March 2008

I will start with the Tips pages from the new booklet, ‘A Practical Guide to Crossover Design’
This is at the bottom of the page.

Any Comments, Tips or Suggestions:- technical@falcon-acoustics.co.uk

Malcolm Jones

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The following company can Repair/Recone/Surround lots of PA & HiFi units.

It is preferable that the cones are undamaged.

D.C. Boultons
click for link

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The List below gives Equivalent wire gauge sizes.

Wire in Europe has been sold in Metric form for the last 20+ years.

Wire Gauge
AWG (American Wire Gauge)
or B & S
SWG (Standard Wire Gauge - UK)
 
Inches
mm
Inches
mm
Nearest stock Falcon metric sizes
10
0.1019
2.59
0.1280
3.25
 
12
0.0808
2.05
0.1040
2.64
 
14
0.0641
1.63
0.0800
2.03
 
16
0.0508
1.29
0.0640
1.63
 
18
0.0403
1.02
0.0480
1.22
1.25mm
190.3590.9120.0401.0161.00mm
20
0.0320
0.813
0.0360
0.914
0.9mm
21
0.0285
0.724
0.0320
0.813
0.8mm
22
0.0253
0.643
0.0280
0.711
0.71mm
24
0.0201
0.511
0.0220
0.559
0.56mm
26
0.0159
0.404
0.0180
0.457
0.45mm
28
0.0126
0.320
0.0148
0.376
0.355mm
30
0.0100
0.254
0.0124
0.315
 
32
0.0080
0.203
0.0108
0.274
 
34
0.0063
0.160
0.0092
0.234
  
36
0.0051
0.127
0.0076
0.193
 
38
0.0040
0.102
0.0060
0.152
 

Note for metric wire the 'usual' sizes in the range we wind are:-
0.56mm, 0.71mm, 0.8mm, 0.9mm, 1.0mm & 1.25mm


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Special Offers

INDUCTORS

Value
Type
Wire
Approx Quantity
Cost 1-9
Cost
10-50
2.5mH
SSP
1mm
50
£4.94
-10%
3.5mH
SSP
1mm
50
£5.14
-10%
7.5mH
SSP
1mm
50
£6.37
-10%
4.7mH
SP
1mm
100+
£5.05
-10%
0.6mH
SP
1mm
70
£2.66
-10%
9.0mH
SP
0.8mm
600
£4.28
-10%
0.93mH
HP
1.25mm
150
£2.87
-10%
8.0mH
HP
0.56mm
350
£2.00
-10%
4.5mH
HP
0.8mm
200
£2.88
-10%

All prices include VAT, carriage as normal (See Page1). Quote 'Special Offer' on your order.

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Tweeter Sensitivities

Tweeter sensitivities/resistance/impedance seem to cause much confusion. It is actually quite simple; it really does not matter….. 'As long as the resistance is sensible'.
It is better to work (with tweeters) by using the Rdc. Nominal 8
Ohm impedance tweeters usually have a 6 Ohm Rdc. and 15 Ohm, a 12 Ohm Rdc. Some manufacturers with 6 Ohm Rdc units call them 6 Ohm! Hence some of the confusion.
So for a nominal 8
Ohm system, a tweeter with an Rdc of 4 to 12 Ohm would be suitable as long as its sensitivity (output), with 2.83 volts applied, is equal to or greater than that of the LF unit with the same applied voltage.

Nominal sensitivities

Audax TWO25AO 90 or 91dB depending upon source
Vifa D27 90 @ 1w/1m, & 91 @ 2.83v/1m - greater because it has a Rdc of 6 Ohm

Sensitivities vary due to:
1. The response not being flat over its usable range. The range over which it is measured will determine the value. If white noise is used, a peak in the response, quite common on many dome tweeters, could give an inflated reading. A sensible sensitivity reading should be from 4-10kHz.
2. There are two normal methods of determining sensitivity:
    a) 1w/1metre. This is one watt into the actual unit, i.e. voltage squared / impedance.
    b) 2.83v/metre. This is measured using 2.83v (equiv. to 1 watt into 8 Ohm) and if the impedance is lower than 8 Ohm it will give a higher reading as more current will be drawn. Conversely lower if a higher impedance.
3. The sensitivities will also vary when a network is used as this also affects the impedance etc. What actually matters then is the output of the tweeter over the range 3 - 12kHz through the network to be used with 2.83v applied. This is because the same voltage is applied to each unit in the system.
4. Although the impedance can be usually be 'ignored' if the sensitivity is quoted with 2.83 volts applied, it must be taken into account in the design of such things as crossovers and Zobel networks.

