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While this might work as a simple fix, or at a crossover frequency that is not close to the speaker frequency response limits, it is not the best solution. For higher slope crossovers, complexity and cost add up quickly.
Filter: This is the real crossover. It blocks undesired frequencies by increasing impedance seen by the amplifier. Made up of capacitors and inductors. There are three types: High pass, low pass and bandpass (high pass and low pass filters used together).
1.
L-pad: Attenuates the output of a speaker, while presenting a constant load to the amplifier. L-pads are made using two resistors that dissipate power that would go to the speaker. It is used to match "volume" levels of different speakers.
2.
Impedance Stabilization: Commonly known as a Zobel circuit. It uses a capacitor and resistor to compensate for the inductive effects of the speaker coil, making the speaker play in a more linear fashion. This also makes the amplifier see a more stable load (speaker impedance varies with frequency). Zobel networks are used on speakers that play lower frequencies, not tweeters.
3.
Capacitors: If you can afford them, try to get Mylar or polypropylene capacitors, especially when they are used in series (highpass filters). For low pass filters, or high capacitance values nonpolarized electrolytic capacitors have to be used.
1.
Inductors: Most critical in low-pass filters, when they are placed in series. For audiophile quality sound, CFAC (Copper-foil-air-core) inductors are probably the best choice, but at a high cost. Most cost/quality effective option is air core inductors for high-end crossovers. At larger inductance values, the series DC resistance in air core inductors becomes a problem. This is when iron core inductors would have to be used.
2.
Resistors: High-power resistors are bulky. Always pick a higher wattage than you would need on average conditions. Get non-inductive resistors for best performance.
3.
L-pads: There are commercially available variable L-pads, or a set can be fabricated using two high-power resistors. If you buy an L-pad, it is very important that you get the right value. I.e: For 4-ohm speakers, get a 4-ohm L-pad. A dual 8-ohm L-pad could be wired in parallel to operate with a single 4-ohm speaker, at twice power handling.
4.
Circuit Boards: Chose double sided copper boards. The thicker the copper coating and insulating material, the better. You can either etch the board with chemicals, or with a Dremel tool.
5.
Inductors gauge/power ratings: In inductors, the gauge of the wire used determines power handling. Common values are: 20 gauge = 180 watts, 18ga = 250 to 300w, 16ga = 500w and 14ga = 800w.
Series/parallel inductors add up in the same way as resistors, capacitors add up in the opposite way (capacitance increases in parallel, decreases in series). For formulas, look at the "speaker/sub wiring" page.
In crossovers with large non-polarized electrolytic caps, sound quality can be improved by bypassing them with a small value (0.01 to 0.47 F) film or foil polypropylene capacitor in parallel (tip courtesy of
Parts Express).
Testing
First, visually trace all the connections and junctions on both sides of the board. Make sure there are no short/open circuits. The second step is to test the board. Check the board to make sure there are no DC short circuits. Connect the board to an amplifier and speaker. You can either use an RTA or test tones to determine the board's frequency response. Use a volume level a bit higher than the background noise in your test environment. If the frequency response (crossover point and slope) do not match theoretical data, you might have a short or loose connection. Re-inspect your circuit.
Frequency (Hertz) 80 100 130 200 280 400 600 800 1000 1200 1800 L
2 ohms C
4 ohms L C L
4.1 mH 1000 F 8.2 mH 500 F 16 mH 3.1 mH 800 F 2.4 mH 600 F 1.6 mH 400 F 1.2 mH 300 F 0.8 mH 200 F 0.5 mH 136 F 0.31 mH 78 F 0.25 mH 66 F 0.16 mH 44 F 6.2 mH 400 F 12 mH 4.7 mH 300 F 10 mH 2.4 mH 150 F 4.7 mH 1.6 mH 100 F 3.3 mH 1.0 mH 68 F 0.62 mH 39 F 0.51 mH 33 F 2.0 mH 1.6 mH 1.2 mH 1.0 mH
0.33 mH 22 F 0.68 mH 10 F
0.16 mH 10 F 0.33 mH 68 H 51 H
5 F
0.10 mH 6.8 F 0.20 mH 3.3 F 4.7 F 0.15 mH 2.2 F 3.3 F 100 H 1.6 F
Frequency (Hertz) 80 100 130 200 280 400 600 800 1000 1200 1800 4000 6000 9000 12000
2 ohms L C
4 ohms L C L
5.6 mH 700 F 11 mH 330 F 22 mH 4.5 mH 550 F 9.1 mH 270 F 18 mH 3.5 mH 470 F 6.8 mH 200 F 15 mH 2.3 mH 330 F 4.7 mH 150 F 9.1 mH 1.7 mH 220 F 3.6 mH 100 F 6.8 mH 1.1 mH 140 F 2.2 mH 68 F 0.75 mH 100 F 1.5 mH 47 F 0.56 mH 68 F 1.0 mH 33 F 0.45 mH 55 F 0.91 mH 27 F 0.38 mH 47 F 0.75 mH 22 F 0.25 mH 33 F 0.50 mH 15 F 75 H 50 H 38 H 4.7 mH 3.0 mH 2.0 mH 1.8 mH 1.5 mH 1.0 mH
0.11 mH 14 F 0.22 mH 6.8 F 0.47 mH 3.3 F 10 F 0.15 mH 4.7 F 0.33 mH 2.2 F 6 F 4.7 F 0.10 mH 3.3 F 0.20 mH 1.5 F 75 H 2.2 F 0.15 mH 1.0 F