It's interesting that these ZXA1 models seems to have the issue, but not others used. There may indeed be a specific A1 model issue. If I recall, the A1 is a 8 inch speaker, correct? I've often thought that perhaps that with this particular speaker size, the amount of output is a little too optimistic, and actually violates the laws of physics?
Thoughts?
Electrovoice - 2 Channel
Response1 (-3 d - B) - 60 Hz - 20 k - Range1 (-10 d - B) - 48 Hz - 20 k - Hz,Maximum Calculated SPL - 123 d - B,Horizontal Coverage - 90 or 50,Vertical Coverage - 50 or 90,Amplifier Power Output - 800 Watts
First, Thermalling out is a good thing as opposed to let's say burning up.
Despite it's proclivity for ruining your event, It is a correct mechanical and electrical response to self protect the speaker from permanent ruin and destruction via fire. But it isn't welcome as an operating condition.
I wonder if perhaps there are other factors at play:
1. Is there any sort of maximizer in play....sending a signal too big for the speaker to handle will result in thermalling(The mackie handbooks tell you that this is definitely a situation where this can occur)
2. Is the volume boosted up above the recommended setting (which coupled with a setting on the master volume of unity or higher, cause overdriving of the speaker input circuitry)
Here is a link fro mEV, that may or may not assist with isolating the issue.
http://www.electrovoice.com/sitefiles/downloads/Safely Driving Your Sound System v2.1.pdf