6n1 SPK Prot Rev 1.2B - With Basic Function How It Works

March 2, 2018 [6N1 AMP PROTECT REV1.
2 / 576PINOY_TECH / PHILIPPINES]
 The full schematic diagram of 1-channel 6n1 amp protect:
Forum Link:  http://www.elab.ph/forum/index.php?topic=46931.msg862501#msg862501
The release of this version is just a revised from original 4n1 proto-type which was previously
organized as a group buy method for ordering factory made PCB. Almost no difference between
the previous and the present revision except for the two extra added features that have
incorporated such as shunting of C7 and thermal cut-off interfacing during extremely hot
temperature developed at amplifier’s heat sink. Furthermore, PCB size has been reduced a little
bit to 100mm to meet the manufacturer’s affordable price. For thermal issue, that will be
required additional component like normally open thermostat or a simple NTC thermistor and
calibration is important in order to insure active function of such feature. However for C7,
shunting will be discussed on later part of this document. Basically, the entire circuit is similar
to the operation of the common uPC1237 Integrated Circuit.
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March 2, 2018 [6N1 AMP PROTECT REV1.2 / 576PINOY_TECH / PHILIPPINES]
 The Power Supply Section:
Alternating current is rectified into Direct Current via D3, 4, 5, & 6, and smoothened via C5 &
C6. The expected DC voltage across C5 if we inject 12Vac at AC1 & 2 terminals will roughly
reach to 17VDC. So voltage ratings for this e-cap must not be lower than that, 25V is good in
terms of safety margin. Author intent to choose higher capacitance reservoir for the purpose of
shunting circuit for delay e-cap, to be discussed few details on dumping section. Relay coils are
the main loads of this circuit, and as per datasheet said it has an average coil resistance of 160
ohms for 12V ratings. This mean, around 75mA is the current consumption per relay. If we have
2 relay loads plus the other routing loops that consume current, meaning total current source
should not be lower than 150mA, 200mA could be ok but of course no one can stop us using
bigger size transformer. Power supply deserved to have indicator for us to insure that the
power is present at the circuit during power-up. So led2 is added on board, and to keep it
simple this does not necessary to be fancy at all. A small 3mm red color led is more than
enough to serve its purpose, of course we are free to use any color according to our desire. R17
can be calculated by simple equation, where R17 = (Vin – Vled) / led Current… LED current can
select according to your desired lumen ranging from 3mA to 20mA while led voltages varies
depending on every color or manufacturer’s specs.
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 The Delay and Switching of Relay:
R15 and C7 perform the main timing delay. Increasing values of R15 & C7 will result into
increase of charging time as well. Q9 is the main switch for relay and its base electrode is
boosted by current driver Q8. The two transistors work as a coupled manner also known as
darlington pair in which a small current fed to the base of Q8 means a huge impact to the base
of Q9, thus switching of Q9 is quite secured. Since two transistors are darlington connected, it is
very obvious that their emitters are connected in series also known as double emitter follower.
Therefore, the total bias voltage intended for it now is dramatically increased to x2 compared
to the ordinary biasing that we can see from a single stage common emitter configuration. But
it’s not just like that because there is additional series ZD3 which has a defined value of 3V. So,
the total required voltage across C7 in order to bring Q9 into saturation mode is equal to the
sum of “V(zd3) + Vbe(Q8) + Vbe(Q9)”. In that case, it is assumed to be 3+0.7+0.7 = 4.4V…
Increasing value of ZD will prolong the delay activation period because it elevates the activation
level for Q8, but due to safety issues for our shunting circuit through transistor method, we
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don’t need to raise the level voltage activation point much higher to keep CE junction of
shunting TR to be in safe side.
As mentioned earlier, a typical coil resistance of SLA 12V relay is approximately 160 ohms as per
datasheet’s specs. That means if we input 12Vdc to that coil, it will consume (12/160) 75mA
current. With heavy load, about 1V most probably the worst case voltage drop across CE
junction of Q9 during saturation point. Of course, it always varies depending on how heavy the
load is. In case of the same, Q9’s power dissipation would be somewhat close to 75mW. TO92
type ecb pinning orientation is fine to use but a bit bigger size like 2SC2383 is suitable as well. In
case of noticeable heating, TO126 like 2SD669 and the like is also a good match due its
convenient way for adding heatsink.
Led3 is only used to indicate faulty or relay off mode condition. Biasing of this led is a bit tricky
if we care about its conflict. Why so? Relay’s behavior is somewhat different from what many
have known it. To go to a deeper theory, relays have its own characteristics that it can activate
on certain voltage and deactivated on different voltage level. For example, a 12V relay specs
can activate at say 9V, it doesn’t mean that at 8V it will be deactivated. To bring exact sample
for one relay’s specs; nominal voltage is 12V, coil resistance is 155Ω, pickup voltage is 9V, drop-
out voltage is 1.2V, maximum allowable voltage is 15.6V… Now here is the basic breakdown;
12V is the recommended or normal supply condition, but at 9V the strength of magnetizing
contour has already the capability to pull the armature. Once the armature is already pulled-in
and fully magnetized, it can only be deactivated once the voltage drops below 1.2V. Now, if we
imagine the led is in series with the coil. In case the transistor Q9 switched off from just recent
ON state condition, led should not sustain the basic 1.2V relay’s minimal drop-off voltage limit.
So, applying ohms law formulas can guarantee that conflicts can be eliminated before hands. In
case of 12 volts supply with given coil resistance of 155Ω and 1.2V limit voltage, we can assume
the needed dropping resistor for led3. To solve that easily, simply use the 1.2V reference and
155 ohms fix value. So the current flowing to the coil during 1.2V limit means 7.74mA. Now we
can use that current flow range for led dropping R. Considering led might have a voltage drop of
say 2.8V (depending on model of course), so at real supply of say 12V – (1.2 + 2.8) / 5mA = 1.6k
(choosing 5mA insure that coil voltage will be way lower than 1.2V)… Our preset resistance
value is 4.7k. Why so? In case our supply reach to 17VDC during no heavy loads, led3 will fed
about 3mA only and it’s enough to give noticeable glow from the led.
 C7 Voltage Charge / Clamping:
As we already know, delay timing is happening via R15 and C7. At first, voltage at C7 is empty,
but then start to replenish via R15 slowly till it reach to activation level for switching. Once the
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switching transistors activates, C7 is no longer increasing charge anymore because it is locked in

