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Construction Manual

Elektor Fortissimo-100
Power Amplifier Kit

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st rter
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Ton Giesberts
 

Elektor Fortissimo-100
Power Amplifier Kit
Designed by Ton Giesberts - Elektor Labs

Construction Manual
V1.0 – date: September 8, 2022,
© Elektor International Media b.v.

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Elektor Fortissimo-100 Power Amplifier Kit

Notice: This manual is only available as a downloadable PDF at:

www.elektor.com/20273.

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 Table of Contents

Table of Contents

Section Page
1 – Kit Contents 7
2 – Introduction 12
3 – Tools Needed 13
4 – Locating and Drilling Holes in the Heatsink,
for the PCB Standoffs 14
5 – Bending the Output Stage Transistor Leads 16
6 – Locating and Drilling Holes in the Heatsink,
for the Transistors 17
7 – Small Resistors and Diodes 19
8 – Axial Power Resistors and IC Socket 20
9 – Small Capacitors and Input Terminal Pins 20
10 – Finishing the Assembly of the Protection PCB 21
11 – Small Transistors, LEDs, Radial Power Resistors,
and Large Capacitors 22
12 – Placing the Loudspeaker-Signal Through-Contact Standoffs 23
13 – Transistors T13…T16 and the Small Heatsinks 24
14 – The Output-Stage Transistors 27
15 – Final Assembly 31
16 – Recommendations for the Enclosure 35
17 – Selecting BC546B/BC556B Transistors for Differential Pairs 36
18 – The SMPS800RE Power Supply 37
19 – Bill of Materials 39
20 – Specifications 43
21 – DC Voltages 45
22 – Web Links 45
23 – Schematics and PCB Layouts 46

Notice
This document is complementary to the information contained in:

1. the editorial article “The Elektor Fortissimo-100 Power

Amplifier” published in Elektor Magazine edition 11&12 2022;

2. the engineering background and discussions posted on the

Elektor Labs website.

Web Links to these publications may be found in Section 22.

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Elektor Fortissimo-100 Power Amplifier Kit

Disclaimer
The circuits described in the manual are for domestic and educational
use only. All drawings, photographs, PCB layouts, and article texts are
copyright Elektor International Media b.v. and may not be reproduced,
transmitted, or stored in any form in whole or in part without the
prior written consent from the Publisher. Patent protection may exist
in respect or circuits and devices described here. The Publisher does
not accept responsibility for failing to identify such patent(s) or other
protection. The Publisher also disclaims any responsibility for the safe
and proper function of reader-assembled projects based upon or from
schematics or information published in or in relation with this Manual.

Published by Elektor International Media b.v., PO Box 11,

NL-6114-JG, Susteren, The Netherlands.
www.elektor.com; www.elektormagazine.com.

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 1 – Kit Contents

1 – Kit Contents

• Two PCBs: amplifier PCB and protection PCB.

• All parts listed in the Bill of Materials (BOM) found at the end of
this document (Section 19).
• Construction Manual – Downloadable PDF.

Figure 1. Contents of the Fortissimo-100 Power Amplifier kit

as supplied by the Elektor Store.

Before embarking on the construction of the Kit, be sure to inspect the

contents using the Bill of Materials and the photos that follow. Check
that all parts are supplied and in usable condition.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 2. The resistors and small capacitors in the kit.

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 1 – Kit Contents

Figure 3. The electrolytic capacitors in the kit.

Figure 4. The small transistors, diodes, and other parts in the kit.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 5. The larger transistors.

Figure 6. The ceramic pads (washers) and the relay in the kit.

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 1 – Kit Contents

Figure 7. The mechanical parts in the kit.

Figure 8. The SK104 heatsinks in the kit.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 9. The SK53-100-SA heatsink in the kit.

2 – Introduction

Notice: It is strongly advised to closely read the entire Construction

Manual before starting the construction of the amplifier.

The design, especially the placement of the power transistors T17–T22

and the PCB, is aimed at easy replication. The mechanical work need-
ed should be possible with simple tools and basic skills like drilling 12
3-mm holes to mount the transistors and fasten the PCB in parallel
with the back of the heatsink. The fin spacing of the selected heatsink
(type SK53-100-SA from Fischer Elektronik) is sufficient for the heads
of the black 3-mm screws while also allowing room for some error.
The PCB is mounted onto the heatsink with six 10-mm long metal
male-female standoffs with 3-mm thread. The 6 transistors of the out-
put stage are electrically insulated with ceramic (Al2O3) pads, marked
by a lower thermal resistance than comparable types. During the final
stage of construction, apply some thermal grease on the back of the
transistors and on the sides of the pads placed against the heatsink.
Only a very thin layer is required! Take precautions not to get the ther-
mal grease on your fingers as most types are toxic.

