Sa mga DIY Members na mahilig mg Design, Re-engineer, Modify or Upgrade ng amplifier, I just want to

share what i studied, i learned and experienced as an Audio Engineer.

The important things to re-design modify or upgrade the amplifier is the Constant Current Source na makikita
nyu sa input section(differential amp) ng amplifier. Ang purpose po nito is to improve linearity even at unstable
voltage rail. In this case, kahit na 150V-270V ang kuryente nyu, the quality of the sound does not change as
long as the output voltage does not reach as high as Voltage rail. Kadalasan kasi pag nag low voltage na
pumapangit na tunog, dahil po yun sa under bias na ang amp. At ang bias from VAS section to Output section is
constant, so kahit mgtaas pa ang kuryente, kampante ka na hindi masusunog amp mu (aware lang sa values ng
capacitor at Vce ng transistors).

Next is the VAS section. Eto yung pair na transistor before ng drivers. Biasing the VAS section depends on the
Load and Voltage rails. Pag under bias po eto probably magiging saturated o distorted ang tunog kahit clipping
pa lng o 3/4 ng max power ng amp mu. Pero pag gumamit ka ng Triple Emitter follower (TEF), no need to
modify the VAS section.

Then the Voltage Divider section. Eto yung may potentiometer(trimmer) at transistor sa gitna ng amp. Purpose
of this section ay ang pag bias ng current, voltage and to compensate the heat emitted by the output transistors.
Make sure na always nakakabit to sa heatsink. This serves as NTC of amplifiers. Kung hindi nakaheatsink to,
habang umiinit ang amp nyu, ang beta gain (hfe) ay tumataas din resulting to increase in bias. In this case, kahit
na half of the power palang ginagamit nyu, the heat still increases. So the proper configuration nito
nakadepebde lng sa pagset ng trimmer.

Kadalasan naririnig natin na pag dinagdagan mu ng power transistor ay lalong lumalakas. Hindi po totoo yun.
Power relies on your Supply Transformer, and class of amplifier you use. The only thing it improves is the
DAMPING FACTOR. The advantage is you can add more load, but the drawback is you need to increase the
bias of the VAS section to compensate the current needed of the output transistor to drive the Load.

Ryan Jan Arellado

Part I

Let’s consider the Konzert 502 Schematic since it is easier to understand the full complementary
and symmetrical design, the price is cheaper and it is available everywhere

The first thing we need to consider in designing an amplifier is to know the maximum load to
drive with and the Voltage rail to supply. Let’s take it as 4ohms (2 speakers) and +/-100Vdc . I
choose this rail since the Vceo of 2SC5200 is 230Vdc. In class AB, the max Voltage rail you will
obtain is half of the Vceo of your output transistor. Dahil sa ng-iiba din ang Voltage ng kuryente
natin, so let’s consider +/-100Vdc. In this case, we are inside the Safe operating area(SOA).

Calculating using Ohm’s Law:

𝑉𝑚𝑎𝑥 100𝑉
𝐼𝑙𝑚𝑎𝑥 = : = 25ampere. – this is the max Idc drawn by speaker.
𝑅𝑙𝑜𝑎𝑑 4𝑜ℎ𝑚

In order to identify how much current needed by VAS stage, we need to consider the dc current
gain (hfe) of the output and driver transistors which can be seen on the datasheet. Remember
that always use the lowest hfe stated wherein that’s the value drawn at ambient temperature. As
the temperature increases, hfe and current also increases. That’s the purpose of Vbe
multiplier(voltage divider) which we will discuss later.

To obtain the VAS current,

𝐼𝑙𝑚𝑎𝑥 25
𝐼𝑣𝑎𝑠 = ; = 0.0071A or 7mA
ℎ𝑓𝑒1∗ℎ𝑓𝑒2𝑥 35∗100

So we need 7mA to drive the load at maximum power. In order to identify the 7ma we don’t need
to put Ammeter to read the current. We can use R4 by using Ohm’s Law., thus we can get the
voltage across R4.

𝑉𝑅4 = 𝐼𝑣𝑎𝑠 ∗ 𝑅4 ; 7𝑚𝐴 ∗ 100 = 0.7V the voltage across R4

Ryan Jan Arellado

Stretching 7mA at that Vrail could take a lot of heat, unless if you use cascaded VAS(we will
discuss later). So we recommend putiing individual heatsinks for VAS pair to stabilize the current
and hfe. As you can see, the R4 in 502 schematics is 680 ohms which is too high when setting up
current. Imagine if you will draw 7mA in that resistance, you would come up 4.76V across it and
that will reduce the max output swing of the signal. So we will change it to 100 ohms to take less
drop across resistor.