place, also called clamped via components connected to it. As we have computed above, the
activating voltage level is about 4.4V. That means the replenishing voltage across that capacitor
does not go beyond the mentioned range. The simplified equivalent circuit can be seen at figure
below.
 Shunting C7 during power off:
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We observed some conflicts during turning off of power and re-turning ON again right after we
turned off the power amplifier. That seems delay circuit is poor to recover due to time required
to completely discharge the timing e-cap to make it ready to do the action for the next coming
cycles. To resolve the issue or for us to make it faster to discharge, a shunting circuit to dump
the voltage from the timing e-cap has been added. By this method, we are not just making the
“re-turning ON” duration faster but rather it also makes the relay coil deactivating faster to
disconnect the loud speaker from amplifier. By then, it prevents shock-off noise which is usually
noticeable as knock sound on speaker during power off.
How shunting circuit work? Q5 & Q6 formed a switching circuit that used to dump-out the
charge of C7 to gnd. Assuming that there is a power applied. A quick supply is fed immediately
to the base of Q5 via D4, R6 & R8. Since the simple psu source is configured as a half wave with
no filter capacitor, no delay is going-on. Making Q5 reacts faster than anyone else and
interrupting supply to be feed to the base of Q6 via R14. Thus, Q6 is OFF and timing R15/C7 is in
action. During turning OFF, Q5 turn off faster than anyone else again due to no energy reserving
cap along path line. Since C5 capacitor is large enough, that means it holds abundant charge
even power line is off. Q6 then has capability to turn ON by way of consuming the remaining C5
charge while shorting C7 to ground. All the rest of relays are immediately off while Q6 remain
latching until it is no more longer holding due to lack of C5 charge. The most important is the
action taken at the very first shot when we power off the circuit, it served its purpose to shunt
C7 to gnd. We could have another method of catering this problem a better way, could be
added for the next coming versions or could be for individual use. To give a little insight, during
turning ON of power, speaker delay timing will resume as usual way. But during power OFF,
relay deactivates earlier before cutting off of main power switch. By then, shock-off noise is
surely no chance to pass towards speaker compared to just synchronizing off method. That
simple trick can be done all by using common passive components.
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 DC Detection mode for DC offset:
Q2 & Q3 are those transistors used as DC detectors. When a huge amount of DC is presented
across C2 and C3, either Q2 or Q3 will react depending on what DC polarities are coming in. For
positive DC offset Q3 is responsible while Q2 for negative. To give little understanding how it
works; during amplifier’s failure or let say one of the power transistors got shorted, full DC rail
will feed to its output terminal and it will result into a total destructions of our loud speakers.
To avoid such phenomena, the relay that connecting speakers to our amp should immediately
cut-off. To be able to do that, we have to interrupt the supply going to Q9 and the best &
easiest way is to shunt C7 to gnd. So Q7 is used to help doing that action. Under normal running
condition, Q7 is OFF at all time except when there is DC offset appeared on amp’s output. As
we have said, when one of the power transistors got shorted, huge DC will feed towards amp’s
output. Assuming positive rail is feed to the output. That means base of Q3 will receive higher
potential with respect to its emitter. Since it is configured as common emitter, small amount of
DC going to its base means enough for it to react. Thus, it switched ON and pulling the base of
Q7 to negative potential. Hence, turning Q7 ON also and dumping the charge of C7 towards
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ground. This makes the operation of relay to be partially disabled. On the other hand, when
negative DC offset is present at amp’s output, Q2’s emitter electrode received much lower
potential with respect to its base in which it is configured as common base. Wherefore, base
becoming more positive with respect to its emitter, hence Q2 turn fully ON. Then again bringing
Q7’s base to lower potential that makes it ON again and operation of relay is again interrupted.
R5 with R10 plus BE junction of Q2 & 3 form a voltage dividing for abnormal DC offset feeding
condition. Our test result can handle even over 100VDC range DC offset without failing Q2 &
Q3. For some users, that very abnormal DC output makes more sense than focusing on lower
offset voltage.
During AC feeding condition or the so called normal amplifier’s RMS output, that AC output has
an equivalent peak voltage that triggering Q2 & Q3 which eventually sending false signal to Q7.
In order to surpass that problem, a smart and simple solution is to bypass AC signal to ground
level. Thus C2 & C3 are there to arrest any AC signal coming in. With the help of R5, huge RMS
coming-in will be reduced dramatically into lower AC signals. Thus, capacitor easily blocks them
by simply shorting signals to ground. A single non-polar e-cap can do that perfectly, but for
