350 Watt Self Oscillating Class D Amplifier

350 Watt Self Oscillating Class D Amplifier

Introduction and why I made this instructable:

On the web, there are multitudes of tutorials displaying folks the way to construct their very own class D amplifiers. They’re environment friendly, easy to know, and all use the identical normal topology. There’s a high-frequency triangle wave being generated by one a part of the circuit, and it’s in contrast with the audio sign to modulate the output switches (virtually at all times MOSFETs) on and off. The vast majority of these “DIY Class D” designs haven’t any suggestions, and those that do solely sound clear within the bass area. They make considerably acceptable subwoofer amplifiers, however have vital distortion within the treble areas. Those with out suggestions, owing to dead-time required for MOSFET switching, have a output waveform that appears type of like a triangle wave, versus a sine wave. Important undesirable harmonics are current, resulting in a noticeable lower in sound high quality that makes music sound type of like its popping out of a trumpet. The considerably trumpety, not-so-punchy sound of my earlier class D amplifier is why I made a decision to analysis and construct an amplifier utilizing this obscure, underutilized topology.

Nevertheless, the traditional “triangle wave comparator” shouldn’t be the one method to assemble a category D amplifier. There’s a higher manner. As an alternative of getting an oscillator modulate the sign, why not make your complete amplifier the oscillator? The output MOSFETs are pushed (by way of appropriate drive circuitry) by the output of a comparator with the optimistic enter receiving the incoming audio and the unfavourable enter receiving a (scaled-down) model of the amplifier’s output voltage. Hysteresis is used within the comparator to manage the frequency of operation and stop unstable, excessive frequency resonant modes. Moreover, a RC snubber community is used throughout the output to suppress ringing on the output filter’s resonant frequency and reduce the part shift to close 90 levels on the amplifier’s working frequency of round 100 Khz. Omission of this straightforward however vital filter will trigger the amplifier to self-destruct, as voltages of a number of hundred volts could also be generated, destroying the filter capacitors immediately.

Precept of operation:

Assume the amplifier is first began and all voltages are at zero. Attributable to it is hysteresis, the comparator will resolve to to tug the output both optimistic or unfavourable. For this instance, we’ll assume that the comparator pulls the output unfavourable. Inside a couple of tens of microseconds, the output voltage of the amplifier has decreased sufficient to flip the comparator and ship the voltage going again up once more, and this cycle repeats round 60 to 100 thousand occasions each second, retaining the specified voltage on the output. As a result of filter inductor’s excessive impedance and the filter capacitor’s low impedance at this frequency, there may be not a lot noise on the output, and as a result of excessive working frequency, it’s far above the audible vary. If the enter voltage will increase, the output voltage will enhance sufficient that the suggestions voltage reaches the output voltage. On this manner amplification is achieved.

Benefits over customary class D:

1. Extraordinarily low output impedance: As a result of the output MOSFETs won’t swap again till the specified output voltage after the filter is reached, the impedance of the output is just about zero. Even with a zero.1 volt distinction between the precise and desired output voltage, the circuit will dump amps into the output till the voltage flips the comparator again (or one thing blows).

2. Potential to cleanly drive reactive masses: As a result of extraordinarily low output impedance, self-oscillating class D can drive multi-way speaker programs with giant impedance dips and peaks with little or no harmonic distortion. Ported subwoofer programs with low impedance on the port’s resonant frequency are a main instance of a speaker feedback-less “triangle wave comparator” amplifier would battle to drive properly.

Three. Extensive frequency response: Because the frequency will increase, the amplifier will try and compensate by various the obligation cycle extra to maintain the suggestions voltage matched with the enter voltage. As a result of filter’s attenuation of excessive frequencies, excessive frequencies will begin to clip at a decrease voltage stage than decrease ones, however as a result of music having vastly extra electrical energy within the bass than the treble (roughly a 1/f distribution, extra should you use bass enhance), this isn’t a problem by any means.

four. Stability: If correctly designed and with a snubber community in place, the almost 90° part margin of the output filter on the working frequency ensures that the amplifier won’t grow to be unstable, even when driving heavy masses underneath heavy clipping. You may blow one thing, seemingly your audio system or subs, earlier than the amp goes unstable.

5. Effectivity and small measurement: As a result of self-regulating nature of the amplifier, including loads of useless time to the MOSFET switching waveforms doesn’t have an effect on the sound high quality. Full-load efficiencies of properly upwards of 90% are potential with a great high quality inductor and MOSFETs (I take advantage of IRFB4115s in my amplifier). Consequently, a comparatively small warmth sink on the FETs is ample and a fan is barely required if working inside an insulated enclosure at excessive energy.

Trainer Notes

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Step 1: Elements, Provides, and Stipulations

  • Stipulations:

Constructing any sort of high-power circuit, particularly one designed to cleanly reproduce audio, requires a data of primary electronics ideas. You’ll need to know the way capacitors, inductors, resistors, MOSFETs, and op-amps work in addition to the way to correctly design a power-handling circuit board. You additionally must know the way to solder through-hole elements and the way to use stripboard (or construct a PCB). This tutorial is geared in the direction of individuals who have constructed reasonably difficult circuits earlier than. In depth analog data shouldn’t be wanted, as a lot of the subcircuits in any class D amplifier take care of simply two voltage ranges – on or off.

