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Features:
The most significant part of this project is the power supply, as it requires three different voltages. It has to deliver 220 VDC for the pre-amp, 92 VDC for the PA and 6.3 VDC for the tube filaments. Total power demand is 34 Watts where aproximately 32 Watts is dissipated as heat.
Two versions of the PSU are suggested below. The first version requires a custom made transformer but is otherwise strait forward.
The second PSU version uses separate units for the plate voltage and filament voltage. Most of the components are ready available except the voltage regulator, which is DIY. The plate transformer TR1 is generating U1 for the PA and U2 for the pre-amp stage. A voltage doubler is producing the higher U2 voltage. For the filament supply a modified computer PSU may be utilized as shown here.
CIRCUIT DESCRIPTION
The two-stage amplifier is built on a SRPP input stage employing a 12AT7 medium gain double-triode and a powerfull pure class A cathode follower, employing the russian made 6C19P power triode. Negative Feedback is optional and may be switched on for even less THD and lower output impedance. The 6C19 power triode is biased with two cathode resistors connected parallel. BIAS current is set for aproximately 72mA. However, this small beast is capable of delivering up to 140mA cathode current for short periods of time. Output stage has true 235 Ohms output impedance. This headphone amplifier was designed towards the Bayerdynamic DT770 Pro headphones with 250 Ohms impedance. 
Fig.1 Headphone Amplifier Circuit (one channel shown).
As the PSU dissipates a lot of heat, installing a cooling fan is recommended.

Fig.2 Power Supply Circuit Version 1.

Fig.3 Power Supply Circuit Version 2.
| WARNING Potentially lethal voltages can be present. Do not touch any part of the device with bare hands while under power. After disconnecting power, wait until filter capacitors are discharged. Measure voltage with voltmeter to be sure. If you do not know how to handle high voltage circuits, do not build this device. Get help from a qualified technician. |
Construction
The two channel amplifier circuit and the PSU can be assembled using the traditional point-to-point wiring method. However, for our prototype, we designed a PCB. We have some PCB's available for purchase (see below).
We are still working on an electronic voltage regulator PCB which may be available in the future.
In the mean time there is a regulated PSU available at Ebay that may be utilized for this project: item number 120366398663
Store name: tubeshunter
http://stores.ebay.com/tubeshunter
However, we did not test it for fittness in this project!
Testing
U1=92V output: 635 Ohms 15W or 2 x 1.270k Ohms 7W ( for PSU version II 1350 Ohms 8W or 2 x 2.7k Ohms 4W)
Be prepared to do the tests rapidly as the load resistors will dissipate a lot of heat. The accuracy of the output voltages is importand for the OTL performance and tube longelivitity. Voltages should be as follows:
92V +/- 1 Volt
Connect the load resistors to the appropriet outputs. Make sure that the correct fuses are in place. Apply power and measure the output voltages. If measurements are within limits, the PSU is ready to be connected to the OTL amp. Otherwise the voltages must be corrected.
OTL Amp Testing
It is highly recommended to test the PSU voltages with load resistors first before connecting it to the OTL Amp.
Use the following load resistors for PSU testing:
U2=230V output: 47k Ohms 2W
U3=6.3V filamenrt output: 5 Ohms 10W or 2 x 10 Ohms 5W
220V +/- 15 Volts
6.3V +/- 0.1 Volt
Apply power and let the tubes warm up for 3-5 minutes (Stand-By ON). Next switch Stand-By switch to "operate". Immidiately measure the cathode voltages of each output tube. Cathode voltage should be 17V DC +/- 1V. If not within limits, turn off power quickly and look for wiring errors, solder shorts. Otherwise watch the tubes for any signs of overheating. Only the filament and the cathode (center part of the tube) should glow orange. Any other part of the tube should remain dark. The amp is ready for listening tests.
