Crossover For Subwoofer Circuit Diagram

The crossover network is intended for use when an existing audio installation is to be extended by the addition of a subwoofer. Often, this additional loudspeaker is one that has been lying around for some time. If its frequency response extends down far enough, all is well and good, but a filter is then needed to cut off any frequencies above, say, 150 Hz. Often, a subwoofer network is an active filter, but here this would necessitate an additional power supply. The present network is a passive one, designed so that the speaker signal of the existing system can be used as the input signal.

Crossover For Subwoofer Circuit Diagram 

Crossover For Subwoofer

Since the bass information is present in both (stereo) loudspeakers, the signal for the sub woofer can simply be tapped from one of them. The network is a 1st order low-pass filter with variable input (P1) and presettable cut-off frequency (P2). The signal from the loudspeaker is applied to terminal ‘LSP’. Voltage divider R1-R2-P1 is designed for use with the output signal of an average output amplifier of around d 50 W. The crossover frequency of the network may be varied between 50 Hz and 160 Hz with P2. The values of R3, P2, and C1, are calculated on the assumption that the subwoofer amplifier to be connected to K1 has a standard input resistance of 47 kΩ.

If this figure is lower, the value of C1 will need to be increased slightly. It is advisable to open the volume of the subwoofer amplifier fully and adjust the sound level with P1. This ensures that the input of the subwoofer amplifier cannot be overloaded or damaged. Make sure that the ground of the loudspeaker signal line is linked to the ground of the subwoofer amplifier. If phase reversal is required, this is best done by reversing the wires to the subwoofer. If notwithstanding the above additional protection is desired at the input of the subwoofer amplifier, this is best effected by ‘overload protection ’ elsewhere in this site.

Author: T. Giesberts Copyright: Elektor Electronics
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Crowbar Speaker Protection Circuit Diagram

Crowbar circuits are so-called because their operation is the equivalent of dropping a crowbar (large steel digging implement) across the terminals. It is only ever used as a last resort, and can only be used where the attached circuit is properly fused or incorporates other protective measures.

A crowbar circuit is potentially destructive - if the circuitry only has a minor fault, it will be a major fault by the time a crowbar has done its job. It is not uncommon for the crowbar circuit to be destroyed as well - the purpose is to protect the device(s) attached to the circuit - in this case, a loudspeaker.

Description

There's really nothing to it. A resistor / capacitor circuit isolates the trigger circuit from normal AC signals. Should there be enough DC to activate the DIAC trigger, the cap is discharged into the gate of the TRIAC, which instantly turns on ... hard. A TRIAC has two basic states, on and off. The in-between state exists, but is so fast that it can be ignored for all intents and purposes.

Crowbar Speaker Protection Figure 1 - Crowbar Speaker Protector

The BR100 DIAC (or the equivalent DB3 from ST Microelectronics) is rated for a breakdown voltage of between 28 and 36V - these are not precision devices. Needless to say, using the circuit with supply voltages less than around 40V is not recommended, as you will have a false sense of security. The supply voltage must be higher than the breakdown voltage of the DIAC, or it cannot conduct. Zeners cannot be used as a substitute for lower voltages - a DIAC has a negative impedance characteristic, so when it conducts, it will dump almost the full charge in C1 into the gate of the TRIAC. This is essential to make sure the TRIAC is switched into conduction.

The TRIAC is a common type, and may be substituted if you know the specifications. It's rated at 12A, but the peak current (non-repetitive) is 95A, and it only needs to sustain that until the fuse (or an output transistor) blows. A heatsink is preferred, but there is a good chance that the TRIAC will blow up if it has to protect your speakers, so it may not matter too much. The 0.47 ohm resistor is simply to ensure that the short circuit isn't absolute. This will limit the current a little, and increases the chance that the TRIAC will survive (albeit marginally). Feel free to use a BT139 if it makes you feel better - these are rated at 16A continuous, and 140A non-repetitive peak current.

The peak short circuit current will typically be about 90A for a ±60V supply, allowing ~0.2 ohms for wiring resistance and the intrinsic internal resistance of the TRIAC, plus the equivalent series resistance of the filter capacitors. That's a seriously high current, and it will do an injury to anything that's part of the discharge path. Such high currents are not advised for filter caps either, but being non-repetitive they will almost certainly survive.

