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ICs and modules
Wherever possible, it makes sense for a manufacturer
to settle on a 'standard' design known to function
satisfactorily, thus saving costs. Modules, such as the
Mullard LP1162, appeared in many commercial designs
whether audio or TV. A faulty amplifier could then be
easily replaced with little or no diagnosis.
Early IC power amplifiers were not particularly robust,
some even failing to survive the soldering process! In
response to my call "One recalls Plessey ICs (3W?)
being used for a Practical Electronics / Wireless stereo
amplifier which sported a boltable heatsink tab at each
end (anyone have a copy?)", Steve Radley has kindly
come up trumps with the very detailed Plessey SL403
Application Report 'based on a series of articles written
by Mr Gay (Chief Engineer, Linear Circuits) for 'Practical
Electronics'', dated Jan','70, a PDF of which the author
can supply on request. This design was an introduction
for many, despite the logic series ICs then available, to
microelectronics and the long-awaited miniaturisation
that would surely follow.
The 50 thou square chip was mounted on a steel strap
and an output of between 1 and, optimistically, 3W was
possible.

Note the wider than normal 0.2" pin pitch and that the
image of the IC's boltable attributes is hand-rendered,
typical of the day. Package thermal dissipation (chip to
ambient) was 11C/W. The radiator used 5 sq" of 18swg
copper, aluminium, steel, etc. Plain washers between
bolt-head and nut were advised, and silicon grease
could 'do no harm'. With suitable holes in a PCB the IC
could easily be mounted directly on to a metal enclosure
(negative ground).
Internal circuit layout which included a preamplifier gain
stage that could be used to provide thermal feedback
for the quiescent current. The chip's non-commercial
attributes belie it's high-frequency and 'defence' origins,
the SL403A being a higher voltage pin-compatible
version of the SL402A.

Schematic for a stereo integrated amplifier.

The quoted spec for the above arrangement was 15Hz

to 50kHz 3dB, distortion <1%, noise (ref 2W7) -80dB,
treble +11.5dB/-15dB at 15kHz bass +10dB/-17dB at
40Hz, sensitivity 160mVrms for 2W7 output, crosstalk
-40db. Supply line voltages ranged from 17V4
(quiescent) to 15V8 (both channels driven). The
absolute max supply V was 24V and for operating 21V,
18V being nominal (SL402A 20, 16 and 14V
respectively).
For 'hi-fi', a preamp circuit and 3-way (BMT) amplifier
arrangement were suggested. These were compared
favourably in terms of sonic quality to other discrete
designs capable of 10W (the then new 'commercial
standard', most domestic audio equipment producing
about 3W or less) with 0.1% distortion. Below is the
design which must represent one of the earliest
examples of IC op-amps being used in a 'hi-fi' preamp.

Notable is the additional switch wafer, compared to

other approaches. Below, the SL702C's internal layout
which is quite simple by today's standards, although
capable of a useful frequency range of 10MHz.

Specs were surprisingly good and would withstand

comparison with modern offerings, a tape output being
best taken from the top of the volume control.

Typical of those found in PE and PW, a stripboard layout

for a complete stereo preamp is shown below.

These, although not perfect, were of immense practical

use to a new-comer learning how to solder. Below, the
circuit diagram for the 3-way amplifier. The speaker
units suggested were the Goodman's Audiom 61, Midax
and Trebax, all of which were 15R.

The 2R2, 1mF filter gives 12dB attenuation at 300Hz

and 17dB at 500Hz, etc, of supply by-products (Trx = 2
x 6V3 in series, 5mF smoothing). The upper pots (VRs
5, 7 and 9) set the output DC, the lower ones (VRs 6, 8
and 10) the stage gain. Another stripboard layout for
the above. The + terminal of C28 (bass output coupler)
is shown disconnected,

a suggested heat-sink arrangement being (cut-away

intended for C46 and not C47)

The quoted spec for the above arrangement was 3Wrms

per channel into 15R, 13Hz to 100kHz 3dB, THD at full
output 0.3%, noise -90dB, treble 15dB at 15kHz and
bass 18db at 20Hz, sensitivity - radio 35mVrms,
ceramic pu 400mVrms, mag pu 2.5mVrms at 1kHz,
crosstalk <40db at 1kHz.
Although costs and complexity for an amateur were
higher the appeal of this approach was tangible, being
'cutting-edge', 'ahead of it's time' and sonically
impressive despite the higher powers then being
adopted. At the end of the application note, reference is
made to 'a typical commercial Hi-Fi system' (SP25?
deck, Linton type speakers) made by Britmac Electrical
Co Ltd, using the SL400 series. Were there others? It is
assumed that these devices were marketed as the
unsuccessful Sinclair IC-10, Plessey apparently
exhibiting little enthusiasm.
"The Sinclair IC was actually made by
Plessey and rebranded and rerated to 12W
by Sinclair. But this was none of your
namby-pamby RMS Watts - more like peak
power into minimum Ohms on a leapTuesday. The real IC rating for the Plessey
SL404 (or a number something like that)
was about 3W. I remember the Plessey
Semiconductors rep, back in the '70s or
'80s, telling me they were indebted to
Sinclair for finding a real wear-out
mechanism in that IC. Apparently, at high

