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diy article DEMONSTRATION  -  The Bugle Single 45 Amplifier
the bugle single 45 amplifier
by Gordon Rankin, Wavelength Audio

For some time now I have been building obscure amplifiers under the names of some of the better brass instruments. The Trumpet was my original name for the Baby Ongaku from SP #9, the Flugelhom is an interstage coupled parallel 45 amplifier and the Trombone is a cool 3008 circuit. All of these designs are less than apt for today's market because of one attribute or another-unavailable tubes, "weird" idea, not enough power for the US (bull-head-ed) market.

Today we are going to analyze my favorite from this collection, the Bugle. The Bugle is a stereo 45 amplifier yielding a generous 2.5W of power. I don't even try to sell this amp anymore because of time and sketchy availability of the 45 tube, but sound-wise

this amp would be a good investment for the DIY hobbyist. It is designed to be a simple, high performance circuit that also would be simple to build.

One nice thing is that a 45 is always a sin-gle plate tube and a lot easier and cheaper to find than the single plate 2A3. Also, there are rumblings that the Chinese are remaking the 45 tube, but I haven't seen any yet myself!

When designing an amplifier, I always start by characterizing the speakers and work my way back. I would estimate a good speaker of 95dB sensitivity or better at 8 ohms or higher to be right for this project.

So, let's pick the super-sounding 45 tube, which has a dissipation of 10W on the plate. In my experience the 45 is best with no more than 35mA plate current. We can take the plate voltage up to 275V at that point. I believe that when using the 45 (as well as other directly heated triodes) that self bias is best. The required bias at 275V for 35 mA plate current is -55V (actually, based on the dozens of 45s I have tested, you can expect between 52-54V in real life), which when added to the 275V plate voltage makes for a

total B+requirement of 330V. From here, we can calculate the rest of the output stage by selecting the output transformer and the biasing resistor. The plate impedance for a 45 running at 35mA is 1700 ohms. For the best results when using triodes, the transformer primary impedance should at be at least three times the plate impedance of the tube. Since there are no 5.1K primaries in stock, we can easily make do with a 5K primary transformer with a rating of about 35 mA or more.

The bias voltage is between 52-54V volts so, by Ohm's Law, we divide the mean voltage by 35mA and get a bias resistor of 1514 ohms or better yet use a readily available 1.5K unit.

We can determine the wattage dissipated of this resistor by I squared x R = 1.8375W I try to de-rate all my wattages by a factor of 5 for long life and stability. In this application, I would use at least a 10W rated part. In my version, I used the 12W Mills MRB-12 resistor because they are really nice units at that wattage.

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the bugle single 45 amplifier
click for bigger pic   The Wave Length Audio Bugle Stereo 45 SE - great amp but no a big seller amoung the power-crazy mainstream market at 2.5Watts per side!

We can see from Sidebar A that the bypass capacitor we need is at least 22uF. A SCR AEON 24uF/250V would work fine. For the drive stage, we see from Sidebar B that we need a slew rate drive current of 1.1 ma or better. Actually we reach the maximum output well before the bias voltage of To get the most out of an input stage I try to set it up so that with a IV input to the amplifier, I get the maximum output. I then bias the gain stage so that the bias voltage is a factor of 1.5 to 2 times the IV input (i.e., -1.5V to -2V of biasing). This
is done so that the input stage does not clip before the output does.

In the Bugle, I originally set everything up for the 6072A, one of my favorite tubes. Then I also found that with the same bias-ing resistors, the 5751 also worked and provided a higher overall gain. I biased the 6072A at 2V @ 2mA at about 140V per plate in SRPP mode. The bias resistors for each section work out to be 1 K.

I find the SRPP drive stage to be good sounding, and easy to implement, offering a lot better output capacity than plate load-ing the same tubes. Because there is enough local feedback in an SRPP so that it is not beating the tube for maximum gain, I find it vastly superior in sound to all the types of the mu follower designs. Following this logic, a simple plate loaded tube should sound best, and maybe it does, but then you have to use two stages and that introduces another set of problems. In my experience, the SRPP is the best sounding simple way to go.

At 2mA, the 6072A has plenty of slew rate current. This design has an output impedance of about 15K. The 45 has a

maximum grid resistance of 1 M in self bias mode. If we use a resistance of 470K [I found some of the globe 45s draw grid current when a higher value is used) we can determine the necessary coupling capacitor.

I found that the best plan for bypassing is to use 5Hz as the limiting low end for cal-culations. Most designers go way over-board with the bypass capacitance, slowing things down. So we have 1/[2*PI*F*R) = 1/(2*PP5M70K) = 0.0677uF. I use a 0.047uF for a low end response of 7.2Hz, plenty for this type of amplifier.

Also, the smaller the capacitor the better the sound. Lately the largest coupling capacitor that I can stand is a 0.25uF in an amplifier. I would try the Audio Note cop-per or silver foil or the Hovland MusiCaps. Since there is a potential of 140V across the capacitor, a 400V or higher voltage rat-ing is required.

Okay, so we have the gain, output stage, now we need the power supply. The 45 requires a 2.5V filament at 1.5A, 6072A needs 6.3V/0.3A each, and we need a sup-ply B+voltage of 330V.

