AEM600LateralMOSFETPowerAudioAmplifier

This amplifier design is based on the famous AEM5000 Audio, designed by David Tilbrook
back in January 1981. This series of amplifiers was built around new (at the time) Hitachi lateral power
MOSFETs. Most amplifiers at the time (and now as well) used bipolar output drivers. Bipolar transistors
are cheap and plentiful. But they have relatively high transconductance, and can operate reasonably fast.
However they have some drawbacks when used at high power. The main one is thermal runaway. The
gain of a bipolar transistor increases as it gets hotter. That means that if there's any imbalance between
output transistors, the hottest one will pass most of the current, getting hotter until it ultimately fail.
MOSFETs don't have this problem. Their gain decreases with temperature, so they share the load well.
Most power MOS-FETs (VMOS, trench-FETs, Hex-FETs, etc) use a vertical structure, where the
current flows vertically. This has the advantage of a very low R
ds
and hence high efficiency, but poor
linearity or capacitance. Lateral MOS-FETs are a much simpler structure, where the gate oxide is
formed on a flat substrate, and the current flows across the substrate. This results in well defined,
controllable device parameters, good linearity, and relatively low gate capacitance. However, the R
ds
of
lateral MOSFETs has larger values than the vertical ones. MOSFETs also have a high input impedance
at low frequencies, and are capable (when driven by a suitable source) of extremely high slew-rates. Of
course this very attribute makes them rather prone to HF oscillation when improperly compensated, but
with careful design they're capable of impressive performances.

Figure1: Complete assembled AEM6000 Audio Amplifier and mounted on the heatsink.

Amplifier Specifications:
Continuous Output Power: 100W at 8 load impedance or 200W at 4 load impedance.
Maximum Output Power with TDH values below 0.1% is 126W at 8 or 247W at 4.
Very low THD values, of 0.001% from 0.01W to over 100W.
Very wide frequency response, from 10Hz up to 1MHz.
Better than 0.1dB linearity from 10Hz to 24KHz and 3dB from 5Hz to 160KHz.
Very Good S/N Ratio, of at least 116dB with an output noise of maximum 50uV.
No Output Feedback Class AB Audio Amplifier offer very good linearity.
Completely assembled PCB and on request, mounted directly onto the heat sink.
Power supply filtering capacitors are added on-board for better performances and space saving.
Power supply requirements: +- 54V for an output Power level of 100W at 8.
The schematic of this amplifier is based on the famous AEM5000 Audio, designed by David
Tilbrook back in January 1981. However, since the original design was made almost 30 years ago, it was
using components available at that time, and which were just new released. In the meantime, there was a
huge progress in the semiconductors industry and many new parts were released, with much better
parameters than the original ones used in the first design. This allows to improve the original design and
add even more performance that it hat at that time.
First update was made with the input stage, where linearity and extremely low noise was a very
important issue. Instead of the original transistors, ECG461, SST404 differential input J-FET Amp was
chosen. The SST404 series of high-performance monolithic dual JFETs features extremely low noise,
tight offset voltage and low drift over temperature specifications, and is targeted for use in a wide range
of precision instrumentation applications. This series has a wide selection of offset and drift
specifications with the SST404 featuring a 5-mV offset and 10 V/C drift.
Next parts which were replaced are the MMBTA06 and MMBTA56 low power Bipolar
Transistors, in SOT23 Case. The original was BC547 and BC557.