practical reason, a series two e-caps will result into same non-polar idea. Advantage is, it is easy
for everyone to come-up into that solution instead of looking for costly or non fast moving
capacitors in the market. Some builders take some risks of using a bit higher voltage single
piece polarized capacitor. It also works, but for some reasons, there is no assurance that it will
last without damaging dielectric due to polarity issue.
 Clipping Indicator:
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Clipping circuit is not actually a detector to detect any clipping behavior but rather a simple
indicator to determine the limit of amplifier’s maximum output. It is not something that we just
build and plug & play module but rather a circuit that we need to preset some values to make it
compatible to our amplifier’ rail. Many may probably mislead as to whether the clip circuit
detects the amplifiers clipping point but for somebody who has already familiar about its basic
operation it would be easy for him to understand the entire function of our revised version.
Hence, clip circuit is something that we are just presetting its reacting point to dictate when it
will be going to turn ON or not. For some reasons, we can consider of saying it is a detector by
way of pointing it to the section of reference voltage. The output of amp is being detected
when it became close enough to overtake our preset reference voltage, but must be bear in
mind that it is not detecting the real clip behavior of the amp output.
The circuit operation is simple and it looks very similar to a single stage transistor with series
reversed bias zener diode connected to its emitter as seen on left figure. Considering the same,
the base will not be activated unless the signal will overtake the voltage avalanched value of
series zener diode plus transistor’s Vbe value. In case of say we have 10V zener on emitter, then
10V + 0.7Vbe = 10.7V total… By then when we inject that supply to its base, the transistor will
assumed to turn ON by all means. But wait a minute, that’s not just like that! Since the zener is
assumed to be connected in series with emitter, collector’s current also affected if we are just
sourcing out voltage from a low supply source. These means that at constant low voltage
source of say 12V, it is not enough to glow any 2.8V led load. To come up with a very simple
solution, instead of connecting ZD to the emitter of our clip tranny, we just simply replace ZD’s
position towards base but must be configured on same manner as configured on emitter’s
voltage loop. Meaning that avalanche voltage or the triggering point for the base would
basically the same while collector current is now being useful even supplying low voltage taken
from local 12V source.
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 Basic Reference Voltage Calculation:
To come up with basic clipping assumption and define its Zener’s value, we will be using first
the simple apex clip indicator circuit and explore its operation… Q1 & Q2 are representing the
power output of audio amplifier section. For the sake of simplicity, we will be simplifying Q1
and the symbol VR is used as substitute for Collector Emitter junction. On this clip circuit, we
will only focus on Q1’s behavior during normal operation. During amp’s idle, output and ground
level are at equilibrium, ideally no potential difference between the two or the so called dc
offset. Zd1 is the main reference value and is preset to 15V which directly hooked-up to positive
side of main rail, and it is conducting at all time towards R3. Assuming we have a supply rail of
say 70VDC, 15V will be consumed by zener and the remaining voltage will pass through the next
series string which is the resistor. If we have a value of say 10k, current flowing to that string
can be calculated through (Vcc – Vzd) / R3, which is equal to 5.5mA. When audio amplifier is
said to be at moderate sounding level, the output amplitude also swing moderately and the
equivalent CE junction resistance of the present conducting transistor is still quite high compare
to the zener diode. That means zener is still more conductive compared to CEJ of Q1. As we
turn the volume louder, CE junction keeps on decreasing until it overtook the conduction of
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zener D. Then LED2 start to react ‘till zener’s avalanche collapse that causes to stop zd’s
conduction and current flows will be concentrated only on led’s string instead. However, output
is constantly changing depending on the strength of input signals, through signal variations CEJ
also widely varies. That means led current is kept on varying which result into noticeable
transitions from dim to bright lighting condition depending on the ambivalence against
paralleled zener. At that point, it indicates that the conduction of transistor is getting closer to
the edge of main rail which results into a dead-end corner or no sustainable supply at all. While
if we still continued increasing the volume further, we are pushing the power transistor to
conduct harder but to no more avail to feed output due to lack of sourcing supply to pass
through. That case, it would result into chopped output amplitude which is basically known as
clipping outputs. To prevent that from happening, certain limits have to be assigned to
determine that the maximum rail should not be completely consumed. In some cases, 15VDC is