Construction & Use

Apart from the obvious requirement that you don't make any mistakes, construction is not critical. Wiring needs to be of a reasonable gauge, and should be tied down with cable ties or similar. C1 must be polyester. While a non-polarised electrolytic would seem to be acceptable, the circuit will operate if the capacitor should dry out over the years. This means it will lose capacitance, and at some point, the crowbar may operate on normal programme material. This would not be good, as it will blow up your amplifier!

Make sure that all connections are secure and well soldered. Remember that this is the last chance for your speakers, so it needs to be able to remain inactive for years and years - hopefully it will never happen. The circuit doesn't have to be mounted in the amplifier chassis - it can be installed in your speaker cabinet. Nothing gets hot unless it operates, at which point no-one really cares - it just has to save the speakers from destruction once to have been worthwhile.

Remember that the crowbar circuit absolutely must never be allowed to operate with any normal signal. A perfectly good amplifier that triggers the circuit because of a high-level bass signal (for example) will very likely be seriously damaged if the crowbar activates. To verify that no signal can trigger it, you may want to (temporarily) use a small lamp in place of R2, and drive the amp to maximum power with bass-heavy material.

A speaker does not need to be connected. If the lamp flashes, your amp would have been damaged. If this occurs, you may want to increase the value of C1. Note that bipolar electrolytics should never be used for C1, because they can dry out and lose capacitance as they age. This could cause the circuit to false-trigger.
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Making High Quality iPod - iPhone Speakers

This high quality and low cost speaker was designed to be used for iPod or iPhone with the use of old car Hi-Fi speaker and some computer components. Other materials used are shown in the image below and they include an amplifier, 240V-12V power supply, tweeters, crossovers, sealed lead acid battery, MDF, filler, Apple universal dock & remote, glue, nails, and white gloss paint.



The front baffle board was drawn on a piece of MDF in order to use it as a template to make the rear of the box. The dimensions of the box based on the speaker do not necessarily need to be exact because the speakers were quite old as it comes from an old Renault 19.

From the photo of the round bits below, the trusty circular saw was used to cut loads of 1 inch by 15 cm strips of MDF. Between the front and rear baffle, the strips were glued and nailed. The baffles were cut out using a jigsaw and the strips were kept as close to each other as possible.

Hacks and Mods: PodiPhone Speaker with High Quality

The first coat of filler can take 3 batches to finish and they were applied as neatly as it can after being mixed up. Until it was somewhere near as shown below, a few more coats can be applied. A surform will be applied until it was about the right shape once the first coat of filler had set. Sanding could be done by hand or it would be better to use an electric sander if available. A jigsaw was used to cut out the speaker and tweeter holes as shown below and a flange for the speaker to sit into was made using the router.

Hacks and Mods: PodiPhone Speaker with High Quality

Hacks and Mods: PodiPhone Speaker with High Quality
A hole of about 12mm on the top and 3mm on the back were drilled once all the holes were cut. The edges were masked up and the baffle was spray painted in matt black as shown below. The first layer of white primer can be applied once the black was dry and the masking tape was removed. A couple of coats of normal white primer was applied and then followed by a light sand. In between, a bit of sanding was applied as 3 coats of white gloss were given.
Hacks and Mods: PodiPhone Speaker with High Quality

Hacks and Mods: PodiPhone Speaker with High Quality

A grill for the front had to be made for the full fake Apple. To mark out the shape on a scrap bit of 5mm laminate flooring, this was a simple matter of using the box as a template and then sprayed it in matt black. Some black nylon cloth was glued onto the panel with some spray carpet adhesive when the paint was dry as shown in the image below.

Some black drywall screws were used to screw the 13cm speaker into the box as well as the amp and crossover networks and epoxy resin was used to glue the tweeters. After soldering all the connections, the lead acid battery was glued inside as shown in the next image. The amp of the battery was powered by wiring the 12V to the battery. The iPod universal dock was glued on the top of the box with wires for USB and audio. The finished product of cool looking iPod speaker is also shown below.

Hacks and Mods: PodiPhone Speaker with High Quality

Hacks and Mods: PodiPhone Speaker with High Quality
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