DIY 2A3 SET Amp

Tube amps are fundamentally simple devices.

When I was planning it I came across the Loftin White design, and was enamored with the direct coupling (no coupling caps). I started with a variant of that design, I modified it to make the load line a bit more friendly for headphone loads.

SRPP was also something that I was enamored with at the time, I copied a design, because at the time I didn’t really understand it well, I have a better grasp now.

PSU is entirely my fault, I went SS Rectified and regulated, in part because I intended to reuse it, and in part because I wasn’t 100% certain my calculations for load were good enough to hit 400V without the regulator. When I first purchased the parts I misremembered the current requirement, and as a result I have 2 independent PSU’s (1 per channel).

It’s a learning exercise, My intent was to start with AC heaters, swap to DC heaters, so I could evaluate whether the extra complexity was worth it. Try removing the Bypass caps, which in effect adds a degree of local feedback. Start with a transformer designed for speakers and swap to a transformer designed for headphone loads (it’s still sitting in a box while I work through minimizing the noise).
Understand better the difficulties of physical layout.

Things I’ve learned so far

The issue with the Loftin white design, is partly cost, running a higher B+ (400 vs 250) makes everything more expensive, but you also need to lift the cathode on the Power tube by 150V, that’s a lot of resistor and they can carry significant current in the case of a tube failure.

The issue with the SRPP is because the upper triode has it’s cathode lifted to 1/2 B+, you have to be careful not to exceed the maximum Cathode to Heater voltage for the tube, in practice that requires me to lift it’s heater by 50V, so both 1/2’s of the tube are in spec. The way I chose to do that complicates them sharing a heater supply, again adding cost.

Point to point wiring is painful, and managing grounds in any design requires careful thought.

Neither of those first two things make them bad choices, removing the coupling capacitor removes a source of phase shift in the amp.
The SRPP is a push pull circuit with low output impedance. Though I’m not really exploiting the latter aspect given it’s driving a tube stage with probably >>1 Meg Ohm input impedance.
The amp sounds really good, to the point I need to plug it into a real DAC.
This week I should have enough bits and pieces to actually measure it, it’ll be interesting to compare that to the simulations.

I were building another DHT amp, I’d probably go capacitively coupled, with a CCS on the anode of the input triode. But mostly to see what the difference ends up being.
I’d probably have a few circuit boards made up for it, the cost isn’t a significant portion of the build, and it’s way easier to solder a board with a dozen parts on it than it is to wire those same dozen parts point to point.

I have a Hybrid design I’ve been playing with Triode into SE Mosfet output, that I might build next though.

6 Likes

My enthusiasm for these DIY threads is great, whenever one pops up i make sure to activate it so that i can follow along, problem is i barely understand anything much of what is being pictured or spoken about :crazy_face: I’m not very electronics technical and not educated at all beyond a few basics, but damned if i’m not a great cheerleader :beers: :hugs:

4 Likes

Some measurements using my hack job measurement rig, and REW.
30 Ohm Dummy load 1V RMS in, which is still much higher than I’d listen at that would probably be closer to 300mV.

Notable things

  • The amp isn’t broken.
  • has good frequency extension, the actual -3dB points are over 30KHz and below 10Hz
  • Power supply hum is the predominant noise, it doesn’t change at all with Volume

The 60Hz noise is likely the heaters, most likely the AC heater on the 2A3, so I feel good about the messing around involved in moving to a DC heater for it (once the parts arrive).

Harmonic distortion is pretty much what I expected, 2nd Harmonic is 50dB’s down at 1V RMS ~0.3% which is about what I expected, with 3rd harmonic falling away to -70dB.

I ordered some parts to put together a “real” load box, at which point I’ll test it into various loads, though I don’t expect radical differences, it’ll be an interesting experiment.

TBH I could have guessed most of this just from listening to it, but it’s nice to have a baseline on the mains noise to compare to after the DC heater change, and confirmation nothing is out of whack.

5 Likes

DC filament supplies tested

It’s basically 3 very overengineered linear PSU’s, and not for the faint of heart right now, since it isn’t grounded and there’s a lot of exposed 110 there.

I mis-sized the diodes on the PCB, so the bottom 2 in the picture I had o attach them with fly leads which was not what I’d call fun.
The heatsinks on the bottom 2 regulators hit about 230F, it’s still in spec for the regulator, But I’d like to use a smaller transformer to reduce the temperature, but I can’t find one in the voltage range I need with the current output. I guess i could try running an unregulated 2.5V supply. I also couldn’t find any bigger heatsinks.

The overall amp now insanely requires 3 IEC connectors, and contains 5 mains Transformers (will be 4 eventually) it actually contains 7 mains transformers right now, but 2 aren’t being used.

I have parts for a single transformer Mains Voltage PSU with a tube rectifier coming, at which point I’ll put the PSU in a box.

Anyway the net result of all of that is, it eliminates all the noise, and it sounds really very good, I really wouldn’t bother with a AC supplies again, I’ll do some measurements tomorrow, but pretty much it just made it sound quieter, which opened up the stage a bit more.

11 Likes

And to prove everything doesn’t go problem free I had a board made up for the high voltage power supply.
One extremely loud bang and shrapnel from the diodes hitting me (no permanent damage to me at least).

It took me a while to track down why, the diodes were obviously exposed to much more current than expected, but it’s the mosfet that failed first, probably resulting in a short that then destroyed the diodes.
The cause of the issue, I didn’t realize that in KiCAD when you select a transistor for the schematic, you also select it’s pin out, I’d selected the spice simulation model that had the wrong default pinout, so the Drain and Gate pins are swapped on the PCB. Guess I won’t make that mistake again.