| AMPLIFIER MAIN PARTS | ||||
|---|---|---|---|---|
| REF. # | DESCRIPTION | QUANTITY | PART No: | SUPPLIER |
| P1 | Potentiometer 100K A audio | 2 | any | na |
| NA | 9 pin tube socket, PCB mnt. | 4 | P-ST9-222 | www.tubesandmore.com |
| NA | 1/4" phono output jack - stereo | 1 | S-H601C | www.tubesandmore.com |
| NA | RCA input jack | 2 | any | www.tubesandmore.com |
| NA | PCB stand-off | 4 | any | na |
| V1, V2 | Dual Triode | 2 | 12AT7 | www.tubesandmore.com |
| V3, V4 | Power Triode | 2 | 6C19P | www.ebay.com |
| na | PCB | 1 | G10 | see below |
COMPONENTS: (numbers in brackets = right channel) Resistors (0.25W 5% unless noted otherwise): Capacitors R1 (R7) = 820k C1 (C5) = 0.22uF 100V plastic film R2 (R8) = 180R C2 (C7) = 0.15uF 630V plastic film R3 (R9) = 680R 0.5W C3 (C8) = 47uF 16V electrolytic R4 (R11) = 820R 0.5W C4 (C9) = 4.7uF 350V electrolytic R5 (R12) = 220R C10 (C11) = 220uF 50V electrolytic R6 (R10) = 330K C12 (C13) = 1uF 250V plastic film R13 R16 (R19 R22) = 10K C14 = 10uF 350V electrolytic R14 R15 (R20 R21) = 470R 3W-4W R18 (R24) = 15K 0.5W R18 R16 (R19 R22) = 10K R30 = 4.7k 0.5W
| POWER SUPPLY PARTS VERSION 1 | ||||
|---|---|---|---|---|
| REF. # | DESCRIPTION | QUANTITY | PART No: | SUPPLIER |
| TR1 | Power Transformer | 1 | custom order | na |
| L1 | Hammond Filter Choke | 1 | 159Q | www.tubesandmore.com |
| BR1 | Bridge Rectifier 400V 2A | 1 | 583-RS207L | www.mouser.com |
| BR2 | Bridge Rectifier 50V 4A | 1 | 583-RS207L | www.mouser.com |
| C101, C102 | Capacitor 220uF/200V | 2 | C-ET100-350 | www.tubesandmore.com |
| C103, C104 | Capacitor 47uF/350V | 2 | C-ET47-350 | www.tubesandmore.com |
| C105, C106 | Capacitor 4700uF/25V | 2 | C-ET47-350 | www.tubesandmore.com |
| R30 | Power Resistor 8.2k 1W | 1 | NA | NA |
| TR1 Specification | ||||
| Primary Voltage | Secondary 1 Rating | Secondary 2 Rating | Secondary 3 Rating | SUPPLIER |
| 115V/230V | 176V CT 0.2A (2 x 88V) | 220V 0.04A | 8V 3A | Custom Order |
| POWER SUPPLY PARTS VERSION 2 | ||||
|---|---|---|---|---|
| REF. # | DESCRIPTION | QUANTITY | PART No: | SUPPLIER |
| TR1 | Power Transformer | 1 | 553-VPS190-230 | www.mouser.com/ |
| TR2 | Filament Transformer | 1 | 553-FD7-16 | www.mouser.com |
| BR1 | Bridge Rectifier 400V 2A | 1 | 583-RS207L | www.mouser.com |
| BR2 | Bridge Rectifier 50V 4A | 1 | 583-RS207L | www.mouser.com |
| C101, C102 | Capacitor 220uF/200V | 2 | C-ET100-350 | www.tubesandmore.com |
| C103, C104 | Capacitor 47uF/350V | 2 | C-ET47-350 | www.tubesandmore.com |
| C105, C106 | Capacitor 4700uF/25V | 2 | C-ET47-350 | www.tubesandmore.com |
| R30 | Power Resistor 8.2k 1W | 1 | NA | NA |
| TR1 Specification | ||||
| Primary Voltage | Secondary 1 Rating | Secondary 2 Rating | Secondary 3 Rating | SUPPLIER |
| 115V/230V | 176V CT 0.2A (2 x 88V) | 220V 0.04A | 8V 3A | Custom Order |
| DISCLAIMER OF LIABILITY: THESE PROJECTS ARE PROVIDED 'AS-IS', WITH NO WARRANTY OF ANY KIND. USE OF THESE CIRCUITS SHALL BE ENTIRELY AT THE USER'S OWN RISK. All rights reserved. You may build these circiuts privately for your own use. You may NOT build or sell them for commercial profit without our permission! |