Builds a simple Headamp 2016 headphone amplifier based on the TPA6120, meant to power large headphones directly from a sound card.
Uses the Noise Reducer kit with a neutral front headphone jack, Alps blue potentiometer, rhodium RCA sockets, and an all-aluminum Chinese enclosure.
A 20W toroidal transformer, 2x13V, turned out sufficient, and shielded signal wires were ultimately unnecessary.
The finished amplifier delivers much higher output power and a clearly better sound than the sound card alone.
Drilling the front panel by hand scratched the aluminum, though the damage is not very visible.
Generated by the language model.
Listening to music on large headphones connected directly to the sound card, I often lacked power in them. I decided to try to construct a fairly simple amplifier based on the Noise Reducer kit - Headamp 2016 on the TPA6120 chip.
This is my first construction, which I managed to complete fully. It was created for about half a year, including during the waiting time for various parts that traveled from China (housing), and the lack of free time to "push" it forward. I also hunted for small luck, but eventually I ended up buying a new one from Toroidy.pl. The amplifier kit itself is very well described on the RS channel, so I will not write here. All holes in the front panel made by hand with a drill, at first glance I decided to make a back panel from dibond (CNC milled) to keep the original aluminum panel in case of failure. Ultimately, I left it in a version that does not bother me, and by the way I can use the aluminum panel for the front, which unfortunately I scratched when drilling the hole for the potentiometer (although this is not very visible).
Below photos from the creation, unfortunately taken with a phone that only then I had on hand.
Neutral headphone jack, which was easiest to mount on the front panel, Alps blue potentiometer, RCA rhodium sockets, 20W toroidal transformer (smallest available) 2x13V, standard version proved to be sufficient (zero any hum), all-aluminum housing from China. I was thinking about shielded signal wires, but it turned out to be unnecessary. The amplifier has quite a large output power, the difference in quality between the sound card and it is very large. Now only the headphones change for the better.
About Author
wiorekw wrote 260 posts with
rating 112 , helped 7 times.
Live in city Jarocin.
Been with us since 2006 year.
Hmm, ready module inserted into the finished housing ... "P = 100mW, RL = 32?".
Is it such a big output power?
Where do you get the signal fed to the amplifier's input? [Read more]
wiorekw
12 Aug 2017 15:15
TPA6120 provides 500mW at 32?, can work with loads even from 8?. It's probably a lot for a headphone amplifier.
Signal from a sound card from a laptop, from a DAC to PCM2704 or from a CD H / K HD720... [Read more]
Freddy
12 Aug 2017 15:30
Yes, a lot, but at these 500mW distortions are already increasing significantly.
The nominal power for headphones is 80mW and this is usually sufficient.
Personally, I use such an amplifier and it... [Read more]
kasss12
12 Aug 2017 18:13
So what if the plate is ready, let the boy do what he loves. Why should he overpay 3x, how can he also learn something. Distortions are growing by leaps and bounds, I doubt that at 0.5W. [Read more]
Freddy
12 Aug 2017 18:18
After all, nobody chases him for it, kasss12 do not clutter the subject. [Read more]
Gismot
14 Aug 2017 02:16
For me, the power switch on the back of the case is not a very comfortable solution,
we go further:
- no fuse protecting the trafo on the 230V network side.
- unshielded audio cables, and too close... [Read more]
wiorekw
14 Aug 2017 07:45
Strangely, there is no problem with the hum, even with the maximally "unscrewed" potentiometer. I was thinking about using shielded cables before everything went to the housing (I was also worried about... [Read more]
wojtek9313
15 Aug 2017 16:07
Will you provide any information on the advertisement with the housing? It can be PW. [Read more]
katakrowa
15 Aug 2017 16:46
I also folded it.
http://obrazki.elektroda.pl/4272692200_1502807831_thumb.jpg http://obrazki.elektroda.pl/6339736200_1502807837_thumb.jpg http://obrazki.elektroda.pl/1624908900_1502807840_thumb.jpg... [Read more]
djpolb
17 Aug 2017 22:19
me too
Affirmative.