power, one of the internal substrate

metallisations gradually eroded/migrated,
due to high current flow, until it ruptured.
This did not happen at Plessey's rated
power output. Mike" (sourced by
Cherukupalli Rama Murthy).
Manufacturers then put similar dissipations into normal
DIL packages, some with side-wings which could be
soldered to the PCB or have fins clamped to them. One
type was best mounted vertically to obtain the highest
air-flow through it's integrated fins.

Such packages were used for amplifier circuits in TVs,

many of whose PCBs were mounted vertically. Cheap
record-players that mounted this type upside-down
suffered the highest failure rates.
Intended for the then ('70s) popular 'home constructor'
market and bearing an uncannily striking physical
resemblance to the Texas Instruments SN760**N series
(requests for data sheets for which have been received,
are there any out there? Those below appear to match
SN76013), the Sinclair Super IC-12 was one of these,
the schematic for which is shown below

the recommended configuration being

Most significant for the author, as was common at this

time, is the lack of protection circuitry, current limiting,
clamps, etc. Service arrangements were offered for
failed assembly attempts.
A variety of 'add-on' circuits were suggested to increase
versatility and were sold as kits.

Points 'fb A' (Kit 1) could be commoned and the

respective 'fb Bs' were selected via a switch paralleled
with another that then switched the designated input
signal. Kit 2 accommodated ceramic and crystal pickups
and microphones.
Other preamp suggestions were made although these
ICs could be used with the Sinclair Project 60 (and later
80 preamp modules which preceeded the tiny Sinclair
2000/3000 integrated amplifiers). These included tone
controls that could come before the IC or be integrated
with it. A balance, volume control and input (DIN
convention) switching completed a stereo layout.
With the power supply (transformer 20V max >0.5A),
all could be fitted into the plinth of a record-player,
typically a Garrard SP25 mk3. With a Goldring G800
cartridge and a pair of Wharfedale Lintons, this would
have typified a (UK) first 'hi-fi'. With, usually, a lack of
screening and the low sensitivities at high impedances
mains hum and RF break-through could prove
problematic. Similarly, a hotspot in a plinth (mains
transformer) could warp a record left on it if ventilation
wasn't considered. The addition of a ramped regulator in
this kind of situation reduces hum, crosstalk and switchon thumps, giving quite acceptable performance. An
example is shown below (reduce output voltage for IC12).

The very informative construction manual suggested

other applications, such as a Wien-bridge oscillator,
bridge (doubling the output voltage swing) and DC
amplifiers.

For best results using this configuration; ensure a very

low impedance between both IC's earth returns, use 1%
resistors in feedback networks (2 x 100R & 3 x 27k,
match 100F caps), select load to draw <1A maximum
and set offset pot for minimum voltage across load with
input shorted.
The heatsinks from this type of IC could be removed
from 'dead' ones and re-used for power transistors. A
recent application used them for some class D ICs.
A higher output from a DIL package was offered by the
TDA2020 (sourced by C. Rama Murthy)
"which was the first Monolithic mono (1 ch)
Hi-Fi amp, 20W into 8 Ohms, in DIP
package (staggered pin layout) with integral
heatsink tab and was available in 1975 as
per the catalogue of SGS ATES (the then
Italian company ,which later became

STmicro). The THD was very low and the IC

could be used both on single and dual
supplies. It could also be bridged for higher
power. There was also a driver IC available
(TDA2020D) which was to drive two power
transistors in Push Pull configuration for
twice the power. This IC was featured for
DIY enthusiasts in Elektor Holland in Feb
1979 and UK in April 1979 and was soon
available also in India in the form of kits
with heatsinks to facilitate the constructor. I
did it in 1980 or 1981.
The problem was that with rated voltage,
heatsink was needed to keep the IC safe
even without load to dissipate the quiscent
power. Otherwise ICs were getting hot and
failing-the onchip thermal protection was
not probably very effective. Maybe SOA
limitation was not well understood and kit
designers took data sheet values literally?"