We have a sheet showing the various fitting dimensions for a range of tweeters,
both current and discontinued (for fixing size reference).
TWEETER fitting sizes.pdf (9kBytes)

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UNIT‘SWAP’ Section

This will be converted to a separate page if it takes off

Please let us know of any problems etc.  Falcon takes no responsibility about these items; this is only a contact/swap board.

DO LET ME KNOW WHEN ANY ARE SOLD SO I CAN TAKE THEM OFF. 

We will however withdraw any mention if problems are reported.
Items are unknown to FALCON and items are at Buyers/Sellers risk
Send details by e-mail and we will put them on the page
MUSTS:- E-mail address, Postal address (Falcon use), Unit description and SP number. e.g. B200  SP 1014
Age - usually a code on the unit leg  e.g. G1378, Usage and Price if selling or buying. Other if swap.
Contact is direct to ‘advertiser’.

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NEW

No.
Mfs.
Unit
Use
Condition
2
Kelly
Ribbon Horn
 ?
Good
4
GEC
Metal Cone Unit
?
Good

Contact
weegenaar@clear.net.nz

New Zealand
Notified 15/3/2008

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WANTED

No.
Mfs.
Unit
SP Number
Use
Condition
1 or 2
KEF
B200
SP 1039 (104 type)
 
Good

Offer price £10 each

Contact
W Hateley
wilfros@wanadoo.fr - Notified 1/2/04
Beds.

DO LET ME KNOW WHEN ANY ARE SOLD SO I CAN TAKE THEM OFF. 

IT WILL ALSO SAVE YOU THE HASSLE OF UNWANTED E-MAILS !

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TEP S1-W networks

 

( .pdf LEAFLET ) 137k

2 way crossover approx 200-250Hz. 7 components. 2 x 4.7mH SP/LL 1mm wire & HP/LL inductor. On PCB 10.
Works with bookshelf speakers coupled with 2 LF unit systems

£14.00 + p&p
£7.00 + p&p

  

LINN Networks

(Linn) Special PCB (Isobarik's B139B/B110A/ScanSpeak D2008 or Hiquphon)
Size 126 mm x 165mm x 40mm
These are suitable up to S/N 6699 / 6700 in
1988.


(Note that Linn used an earlier numbering system 10,000 to 11,000+ from 1976 to 1980)
After this LINN changed to a high slope 4 Ohm network, which was fitted into the stand.

These Crossovers are now sold out.

Each £25.00 + £6.00 p&p per pair.
8 ohm hence 2 networks needed per system,
(One per set of units). Hence
4 per stereo system pair.

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Below is the Tips page from the Falcon booklet, ‘"A Practical Guide to Crossover& System Design"

Available from Falcon, 28+ pages, A5 format @ £3.00 +p&p

Use this in conjunction with our other booklet "Active Loudspeaker Crossover Filters and Sub-Bass"
This also includes details on types of loading and cabinet volume calculations.

Also available from Falcon, 32 pages, A5 format @ £3.00 +p&p

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Tips

·        Make a predesigned kit.  Even if you want to play, use this as a starting point.  The designer has probably got lots of test equipment and many years of experience.

·        Do not expect a theoretically designed network to be anything like optimum.  It will work - probably, but the performance could be the difference between a CITROEN 2CV and a Formula 1.  Both work,  but. . . . . . .

·        Make a quick and unfinished ‘pre-production’ test box.

·        When initially designing the system, use the Small-Thiele parameters of the chosen bass unit to determine the nett volume of the enclosure required.  Additional volume should be added for cabinet wall damping, bracing shelves and battening etc.  Then add about 10% (minimum) to the calculated volume.  The volume can be reduced by adding wooden blocks or bricks, but you cannot easily increase the box size.

·        When working out the box size, do take into account the Rdc of the inductor(s) in series with the bass unit.  They can significantly alter the unit ‘Qtc’.  Start with 0.3 Ohm - 0.5 Ohm or 0.6 Ohm to 1.0 Ohm if using Air Cored       See Fig.6 p.11

·        Determine the frontal width required - this is the main diffraction-causing dimension and should be kept constant during the design process. [1] Is it wide enough for the bass unit to fit in?  The height is next determined. This is normally a function of aesthetics (golden ratios) and whether the cabinet is to be stand or floor mounted.  Test that the units plus spacing will fit in the height chosen.  The depth is then easily calculated.  This dimension is the one to change on your final cabinets as it has minimal effect on the response curve.

·        If making a column speaker it is a good idea to partition a small ‘box’ on the bottom and fill this with washed, dry sharp sand. Use pointed cones for good LF system anchorage.

·        If modifying an existing system do not put the MF &/or H.F. units into a narrower box or baffle as this will have major consequences on the diffraction effects.  The crossover will have to be redesigned. Probably an increase in the value of the LF section input inductor.

