Stuffed Crust (176 inspired tube class A compressor)

So we can break the tuning down to the constituent parts of the compressor:
1. The variable first stage - how the signal changes over changing bias and how do we tailor the stage accordingly.
2. The gain stage - this will be a constant gain, thus all we need todo is tailor to not distort and provide the signal size for the control
3a. The control peak threshold - how much energy is provided by the size of signal and the base grid point
3b. The control RC curve - how fast the attack and release responses are with that energy 'pump'. This will also affect the mapping between loudness of the signal and the attenuation - this will be the major non-linear component in terms of curve design. The cap also acts as a cathode bypass, so the value of the capacitance also affects the frequency response. f=1/(2pi*Rk*Ck).
4. The cathode follower - this is simply tuning it so it doesn't distort and drives.

So to point one - the "variable mu".

I'm not going to cover tube load lines - I would point you in the direction of Merlin "the valve wizard" as his site (although he sells a book on tube design) has on his site the free to download chapter on designing with tubes which includes the load lines.

The 12BH7A-STR is a low amplification but more linear equivalent tube to the 12AU7.

Drawing the load line:
* At zero current our Ra will have zero voltage drop and so our tube will see the 327Vdc B+.
* At a short circuit, the tube will see 20mA at 0V assuming a Ra of 327/0.020 = 16,350 ohms.

This 16K Ra sets the load line slope. The lower the resistance, the steeper the slope, and vice versa. One thing to note here is a point on sound - a higher voltage will give a better cleaner/fatter sound but worse overdrive, and a lower is the opposite. So more resistance = more voltage drop. Hence we see 100K in Marshalls.. as we're not attempting to add tonal colour or distortion, we're going to keep to the lower end of the spectrum.

However out 6k2 we have at the moment needs an increase - the line is too steep and so we get minimal output and high current.

So here is our load line at 16K. 20mA is off the top.. we'll revisit this next post (AC line, following stage impedance and cathode lines) but it gives an approximate picture:

Screenshot 2025-08-01 at 12.42.41.png

The normal operating point bias for the tube is set using the cathode resistor. This is set so the cathode sits at about +4.8Vdc. This means that when the grid bias is 0Vg that actually the tube sees the grid's bias as -4.8Vg. That's the red dot on the line. The curved lines are the grid voltages that the tube sees.
The operating point is the 0V point of the input sine wave - the +Vpk will move up the line towards 0Vg and the -Vpk will move down the line. I have demonstrated the points of a 4.8*2 = 9.6 Vpp signal would be and the output (blue lines and blue text) - so for a 9.6Vpp we get 155Vpp output.

The variable grid bias will shift the operating point down the line. So as the control board decreases the voltages, it pulls the operating point further down the loadline. I've put a purple dot showing the -13Vg (remember we have cathode +4.8V, so the control board only drops it by 8.2Vdc). The effect of the 9.6Vpp input signal peaks are now at -9Vg and -17.5Vg ... the purple dashed line and text show the non-linear compression... the 9.6Vpp now only outputs 80Vpp and not 155Vpp (a fully linear 1:1 would be 81Vpp). Dropping beyond -13V becomes increasingly non-linear and will start affecting the waveforms.

So our max attenuation will be 20*log10(80/155) = -5.745 dB of the loudest signal 9.6Vpp it will drop it to 4.95Vpp. I'm not going to play too much with dB simply because we end up needing to set a reference level if we're talking absolute.

So you can see a minor curve I was talking about in my previous post appearing through the non-linearity of the tube. Changing the Ra and the tube to be a more non-linear tube such as the 12ax7, would see more of a bend. However we can also influence the curve in the control component - how fast the capacitor charges and how much it reduces.. but more on that in a later post.

So you can see I'm looking at the first stage:
* I've set a maximum input signal of 9.6Vpp - we could go smaller but this is clean sound. I'm in two minds to reduce the further, it would allow for more compression range. I could set 3.47Vpp by setting the cathode resistance.
* I've increased the load line to 16K, although a higher value would change the load line (flatter) and it could make it more linear (more perpendicular to the grid lines) - I'm constrained by the resistors I have.
* we now know our scaling and limits for our control board tuning.
* we know the output Vpp range that will hit the next stage - and we know the input grid range (we're going to bias in the same way but we don't need to bias the next stage flexibly - so we have more head room to play with. The output from that stage will be amplification again - that we need for our control system.