anticipated voltage boundary, and that set of limitation is worth enough warning for us that our
amp is going closer to clipping zone. Of course that clipping assumption always varies
depending on how we construct our amp particularly at very low impedance loads. Some
claimed that their amps have very less CEJ voltage losses before clipping occurred. To
determine the basic losses, during FTC test we can hook-up two different meters while
measuring DC rail vs AC out, then convert RMS output into peak and subtract that value to the
present DC rail reading. In case of say 70Vdc, our clean output for example is 41Vrms. We can
multiply that to the square root of 2 which is equivalent to 58V. In case the main rail sagged to
let say 65V, means 7V is our total looses at CEJ which is already a good sign of excellent build.
Going back to clip calculation, apex clip circuit required to tap the zener at amplifier’s rail. By all
means zener is required to connect on that rail otherwise clipping reference will be no longer
reliable if we just connect it to any other source of power. Hence, an additional connector is
required just to wire-up diode to the main rail. To eliminate that hassle and make the wiring
lesser, clipping circuit can be simplified a little bit. By adapting the same concept while
treasuring it through different schem, we will be assigning the zener diode to tap on the base of
clip circuit instead of directly hooking to the main rail. For me the easiest equation for simple
apex clip circuit can be expressed as; “Vac source minus rms output before clipping
equals zener value”  (CEJ Vlosses * Sqrt of 2)… i.e 50Vac – 40Vac = 10 * 1.414 = 14V, hence
15V ZD is okay but we can set tolerance on our own. Nevertheless, actual test through scope
makes a perfect choice for selecting zener. But take note that clipping occur at lower
impedance load would be totally different from higher one, so select the average.
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To summarized the formula, Zener value = Vin – Vout. Since 15V is only defined as constant,
you can change the value if you wish to, but for now we will be using the same value. To rumble
from same formula, we can cater it now by Zener value = Vin – constant. In case of 70 – 15 =
55V.. Therefore, 55 is our zener diode, but as we noticed, there are some resistors along the
way and that also consume current. Means there is also voltage drop across them. The
anticipated voltage lost is about 2V. So from 55-2 = 53V.. Through ZD list table, confirm if there
is closest zener value that known to be available in the market to buy.
 Clip Circuit Comparison:
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For the sake of comparison, I am bringing the circuit which was featured in Leach amp
4.5version. Concentrating on dashes lines, R4 is the main hostile which is hook-up to the main
supply, in this case it is in negative rail. The center jointed of R1 & R4 will be the common point
and it is connected to Q1’s base, likewise R2 & R3 for Q2. During idle, Emitters of Q1 & Q2 are
at the same potential with respect to the common gnd. Since base of Q1 is biased negatively
through R4, Q1 is said to be at OFF mode, likewise the same for Q2. Assuming that we have a
supply rail of say +/-70V, R4 current means; 70 – 0.7 / 16k = 4.33mA… To calculate the
equilibrium potential for R1, we will be using the same current as current flowing towards R4.
Hence, 12k x 4.33ma = 52V… This mean the potential difference between R2 & R4 is 18V. So
here is the reference voltage. If the voltage feed by the amp increases further, 18V become
lower ‘till it hits the triggering voltage for Q1 & 2. I’m not going to dissect its operation further,
just observe the differences? Apex used constant 15 values while for Leach is something
variable due to flexibility of current flowing through R4 and R3 depending on how much voltage
we supplied on rails, but there is something in common here which are the close similarities of
sets of voltage boundaries before the main rail.
 OCP (Over Current Protection) Overload, Short Circuit, etc…
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Every amplifier deserved to have a protection depending on how we integrate the protection
for it. Some relies only on fuse basis for quick and easy solution plus simplicity, that’s fine.
However, it is not always 100% guarantee because fuse will only blow after overloading its
assigned current limit. Often times choosing fuse ratings is a matter of estimate without
substantial basis. Assuming we have calculated thoroughly to find correct value, some
considerations must come-up to our mind as to whether how the manufacturers declared its
current ratings if we knew from that fact that they tested and calibrated it on different voltage
ratings while we are going to use it on different voltage range. Aside from that, an annoying
moment to replace the said fuse when breakdown happened at the very crowd gathering is also
embarrassing. But the worst and most commonly bad habit is at the moment that you are going
to troubleshoot while you have no spare for the fuse to be replaced, a piece of wire to bypass
the fuse is the usual remedy which commonly results in a temporary permanent use. What
happen to that protection then, useless it may seems in the long run! So why not use an
electronic guard and incorporate it on our circuit to come up with reliable, non-annoying, and
