method is to use a digital potentiometer with a chain of resistors on-chip and by selecting different contact points within this chain. To select the proper point electronic switches are found on-chip. These switches are known to effect the clarity of the signal. Moreover additional circuitry is required to control the potentiometer. This kind of circuitry is rather expensive if used in a product that is produced in small numbers only.
As for crackling noises. As BenG indicated these are most likely due to some oxidation or dirt on the slider or conductive path inside the potentiometer. They normally disappear after a certain period of use. Of course it shouldn't be there from the beginning, but as I don't produce these potentiometers myself I unfortunately don't have any control on this one. Again be noted that the potentiometer on the PORTA CORDA is sealed and therefore no external dust could have entered the pot after being made.
Last note: As far as parts-quality and build-quality are involved it's rather unfair to compare a product like the PC or the TA with a PCDP of $100,-.
Portable CD-players are made in large series (>> 100.000) by computer controlled assembly lines. The PC is completely made by hand and is produced in small numbers only. Bying parts in small numbers is expensive and the labour to produce one amp also isn't cheap. In my opinion the PC is a good deal, very well worth its money. It's not a perfect amp but a better amp simply costs more.
Cheers,
Jan