Are we talking about one such amp per headphone or headphone distribution amps?
One 120W stereo amp per headphone. The amps were driven from a volume-controlled headphone output of the console, each user had his own amp and volume control.
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Anyway, 120W sounds like you have to turn the volume all the way down and hardly touch it... When you reduced the gain, did they use the full volume control range?
The controls I pre-set were front panel gain controls on a unit like this:
Speaker outputs wired to the headphone jacks directly. Yikes. It wasn't me, I didn't do it!
The controls were set to the user's volume control could go full up and be dangerously loud, but the amp controls were turned down quite a ways. Sorry, that one's out of my head. I just know to turn it all down and make it right I had to build fixed pads to put in front of the amp, something like 15-20dB.
Maybe the cans were high ohm (2k) ones requiring lots of voltage?
Well, nothing requires THAT much voltage
!! They were some kind of Sony headphones, late 1990s, about $30/set, not high Z at all, probably like 20-30 ohms, would have worked in a late 90s Walman. They would destroy headphones, no point in getting anything good, they wouldn't last any longer. All mechanical failures like broken earpiece yokes, internal wiring breakage (not worth my time to fix) etc., no blown drivers though Amazingly. We had one announcer with a set of Sennheiser HD-414, I got her those bright yellow pads, and she loved them. Didn't run her cans hot at all because open design cans would be an instant feedback problem into an announce mic.
By comparison, at another station I built in the early 1980s (classical), we built our own headphone amps, doubt they even did 1 watt, but they fit in a little metal box just below the desk top. The headphones were Yamaha YH-1 and YH-2 (I'm actually surprised I still remember that!), we had a bunch of them, even for remote recording. They lasted forever, nobody cranked them loud, and they sounded pretty nice. We had a set of early Stax Lambda in the music recording studio. I owned a set of YHD-2 back then, they sounded great, and folded flat in my brief case.