𝑉 = 𝑖𝑅 ; 0.007 ∗ 680 = 4.76𝑉

That is why most of the amplifier design nowadays, driver circuit rail is separated from output
rail to reduce ripple, voltage drop and stabilize the overall gain. And Driver rail is always higher
than output rail.

So how can we set 7mA?

Differential stage and constant current is responsible for setting and maintaining VAS current.
Differential stage differentiate the input signal and the feedback signal, while constant current
regulates the voltage and keeping them stable so that the gain is linear even at unstable Voltage
rail.

Let’s consider this circuit as a reference in modifying. Anyway hindi fixed ang mga values, we
need to calculate to come up a 7mA at VAS stage. Solving this simple circuit, hindi pa kakasya to
sa isang papel. I can calculate this using complex math function pero yung iba hindi na
naiintindihan. So we will make it in a simpiest way even in a technical way, not more
theoretically.

Ryan Jan Arellado

To obtain 7mA, we will need to get the exact voltage across R7. Why? Because we have to
identify how much current the 2n5551 needed. Since the voltage across R3 in is 0.7V,

Thus; 𝑽𝑹𝟕 = 𝑉𝑟3 + 𝑉𝑏𝑒; 0.7𝑉 + 0.6𝑉 = 1.3V – this is the voltage across R7.

Masasabi natin na ang collector current(Ic) ng 2N5551 is also the current of R7 since naka series
sila.
𝑉𝑟7 1.3𝑣
Therefore; 𝟕 = 𝐼𝑐 = ; = 1.08mA -- this also the collector current of 2N5551
𝑅7 1.2𝑘

Ang aim po natin ngayun is to identify the exact value ng R5.

33k is not the exact value.

Using kirchoffs equivalent circuit; eto po ang loop;

−𝐼𝑏𝑅9 − 𝑉𝑏𝑒 − 𝐼𝑒(𝑅2 + 𝑅5) − (−27𝑣 ) = 0

𝐼𝑒(𝑅2 + 𝑅5) = 27 − 𝑉𝑏𝑒 − 𝐼𝑏𝑅9

27−𝑉𝑏𝑒−𝐼𝑏𝑅9
(𝑅2 + 𝑅5) = ; but we can say Ic is approx = Ie
𝐼𝑒
and IbR9 is Vb or Vr9 which is almost insignificant. Vb=0V
27−0.6
So (. 1𝑘 + 𝑅5) = =24.4k ; R5=24.4k - .1k; R5 = 24.3k
1.08𝑚𝐴

At the end of the day, you will need to test actually the exact
value of R5 since there is no resistor with a value of 24.3k.

Ryan Jan Arellado

Changing the value of R5 will change the VAS current. Take note that when modifying this
scenario, you have to disconnect the Output Transistor to keep you safe. And set aside the biasing
of quiescent current.

So for solving the value of R6, we will use the range of input voltage from 150V-270V AC. But in
this case, we will consider the Vrail of Output Transistor is separate from this stage. We
will assume that Vrail of Power Transistor is lower than +/-100Vdc. Let’s focus on this stage.

Using ratio and proportion, we can get the range of our Vrail at normal voltage of 220Vac;
𝑉𝑖𝑛1 𝑉𝑖𝑛2 220𝑉𝑎𝑐 150𝑉𝑎𝑐 150𝑉𝑎𝑐∗100𝑉𝑑𝑐
: ; : ; 𝑢𝑡2 = ; 𝑽𝒐𝒖𝒕𝟐 = 𝟔𝟖. 𝟏𝟖𝑽𝒅𝒄 (@150Vac)
𝑉𝑜𝑢𝑡1 𝑉𝑜𝑢𝑡2 100𝑉𝑑𝑐 𝑉𝑜𝑢𝑡2 220𝑉𝑎𝑐

𝑉𝑖𝑛1 𝑉𝑖𝑛3 220𝑉𝑎𝑐 270𝑉𝑎𝑐 270𝑉𝑎𝑐∗100𝑉𝑑𝑐

: ; : ; 𝑢𝑡3 = ; 𝑽𝒐𝒖𝒕𝟑 = 𝟏𝟐𝟐. 𝟕𝟐𝑽𝒅𝒄 (@270Vac)
𝑉𝑜𝑢𝑡1 𝑉𝑜𝑢𝑡3 100𝑑𝑐 𝑉𝑜𝑢𝑡3 220𝑉𝑎𝑐

And now this voltage ranging 68.18Vdc – 122.72Vdc will be our basis in computing CCS to get
the value of R6. We know that the current drawn by Differential stage is just 1.08mA, let’s
consider the minimum current we will use at the lowest input voltage is 5mA. Why? To assure
that the voltage across the zener will not drop below 27Vdc. Imin = 5mA
1𝑊
And the maximum current of the zener diode(1Watt) can handle is 𝐼𝑑 = =.037A or 37mA.
27𝑉𝑑𝑐

Using Kirchoff’s Magic; calculating the lowest input Vac.