The DC protection and relay circuit are placed on a second, smaller

PCB placed in parallel with the amplifier PCB. Six 30-mm long male-fe-
male metal standoffs ensure a solid construction. Standoffs K3 and K4

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 3 – Tools Needed

(amplifier PCB) connect the output of the amplifier to K6 (LS+) and K7

(LS–) on the protection PCB and from there via the relay and output
terminals K8 and K9 to the loudspeaker. “Faston” connectors K8 and
K9 (PCB versions) make sure the series resistance of this connection
to the cable is extremely low.

On the finished amplifier, the screw heads should be on the back of the
heatsink. Black screws won’t stand out that much when looking at the
back of the heatsink. Black Allen-type screws are used for the tran-
sistors (with internal hexagonal recesses). Strangely enough, black
16-mm long screws are few and between at many electronic part dis-
tributors.

Selected parts shown in the photos may have different values or

shapes in your kit. This is because the amplifier shown was a first
prototype for testing.

3 – Tools Needed

• Soldering equipment for through-hole components. Soldering

iron rated at 100 watts minimum. Also recommended is an ex-
tra-long tip for soldering the transistors in the output stage.
• Small pliers with flat jaws.
• Pliers with special jaws for pressing a thermal relief (bend) in
the leads of the push-pull transistors. Alternatively: pliers with
round jaws.
• Pozidriv screwdriver (depends on the exact type of screws in the
kit).
• 2.5-mm tool for hex screws (Allen wrench; also depends on the
exact type of screws in the kit).
• Drill stands or similar tool with 3-mm drill bit to drill 12 3-mm
holes in the large heatsink. Consider using a 3.2-mm drill bit if
accuracy of drilling is sub optimal).
• 10-mm drill bit or similar rod or tube for use as a former to wind
the air inductor on.

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Elektor Fortissimo-100 Power Amplifier Kit

4–L
 ocating and Drilling Holes in the
Heatsink, for the PCB Standoffs

Figure 10. The bare PC boards for the amplifier and protection
circuitry, as supplied in the kit.

Figure 11. Amplifier PCB used as drilling template.

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4 – Locating and Drilling Holes in the Heatsink, for the PCB Standoffs

The amplifier PCB is placed in the center on the heatsink, 1 mm from

the edge where C1 is located, and fixed temporarily with sellotape so
the six positions for the metal standoffs can be marked out (scored).
Use a 3.5-mm drill bit and with some pressure turn it counterclockwise
in the six holes located at the short sides of the PCB, taking great care
to avoid damage to the PCB. Do not score the positions K3 and
K4. Being the outputs of the amplifier, they must never be in electrical
contact with the heatsink! All six holes are located at ample distances
from the heatsink fins to allow room for the screw heads including a
small error margin.

Figure 12. Standoffs secured in place for the PCB to be mounted.

After the six 3-mm holes are drilled, the six 10-mm standoffs are
mounted on the heatsink and fastened with the black 12-mm M3
screws. Next, check if the PCB fits accurately on the six standoffs. If
not, consider filing out one or more holes to slightly correct the position
of the standoff(s).

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Elektor Fortissimo-100 Power Amplifier Kit

5–B
 ending the Output Stage Transistor
Leads

Figure 13. Bent leads of the TO-220 and TO-264

transistors in the output stage.

Bend all leads of the transistors (T17–T22) perpendicular toward the

front of the transistors (Figure 13). To avoid excessive force exerted
from the leads to the package of the large power transistors, use a
2-mm drill bit and a small vice. Gently clamp the pins and the drill bit
between the vice jaws. Use a flat piece of material to bend all leads
toward the front of the transistor. Bending the leads of the smaller
TO-220 packages can be done with flat-jaw pliers. Bend them at 1 mm
from the package, where the leads become smaller.

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 6 – Locating and Drilling Holes in the Heatsink, for the Transistors

6–L
 ocating and Drilling Holes in the
Heatsink, for the Transistors

Figure 14. Preparations for marking the 3-mm holes

required for the transistors.

Before mounting any parts on the PCB, locate the position of the holes
for the six screws to secure the transistors to the heatsink. Figure 14
shows the PCB with the 6 power stage transistors temporarily fitted
(i.e., not soldered) to permit marking out the positions of the six 3-mm
holes. Also, the ceramic insulation pads must be placed between the
transistors and the heatsink since this can affect the exact position of
the holes. In this prototype, the four holes for the power transistors are
approximately 8.8 mm from the edge of the heatsink, and the smaller
transistors, at 11.5 mm. However, this can vary, and the exact location
depends on the exact position of the bend in the transistor leads. It’s
unlikely that a drilling reference for the heatsink indicates the correct
positions of the transistors. Mark (score) the six holes using a 3-mm
drill bit. Using your fingers and with some force, turn the bit counter-
clockwise through the aligned holes in the transistors and pads.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 15. Marked-out positions for the

six holes to be drilled (prototype).

