• WARNING: Tube/Valve amplifiers use potentially LETHAL HIGH VOLTAGES.
    Building, troubleshooting and testing of these amplifiers should only be
    performed by someone who is thoroughly familiar with
    the safety precautions around high voltages.

Zener diodes as protection clippers

Someone recently asked how much distortion might be introduced by using a couple of zeners as voltage limiting elements at the output of a preamp. Since this isn't something that can be guessed at from an armchair, everyone went very quiet. I was interested to know the answer, so I did a few measurements using some ordinary 10V and 16V zeners. There's nothing special about the zeners (BZX79Cxx). I just chose them because I had them to hand, and they seemed like suitable values that might be used to protect downstream solid-state equipment.

Here you can see distortion versus level at 1kHz (measurement bandwidth <10Hz-80kHz, 100k load resistance). The rise below 1Vrms is purely noise added by the series resistor. Above this distortion rises, but is lower than most valve distortion up until the clipping point. I was actually surprised at how well the clipping point is defined.
Zener_Clipping1_zps486c8f59.png


Here you can see distortion versus frequency at different signal levels below the clipping point. Offhand I suppose the rise with frequency is due to nonlinear diode capacitance. For signal levels up to 1Vrms the distortion is certainly less than valve distortion.
Above this, distortion at high frequencies could intrude, but since high frequency contect on music typically falls at 40dB/octave above 2kHz, I doubt you would ever hear anything. How often do you send out signals to SS equipment at 5Vrms?
Zener_Clipping2_zpsad21c017.png


Unsurprisingly, for the least distortion, use the highest zener voltage you can get away with, and use the smallest series resistance.
 
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Merlin,

The THD rise with frequency is possibly the most remarkable part of your study. As the hearing is more forgiving w.r.t. distortion in the low frequencies than in the high frequencies, this irregularity will be noticed. Does a equal-loudness contours curve exist for distortion?
 
Merlin, the soft clip aspect of the 4V7 string versus 16V part is consistent with tests I did to clone a Magnatone varistor, where the aim was to identify parts with as soft a knee as possible. The hassle I had was that the varistor needed a 110V capability so I ended up with 32 of 3V9 zeners in series - at least the clipping action here only needs a few zeners in series.
 
This does work, but you do have to pay attention to how those rails are implemented. You will want some energy storage (capacitor) and a load, at least a small one. If you just try to feed a signal backwards into a 3 terminal voltage regulator directly, for example, the output voltage will rise and you won’t clamp where you think you are supposed to. If you have an energy reservoir and some way to dissipate it, the clamps work as expected.