quite simple solution. A single stage transistor Q1 is used to take action for the said issue. How
it works is simple! During heavy loads or short circuit condition, emitter resistor of power
output transistor builds a huge amount of voltage that feeds towards base of Q1. If that
suppressed voltage hits the base reacting point, Q1 switched ON, making C7 to partially short
towards ground via Q7. Relay is then temporarily deactivated and the heavy load is
immediately disconnected from the amp. By then, the voltage builds at emitter resistor drops
and Q1 returned to the same OFF condition again but the cycle is kept on repeating until you
removed the shorted connections at the output. In this ON & OFF behavior of relay with certain
intervals does not necessarily mean that we are not going to do any action upon observing such
abnormalities. We must be aware that it is not a normal operation for the amplifier and the
situation can still lead to failure of some affected components if we do not take immediate
action to resolve the faulty problem.
 Calculations:
Before using any protection, the first thing to determine is the maximum capability of the unit
to be protected. It is not just we connect the ocp and say okay it will protect according to our
desired limit without manipulating anything. No it isn’t that way! To get benefits with over
current protection circuit, know first the activation voltage for Q1 by way of applying variable
power supply to be injected at +ocp’s terminals & emitter line for Q1. Increase the voltage of
the injected psu slowly until you hear the deactivation moment for relay. Upon observing the
reactions, take note of the triggering voltage. Make some experiments by changing several
values for R1 and record all for their reacting voltages. This method is to give you some ideas
when you need to elevate or degrade the sensitivity of protect circuit. Then the next thing is to
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know the amplifier’s maximum power handling capability. If you have no information regarding
that data, that would be confusing because declarations of such power are widely varies due to
many standard way of calculations, some may probably just anticipations and some are very
conservative thru way of doing FTC tests. Take note that we are talking about maximum power
handling, it doesn’t mean that an amplifier can run on 8 & 4 ohms load smoothly, for 2 ohms is
not anymore. It is still possible but only on certain volume level. Remember that on low volume
level the output power is quite low as well, unless the output power won’t reach the
overloading limit, the amp can still run normally without severe overheating or fatigue
operations. We will find it out later.
To compute for the basic input sensitivity with the defined values, just focus on R1 & R3, they
are the main voltage divider. We knew that base activation voltage is ranging from 0.6 ~ 0.7V
and the average is somewhat close to 0.65 in common trannies, maximum saturation could be
1V or so. Assuming 0.65 is enough activation voltage, then base to emitter region which is in
parallel to R3 is equal to the said 0.65V. Through combinations of R1 & R3, we can solve now
the input required voltage in order to achieved 0.65V across R3. Don’t be confused on
mentioning R3 alone, that’s merely used in order to figure out the terminal point which
pointing exactly to the Vbe of Q1… By applying ohms law formula where V(input) = (((R1 + R3) /
R3) * 0.65V), then input required voltage must be 1.78V. This mean, it should be the voltage
across emitter resistor of power output transistor in order to react our ocp. Now if we have
0.22, 0.33, 0.47 ohms emitter resistor and we have known numbers of paralleled output
trannies, do we think that 1.78V can be possible to get across each those values? What would
be the total flow of current and anticipated maximum capability of amp if that is the case?
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Let’s take a look and apply practical calculation. Assuming we have clean 300W finished product
output at 8Ω load. That means 6.12Arms is presumed total current flow (sqrt of P/R) with about
49Vrms output during max volume level (sqrt of P*R). If the volume adjustment level decrease,
obviously the output voltage and current also decrease, hence wattage decrease. Now, if we
chosen to use 0.22Ω Emitter Resistor and we can say we have 5 paralleled output pair trannies,
then each pair is forced to handle 1.224A current during maximum power output (total current
/ # of pairs). Formula can be summarized through IreMax = (sqrt of P/R) / 5. At that range, the
total accumulated voltage at 0.22Ω is just a matter of 270mVrms which is equivalent to
382mVpeak, that formula can summarize again through VreMax = ((sqrt of P/R) / 5) * 0.22Ω).
This voltage value is way too low to acquired activation level for our protection, therefore ocp
circuit will remain inactive or no response at all in any range because we took the calculations
at supposed maximum range.
In case of heavier load of say 4 ohms, current flow will dramatically change to about 12.24Arms.
This mean each resistor is handling 2.45A, thus Vre now became 539mV. Our feed voltage is still
way too low for the ocp to react. From 8 ohms shifted to 4 ohms load, total current is
dramatically increased by half. Through this, some considerations must take place if the amp
can really able to stand with such load for just 5pairs of power trannies during maximum