Figure 16. Six 3-mm holes drilled for the

transistors in the output stage.

After drilling the holes, place the transistors in position with their
screws. It’s not necessary to secure them with nuts. Check if the PCB
is a perfect fit with all leads and the six standoffs through their holes.

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 7 – Small Resistors and Diodes

Now almost all parts can be fitted on the PCBs. Start with the lowest
components, small resistors and diodes (D1…D5).

7 – Small Resistors and Diodes

Figure 17. The small resistors and diodes

soldered onto the two boards.

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Elektor Fortissimo-100 Power Amplifier Kit

8 – Axial Power Resistors and IC Socket

Figure 18. Axial power resistors and 8-pin IC socket (pos. IC3)
soldered onto the amp board.

9–S
 mall Capacitors and Input Terminal
Pins

Figure 19. The small capacitors also soldered

onto the amplifier board.

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 10 – Finishing the Assembly of the Protection PCB

Place and solder the small capacitors, the smallest ones first: C3, C10,
C11, C32, C4, C5, C12, C2, C13, C14, C18, C19, C29, C17, C33, C28.
Next, the larger/higher-value capacitors: C6, C7, C8, C9, C30, C31,
C34 , input terminal pins, C1.

10 – Finishing the Assembly of the

Protection PCB

Figure 20. To finish the protection board, solder the

relay and the air-cored inductor onto the board.

Figure 21. The completed protection board

(PCB 210364-1 v1.1 shown).

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Elektor Fortissimo-100 Power Amplifier Kit

At this point, finish fitting the rest of the components on the small PCB:
T23, T26, T27, T24, T25, K5, Faston tabs K8 and K9 (including two
8-mm M3 screws/nuts/washers and finally, the inductor (13 turns of
1.5-mm diameter enameled copper wire), and relay RE1. The compul-
sory output inductor L1 is made of 13 turns in a single layer using 1.5-
mm diameter enameled copper wire. The Inside diameter should be
10 mm. A 10-mm drill bit can be an aid in winding the inductor. Keep
the two ends long enough to place the inductor above R76 and check if
the distance of the two ends corresponds with the footprint and are in
line. R76 suppresses possible ringing. Use a hobby knife to scrape the
enamel insulation off the inductor wire ends, then pre-tin them lightly.
LED5 is to be mounted on the front of the enclosure of the amplifier,
and is connected by thin stranded wire, if so desired.

11 – Small Transistors, LEDs, Radial Power

Resistors, and Large Capacitors

Figure 22. Small transistors, rectangular LEDs, radial power resistors

and large capacitors soldered onto the amp board.

Now, T5, T6, T7, T8 and LED1, LED2, LED3, LED4 can be inserted and
soldered. For best thermal coupling, Place the chip inside the LED half-
way the package of the transistor that’s next to it, and flush against
the transistor.

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 12 – Placing the Loudspeaker-Signal Through-Contact Standoffs

If you have enough transistors, it’s favorable to select the input tran-
sistors pairs T1/T2 and T3/T4 for identical UBE and hFE values. The
same applies to the transistors in the second differential amplifiers, T9/
T10 and T11/T12. See the end of this document for details (Section 17
– Selecting BC546B/BC556B for Differential Pairs). When soldering the
pairs, make sure the flat sides remain in good contact, since a maxi-
mum contact surface guarantees proper thermal coupling.

Next, the radial power resistors R50, R51, R54, R55, capacitors C15
and C16, and capacitors C20...C27 can be fitted and soldered.

12 – Placing the Loudspeaker-Signal

Through-Contact Standoffs

Figure 23. Two 30-mm M3 male-female standoffs are

attached to the pads of K3 and K4.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 24. Each of the two 30-mm standoffs is secured with an

8-mm M3 cheese head screw.

The two metal standoffs that connect the amplifier output lines of the
main PCB to the smaller PCB above it can now be fitted and secured
with an 8-mm long M3 cheese head screw.

13 – Transistors T13…T16 and the Small

Heatsinks

Figure 25. Special pliers and an example of the

“thermal relief” bend in the leads needed for T13…T16.

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 13 – Transistors T13…T16 and the Small Heatsinks

Transistors T13-T14 and T15-T16 can now be mounted on the small

heatsinks. A thermal relief in the leads of each transistor is recom-
mended to reduce mechanical stress caused by temperature changes.
It’s best to make a small bend in the leads, away from the heatsink.
Figure 25 shows the special pliers required to do this, and a success-
fully “shaped” transistor. Alternatively, pliers with round jaws can be
used for this job. The bend must be close enough to the package, per-
mitting the pins of the transistors to pass through the PCB.

Figure 26. Two transistors mounted at

each side of the small heatsink.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 27. The two small heatsinks and

transistors T13…T16 soldered in place.