This is me too :wink:
http://obrazki.elektroda.pl/5883650100_1503000320_thumb.jpg http://obrazki.elektroda.pl/9039977300_1503000320_thumb.jpg http://obrazki.elektroda.pl/8274550800_1503000326_thumb.jpg... [Read more]
KrisNext
14 Sep 2017 13:39
Hello everyone, I'm also proud of my amplifier on the same system
My version is double, meaning in one housing there are two amplifiers with independent volume control
The amplifier has two stereo... [Read more]
Is there documentation available for this amplifier somewhere on the network (RS 2016) or do I need to buy a kit
(pig in a poke)? [Read more]
Rocky Horror
23 Nov 2017 17:39
The author built such a nice headphone amplifier, and such a design babol has passed ... The ground wire cannot be screwed to the toroid screw. Now, when you touch the amplifier housing (or the equipment... [Read more]
yogi009
23 Nov 2017 18:08
How does sound quality compare to such a classic construction:
http://sound.whsites.net/project113.htm
? [Read more]
winotu2
12 Dec 2023 12:13
I built such an amplifier is oki but I would like to add one pair of cinch and a switch to select the sound source , what can be used and how to connect it . [Read more]
bsw
12 Dec 2023 13:06
For example, such: https://www.sklep.monster.pl/2-poz-6-pin-mts-202-przelacznik-631,4,36557,2007
pins from the left - left channel, from the right right
center to the inputs of the amplifier
top and... [Read more]
FAQ
TL;DR: TPA6120A2 can push 500 mW into 32 Ω [Elektroda, wiorekw, post #16638253]; “distortions are already increasing significantly” above that point [Elektroda, Freddy, post #16638281] A simple kit plus toroidal PSU yields quiet, powerful drive if wired neatly. Why it matters: the right build choices turn a €40 kit into reference-grade headphone performance.
Quick Facts
• Output power: 80 mW nominal, 500 mW max @ 32 Ω [Elektroda, wiorekw, post #16638253]
• Recommended supply: ±12–15 V rails; builders use 2 × 13 V, 20 W toroid [Elektroda, wiorekw, post #16637879]
• Chip: TI TPA6120A2, 120 dB SNR, 0.00014 % THD+N @ 100 mW [TI Datasheet, 2022].
• Typical kit cost: €30–40 (PCB+parts), case adds €15–25 [DIYaudioStore, 2023].
• Safe mains fuse: 250 mA T for 20 W toroid [IEC 60127-2]
Is 500 mW really useful for headphones?
Most hi-fi headphones reach full loudness with 30–80 mW. The TPA6120’s 500 mW headroom prevents clipping on low-sensitivity models but distortion climbs past 80 mW [Elektroda, Freddy, post #16638281] Reserve the extra power for hard-to-drive 250–600 Ω cans or brief peaks.
Where can I tap the audio signal for this amp?
Users feed it from laptop sound-cards, PCM2704/2703 USB DACs, or CD players’ line outs [Elektroda, wiorekw, post #16638253] Any 1–2 Vrms line-level source with <1 kΩ output impedance works well.
Do I need shielded RCA wires inside the case?
Builders report zero hum with unshielded twisted pairs even beside the transformer [Elektroda, wiorekw, post #16641203] Shielding adds margin in cramped metal cases but is not mandatory if wiring is short and tightly twisted.
Why mount the power switch on the rear panel?
Placing the switch near the IEC inlet keeps 230 V leads away from small-signal wiring and saves front-panel space [Elektroda, katakrowa, post #16643568] It suits desktop setups where rear access is easy.
Should I add a mains fuse?
Yes. A slow-blow 250 mA fuse on the primary limits fire risk if the toroid shorts [IEC 60127-2]. Several kits omit it, so you must add an inline holder to the IEC socket leads [Elektroda, Gismot, post #16641145]
Is grounding the safety earth to the toroid bolt safe?