Figure 2: AEM6000 Audio Amplifier Schematic Diagram
R40
0.22R 3W
R37
220R
R36
220R
R38
220R
R39
220R
C9
18pF
C10
18pF
Q7
MMBTA06
Q8
MMBTA06
R10
10K1W
Q6
MMBTA56
Q5
MMBTA56
R8
180R 1%
R4
330R
R5
330R
R7
27K1%
R6
27K1%
R3
1K
R1
100K C2
1n POLY
C3
47p
R41
0.22R 3W
R42
0.22R 3W
R43
0.22R 3W
R46
12R 3W
C14
22n POLY
C18
3300u 80V
C15
3300u 80V
C22
2u2 POLY
T1
IN+
T2
IN-
T5
+50V
T3
OUT
T6
-50V
C1
470n POLY
Q1A
SST404
Q1B
SST404
R11
680R
RV1
20K
ZD1
12V
R13
120R 1%
R14
10K1W
R9
4K7
R12
3K9
Q10
MJE340
Q11
MJE340
Q12
MJE340
R20
390R 1%
R21
220R 1%
R22
220R 1%
R23
150R
R24
150R
R25
150R
R26
150R
R31
220R 1%
R32
220R 1%
Q9
MJE350
Q13
MJE350
Q14
MJE350
R27
680R 1%
R28
680R 1%
R29
680R 1%
R30
680R 1%
R19
390R 1%
D1
LL4148
D2
LL4148
D3
LL4148
D4
LL4148
D5
LL4148
D6
LL4148
R33
39R
R34
39R
R51
15R
R52
15R
R53
15R
R54
15R
Q17
MJE340
Q18
MJE340
Q15
MJE350
Q16
MJE350
R35
220R
C7
15p MICA
C8
15p MICA
ZD2
12V
ZD3
12V
ZD4
12V
ZD5
12V
D7
LL4148
D8
LL4148
D9
LL4148
D10
LL4148
R15
22R
R16
22R
R48
6K2
R49
1K
C6
15p MICA
RV2
200R
R44
22R
R45
22R
C11
18pF
C12
18pF
C21
2u2 POLY
T4
GND
C4
220u 100V
C5
220u 100V
R2
1R 1W
R17
10K1W
R18
10K1W
+50V
-50V
C19
3300u 80V
C16
3300u 80V
C17
3300u 80V
C20
3300u 80V
T7
TERM
T8
TERM
T9
TERM
T10
TERM
T11
TERM
T12
GND
C23
100n POLY
C24
100n POLY
C25
100n POLY
C26
100n POLY
Q4
MMBTA06
Q3
MMBTA06
Q19
2SK1058
Q21
2SJ162
Q22
2SJ162
Q20
2SK1058
Next replaced parts were the Power MOS-FET Transistors, instead of 2SK176 and 2SJ56 it uses
the newer ones, 2SK1058 and 2SJ162, in insulated TO-3P case, which allows more easy installing and
insulation on the heat sink. They also have better parameters than the original ones, and this contribute
to the increased amplifier overall performance.
Besides the improvements which were brought by updating some parts, others were made by
adding few more components and by designing a tight and balanced Printed Circuit Board, which allows
the amplifier to operate with high performances with a very wide frequency response and without any
risk of instability or degrading performances. For this reason, large electrolytic capacitors were added on
each supply rail, mounted on board, close to the power MOS-FET transistors. In addition to this, some
high quality mica capacitors and polystyrene capacitors were added as bypass for the electrolytic
capacitors and on the Power Transistors Gates. Using this capacitors ensure minimal distortion creeps in
through capacitor nonlinearities. The PCB Layout has a major contribution to the overall performance,
minimizing the Ground Loops and making the High Current carry tracks as short as possible and as wide
as possible. Wherever was enough space, copper pour was used. Also the thickness of the copper foil on
the PCB is 3 Oz thick, which is 3 times the normal thickness, of just one Oz used on most of the PCBs.
To help designing the schematic for this amplifier, an important contribution was brought by Linear
Technologys SPICE Simulator, which is a powerful tool in design and analysis of the electronic circuits
behavior. Using this tool, allows to chose and simulate various components and values for them, so the
result can be improved.
One very important aspect which have to be considered is the thermal design. A class AB
Power Audio Amplifier has maximum theoretical Efficiency of about 70%. This value is almost
impossible to achieve in practice with good THD values and linearity. So, a compromise should be made,
in favor of the sound quality. This will lead to a lower electrical efficiency, especially at low Output
Power. The main reason for lower efficiency is the idle current and losses which occur in the signal and
driving stages of the amplifier. The maximum dissipated power, will occur at High Output Power Levels,
when the amplifier drives low impedance loads with high signal amplitude. It was calculated that with
+/-56V supplies, worst case dissipation occurs at 150W into 4 load Impedance, of 155W. Most of this
dissipated power is dissipated by the output transistors, which share equally the dissipated power.
However, audio signal power spectrum is much poorer than the pure sine wave signal, usually just of
the power of the pure sine wave and with peaks of of the pure sine wave. In order to remove the heat
generated by this power dissipation, an external heat sink with thermal resistance of maximum 0.5 C/W
is required. A good choice is an extruded aluminum heat sink profile with vertical fins and with the size
of at least 160x100x40mm, or horizontal fins option, if is intended to be mounted inside amplifier
housing and use forced air cooling. Test results proved that the maximum temperature rise of the heat
sink when the amplifier is used to play moderate volume of music on 8 load impedance is maximum
36C. This means that on an ambient temperature of 20C the heat sink temperature will be 56C. For
higher power levels or 4 load impedance, forced air cooling may be required, to maintain the heat sink
temperature under 85C
To be able to take advantage of the full performances of this amplifier, the short-circuit and over-
current protection was not included. The reason is because this may trip at the peak levels of the sound,
and also can introduce distortions. In fact, most of the High-End audio amplifiers doesnt have the over-
current and short-circuit protection included onto the amplifier board, but it has on an external board
dedicated for this purpose. When using this amplifier, special care should be taken to not overload the
amplifier with very low load impedances, the minimum load impedance should be 4, but is preferable
to use 8 load impedance, since the amplifier will have the best performances .
Installation Guide:
To set-up and run this amplifier, need to follow some basic steps. First the amplifier module need
to be installed into a case, preferable on the side of the case with each heat sink exposed for natural
convection cooling. Note that should avoid covering the top and bottom of the heat sink fins, by the case
cover or by stacking the amplifier in an audio system. In some cases, if the amplifier is used to play high
level of audio signal for long time, the heat sink may get very hot, too hot to be touched. In this case,
forced air cooling may be an option, using a small DC Brushless Fan, like those used on the computer
power supply.
Next step is wiring the amplifier to the power supply, signal source, and output to the protection
board and loudspeakers output. First of all, need to use a rectified and well filtered Linear DC Power
Supply. A good choice can be either Power Supply 6x10000uF at 63V or Power Supply 6x15000uF
at 63V or even Power Supply 6x18000uF at 71V. All this Linear Power Supplies are available for
purchasing on the www.connexelectronic.com. The Linear DC Power Supply should be powered from a
mains transformer, preferable Thoroidal type, since this type of transformers have improved
performances for Audio Amplifiers. The size and power rating of this transformer depends on the
required Output Power Lever. For 100W at 8 load impedance the transformer should have at least
360VA Power rating and have two identical windings of 40V AC at 5 A. After rectification and filtering
this will be +- 54V DC. If the amplifier is intended to be used on 4 load impedances, the Power rating
of the transformer should be double. Using two identical transformers instead of one, one for each
channel, is a good choice, will enable better performances and a better channels separation. An
alternative to the linear supply is to use a SMPS (Switched Mode Power Supply). The main advantage is
that the SMPS is more compact and lightweight compared with classical linear supply and have load and
line regulation. Some of them, those who have active PFC will allow universal mains input voltage as
well, which is good to take into account when the amplifier is used in various places, with different
mains voltages available. Few models of SMPS are available on the www.connexelectronic.com website.