Before securing the transistors on the heatsinks, apply a small amount

of thermal grease to the back of each transistor. No insulation is need-
ed since the package of these transistors is completely plastic. Place
the head of the screw toward the input of the PCB, but don’t tighten
the screw yet. You can only use a screwdriver from this side to fasten
the screw. Place an M3 metal washer between the head of the screw
and the transistor. Figure 26 shows the transistors secured to the small
heatsink. Solder the pins of the two heatsinks to the PCB first and only
then tighten the screws of the transistors. Be sure to use pliers to hold
the nut on the other side of the heatsink. Only then, proceed to solder-
ing the transistor leads.

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 14 – The Output-Stage Transistors

14 – The Output-Stage Transistors

Figure 28. View of the PCB and the output stage transistors
provisionally secured to the heatsink.

Figure 28 shows the six output stage transistors fastened temporarily

with screws and nuts to enable them to be soldered. Also, the PCB is
fixed onto the 10-mm long standoffs on the heatsink with 30-mm long
standoffs (or use nuts for now). Also, place the ceramic washers for
the transistors and the insulating bushes for the TO-220 transistors
since all of this can influence the exact location of each transistor.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 29. The output stage transistors are soldered, and thermal
grease is applied to their backs.

As a minimum, solder the two leads at either side of each large power
transistor without melting any plastic of various capacitors. Do more
leads if possible. A longer soldering tip is recommended. All leads of
T17 and T18 can be soldered from the top. When this is done, remove
the screws that hold the transistors first and then the standoffs that
hold the PCB. Carefully take the PCB off the heatsink and make sure
not to bend the transistors. Now, the transistors are attached to the
PCB at their final position. Solder the rest of the leads from the bottom
side. 2-way screw terminal block K2 was not soldered yet to give better
access to the leads of T19 and this should be done now. Then apply a
very thin layer of thermal grease to the back of the six transistors and
one side of each ceramic washer that is placed against the heatsink.

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 14 – The Output-Stage Transistors

Figure 30. Slide the ceramic washers (pads) over the screw threads
before positioning the PCB with the transistors.

Place the heatsink upright with the holes for the transistors at the top.
Insert the six (black) screws halfway through the heatsink. The 16-
mm, black screws take T19…T22, and the 12-mm, black screws take
T17 and T18. Slide the ceramic washers with the greased side over the
screws against the heatsink as shown in Figure 30 (in the prototype, 6
off black 16-mm screws were used).

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 31. Top view of the finished amp PCB with the output stage
transistors secured to the heatsink.

Carefully maneuver the PCB onto the standoffs on the heatsink, mak-
ing sure the screws pass through the transistor holes while the ceramic
washers remain in position. Place and tighten the four 30-mm stand-
offs and the two M3 nuts to fix the PCB securely to the heatsink. Also
use M3 washers to fix the four power transistors and don’t forget the
insulating bushes for T17 and T18 (type IB 6 from Fischer Elektronik
or similar). Tighten the six screws. Place IC3 in its socket. Figure 31
shows the practically finished power amplifier.

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 15 – Final Assembly

Figure 32. Rear view of the heatsink after 12 screws are tightened.

15 – Final Assembly

The finished protection PCB can now be placed on the six 30-mm
standoffs and fastened with six M3 nuts.

The following three images show the (almost) finished module. Only
the connection of the +40 V power supply between the two PCBs (K2
to K5) is missing. The photos show the construction of the first com-
pleted prototype for measurements conducted at Elektor Labs. At this
stage LED5 wasn’t fitted on the protection PCB.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 33. Left-side view of the Fortissimo-100 Power Amplifier.

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 15 – Final Assembly

Figure 34. Right-side view of the Fortissimo-100 amplifier.

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 35. Broadside view of the Fortissimo-100’s output stage.

Figures 33, 34, and 35 show the assembly and initial wiring of the first
prototype for measurements.

Figure 36. The finished Fortissimo-100 Audio Power Amplifier

that was used for testing.

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 16 – Recommendations for the Enclosure

Figure 36 shows the finished amplifier with the two wires installed be-
tween K2 and K5, and with LED5 now PCB-mounted.

16 – Recommendations for the Enclosure

Before drilling holes in the heatsink, consider the enclosure you want
to use for the Fortissimo-100 Audio Power Amplifier — specifically,
how to secure the heatsink to the back of the enclosure. In case of a
standard enclosure, the back panel is probably traded for separate alu-
minum plates, which is easier than making large openings in a metal
panel. At both sides of the heatsink, enough room is available for M4
screws between the outer fins and going besides the PCB.

Because the amplifier PCB is close to the heatsink there must be

enough holes to permit generous ventilation at the top and bottom.
Even better is a wide slot going the full length of the PCB (or longer)
alongside the heatsink in the top and bottom panels, thus guarantee-
ing a good convection of air between the PCB and the heatsink. Also,
the remainder of the enclosure’s top and bottom sides should have
plenty of ventilation holes considering that the power supply will get
hot, too.