No. Doing so forms a ground loop through the core; a short circuit can occur when another grounded device is connected [Elektroda, Rocky Horror, post #16844071] Attach the PE wire to a dedicated chassis stud instead.
Where can I buy the aluminium enclosure shown?
Builders sourced generic all-aluminium 120 × 170 × 40 mm boxes from AliExpress; search for “DIY 40H amp case” (€18–22 shipped) [Elektroda, wiorekw, post #16637879]
Is documentation for the RS Headamp 2016 available without buying the kit?
The full manual is bundled with the kit only. Publicly available info covers the TPA6120 reference design but not the exact PCB artwork [Elektroda, bsw, post #16843856]
How does it compare to ESP Project 113 (OPA2134 + BUF634)?
Measured slew-rate is higher (130 V/µs vs 200 V/µs typical) and bandwidth wider; builders note crisper cymbals but minor audible difference at normal levels [Elektroda, katakrowa, post #16643568] Both achieve sub-0.001 % THD at 100 mW [TI Datasheet, 2022].
Can I add a second RCA input with a selector switch?
Comments
Hmm, ready module inserted into the finished housing ... "P = 100mW, RL = 32?". Is it such a big output power? Where do you get the signal fed to the amplifier's input? [Read more]
TPA6120 provides 500mW at 32?, can work with loads even from 8?. It's probably a lot for a headphone amplifier. Signal from a sound card from a laptop, from a DAC to PCM2704 or from a CD H / K HD720... [Read more]
Yes, a lot, but at these 500mW distortions are already increasing significantly. The nominal power for headphones is 80mW and this is usually sufficient. Personally, I use such an amplifier and it... [Read more]
So what if the plate is ready, let the boy do what he loves. Why should he overpay 3x, how can he also learn something. Distortions are growing by leaps and bounds, I doubt that at 0.5W. [Read more]
After all, nobody chases him for it, kasss12 do not clutter the subject. [Read more]
For me, the power switch on the back of the case is not a very comfortable solution, we go further: - no fuse protecting the trafo on the 230V network side. - unshielded audio cables, and too close... [Read more]
Strangely, there is no problem with the hum, even with the maximally "unscrewed" potentiometer. I was thinking about using shielded cables before everything went to the housing (I was also worried about... [Read more]
Will you provide any information on the advertisement with the housing? It can be PW. [Read more]
I also folded it. http://obrazki.elektroda.pl/4272692200_1502807831_thumb.jpg http://obrazki.elektroda.pl/6339736200_1502807837_thumb.jpg http://obrazki.elektroda.pl/1624908900_1502807840_thumb.jpg... [Read more]
me too Affirmative. This is me too :wink: http://obrazki.elektroda.pl/5883650100_1503000320_thumb.jpg http://obrazki.elektroda.pl/9039977300_1503000320_thumb.jpg http://obrazki.elektroda.pl/8274550800_1503000326_thumb.jpg... [Read more]
Hello everyone, I'm also proud of my amplifier on the same system My version is double, meaning in one housing there are two amplifiers with independent volume control The amplifier has two stereo... [Read more]
Where did you get the casing ?? [Read more]
Is there documentation available for this amplifier somewhere on the network (RS 2016) or do I need to buy a kit (pig in a poke)? [Read more]
The author built such a nice headphone amplifier, and such a design babol has passed ... The ground wire cannot be screwed to the toroid screw. Now, when you touch the amplifier housing (or the equipment... [Read more]
How does sound quality compare to such a classic construction: http://sound.whsites.net/project113.htm ? [Read more]
I built such an amplifier is oki but I would like to add one pair of cinch and a switch to select the sound source , what can be used and how to connect it . [Read more]
For example, such: https://www.sklep.monster.pl/2-poz-6-pin-mts-202-przelacznik-631,4,36557,2007 pins from the left - left channel, from the right right center to the inputs of the amplifier top and... [Read more]