volume level. That will depend on what quality and specs of power transistors being used.
Assuming we have 300Wmax @ 8 ohms load. What would be the approximate comparison
between 8 ohms load with max volume versus 4 ohms load with 50% volume reduction? At
sudden assumption, it is look same power output, let’s try to find out what ohms law can show
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to us using practical equation. 50% of 49V/2 = 24.5V,,, P = 24.5^2/4 = 150W,,, I = sqrt (150/4) =
6.12Ampere,,, P = 24.5x6.12 = 150W. Therefore, the so called 300W @ 8 ohms Pmax becomes
150W at 50% volume adjustment for 4 ohms load. So this only established that the amp can
handle lower impedance load provided that volume control is not set to maximum range. Take
note of this practical analysis, because some may probably asks later why the amp is kept on
turning off during increasing volume which was only happened right after connecting ocp
circuit. The other way around is probably, may ask why the ocp is not activating during low
volume setting while shorting the output! Let’s make this thing clear, ocp setting will vary
depending on our amp’s build and if it isn’t computed accordingly, the ocp is useless, or could
be bothering if calibrated incorrectly. It’s a matter of individual setup how to set the amp’s
protection because we cannot generalize it for all amps due to wide variations of our builds.
Therefore, protection should be calculated thoroughly to suite with the amp short circuit
capability. I will try if I can create a universal excel calculator later.
 Thermal Circuit Adaptation:
You may probably notice that some amplifiers are thermally protected but some may also not.
This protection is not usually mandatory especially if the amps are built and tested accordingly.
No reason that the temperature will rise abnormally if the amps are designed thoroughly with
appropriate heat sinking and equipped with proper ventilation & cooling like blowers. However,
cooling could fail any time unexpectedly plus some abuses of operations from end users can
also contribute failures which could result into abnormal rising of temperature inside the amp
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that lead into drastic damages of components particularly the power output stage. Although
the chance is very rare and the ratio of that scenario is too small, our circuit is possible to add
thermal protection to cut off loads during extremely hot temperature. Therefore, terminals TH1
& 2 are readily available to engage into that option.
It is true and not practical to cut-off the music during the moment when the occasion is ongoing
but the reality is if the amp is already undergo thermal abnormalities we have to put in mind
that there must be something went wrong already inside the unit. With that occurrence we
should apply immediate action to avoid serious damages. The first impression of anyone who
has direct knowledge that the unit is in danger while he is probably in the state of bothered
emotions, is to simply turn off the power switch of the amp. We usually don’t need to wait until
the magic smoke comes out to take off the socket from power mains to prevent anything from
severe breakdown. If those instances are occurring, it would be more alarming and curious for
the crowd who’s viewing what you are doing with your panic and erratic movements. Would it
be a circuit that let the amp ran some more time while it shifted into different condition, let say
lowering the sound level to compensate for the rising of temp or let the sound completely cut-
off for you to fully pay attention to your unit? You can ignore the thermal protection and let the
amp run just like what it can handle for what it seems to be, still it’s up to our own judgment to
pick our choices.
The adaptation of thermal protect is not so complex. Only a matter of Normally Open thermal
switch can be hooked to the heatsink and interconnect the wire to the board easily. Another
simple option is to use ordinary NTC thermistor which has proper decrement response
resistance to oppose R8 when certain temperature reached to target range. When you picked
an incompatible response, a matter of adding resistors to connect in series or parallel method
to the TH should not be a big deal to meet the required current opposition for R8.
How the circuit works is simple. The input source voltage before Q5 is regulated to 3V via ZD2
and it is reduced a little bit via R8 and R10 respectively. However, base to emitter junction will
only fetch appropriate amount of current to run Q5 into saturation mode. If voltage drop is way
lower than conducting point, Q5 will turn off and the relay operation is disabled.
Anticipated Power Dissipation of each power transistor during Max Push & Pull condition with 8
ohms load can be determined, PdissMax = (Vin –Vout) * Ic, likewise Vce*Ic = 60-49 * 1.22 =
13W, that means for 5 pairs it would be 65W total heat dissipation during maximum power,,
PdissMin = 60+49 * idle current = 4.36W (in case of 40mA output bias)… At 4 ohms load;
PdissMax = (Vin –Vout) * Ic, = 60-49 * 2.44 = 27W. Enough size heatsink would easily take
proper absorptions for it, this does not necessary for us to be afraid of thermal runaway.
18
The PCB Design
Bottom Layer
Top Layer
19
Parts Placement Guide 3D Design
The Kit
20
Parts List
21
 Basic Constructions & Testing prior to use in actual operation:

1. Delay & switching: assemble first the components for DC rectifications, relays &
delay circuits. Apply 12V power and test if the swicthing of relay is working.
These components are; Faston TER, D3, D4, D5, D6, C5, C6, R17, Led2, R15, C7,
ZD3, Q8, Q9, Rly1. Likewise, R23, C12, ZD6, Q17, Q18, Rly2.
2. Continue assembling for the rest of spare parts. You can proceed through stage
by stage method assembly and do testing each of every stages if you want.
Through this method you can easily troubleshoot which stage can create
problem in case you assembled incorrectly.
3. Shunting: turn ON/OFF/ON the power supply then observe the quick recovery of
timing R/C, if after turning OFF then you switch it ON again and the delay is
started from initial timing means shunting is working okay. Components are;
R14, Q5, Q6, ZD2, R6, R8, R10… R31, Q14, Q15, ZD5, R25, R27.
4. DC detection stage: Use variable DC power supply then inject it to the “Amp Out
Terminal and Ground”. No matter what prior polarity you injected, just reverse
later for second polarity test. From lower DC input, say zero volt, slowly increase
the voltage ‘till you observe if the relay is deactivating. Once observing the
relay’s click sound, take note of the DC input sensitivity. That will be the
minimum DC detection for that polarity, probably something close to 2V.
Responsible parts; R5, C2, C3, R9, Q2, Q3, D8, R16, Q7… R23, C9, C10, R26, Q11,
Q12, D13, R33, Q16.
5. OCP (Over Current Protection): Use again variable power supply. Inject it to
“+ocp & amp out terminals”, this time must be ONLY positive to OCP and
Negative to Amp Out terminals. Increase the voltage slowly ‘till you hear the
relay click sound. Observe for the voltage activation sensitivity. R1 & R19 must
be manipulated accordingly, you have to base the sensitivity according to your
amp capability to avail the correct protection. Theory of operation is already
discussed on earlier part of this doc. Parts; R1, R2, D1, R3, C1, Q1, R4, D7… R19,
R20, D10, R21, C8, Q10, R22, D12.
6. Clip Indicator: Led 1 & 4 are for near to end rail indicators. They are those
indicators that tell us if the amp is getting closer to consume the maximum
supply rail. You can also test on simulated operation if it is match to your amp’s
rail by injecting high DC input to the “Amp’s Out Terminals and Ground”. In case
you have known DC rail, just minus constant 17 and the remaining value must be
the value assigned for your ZD1 & 4. Example, 100VDC – 17 = 83V, find on zener
diode’s table sheet which closest value is available in the market to buy, 2 series
ZD can do. To test, you can inject higher DC supply to “Amp Out & Ground”
according to that zener value. Polarity for testing is important. Positive for Amp
22
Out and Negative for Ground. Never mind the click sound of relay, it doesn’t
conflict on real function. Perhaps a good chance for testing higher DC durability
for your input DC detection stage. If you have no high DC psu for testing clip
circuit, you can leave it and let the amp real AC output do the testing itself. The
83V peak would be equal to 58Vrms output. Once your amp reach to that
output, clip led should light. Responsible parts; D2, ZD1, R7, C4, R11, R12, R13,
Led1, Q4… D11, ZD4, R24, C11, R28, R29, R30, Led4, Q13.
Disclaimer:
Your safety is your own responsibility including proper use of equipment, tools &
safety gears. Author has no liabilities whether you have adequate skill and
experiences. Power tools, electricity, and other resources to be used for this project
are considered dangerous if not use properly with adequate precautions. If you are
a newbie, younger person, or inexperienced with electrical and electronics devices,
do not hesitate to ask for guidance from qualified professionals.
23
1 2 3 4 5 6 7 8
1N4007 1000uF
D5
C6
AC1 D6
1K 1K
C7
+
A 12VAC 1N4007 R11 R15 A
D71N4007 104 R12 R13
AC2 4K7 220K
D8 AGND LED1 LED2
L1
1N4007 RLY1
O
Clip Intented for 80V Rail, CLIP PWR
D3 D11 P1
else replace value of ZD1 1N4007 AGND CLIP IND. Tr
R5 R9 AGND 1N4007
L2
S
[ Vcc-17 = ZD value ] 2N5551 SPK (R)
2K2 10K Q4
ZD1
+
C5 R10 RLY1
D4 2N5551
+
62VZ 2.2uF 22K Q6 C8 SLA-RLY
1N4007
TH CONN. 100uF
AGND AGND AGND
R6 2N5551 DELAY SW. Tr
TO REF. Q5 AGND
10K 1K 3VZ 2N5551
D9
AGND Q8
OCP Tr C2
+
D2 R3 R8 1N4148
R1 1N4007 4.7uF 1K ZD2 R16
B R14 4K7 B
AGND
Q1 22K
100R QUICK OFF Tr
+OCP (R) R2 2N5551 AGND AGND Q9
D10 BD139 LED3
3K9 Q2
C1 FAULT
1N4007 2N5551 2N5401
104 1N4148 AGND
D1 NEG DETECT Tr Q7
LATCHING SW. Tr AGND
AMP OUT (R) R4 AGND Q3
AGND
AGND 22K POS DETECT Tr
C3 2N5551
GND 100uF
+
10K
+
C4 R7
AGND
AGND 100uF
AGND AGND
C C
12VDC
1K
R28
R29 R30
4K7 220K
LED4 RLY2
L1
S
CLIP
D14 D17 P1
1N4007 CLIP IND. Tr 1N4007
Clip Intented for 80V Rail, R22 R26
O
L2
2N5551 SPK (R)
else replace value of ZD4
2K2 10K Q13
[ Vcc-17 = ZD value ] ZD3
+
C12 R27 RLY2