To keep the length of the supply wires to an absolute minimum, the

output of the power supply should be positioned as close as possible
to screw terminal block K1 on the amplifier PCB. The type SMPS800RE
switch-mode power supply (SMPS) is recommended for use. Accord-
ing to the SMPS800RE’s datasheet, extra output capacitors are not
recommended: [quote] ‘if the capacitance is too high the over-current
protection might trip during power ON’. [end quote] The maximum
conductor cross sectional area (csa) of the wire inserted in the PCB
terminal block type MKDSN 1,5/ 3-5,08 supplied in the kit is 1.5 mm2.
However, the size of the pads at the top side of K1 permit soldering
much thicker wire directly onto the PCB. In the Elektor prototype ver-
sion, the output of the SMPS has three “Faston” (a.k.a. spade) termi-
nals, hence thicker wire is not a problem here.

Important Notice
The design of the PCB is explicitly intended for use as a mono am-
plifier! Do not use a single power supply for two amplifiers. This will
cause ground loops and degrade performance of the amplifiers and can

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Elektor Fortissimo-100 Power Amplifier Kit

even cause instabilities and oscillations due to the high speed of the
amplifier as its gain-bandwidth product is 2.8 GHz! Star-Ground of the
amplifier is in the center of the PCB, located at the loudspeaker Ground
connection, K4. Only there, the Ground connections of power supply,
loudspeaker and combined input and feedback come together.

17 – Selecting BC546B/BC556B Transistors

for Differential Pairs

Figure 37. Test circuits for selecting matched transistors

for use in the differential amplifier stages

To select the transistors for the differential input stages, simple circuits
can be built on a breadboard. Use SIL or IC sockets to easily swap
TUT’s or use a solderless breadboard. For lowest offset, it’s best to use
two transistors placed or clamped against each other and then meas-
ure the potential difference between the 3.3-kΩ resistors as pictured
in Figure 37. The base currents can be measured across the 10-kΩ
resistors. Preferably the hFE of the NPN device is identical to that of
the PNP device. Swap transistors for the lowest offset between the
collector resistors. Always turn off the power supply before removing
or inserting a transistor as this measurement is less temperature de-
pendent. As a simpler way is to measure each transistor separately,
tabulate UBE and hFE values and select the best matches. This is much

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 18 – The SMPS800RE Power Supply

more temperature dependent, though. You can use a 40 VDC power

supply for the collector voltage if available. 6k8 should be a little lower
(6k2) if you want to measure at 2.4 mA.

For the second differential stages, a few things need to be adapted.

The current per transistor must be increased to approximately 9 mA
(the values between parentheses). Select the common-emitter resis-
tor and negative supply voltage to set a total current of 18 mA.

When using the differential test circuit, keep one transistor in place in
the test circuit and change the other one with all the others. Again,
turn off the power supply each time when removing or inserting an-
other transistor! Measure and make a note of each offset per newly in-
serted transistor. Wait for the offset to settle to a stable reading. Place
all available transistors in a piece of anti-static foam and use pliers to
swap them on the breadboard. If not, the body heat of your fingers
will seriously affect the time it takes for the reading to stabilize. Maybe
a better transistor pair can be found by choosing two transistors with
closer or — ideally — identical offsets. The best pair should be used for
the first differential amplifier at the input, i.e., the NPN pair and the
PNP pair, and the next best combination goes in the second stages.

18 – The SMPS800RE Power Supply

Figure 38. The Fortissimo-100 amplifier experimentally

connected to the SMPS800RE power supply.

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Elektor Fortissimo-100 Power Amplifier Kit

While using the SMPS880RE power supply, the distortion and noise
measurements conducted on the Fortissimo-100 showed that an extra
mains (AC line) filter and a common-mode filter at the output of the
power supply are advantageous to the figures measured. But consider
this: the levels are extremely low and we’re talking about microvolts.

The following plot shows an FFT of 1 kHz at 1 W in an 8-ohm load us-

ing the SMPS800RE as a power supply for the Fortissimo-100 amplifier
built with parts from a kit. The spectrum is essentially clean, right up
130 kHz. Only at higher power levels, the switching frequency is seen
to shift below 130 kHz. In an enclosure, tie the three wires from the
power supply to the amplifier closely together. This will minimize the
risk of magnetic fields interfering with the amplifier. Recommendation:
also clamp on a sufficiently large, split-ferrite core for EMI suppression,
making sure it fits around all three wires to enable it to function as a
common-mode filter.

At the mains side of the SMPS800RE, a small screw terminal for a pow-
er switch is available. If not connected, the power supply won’t start
(the red wire in the photo)! The IEC-type AC power connector is not
soldered yet and can be replaced (remove the two screws) by a 3-way
screw terminal block with 7.5 mm (0.3 inch approx.) lead spacing. Use
a good AC line filter in the side area of the enclosure to connect the
mains through this 3-way screw terminal block.
Follow all safety regulations regarding AC line voltages rele-
vant to your country!

