Tom.G said:
Try a 1N34 Germanium diode in series with R8, along with a 47K resistor on Q5 between B & E. Duplicate at R15, Q12. Watch the diode polarities.
Actually I was playing with the values of R74 and R78 in my own schematic in post #8, it will work out. In the existing circuit, the idle current through Q44 is about 17mA, when it goes up to about 40mA, Q41 will start to turn on and limit the current. Say if I increase R74 to 20 ohm and R78 reduce to 30 ohm, I can keep the open loop gain the same without disturbing the poles and zeros. At 17mA idle current, voltage drop across R74 is 0.34V. I would use a schottky diode instead of 1N34. The voltage across the base emitter of Q41 is very close to zero. But if the current of Q44 increase to 30mA, Q41 will start to turn on and limit the current.
It's too late for this run of pcb. I am using SMD components, I looked at the layout, it's hard to modify it and keep it sturdy. There is no room for through hole components. For now, either I find a better transistor, or literally remove the Q41 ( same on the other side) and call it a day. Most amps don't even have this protection anyway. Only time it happens is when something in the following stage burn and clamp to ground or to the other voltage rail. Put it in this way, if the output stage burn, burning one more transistor is not the end of the world!
There goes to show just because the circuit is used in other production amps does not mean it is correct. There are a few amps that have this circuit like the schematic of Acurus I posted in post #6. That one is even worst, at least when I copy the circuit, I put R74 and R78 divider to lower the voltage across the base emitter of Q41. Those amps must either have worst leakage problem or they run at much lower current and thereby have much lower frequency response than my amp. ( this affect the slew rate of the amp). Acurus is not exactly a cheap amp, I paid over $1000 at the time already.
Thanks