𝑉𝑜𝑢𝑡2−27
𝑉𝑜𝑢𝑡2 − 𝐼𝑚𝑖𝑛(𝑅6) − 27𝑉𝑑𝑐 = 0 ; 𝑅6 =
𝐼𝑚𝑖𝑛

68.18𝑉𝑑𝑐−27𝑉𝑑𝑐 𝑉𝑜𝑢𝑡3−27𝑉 122.72𝑉𝑑𝑐−27

𝑅6 = ; R6 = 8.2k. 𝐼𝑚𝑎𝑥 = ; = 𝟏𝟏. 𝟓𝟖𝒎𝑨
5𝑚𝐴 𝑅6 8.2𝑘

So the range of current drawn by CCS is 5mA – 11mA which is far from max current of Zener. The
circuit can stabilize the gain at a that certain range. And computing the size of 8.2k is 𝑃𝑟6 =
𝐼𝑚𝑎𝑥 ∗ 𝑉𝑜𝑢𝑡3 ; 11.5𝑚𝐴 ∗ 122.72𝑉𝑑𝑐 = 1.4𝑊 (use 3-5W)

Ryan Jan Arellado

Part II

Now the schematic has been modified according to the specified Voltage and Load. What we will
do next is the biasing of quiescent current required by driver and output transistors. This is done
by Vbe multiplier(Voltage Divider) which can be seen in the middle of the circuit. Normally to
obtain the correct biasing, the emitter resistor (R2) of output transistor
must have a 26mV to avoid any crossover distortion.

But technically, you don’t need to reach that quiescent setting. 0.4Vdc
lang across R3 would be enough to minimize crossover distortion. Ang
purpose nito is to avoid idling the 5200/1943 to turn on kung walang
signal. In this case, ma maximize ang Vceo ng output transistor (if Ib=0,
Vce > 230Vdc). Now to set the quiescent current, palitan nyu ng trimmer
ang R23 ng 5Kohm or resistor from 5k to the lowest.

Para naman sa cascoding VAS, this essentially done kng mas mataas pa ang
Vcc mu above 100V. Rail to rail voltage will be divided by 4 VAS
transistors. And the effect, less heat dissipate by each transistor
while more current can be drawn, reduces base-collector
capacitance as voltage varies and has a high bandwidth compare
to conventional VAS. Remember, ang VAS ay di nawawalan ng
current because it operates as classA. Vceo of transistor must be
properly observe. You must not exceed as what Vceo the
datasheet shows. If Vceo=230Vdc, max Vrail we only be below +/-
115Vdc. Pero kung Cascoced VAS, Vrail can be reach up to +/-
200Vdc since 4 transistor are used.

For Triple Emmiter Follower (TEF), this is usually done kung

gusto mu mg dagdag ng output transistor wherein d mu na
kailangan baguhin ang VAS. Typically ang dinadagdag na driver
ay mismong 5200/1943. This increase the current gain for the needs of
parallel transistors and can drive more Load as long as the Transformer can
sustain more current. But the drawback is you need to release more voltage
on Vbe multiplier para ma bias ang quiescent current ng TEF. In this case,
ang Vbe multiplier can set the current need for TEF.

Next page are is how to modify the schematics step by step.

Ryan Jan Arellado

This page will show you the steps in Modifying the schematic. Wala tayung idagdag o kukunin na
components. Only parts replacements para madali sa tech natin maintindihan.

Figure above shows the original schematic of AV502. All red text s are the parts needs to replace.

1. Before doing anything, disconnect the base of output transistors until it is fully biased to
avoid any damage. Or you can disconnect them all.
TAKE NOTE
-MJE15032/33 can be change into C4793/A1837 IF Vrail is less than 100Vdc.
-TIP122 can be change to BD139, C4793 or MJE340 depends on the availability. The only
difference is the hfe. But VR5k can compensate that anyway.
-The Value of R can be determine later for setting up the voltage of VAS. From 24k - 27k.
- MJE340/350 have different pinout compare to the previous 2N5401/5551. So be careful
in changing them.
-Asterisk above indicates the heatsink needs to use.
* means it needs separate Heatsink
** means it must be mounted on main Heatsink
-8.2k must be 3W - 5W compensate the heat and the current needed by zener.

2. Now replace all the parts that indicates above. All resistors except 8.2k are 1/4W. you can
add more output transistors if you want.

Next page is the Voltage value of some parts to be set as reference.

Ryan Jan Arellado

Ryan Jan Arellado