Figure 39. FFT of 1 kHz at 1 W and an 8 Ω load.

● 38
 19 – Bill of Materials

The Levels of the 2nd and 3rd harmonic are –112.6 dB and –118.5 dB
down, respectively. THD amounts to a trifling 0.00026%.

19 – Bill of Materials

(PCB 210634-1 v1.1, schematic v1.2)

Resistor (small 0.6 W resistors are metal film)

R1,R74 = 1 MΩ, 1%, 0.6 W
R2,R4 = 390 Ω, 1%, 0.6 W
R3,R5,R20,R23,R64,R66,R69 = 10 kΩ, 1%, 0.6 W
R6,R67 = 1 kΩ, 1%, 0.6 W
R7,R8,R13,R14,R60,R61 = 3.3 kΩ, 1%, 0.6 W
R9,R15,R27,R28,R33,R34 = 120 Ω, 1%, 0.6 W
R10,R11,R16,R17 = 68 Ω, 1%, 0.6 W
R12,R18 = 5.6 kΩ, 5%, 1 W, metal film or metal oxide, body size 5 x
12 mm max.
R19,R22,R48,R49,R52,R53 = 220 Ω, 1%, 0.6 W
R21,R24 = 33 Ω, 1%, 0.6 W
R25,R26 = 56 Ω, 1%, 0.6 W
R29,R30,R35 R36 = 27 Ω, 1%, 0.6 W
R31,R37 = 1 Ω, 1%, 0.6W
R32,R38 = 1.5 kΩ, 5%, 1 W, metal film or metal oxide,
body size 5 x 12 mm max.

In KIT: MFP1-1K5 JI (TT Electronics/Welwyn),

small size 6.2 x 2.5 mm
R39,R40,R41,R42 = 22 Ω, 1%, 0.6 W
R43 = 6.8 kΩ, 5%, 1 W, metal film or metal oxide,
body size 5 x 12 mm max.
R44,R47 = 680 Ω, 5%, 3 W, metal film or metal oxide,
body size 5.5 x 16 mm max.
R45,R46 = 1 kΩ, 5%, 2 W , metal film or metal oxide,
body size 5 x 12 mm max.
R50,R51,R54,R55 = 0.22 Ω, 5%, 5 W, metal plate, radial,
lead spacing 9 mm, body size 5 x 14 mm, BPR58CR22J Koa
R56 = 4.7 Ω, 5%, 2 W, metal film or metal oxide,
body size 5 x 12 mm max.
R57 = 220 kΩ, 1%, 0.6 W
R58,R59 = 2.2 MΩ, 1%, 0.6 W

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Elektor Fortissimo-100 Power Amplifier Kit

R62 = 1.2 kΩ, 1%, 0.6 W

R63 = 270 Ω, 1%, 0.6 W
R65,R70,R71 = 10 MΩ, 1%, 0.6 W
R68 = 0 Ω, jumper wire
R72 = 3.3 MΩ, 1%, 0.6 W
R73 = 100 kΩ, 1%, 0.6 W
R75 = 150 kΩ, 1%, 0.6 W
R76 = 10R, 5%, 2 W, metal film or metal oxide,
body size 5 x 12 mm max.

Capacitors
C1 = 4.7 µF, 5%, 50 VDC, pitch 5/7.5 mm, PET,
body size 7.6 x 9.7 mm max.
C2 = 1.5 nF, 5%, 100 VDC, pitch 5 mm,
body size 2.5 x 7.2 mm max.
C3 = 10 pF, ±0.5 pF, 100 V, pitch 5 mm,
C0G/NP0 (FG28C0G2A100DNT00 TDK)
C4,C5 = 1 nF, 5%, 63 VDC, pitch 5 mm, PET,
body size 2.5 x 7.2 mm max.
C6,C7,C8,C9 = 100 µF, 20%, 16 V, D 6.3 mm, preferably 105°C
C10,C11 = 220 pF, 5%, 100 VDC, pitch 5 mm, C0G/NP0,
body size 2.5 x 7.2 mm max.
C12 = 100 pF, 5%, 100 V, pitch 5 mm, PP,
body size 4.5 x 7.2 mm max.
(FKP2D001001D00JSSD Wima)
C13,C14,C18,C19,C29 = 100 nF, 5%, 100 VDC, pitch 5 mm, PET,
body size 2.5 x 7.2 mm max.
C15,C16 = 680 µF, 20%, 35 VDC, D 12.5 mm, pitch 5 mm,
5000h@105°C
(35ZL680MEFC12.5X20 Rubycon)
C17 = 100 nF, 5%, 160 VDC, pitch 5 mm, PP, body size, 5 x 7.2 mm
max. (R79GC3100Z340J Kemet)
C20,C21,C22,C23,C24,C25,C26,C27 = 680 µF, 20%, 50 VDC,
D 13.5 mm max., pitch 5 mm, 10000h@105°C
(50ZLJ680M12.5X25 Rubycon or EEUFS1H681 Panasonic)
C28 = 2.2 µF, 10%, 50 VDC, pitch 5/7.5 mm, PET,
body size 7.6 x 9.7 mm max.
C30,C31 = 10 µF, 20%, 63 VDC, D 6.3 mm, pitch 2.5 mm,
preferably 105°C
(EEUEB1J100SH Panasonic)