Figure 3: AEM6000 Audio Amplifier Linear Supply Connection Diagram
The input signal path should pass thru a volume potentiometer, to be able to adjust the output
power, and volume to the desired value. The signal cables and connectors should be very good quality,
shielded, and with shield connected to Signal GND in a single point, avoiding Ground loops which will
drastically decrease performances, increase noise, and make the amplifier unstable. The input signal
cables should be very short, and routed far from the mains transformer or the output section or wires to
avoid interferences which will lead to noise and instability.
1
2
3
AC In
1
2
3
Out 1
D1
BYW29 10mF
C3
333
R1
100nF
C12
10mF
C9
10mF
C4
10mF
C10
10mF
C5
10mF
C11
100nF
C6
333
R2
D2
BYW29
D3
BYW29
D4
BYW29
1
2
3
Out 2
47n
C2
47n
C8
47n
C1
47n
C7
Fuse 1 10A
Fuse 2 10A
AC1
AC2
V+
V-
333
R3
LED1
T?
Toroidal Transformer
1
2
3
J?
Mains Connector
Fuse 3 5A
PS18K71 Board
AEM6000 Left
AEM6000 Right
V+
V-
GND
V+
V-
GND
The output signal from the Power Amplifier Module should be routed thru a speaker protection
board who has the role to delay the amplifier connection to the loudspeaker to prevent the click and pop
noise when power ON or OFF the amplifier, and to protect the loudspeakers in case of amplifier
malfunction when DC component may be present on the amplifier output. To use the Speaker
Protection Circuit, just connect the outputs of the amplifier to the inputs of the Speaker Protection
Circuit for both Left and Right Channels. The Speaker Protection Circuit requires an auxiliary voltage to
be provided from a winding of the mains transformer, the value of this voltage should be between 9V
AC to 12V AC. For higher voltage values, some components from the Speaker Protection Circuit board
need to be replaced. The schematic of the Speaker Protection Circuit can be seen in the Figure 4.
Another useful module for the amplifier will be Power Soft Start Circuit, which will allow the
slow start the mains transformer until the Filtering Capacitors are charged and also remote control the
amplifier startup. For more information about the Power Soft Start Circuit, please visit the product page
at www.connexelectronic.com.

Figure 4: Speaker Protection Circuit Schematic.

For more information about the AEM6000 Audio Amplifier, do not hesitate to contact me thru
www.connexelectronic.com website.

Disclaimer:
The AEM6000 Audio Amplifier Module shall be used according with the instructions provided
in this document. The user should NOT attempt to modify or change any of the parameters of this
product, which can lead to malfunction. The manufacturer of the product, PCBstuff, and the official
distributor, Connexelectronic, will not be liable for any kind of loss or damage, including but not
limited to incidental or consequential damages. Due to the high level of voltages on this board, the user
should take all the caution measures needed when working with high voltage levels, should not touch
any unisolated part of the board or connectors, or short-circuit any part of the board or connectors. Any
misusage will be made on user responsibility.
The manufacturer PCBstuff reserve the right to make changes or modifications on both the
product functions and performances without notice. The AEM6000 Audio Amplifier Module schematic
and PCB design is based on a freeware project which is public on the internet.

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D1
1N4148
100uF
C6 4.7uF
C5
22nF
C4
100uF
C3
D4 1N4001
+Vcc
56K
R3
56K
R8
4K7
R1
100K
R9
10R
R4
15K
R7
56K
R2
5
7
3
2
1
6
8
4
K1
Relay 2x10A
D6
1N4001
LED1
3K3
R5
LED2
3K3
R6
D3
1N4001
D5
1N4001
D2
1N4001
1
2
3
4
J2
Power
100n
C1
1000uF
C2
F1 10A
F2 10A
1
2
3
4
5
J1
Signal