I too am noticing this problem with my 2010 Mac mini. It only started for me after upgrading to 10.7.2.
My Mini is connected to an AV receiver via HDMI. When waking the Mac from sleep to play music the sound will come out of the internal speaker (no headphones or jacks connected). The system refuses to select the HDMI output in System Preferences.
I find that restarting the Mini with the AV reciever turned on seems make it output through the HDMI, but it is annoying to have to do this every time I want to just listen to music.
Just to keep everyone updated, I've opened a support case with Apple and been in touch with the product specialists in Cork, Ireland.
I've sent detailed logs to Apple using their Capture Data tool, and understand that this information, along with an accurate problem discription, has been forwarded to engineering.
I'll post again when I get a further update from Apple.
I have the new Mini 2011, i7 6630 256 mb, etc. It replaced my early 2009 mini with the 9400m graphics.
In both cases, this worked for me;
I use VLC for playback in case of .mkv files and QT 7 for anything made with Quicktime like FCP X. (QT 7 allows you to replace the original soundtrack from your movie, pcm (uncompressed) to ac3 (compressed) which is Dolby Digital on your amp.
A Toslink cable from the headphonejack goes into my amp. I use the standard HDMI to DVI connector which is supplied with the mini that goes into my TV.
1. Delete everything that your mini doesn't originally have like Plex and such. You DON'T need it !
2. Go to this site and follow ALL instructions. (You'll only need to do this once)
3. Additional to these instructions; don't use the HDMI-output in Audio Midi Setup but the INTERNAL OUTPUT. When u select the HDMI-output in the left colmn, you'll introduce internal conflicts
Keep into account that the Audio Midi Setup has a tendency to jump back from 48 Hz to 44.1 Hz which results in the 'cracking noise' after a reboot.
The core-problem is that OSX doesn't pass the audio correctly through to your amp. Keep that in mind. Once you fix this, you can play anything you can throw at your Mini.
Good luck !
If you have questions, post them here.
As i described above, i use a Toslink cable (with an extentionjack) from the headphone jack. The headphonejack has both minijack for analog headphones and digital optical output for the Toslink cable.
My mini came with a HDMI to DVI-cable. The DVI-cable goes into a DVI to HDMI adapter which you can buy under 10$ in any computer store.
The thing is that the audio-signal from the HDMI connector on your mini screws up the coded Dolby signal. AND it shuts off your outputsignal from your Digital headphone output since it cannot process audiosignals from both output-terminals at the same time.
The HDMI to DVI-connector is a dead end for the audio because DVI is the same signal as HDMI but without audio.
I hope you can still follow me ;-)
Just to be clear;
I use two separate cables; one for audio that goes into my Denon amp via the Toslink digital heaphone output and one for the display, which is my TV.
The Display signal comes from the HDMI output terminal on the mini. For that i use the HDMI to DVI. The DVI-end goes into the DVI to HDMI-connector from the local electronics store. The HDMI-end goes into my Sony TV.
Why is this important ? Again; if the mini detects audio-throughput on the HDMI-terminal, it kills the Digital output-terminal. And you dont want this because the audiosignal on the HDMI-terminal is screwed up.
I think this has to do with HDMI-protocol and DRM.
I dont think i can be more elaborate on this.
And dont forget to follow the instructions on this site ! (Install Perian and copy the command in Terminal)
The issue which a number of users in this thread are experiencing is that after upgrading to 10.7.2, outputting audio via HDMI is not possible when the headphone / audio out jack has a device plugged into it.
Previously, it was possible to route the system / default audio to HDMI whilst headphones or amplifiers were plugged in. After upgrading to 10.7.2, this behaviour has changed which has created an issue for those who are using their Mac Mini's as media servers and wish to dynamically switch audio outputs between HDMI and the headphone / audio out jack.
It is unlikely that the issue being described in this thread is related to DRM, as removing any device plugged in to the headphone / audio out restores HDMI audio output immediately.
Once again, thanks for the clarification.
I've now recieved a reply from one of the Senior Technical Advisors at AppleCare who was kind enough to follow up with engineering.
Apparently this change was intentional in 10.7.2 to bring the behaviour of the headphone jack in line with the experience of users who have external displays connected via Thunderbolt !
See this support note; http://support.apple.com/kb/TS4113
I've replied to this advice by pointing out that this change actually removes functionality that was present in 10.7.0 / 10.7.1 and requested that the issue is esculated back to engineering for further comment..
I'll post again when I recieve the next reply.
I"ve just been through the same issue with a mid-2010 Macbook Pro, GeForce GT 330M and recent update to 10.7.2.
I had it working fine with a Moshi Mini Display port to hdmi cable, all in one without adapter, when on 10.7.x. When updated to 10.7.2 and trying to get audio through the stereo while using hdmi to the TV, I got no audio. Restarted in any number of configurations - hdmi and audio cables in or not - and could not get audio anywhere if the hdmi cable was in, whether the headphone jack was occupied or not.
Full shutdowns and restarts didn't fix it. Have read that it confuses the ports being used but for how long? Could they have memory after a shutdown?
I got home, plugged the Moshi between computer and TV here, left the headphone jack empty, and have fine audio and video through the TV.
My advice - don't try to use the headphone jack when using hdmi on a computer that can support audio through the hdmi.
Best of luck, all.
I've joined the game a little late but I too have had the Headphone/HDMI problem on my Mac Mini 10.8.4 I can get round this by using Soundflower/Soundflowerbed (Look it up on Google). I can now route the Audio to either the Headphone socket or to the HDMI port via Soundfower.
I can't see why Apple changed from manual to auto setup, it just seems to inconvenience everybody. Thought I wouldn't need Soundflower after sorting out the problems with my AV Receiver but Apple have introduced another. Oh well.