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I've got denon ah-d1001 (32ohm) and I also think that Zero gain is bad for low impedance and sensitive headphones... IMO sound is distorted at low volumes and too harsh/loud at volume that distortion is not as presented.
I did not have enough low watt resistors to do a final job this weekend, but I did reduce the gain for my Zero 09 DAC slightly, as a headphone amplifier for HD 485.
In the duel op amp in the zero 09 headphone amp, one channel set up as a non inverting buffer with 100% feedback, driving the volume control. The other half of the duel op amp seemed on my brief look to be part of the transistor drive circuit of the headphones, so the side effects of changes seemed to require more understanding of the circuit and some re-engineering, I took the option to reduce the volume rather than reducing the amps gain after the volume control.
I changed the output resister from the non inverting buffer output to the volume control. The original value was 1K in series with a 100K volume control. I changed this to 15K 1/4 Watt, (the PCB holes are small) resistor in series with the 100K volume control. I will probably letter try some higher values including 22K, 47K, 100K, 150K and 200K. With the 15K series resistor, the gain is not significantly changed, but for me the volume range I listen too at work is now outside the volume controls poor tracking range, so it was worth the effort.
Increasing the load the inverting buffer has to drive, should have no negative effects, I would even suggest that driving a higher load would improve the performance since the op amp should be driving the load in Class A. Provided you don't reduce the System gain too much and thermal noise becomes an issue. This should be no issue with the relatively resistors I suggest testing to match your system.
The total cost of this modification is in the area of 0.10 Euro, yes ten cents, and will make my work listening volume a little lower and more comfortable, If you are having issues with the volume control this might be the change you should start with.
I used a cheap 19 Euro soldering iron, with a thermostat (thermostats improve your soldering), a cheap solder removing tool, (About 5 Euro which is recommended to anyone who has a soldering iron) some multi core solder, and I also used a resistance meter (as a contact tester) to track components (The resister is next to the op amp) on the board (checking that I had followed the track correctly which is hard to do just by eye), and a simple screwdriver to take the zero apart.
For my use I suspect I will buy at least 10 of each value of resistor for my stores, I would suggest 22K, 47K, 100K, 150K and 200K resistor low watt 1% tolerance resisters with thin leads suitable for this job. If none of these reduce the volume range enough for me, I will then look at replacing the potentiometer, with a 10K or 50K Log values and keeping the load between 100K and 300K. This is the series resistance, or the resistance for the potentiometer plus your changed resistor. I expect I no lower than 100K for fear of loading the op amp (moving out of class a), or higher than 500K for fear of thermal noise.
Owen Hamburg