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To get the most out of an input stage I try to set it up so that with a IV input to the amplifier, I get the maximum output. I then bias the gain stage so that the bias voltage is a factor of 1.5 to 2 times the IV input (i.e., -1.5V to -2V of biasing). This is done so that the input stage does not clip before the output does.

In the Bugle, I originally set everything up for the 6072A, one of my favorite tubes. Then I also found that with the same bias-ing resistors, the 5751 also worked and provided a higher overall gain. I biased the 6072A at 2V @ 2mA at about 140V per plate in SRPP mode. The bias resistors for each section work out to be 1 K.

I find the SRPP drive stage to be good sounding, and easy to implement, offering a lot better output capacity than plate load-ing the same tubes. Because there is enough local feedback in an SRPP so that it is not beating the tube for maximum gain, I find it vastly superior in sound to all the types of the mu follower designs. Following this logic, a simple plate loaded tube should sound best, and maybe it does, but then you have to use two stages and that introduces another set of problems. In my experience,

the SRPP is the best sounding simple way to go.

At 2mA, the 6072A has plenty of slew rate current. This design has an output impedance of about 15K. The 45 has a maximum grid resistance of 1 M in self bias mode. If we use a resistance of 470K [I found some of the globe 45s draw grid current when a higher value is used) we can determine the necessary coupling capacitor.

I found that the best plan for bypassing is to use 5Hz as the limiting low end for cal-culations. Most designers go way over-board with the bypass capacitance, slowing things down. So we have 1/[2*PI*F*R) = 1/(2*PP5M70K) = 0.0677uF. I use a 0.047uF for a low end response of 7.2Hz, plenty for this type of amplifier.

Also, the smaller the capacitor the better the sound. Lately the largest coupling capacitor that I can stand is a 0.25uF in an amplifier. I would try the Audio Note cop-per or silver foil or the Hovland MusiCaps. Since there is a potential of 140V across the capacitor, a 400V or higher voltage rat-ing is required

Okay, so we have the gain, output stage, now we need the power supply. The 45 requires a 2.5V filament at 1.5A, 6072A needs 6.3V/0.3A each, and we need a sup-ply B+voltage of 330V.

I prefer a choke loaded power supply over a Pi filter because the bass is so much faster and punchier with choke input. For this design I would use the 5AR4/GZ34 rectifier because of the low B+. If you are building an amplifier with a higher B+ voltage, then you may have to use its big-ger brother the GZ37. To determine the transformer necessary for the desired B+ output using the curves supplied by Amperex we see that we need a plate to plate voltage of 700-720 for the full dissi-pation of some 80mA [stereo circuit).

What I do to trim the voltage is to add the input capacitor Cx to get the B+ up to where I want it. The reason the circuit does not come in at the exact voltage shown in the curves is because of the resistance in the choke and losses in the power transformer. A small input cap can be used with a choke input to raise the out-put voltage to make up for these losses.

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With the transformers and chokes I used, the correct value of Cx is 0.68uF. This cap should have a DC voltage rating of 630V or better. Some would say this is a Pi filter but because of the small amount of capaci-tance after the rectifier this is not really the case. It actually acts very much like a choke input. Refer to Chapter 30 in Radiotron Designers Handbook, 4th ed. for details on power supply calculations. [Or look up the power supply chapter in "The Radio Amateur's Handbook," published annually by The American Radio Relay League since the dark ages-ed.]

Ihave found large chokes and smaller capacitors to be the best case for choke loaded supplies, but high capacitance or multiple stage supplies are necessary for low ripple on the supply. Here we will use 2-l00uF in parallel with a 20uF SCR film for a high-C, single-section supply. That will drop the ripple down to less than 30 mV p-p with a 30H Hammond 157G choke for each channel.

Since we have a B+ of 330V we need to drop this voltage for the 6072A by around 55V @ 2ma, requiring a resistor equal to 27.5K ohms. A 27.4K with a wattage of 0.5W or better should do the trick.

Also since the upper cathode of the 6072A [or 5751) will be at 140V+ volts, we want to put a positive voltage on the heaters relative to ground so that the cathodes do not exceed the rating for cath-ode to heater voltage [90V for both types). If we use around 70V, both cath-odes will be in good shape. A voltage divider consisting of 250K and 68.1K resis-tors across the B+ provides the needed 70V bias.

That's it for design, now some parts notes: I use Shinko tantalums for all my 0.5W and 1W needs these are available from Angela Instruments [301)725-0451. The Mills and most of the capacitors are avail-able from Michael Percy [415)669-7181. The chokes are available from Handmade [610) 432-5732. The chassis are available from Experiences Sonores [418)652-8788 FAX-see ad in SP #72 page 50, right pic-ture is the Bugle chassis. The output and power transformers are from my faves MagneQuest [what's that number...) [215) 288-4816. I present this work in the spirit of DIY for the personal, non-commercial, hobby use of SP readers only. I must restrict copying of this schematic, without written permis-sion from Sound Practices and Wavelength Audio. Also, please do not call

me and ask me what color to paint the amplifier. I can respond to e-mail questions only at: wau-dio@cinti.net. No calls pleased Somebody's got to work around here!

Thanks and have a good time. Gordon.

the bugle single 45 amplifier

click for bigger pic   circuit diagram of the 45 Stereo Amplifier
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