● 40
 19 – Bill of Materials

C32 = 10 nF, 10%, 50 VDC, pitch 5 mm, X7R,

body size 2.5 x 7.2 mm max.
C33 = 1 µF, 5%, 63 VDC, pitch 5/7.5 mm, PET,
body size 7.6 x 9.7 mm max.
C34 = 22 µF, 20%, 35 VDC, bi-polar, D 8 mm max.,
pitch 2.5/3.5 mm

Inductor
L1 = 1.5 mm diam. enameled copper wire, < 0.6 m, 13 turns,
ID 10 mm

Semiconductors
D1,D2 = Zener diode 20 V, 5%, 0.4 W, DO-35
(BZX79-C20,113 Nexperia)
D3 = Zener diode 33 V, 5%, 1.3 W, DO-41
(BZV85-C33,113 Nexperia)
D4,D5 = 1N4148, DO-35
LED1,LED2,LED3,LED4 = LED, red, 2 x 5 mm rectangular
(MCL453MD Multicomp Pro)
LED5 = LED, green, 5 mm, T-1 3/4 (5 mm)
T1,T2,T6,T7,T9,T10,T23,T26,T27 = BC546B, TO-92
T3,T4,T5,T8,T11,T12,T24 = BC556B, TO-92
T13,T14 = KSA1381, TO-126
T15,T16 = KSC3503, TO-126
T17 = MJE15032G, TO-220
T18 = MJE15033,G TO-220
T19,T20 = NJL3281DG, TO−264, 5 LEAD
T21,T22 = NJL1302DG, TO−264, 5 LEAD
T25 = BS170, TO-92
IC1, IC2 = LM334Z, TO-92
IC3 = OPA177FP, DIP-8

Miscellaneous
K1 = 3way terminal block, pitch 5 mm (1729131, MKDSN 1,5/
3-5,08 Phoenix Contact)
K2,K5 = 2way terminal block, pitch 5 mm (1729128 or MKDSN 1,5/
2-5,08 Phoenix Contact)
INPUT = 2 x Press Mount Terminal Pin, 1.3 mm,
PCB hole size 1.4 mm (13.14.419 Ettinger)

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Elektor Fortissimo-100 Power Amplifier Kit

K3,K4 (=K6,K7) + 4 for 2nd PCB = metal standoff, 30 mm, M3,

male-female (so 6 in total)
K8,K9 = Faston PCB, hole 3.3 mm, tab 6.35mm x 0.81mm
(42822-2 Amp/TE Connectivity or similar)
RE1 = Relay 16 A /250 VAC/30 VDC, G2R-1-E 48DC Omron
4 x M3 screw, 16 mm, black (T19/T20/T21/T22 to heatsink,
839672 Toolcraft)
8 x M3 screw, 12 mm, black (standoff PCB/T17/T18 to heatsink,
M312 PRSTMCB100- TR Fastenings)
4 x M3 screw, 8 mm (fasten 2 LSP standoffs and 2 Faston tabs)
18 x M3 nut
8 x M3 washer, plain, steel
6 x metal standoff, 10 mm, M3, male-female (PCB to heatsink)
HS1,HS2 = Heatsink, 9 °C/W, H 50.8 mm, SK 104 50,8 ST Fischer
Elektronik
T17-T22 = Heatsink, 0.6 °C/W, 100x180x48mm, SK53-100-SA
Fischer Elektronik
T19,T20,T21,T22 = Ceramic thermal pad, 23 x 20 mm x 2 mm
(SL-012-AL20 Silfox)
T17,T18 = Ceramic thermal pad, 18 x 12 x 1.5 mm
(SL-019-AL15, Silfox)
T17,T18 = Insulating bushing, TO-220 (IB 6, Fischer Elektronik)
IC3 = DIP-8 IC socket

Figure 40. Detail: 1-watt resistors R18 and R38 —

notice the size of R38.

The photo shows two different 1-watt resistors. Because of current

component shortages, some resistors and capacitors in the kit may
come from different series and manufacturers than mentioned in the
BOM and shown in the photos.

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 20 – Specifications

20 – Specifications

Power source used: laboratory power supply rated 2 x 40 V DC, regu-
lated + 2 x 10000 µF/50 V close to K1.