In the next post I'll get on to the next stage but for now that will do - but I may come back an rework if the later stages offer better range with a lower supported input.
 
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So following on from the first initial stage post. I've updated the ltspice model and added some additional variable parameters. This approach allows me to see roughly how everything will behave.

Screenshot 2025-08-02 at 13.17.18.png

You'll note the use of {parametername} in some of the resistances, capacitances and voltages (control bias). This allow me to use a stepped list to sweep a number of values to see how they behave.

So we've had a look at the initial tuning of the first stage and I've hinted it becomes more complex. This is because the first stage tubes see the output and past the decoupling caps to see the resistance/impedance of the next stage. This impedance changes depending on frequency too - making the impedance AC load line different from the previous load line. We are driving into a high resistance of the next stage (we have a scaling voltage divider built in: ~1Meg:250K) and so the loadline becomes steeper and the resulting first stage Vpp output reduces.
To make it more fun, the cathode load line varies too so the load 'line' is more of a load oval as the signal changes and we have various frequencies.

I've taken a starting operating point of -4.8Vg for the second stage at 12mA. As we're using a long tailed pair. this 9.6V is split into a 4.8Vg bias and a 9.6Vk. This means the tube sees 4.8-9.6 = -4.8 Vg without a signal. We're looking around 112Vpp with the 9.6Vpp large signal and that signal does distort a little (same as the first stage). The standard playing is well within the non-distorted zone.
The -4.8Vg bias will not be changed by the control board but will vary due to the cathode line. However that's not really important at the moment. What is important is - the output for the next stage and the output to the control board, thankfully we have a natural voltage divider in the sequence of plate resistors. The closer to the tube, the larger the voltage swing.

Tuning the second stage output for the directly connected cathode follower (CF) has to take into account the CF input range and the resulting CF current limits. Without scaling, the CF output to the next pedal/amp is over 100+Vpp. Ouch. So, as you can see we tap the output almost at the B+. This naturally scales down the signal Vpp that goes into the upper ecc99 CF grid.

We then tap directly at the tube plates for the control board waveform so we get a 90-100V peak for the control board. A nice hefty asymmetric swing of around 160Vpp... that's got some current moving which helps propel the control board bias.. more of that later.

So back to the first stage... we now (wirth the impedance line and cathode lines) tune the cathode resistance for tube current - we're a little lower than the 12mA but 9.8mA is good.

To get this, what I've done is model the grid bias from 0V to 20V and looked at where the problem come in. Our -13V we looked at in the previous post works well as a maximum for our large 9.6Vpp input we want to scale.. it drops it down nicely as expected - right through the second stage too.

Next up is the tuning of the cathode follower. There's really only one thing we want todo - alter the lower cathode resistor to so our max current through both triodes at peak swing is 60mA or less for out 9.6Vpp input.
The output from the CF is a little large.. in the order of 30Vpp.. but this is why we have a volume/level to allow us to tune this output. Once set to a 9K:1K voltage divider (a 10K pot).. then we get a lovely output that plays well with pedals and amps alike.

Just with the current control board tuning.. this is an example of running the different input voltages:


Screenshot 2025-08-02 at 10.13.29.png

The top panel is the control board bias that influences the first stage grid bias. You can see the larger the wave form input - the larger the negative drop.. the little bumps are the waveform rectification that is responsible for the pull down of the voltage. It follows the you'll see a full wave rectification shape with the slow discharge (the line slowly goes up until the next peak).

The next panel shows the dB for each sized input waveform. Ignore the spikes - those are computational accuracy and not real world accuracy.. the reality is that we will get some phase shift at this level so we will see some odd behaviour close to the crossover points.

The last panel shows the steps of input (blue) value (large is our 9.5Vpp) and the green shows the respective outputs - again the largest output will be from our largest input.

Now the fun.. here's our curve (green) over a 1:1 (blue) at the moment, I've added a couple more steps on the input to make it a little smother curve:
Screenshot 2025-08-02 at 10.30.31.png

The compressor is working, this curve is more of an active attenuator, but we can increase the levels (output pot) and other parameter to make it so the quieter sounds are amplified and allow the curve to bend over the 1:1 and continue to compress the louder sounds. Here's a little output divider change on the CF however ideally we want the a parallel line for the low frequency but it shows the idea:
Screenshot 2025-08-02 at 14.00.18.png
The curve shape is part of the next stage.. tuning the control board which involves looking at a number of things:
* input wave form voltage - the current it imparts, this is not a free ride though as drawing too much current will change output wave shape.
* threshold of the rectification using the control bias voltage
* the attack resistance - how fast the pulses can charge the cap. This is a classic AC rectification RC charge curve.
* the release resistance - how fast the cap can discharge. The is a classic RC discharge curve, mixed with the previous RC charging curve..
* size of the cap - speed of change
The last attack and cap parameters has behave like a low pass filter for the rectified wave form.