The Elektor article (E 21, Jan '77, p1-42) was followed

by mods (E 23, Mar '77, Missing Link, p3-56)

recommended by an updated SGS datasheet which

included two output clamping diodes, the roll-off
capacitor connected to the output instead of pin 10 and
advice that the single supply version (output AC
coupled) should not be used with loads of less than "8R
since the phase shift caused by the capacitor could then
cause damage to the IC". Although magazines like
Elektor, ETI, PW, PE, etc, were enormously informative it
was always an idea to not rush to build a new design,
but to wait until revisions were published to
accommodate modifications resulting from debugging.
Some magazines, obviously, were worse than others,
ETI in particular from the author's point of view.
As the technology improved (TBA8**, etc), power
ratings increased and safety circuits were included
increasing survivability. Sophisticated high current
hybrid opamps, like the 1974 RCA HC2000H (currentlimited) and low-distortion HC2500 (7A each) series,
whose applications included motor control and inverters,
could give useful service in audio appications (HC2500 60W/4R and 200W/4R bridged). The later ('79) Philips
OM931 (30W) and OM961 (60W) were noted for their
'clean' performance.
The 5-pin Pentawatt TO220 TDA series, came a long
way (in terms of output power and protection) from DIL
types (the more recent TDA2050 giving performance
comparable to reasonable discrete designs) and offering
an even smaller PCB footprint.

Below is a bridge layout.

These may not use a centre-tapped mains transformer

and additional output pairs can boost the output
current, eg;

Lower distortion was achievable with the LM1875

(observe PCB layout criteria).
Larger package types, such as the TDA1514 and the
DMOS TDA7294, are useful for compact integrated
active speaker designs and biamping in multi-channel
systems, although slew-rates can vary and output
power estimates can appear optimistic. Some published
projects quote a 40W output for the LM3876 when it's

datasheet gives 56W. The LM3886 can be quoted as

150W, when it's datasheet states 68W.
A compact PCB to fit both the LM3876/86 power amp
ICs appeared in Elektor (Dec 95, Jul/Aug 98).
Experience has suggested that a reasonable working
voltage for types like these, given dissipation and 4-8
ohm loads, is 30V (Tamb = 50C, thermal res =
<3.5C) or less (35V abs max, 18-0-18V transformer
max recommended). A small and simple design might
then look like that below;

Run PA into 8 ohms for best results (heatsink

<3.8C/W), assuming a safe maximum output of
60Wrms or less. Using dual opamps reduces PCB area
and these can be run from zener-stabilised resistive
feeds from the supply lines. Include lots of smoothing.
Once matched to load, gain of PA may be reduced to
give no clipping at all normal control settings with
volume at maximum. Removing feedback RC (47pF18k) will increase slew rate to 16V/S. Mute can be fed
from two diodes and a small electrolytic run from
transformer secondary thus activating before main
smoothers discharge, eg;

A suitable input selector can be that shown below.

Inputs can be fitted with 100k presets for differing

output levels of sources and clamped (back-to-back
zeners set for, say, logic supply level) to prevent
damage from over-drive.
The range of supplies that can be accommodated and
outputs available now is large (the stereo TDA7265
(25+25W/8R) is useful for small hi-fis, stereo TVs, etc)
and high efficiency class D designs can prolong battery
life. The 50W+ TDA7293/4 series, which have DMOS
output devices, offer a robust solution (the '3' can be
paralleled for high currents into low impedances) and

are seen in a number of 'audiophile' amplifiers and kits,

like the Velleman K8040 and the Quasar 1218. In
excess of 100W can be obtained from a single TO3 can
with the TPA12A and LM12CL. Dual audio drivers that
drive output pairs directly, like the TDA7250, can
considerably reduce the component count of a stereo or
bridge-configured PA whilst offering mute, protection
and monitoring of the quiescent current. These were
used in the Lecson Stereo and Quattra ranges (separate
supply for the Q Plus) and the more recent Velleman
K4005B kit. The 12V Coetec TDA7377 dual/quad PA
offers a very low component count, sophisticated
protection and spec.

Class H designs switch in a higher voltage supply rail to

cope with peaks. A good example is the Philips
TDA1560Q IC, intended for automotive use. The
TDA7293/4 datasheets show another.
Some modules can offer excellent specs, compactness
and versatility (see Philips, ILP, Sanyo & Sankyo STK
series, Sage Audio, etc). However, remember that
failure of even the most insignificant and cheapest
internal component can render a fairly hefty lump of
pricey hardware useless. Some potted designs, for
example, might have choice matched and paralleled
output pairs but commercial grade electrolytics whose
temperature rating could have been much better.
Similarly the insulation between output devices and the
heatsink might only amount to a thin layer of metal
oxide. Running these on transformer secondary voltages
nearer their lower limits will improve survivability, as

will clamping the supply and output to avoid damage

from transient spikes if these diodes are omitted from
the supplied design, which was common in many early
examples. For example, a LM1875 can deliver 30W but,
given design and budgeting constraints, might be better
used in a 10W application. Safe operating area (SOA)
protection should be included.
With integrated approaches involving ICs or modules,
sources of future and mechanical / pin-compatible
replacements can be considered, given that output
transistors can be expected to run at higher
temperatures than in discrete formats.
Class D
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