Board looks intact, hopefully nothing else on it destroyed, I think I have spare diodes and mosfet, I’ll need to hack up and patch the board for now or just bite the bullet and order an updated one.

6 Likes

Damn, those little buggers blew up REAL good! Good job figuring out exactly what happened, nothing worse than spending days trying to figure out a hidden problem.

3 Likes

I think they probably had 510V running directly through them to ground when the MOSFET failed so not a big shock they exploded, just glad they didn’t hit me in the eye, I actually covered my face when I connected the power, but they sneakily waited for about 10s before they detonated.

I should have traced the circuit off the board design before I submitted it to be built, but having never encountered the issue I didn’t. I knew the circuit worked, so it was just a question of whether the board was right.

3 Likes

I mean, you cant say you didnt get some spice.

3 Likes

It’s amazing that none of the traces on the board look damaged! out of curiosity how much does it cost to get a one off PCB made? If you don’t mind the reworking to compensate for the wrong pin out, the scorch marks does give it that survivor vibe. lol

2 Likes

Depends on the size, that one was ~$100 including shipping, but it has a thicker PCB than standard, because I have a tube socket soldered to is, and wanted to use it suspended below the top of the box.
Minimum order is 5 units, so I have spares, all wrong in the same way, but desoldering the caps on the board will be a pain, so I’ll probably patch existing board, I just have to cut two tracks and run a couple of patch wires.
If I needed more than 1 I’d reorder them, it’s not a substantial part of the cost of even just the PSU.

Damaged traces would have surprised me, usually what happens is something acts as a fuse, and everything else survives, traces can take a lot of current, so they’re not likely to go first.
Once the mosfet shorted, the diodes were a direct path to ground, but still substantially higher resistance than the traces on the board, so the bulk of the voltage is dropped across the component, they overheat explode, and then theirs no more current to damage anything.

4 Likes

Now with “fixed” Mosfet Wiring.
After tracking down that the other (not exploded) Zenner diode on the board had also failed. It now appears to produce the correct voltage.
So at this point it’s about packaging this and the DC supplies for the heaters into a box.

7 Likes

That’s the rear of the PSU, yes the tube goes in the back!

I actually did most of the work the past weekend, drilling the 200 or so holes wasn’t what I would term fun.
I walked away in disgust when I powered it up and it had a very obvious hum, took me a couple of days to track it down.

My first thought was it had to be the 400V PSU since I’d never used the tube rectified version to power the amp. In the end that was fine.
After prodding with a scope I determined the the DC from the 2 2.5V heaters had a small 60Hz signal sitting on it, this made no sense to me, those I’d tested with the amp, and the fact it was on both I really couldn’t understand.
The cause of the issue believe it or not was the 6ft power cable, when I’d connected the power supply to the amp, I had to adjust the trim pots on the two DC supplies to bring the voltage upto 2.5V, in doing so I’d actually exceeded the maximum voltage the rectifier could deliver from the power transformer.

The reason for this is kind of interesting, the 2A3 has a 2.5V 2.5A heater, that’s a lot of current at a very low voltage, I needed an ~4V Transformer to be able to supply that regulated. I couldn’t find one so I’m using a 6.3V supply that means the regulator has to shed ~12W in heat, which made it run VERY hot. My solution was to add a 1 Ohm resistor in series with the filament, meaning I now needed to supply 5V at 2.5A, but the resistor would be shedding ~6W of the heat rather than the rectifier.
The 6ft power cable added, I’d guess about 200 milliohms of resistance to the circuit, that cost me about 0.5V, so I now had to supply 5.5V to the circuit and the voltage drop over the rectifier was too large to be able to do that. Swap the 1 Ohm resistor for 0.5 Ohm resistor and all fixed.

I kind of knew cabling was an issue with 2A3 heaters, I remember reading somewhere that a PSU should put out 2.6V into the heater because the loss at the socket itself was enough that you’d drop 0.1V before you got to the pin itself.

Other discoveries, apparently I implemented a tube heater soft start by accident, it takes a good 10 seconds for the heaters to get near intended voltage and probably 10-15 minutes after that before the voltage reaches optimal.
The 400V line takes about the same time, to come up, but that isn’t a surprise.

The PSU still has no front panel, or power switch, but appears to be working fine.

I wish I could compare it with the SS rectifier, but I haven’t heard the amp in 3 weeks, and I’m going from dual mono PSU’s to one that shares 400V Power, And the PSU Transformer is at leas 3x the output, and the Choke rated for more than double. If you put a gun to my head I’d say it might be a bit more open than the SS rectified version.

I still have an issue I need to track if I ground the PSU case, I get a really loud hum, so something else is coupled to it somewhere, it’s not obvious to me what, but I have a couple of things I can try.

13 Likes

Please tell me you have a drill press at home. Those could not possibly have come out that perfectly spaced with a hand held drill!

2 Likes

I do have a drill press, but they were actually all drilled with a hand drill.
I have a CNC router that won’t drill the holes, but I could set it up with a spot drill to mark them all, since once it’s spot drilled the bits will naturally center on the spot, it’s just a question of keeping the drill vertical.

4 Likes

And fixed the case ground issue, lose filament from one of the multistranded input wires on the 2.5V supply was touching a brass standoff.

3 Likes

And finally with a power button and front facia installed.
I think I’m just going to put the amp in a wooden box.

10 Likes

Got a name for it yet?

2 Likes