·        Radius the frontal edges of the cabinet (quadrant or bevelled edges), and any reflex ports.

·        Always flush mount the tweeter and preferably the midrange/bass-mid.

·        Use banked capacitors which allows variations to be made easily.  For a theoretical 5mF use a 3.3mF and some smaller values, such as 1mF and 2 x 0.47mF and/or 3 x 0.33mF.  A few 0.1mF capacitors would also be useful. These can be connected in parallel to make up the required value in small steps.  This need not be too expensive as initial tests can be made using Polyester.  Do however use 5% components.

·        As a general range of capacitors the following give 1 - 10 mF in 1 mF steps:-

                  5mF,  2mF,  2mF,  1mF.

      For 0.1mF - 1mF use:- 

                  0.47mF,  0.22mF,  0.22mF,  0.1mF.  This does not give the exact 0.1mF steps, but near enough.  You can of course use 10 x 0.1mF  and 10 x 1mF

·        Do not connect inductors in series to make larger values as this doubles the Rdc.  An inductor wound to double the value will, in theory, have an Rdc 1.41 times the original value.  Due to the extra turns being of larger diameter than the original the factor tends to be 1.5x.  Still better than 2x!  Tapped inductors are available, and although a bit expensive they are cheaper and more convenient than having multiple inductors.

·        Some books suggest deducting the value of the speaker inductance from the series inductor.  DO NOT DO THIS.  It may make the impedance flatter, but will mess up the response shape.  If anything the value needs to be added to counter the unit impedance rise!

·        Resistive attenuation can be used on both midrange and tweeter units, but not on bass units (see Unit ‘Q’ in formulae).  It is however sometimes possible to shunt the bass unit with a high-power resistor.  33 Ohm to 15 Ohm are suggested trial values.  As most midrange / tweeter units are more sensitive than bass units, this is not normally necessary.

·        Computer programs are useful in determining box sizes and loading.  The formulae are quite accurate, or at least as accurate as the Small-Thiele parameters used, although they tend to be a little optimistic by a dB. or so.  Very useful in trying out differing types of loading and checking power handling and excursion limitations.

·        If you like playing and you are not just making a ‘one off’ it could be worth buying a small FFT test set-up.  AIRR with a SoundBlaster 16 bit duplex card, a microphone capsule and a preamp will give frequency response, phase and waterfall curves.  Total price excluding the sound card is less than £120.  Some saving could be made by building your own preamp.

·        Whilst ‘playing’ do use PolySwitches.  These devices have a very low series resistance in their cold condition, but become almost open circuit when the series current heats them above a certain temperature.  Available in a range of currents.  Suggest:       

0.5A for tweeters;

0.9A for bass/mid & midrange;

1.6A for bass.

 

      Very useful for normal use, in particular for tweeters. Much cheaper than units.

·        Zobel networks.                        

Starting points for L.F. units

   

10 Ohm and 10 – 16mFd.

Starting points for L.F./M.F. units

 

10 Ohm and 10mfd.

Starting points for H.F. units

 

8.2 Ohm or 10 Ohm and 2.2mFd.

 

·        Connecting units ‘in phase’

The phase difference between the 18dB. slopes is 90deg. and therefore there is no absolutely correct polarity connection; the acoustic phase shift in the loudspeaker unit determining the actual polarity connection.

An easy and quite accurate method of checking for the 'best-fit' phase is to connect only the two units you wish to test, the other(s) should be disconnected and the network loaded with resistors.#  These need not be exactly the correct resistance, for an 8 Ohm speaker the resistor should be between 6.8 Ohm and 9.1 Ohm with a rating of at least 5 watts. 

A white noise source  -  pickup input with the gain near maximum  (don't touch the pickup or arm!) - de-tuned FM tuner etc.  Move your head between the axes of the two speaker units at a distance of 18" (½ metre).  For correct phase the sound should gradually increase from the axis of one to a maximum midway between the two and decrease down to the axis of the other unit.  Change the polarity of the 'uncertain' unit and try again.  It is usually very obvious which polarity connection gives the correct phase at the crossover point.  Start with the bass unit as the reference and determine the polarity connection of the midrange or tweeter, disconnecting the tweeter on a 3 way.  Once this has been done, disconnect the bass unit for a 3 way and connect the tweeter.  Alter this to give the correct phase match with the midrange.

Whilst this method is not infallible, I have found it 90+% accurate and far more accurate than theory

#  This does not apply to series networks as the unit impedance interacts with all the sections.  In this case the unwanted unit should be covered over to attenuate its output as much as possible.

[1] If building a kit into an existing box the width is important. The crossover was designed for the width of the designed cabinet. 
     The Small-Thiele parameters should then be used to check the suitability of the cabinet volume.