Input sensitivity 1.076 V (94 W/8 Ω, THD = 0.1%,

B = 22 kHz)

Input impedance 10 kΩ

Sinewave power 94 W (8 Ω, THD = 0.1%)

(1 kHz, B = 22kHz) 98 W (8 Ω, THD = 1%)
181 W (4 Ω, THD = 0.1%)
188 W (4 Ω, THD = 1%)
Bandwidth 3.3 Hz – 237 kHz (-3 dB, 1 W/8 Ω)
(Generator 20 Ω) 10.8 Hz – 78 kHz (-0.5 dB, 50 W/8 Ω)

Open-loop bandwidth ≈ 20 kHz

Open-loop gain ≈ 140,000 (8 Ω load)

Slew rate 45 V/µs

Rise time 1.5 µs

Signal to noise ratio 103 dB (B = 22 Hz – 22 kHz linear)

(Referred to 1 W/8 Ω) 106 dBA

Harmonic distortion plus noise

0.0008% (1 kHz, 1 W, 8 Ω, B = 22 kHz)
0.0016% (1 kHz, 1 W, 8 Ω, B = 80 kHz)
0.0016% (20 kHz, 1 W, 8 Ω, B = 80 kHz)
0.0008% (1 kHz, 50 W, 8 Ω, B = 22 kHz)
0.0008% (1 kHz, 50 W, 8 Ω, B = 80 kHz)
0.002% (20 kHz, 50 W, 8 Ω, B = 80 kHz)
0.0012% (1 kHz, 1 W, 4 Ω, B = 22 kHz)
0.002% (1 kHz, 1 W, 4 Ω, B = 80 kHz)
0.0025% (20 kHz, 1 W, 4 Ω, B = 80 kHz)
0.0023% (1 kHz, 100 W, 4 Ω, B = 22 kHz)
0.0023% (1 kHz, 100 W, 4 Ω, B = 80 kHz)
0.0042% (20 kHz, 100 W, 4 Ω, B = 80 kHz)

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Elektor Fortissimo-100 Power Amplifier Kit

Intermodulation Distortion
(50 Hz : 7 kHz = 4 : 1) 0.0012% (1 W, 8 Ω)
0.0015% (50 W, 8 Ω)
0.0024% (1 W, 4 Ω)
0.0041% (100 W, 4 Ω)

Dynamic IM Distortion 0.0016% (1 W, 8 Ω)

(3.15 kHz square wave + 0.001% (50 W, 8 Ω)
15 kHz sine wave) 0.0019% (1 W, 4 Ω)
0.0021% (100W, 4 Ω)

Damping factor 570 (1 kHz, 8 Ω)

(Measured on K8/K9) 315 (20 kHz, 8 Ω)

Power supply detection 36.5 V = Off

(Positive supply only) (slightly temperature dependent)
36.7 = On
(slightly temperature dependent)

DC protection +0.54 V / –0.89 V

Output relay turn-on delay 3.5 s

21 – DC Voltages

DC voltages across various resistors and LEDs:

Resistor Prototype Kit Condition

R7 7.90 V 7.89 V
R8 7.85 V 7.91 V
R13 7.90 V 8.06 V
R14 7.96 V 8.09 V
R19 1.06 V 1.072 V
R22 1.05 V 1.039 V
R27 1.2 V 1.12 V
R28 0.9 V 0.97 V
R33 1.2 V 1.14 V
R34 0.95 V 0.98 V
R25 1.006 V 0.993 V
R26 1.007 V 1.005 V

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 22 – Web Links

R39 0.28 V 0.34 V

R40 0.28 V 0.34 V
R41 0.28 V 0.34 V
R42 0.28 V 0.34 V
R55 18.7 mV 19 mV amp cold
28.3 mV 28 mV amp warmed up;
zero output power

LEDs (average) = 1.675 V

22 – Web Links

Fortissimo-100 Power Amplifier project page on the Elektor

Labs website:
www.elektormagazine.com/labs/fortissimo-100

Fortissimo-100 Power Amplifier Kit on the Elektor Store website:

www.elektor.com/20273

Fortissimo-100 Power Amplifier article published in Elektor Magazine:

www.elektormagazine.com/magazine/NUMBER

QR code

● 45
Elektor Fortissimo-100 Power Amplifier Kit

23 – Schematics and PCB Layouts

Figure 41. Schematic of the amplifier (210364-1 v1.2).

● 46
 23 – Schematics and PCB Layouts

Figure 42. Schematic of the protection circuitry (210364-1 v1.2).

Figure 43. Top overlays of both PCBs (210364-1 v1.1).

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Elektor Fortissimo-100 Power Amplifier Kit

Figure 44. Bottom views of both PCBs (210364-1 v1.1)

Figure 45. Top-side copper layout for both PCBs (210364-1 v1.1).

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 23 – Schematics and PCB Layouts

Figure 46. Bottom-side copper layout for both PCBs (210364-1 v1.1).

● 49