62VZ 2N5551
+
2.2uF 22K Q15 C13 SLA-RLY

AGND 100uF
TH CONN. AGND AGND
D 1K 2N5551 DELAY SW. Tr D
FROM REF. Q14 AGND
10K R23 D15 3VZ 2N5551
AGND Q17
D13 OCP Tr R19 R21 R25 1N4148
R17 ZD4 R32
1N4007 10K 1K R31 4K7
AGND
Q10 22K
100R QUICK OFF Tr Q18
+OCP (L) 2N5551 AGND
R18 D16 DB139 LED5
3K9 AGND
C9 Q11 FAULT
2N5551 1N4148 2N5401 AGND
1N4007 104 Q16
D12 NEG DETECT Tr
LATCHING SW. Tr AGND
AMP OUT (L) R20 AGND Q12
AGND
AGND 22K POS DETECT Tr
C10 2N5551
100uF
+
E 10K E
+
C11 R24
AGND
100uF
AGND AGND
(ACR)576PINOY_TECH / Dly, OCP, DC Offst, Clp Ind / PCB R1.2B - 6.18.2018
1 2 3 4 5 6 7 8
100.00mm
98.00mm
(ACR)576PINOY_TECH / Dly, OCP, DC Offst, Clp Ind / PCB R1.2B - 6.18.2018
Qty Value Description Parts Remarks
3 104/50V Mylar Cap C1, C7, C9 0.1uF
1 1000uF/25V Electrolytic Cap C6
6 100uF/50V Electrolytic Cap C3, C4, C8, C10, C11, C13 35 or 50V
2 2.2uF/100V Electrolytic Cap C5, C12
1 4.7uF/25V Electrolytic Cap C2
D1, D2, D3, D4, D5, D6, D7, D8,

13 1N4007 Rectifier Diode
D11, D12, D13, D14, D17
4 1N4148 Switching D D9, D10, D15, D16

2 3VZ/1W Zener D ZD2, ZD4
2 62VZ/1W Zener D ZD1, ZD3 initail value
2 3mm LED any color LED LED1, LED4
2 3mm LED any color LED LED3, LED5
1 3mm LED any color LED LED2
2 BD139 NPN Transistror Q9, Q18 TO126
Q1, Q2, Q3, Q4, Q5, Q6, Q8,
14 2N5551 NPN Transistror Q10, Q11, Q12, Q13, Q14, TO92
Q15, Q17
2 2N5401 PNP Transistror Q7, Q16 TO92
R6, R8, R11, R15, R23, R25,
7 1K Resistor 1/4W
R28
2 2K2 Resistor 1/4W R5, R22
4 4K7 Resistor 1/4W R12, R16, R29, R32
7 10K Resistor 1/4W R3, R7, R9, R19, R21, R24, R26
6 22K Resistor 1/4W R4, R10, R14, R20, R27, R31

2 220K Resistor 1/4W R13, R30
2 100R Resistor 1/2W R1, R17
2 3K9 Resistor 1/2W R2, R18
2 SLA-RLY SLA L-Type Relay RLY1, RLY2
9 Faston Terminal TER7

6n1 SPK Prot Rev 1.2B - With Basic Function How It Works

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6n1 SPK Prot Rev 1.2B - With Basic Function How It Works

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March 2, 2018 [6N1 AMP PROTECT REV1.

 The full schematic diagram of 1-channel 6n1 amp protect:

Forum Link:  http://www.elab.ph/forum/index.php?topic=46931.msg862501#msg862501

 The Power Supply Section:

 The Delay and Switching of Relay:

 C7 Voltage Charge / Clamping:

switching transistors activates, C7 is no longer increasing charge anymore because it is locked in

 Shunting C7 during power off:

 DC Detection mode for DC offset:

 Basic Reference Voltage Calculation:

 Clip Circuit Comparison:

 OCP (Over Current Protection) Overload, Short Circuit, etc…

 Thermal Circuit Adaptation:

The PCB Design

Parts Placement Guide 3D Design

 Basic Constructions & Testing prior to use in actual operation:

C12 R27 RLY2

2.2uF 22K Q15 C13 SLA-RLY

(ACR)576PINOY_TECH / Dly, OCP, DC Offst, Clp Ind / PCB R1.2B - 6.18.2018

D1, D2, D3, D4, D5, D6, D7, D8,

4 1N4148 Switching D D9, D10, D15, D16

6 22K Resistor 1/4W R4, R10, R14, R20, R27, R31

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