Well, it's been nearly a month since I last posted an update. This weekend, however, sees an uncharacteristic burst of energy and enthusiasm from me, so some progress is being made at last.
As I mentioned in my last post, a lot of the noise was coming in via the volume pot. I've replaced the twisted cables with a short length of screened twin core, which helped a lot. I also found that driving the Power LED from the +12V auxillary supply brought a noisy supply line into close proximity with the volume control. I decided to run the LED from the Fan supply instead and this, along with swapping the twisted pairs for coaxial cable and re-routing the LED cable so it's further from the volume pot, has quietened this amp down a lot.
OK, time for some pics.
[attachment=10459:PICT0415.JPG]
Initial load testing with the fan fitted. The holes at the front are to try and force air across the amp module. I've since added more to the other end of the amp to try and improve air flow. I'm not too happy about the holes being so open - I shall have to do something about that later. The fan is held in place with 2-part plastic rivets.
[attachment=10460:PICT0406.JPG]
My signal generator, built from a Maplins kit years ago, still going strong. I used a triangle wave set at about 200Hz for the load test - no real scientific reason why, it just seemed right.
[attachment=10461:PICT0403.JPG]
This is the dummy load I used for testing the amp. A dozen 25 Watt resistors and a 100 Watter give about 370 Watts of load at about 5 Ohms. The amp ran quite hot after 20 minutes on this load.
[attachment=10462:PICT0407.JPG]
The amp under load, with the clip LED lit. The more observant among you may have noticed that the blue Power LED has moved to the bottom position. This happened as part of the cable re-routing.
[attachment=10463:PICT0418.JPG]
I've stuck some coarse weave speaker cloth across the vent holes. Should keep most things out, but not reduce the airflow too much. It'll also act as a dust filter, but that's definitely not its main purpose.
[attachment=10465:PICT0419.JPG]
Here's the same thing from the other side - not quite as pretty, but no-one's going to see it but you lot. The cloth is glued to the case with epoxy.
[attachment=10467:PICT0420.JPG]
Before re-assembly. I deliberately left enough room for the fan as I had a suspicion it would be needed. Still a tight fit though. Also, I've coloured the amp and PSU black in the hope it improves heat sinking.
I performed a second load test, again using triangle wave set to approx 200Hz, at the very onset of clipping. (The LED indicator 'fades up' as clipping is approached, making this easier to set) The amp still ran pretty hot after 30 minutes of this, although not as hot as previously.
This is a pretty severe test for an amp, as real music has dynamic peaks and troughs, and would not normally be run flat out for 30 minutes like this. However, I would like to try and improve the cooling a little further, so I'm going to try to fit a small vaned heatsink inside the amp, where it will intercept some of the airflow through the case. That's for tomorrow though.
The last thing I've noticed is the fan noise. The fan runs fairly quiet, not noticeably louder than a PC fan in reality, but it seems hugely loud in a quiet room with a dummy load on the anp. I don't think it'll be a problem in the real world of a gig though.
Watch this space...
Andy