I've had a long evening of much experimentation with a multimeter and oscilloscope...
I don't believe it's an under voltage problem as I could power the VL Pedal switcher from a DC linear PSU with it plugged in to the guitar in jack and brought it down to about 7V input and it still didn't get noisy. The Pedal switcher runs it's smoothed 12V to the relays and to the buffer op amp which I don't use. I removed a resistor to the buffers power and it still hummed, so it's definitely not that. The MIDI/opto isolators for midi ports in it runs off a 5V regulator which seemed to be working fine with the AC PSU (15V pk/10.7 RMS -> 13.65 VDC from the rectifier), the phantom power from the Herbie (12VDC -> 10.7V from rectifier), or at least down to the 7V from the DC PSU (don't know what it was past the rectifier but that was still ok out the regulator and noticeably less than the Herbie output). So I think I've happily ruled under voltage out.
I then looked at grounding issues. It seems there is only about 2 Ohms from Pedal switcher chassis ground to the audio out and power ground. So it could well be a ground loop issue. It appears (at least when off!) that the Herbie phantom power is floating as it's open circuit to motherboard ground and chassis. When on though the -ve looks like 0 V and the +ve like 12 V relative to the chassis. It seemed to be able to power the pedal switcher with only the +ve side of the phantom power connected, so it definitely looks like there's a 2nd ground somewhere. Oddly it still buzzes with only the + phantom power connected though (using the pedal switcher to Herbert audio lead as ground). Maybe thas to be expected though I guess if there's current flowing down the audio screen. It has the same 11-ish volts at the main smoothing cap in the pedal switcher when only phantom powered with the +V.
I tried unsoldering the Herbert phantom power and connecting the voodoo labs PSU to a pair of flying leads coming from the pins. It's lovely and quiet, so it's not a MIDI cable interference issue. It means if I do decide to cut a hole in the back of it and put in a DC phantom power jack it should at least work without any nasty surprises!
So overall, it looks like it's some kinda ground loop and doesn't happen with a totally floating/isolated MIDI phantom power. But the Herbert ones look like the -ve is connected to 0V somewhere. Never a problem with a floating audio-free MIDI patch change pedal only, and I'm guessing all the MIDI capable pedals switchers aren't phantom powerable. Trust me to be difficult and try to do something no-one else has tried! Unless there's a fully floating mod I don't think I'll be able to use the Herbie phantom power to run anything that audio passes through with a common audio/power ground. This may be the reason Voodoo Labs never gave that option in the first place.
If there's a mod to totally isolate the Herbert phantom power let me know, but it doesn't look simple. Otherwise I might just buy a DC jack socket and get the drill out. Easier to have a 9V PSU in the rack than out on a long mains lead near the front of the stage and it trying to make my wah pedal hum with the magnetic emissions!
(Unfortunately I wasted quite a while to begin with thinking the Herbie phantom power was noisy by powering the oscilloscope from the opposite side of the room off a multi plug with lots of computers and digital stuff on. Got suspicious, moved it to the 4-way the Herbie was coming off and it suddenly went fine!
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