So it's a bit of a balancing act... and having this ltspice model helps at least hit the target barn... rather than miss the county..
 
Looking at the control board tuning, I've gone through using the parameter stepping - which allows you to plot multiple runs and see the behaviour throughout the system.

With a bias on the control board something interesting happens - we get a low signal input amplification and a high signal input attenuation.
Note that this is without the adjustment to the output pot previously, the lines are bias thresholds of -12V (red) -4V 0V 6V 12V (green):
Screenshot 2025-08-03 at 09.17.29.png

One small benefit here is that our really low -96dB signal drops back to the 1:1. Although I would have liked the 1mV, 10mV 100mV data points to be more aggressively amplified (ie almost like the graph started part way up the Y axis.
So what happens if we change the first stage cathode resistor to allow more current through, changing the operating point? Taking -4V threshold only, then varying the cathode resistance between 150, 250 and 450R we can see the curve move:
Screenshot 2025-08-03 at 09.41.22.png
Looking closer at the lowest signal amplitude it shows that that upper line (150R) gets a kick due to the tube now being more sensitive and running a hotter operating point:
Screenshot 2025-08-03 at 09.44.56.png
This doesn't mean everything is good, the majority of the distorted signals here are from those two amplifying signals:

Screenshot 2025-08-03 at 10.01.12.png
You can see all the 80 stepped passes, and the colour management is a bit of a pain. However the main distortion is from the resistor and bias control increases we've done.

So that means an option here Is to look at increasing the second stage gain - but that too, we're really on our gain limit. So the two stages of 12BH7A amplification factor is starting to bite us a little. A great option here could be to add a 12AX7 on the front stage or between the two existing stages however I don't have one free. If we operated an opamp control and FET, we could make this a little more controlled and even add in a tone stack shaping to make it frequency sensitive too.

However I'll make some changes and test the voltages in real life. It should prove interesting. I've learnt a while ago - ltspice I great for getting a rough idea, but it doesn't replace reality.
 
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So I've gone through and simulated numerous combination and variations of changes.

So in the spirit of the recycling only for the competition, I've been going through all the place I can possibly find some resistor values - including the LED/bleed resistors off the some of the old power supplies, the defunct multimeter sensing resistors, etc.

I'll change the first stage resistances to 18K (parallel 36K) and I have found a couple of 10K from the heater supplies that will give me 10K+2.49K+2.49K+2.49K+1K=18.47 K for the second stage. The existing cathode resistances are trim pots so I can adjust accordingly.

The control board I'll add 5K in series with the attack 10K pot (this oddly becomes the same as the 176), and the release pot I'll add 1Meg in series with the 1Meg pot which then, oddly, resembles the 176's release pot resistance of a 5Meg pot.

I need to work out how to mount the power components inside the box because I've come within an inch of brushing 340Vdc. An alternative is to rehouse to a recycled larger steel box I have. That would allow everything to be inside and I would also put the tubes on a bent 90deg rather than put them output as they are now. The whole thing will be safer, larger, but would fit beside my amp.

I'm starting to get to the point where I hit the limit in not ordering new components.

Update
I’ve moved some of the point to point wired components to strip board which should make it a little easier and safer to move components at a later stage.
I’m planning to get a first test tomorrow some time.
 
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Slightly distracted..

The PTP components are now strip boarded and the boards have been iso'd. I still need to do a little adjustment to ensure a couple aren't going to get a spark over. Tomorrow I'll anneal the alu sheet so that I can bend it and put in the tube mounting holes. Everything can then be mounted in the recycled (and holey) case. it will be safer and the boards can sit on standoffs.
 
Rehoused.. and running. Currently I have the sig gen using into it with the scope - this doesn't have any adjustments yet. It's just come off the lightbulb limiter. Video uploading....


This is the XY plot - it hints at the current curve (see the persistence of vision) but it shows the full wave form, it also shows the distortion (the loop).
IMG_4914.jpg
 
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