Additionally, you will must know the way to use an oscilloscope (simply the fundamental features) and the way to debug circuits that aren’t working as meant. It is rather seemingly, with a circuit of this complexity, that you’ll find yourself having a sub-circuit that doesn’t work the primary time you construct it. Discover and repair the issue earlier than shifting on to the following step, debugging one sub-circuit is way simpler than looking for a fault someplace in your complete board. Oscilloscope utilization is critical to seek out unintended oscillation and confirm that alerts look the best way they need to.

Basic Suggestions:

On any class D amplifier, you should have excessive voltages and currents switching at excessive frequencies, which has the potential to generate a great deal of noise. Additionally, you will have low-power audio circuits which can be delicate to noise and can choose up and amplify it. The enter stage and energy stage must be at reverse ends of the board.

Good grounding, particularly within the energy stage, can also be important. Make it possible for floor wires run immediately from the unfavourable terminal to every gate driver and comparator. It is exhausting to have too many floor wires. If you’re doing this on a printed circuit board, use a floor aircraft for grounding.

Elements you’ll need:

(Message me if I missed any, I am fairly certain this can be a full listing)

(Every part labeled HV must be rated for at the least the boosted voltage to drive the speaker, ideally extra)

(Lots of these could be salvaged from electronics and home equipment thrown in a dumpster, particularly capacitors)

  • 24 volt energy provide able to 375 watts (I used a lithium battery, if utilizing a battery ensure you have a LVC (low voltage cutoff))
  • Enhance energy converter able to offering 350 watts at 65 volts. (Search “Yeeco energy converter 900 watts” on Amazon and you will find the one I used.)
  • “Perf board” or proto-board to construct every thing on. I like to recommend having at the least 15 sq. inches to work with for this venture, 18 if you wish to construct the enter board on the identical board.
  • Heatsink to mount the MOSFETs to
  • 220uf Capacitor
  • 2x 470uf Capacitor, one should be rated for enter voltage (not HV)
  • 2x 470nf Capacitor
  • 1x 1nf Capacitor
  • 12x 100nf Ceramic Capacitor (or you should utilize poly)
  • 2x 100nf Poly capacitor [HV]
  • 1x 1uf Poly capacitor [HV]
  • 1x 470uf LOW ESR Electrolytic capacitor [HV]
  • 2x 1n4003 diode (any diode that may stand up to 2*HV or extra is ok)
  • 1x 10 amp fuse (or quick piece of 30AWG wire throughout a terminal block)
  • 2x 2.5mh inductor (or wind your individual)
  • 4x IRFB4115 Energy MOSFET [HV] [Have to be GENUINE!]
  • Assorted resistors, you may get them off eBay or Amazon for a couple of dollars
  • 4x 2k Trimmer potentiometers
  • 2x KIA4558 Op amp (or comparable audio op amps)
  • 3x LM311 comparators
  • 1x 7808 voltage regulator
  • 1x “Lm2596” buck converter board, you will discover them on eBay or Amazon for a couple of dollars
  • 2x NCP5181 gate driver IC (you may blow some, get extra) [Have to be GENUINE!]
  • Three-pin header to connect with enter board (or extra pins for mechanical rigidity)
  • Wires or terminal blocks for audio system, energy, and many others
  • 18AWG energy wire (for wiring the facility stage)
  • 22 AWG hook-up wire (for wiring every thing else)
  • 200 ohm low energy audio transformer for enter stage
  • Small 12v/200ma (or much less) laptop fan to chill the amplifier (optionally available)

Instruments and provides:

  • Oscilloscope of at the least 2us/div decision with a 1x and 10x probe (you should utilize a 50okay and 5k resistor to make your individual 10x probe)
  • Multimeter that may do voltage, present and resistance
  • Solder and soldering iron (I take advantage of Kester 63/37, GOOD QUALITY lead free additionally works in case you are skilled)
  • Solder sucker, wick, and many others. You WILL make errors on a circuit this massive, particularly when soldering the inductor, it is a ache.
  • Wire cutters and strippers
  • One thing that may generate a sq. wave of some HZ, like a breadboard and a 555 timer

Step 2: Be taught How Self-Oscillating Class D Works (optionally available However Really useful)

Earlier than you start, it is a good suggestion to get to know the way the circuit truly works. It would assist drastically with any issues you might need additional on, and can aid you perceive what every a part of the total schematic does.

The primary picture is a graph produced by LTSpice displaying the amplifier’s response to an instantaneous enter voltage change. As you may see from the graph, the inexperienced line tries to comply with the blue line. As quickly because the enter adjustments, the inexperienced line goes up as quick as it will probably and settles with minimal overshoot. The crimson line is the voltage of the output stage earlier than the filter. After the change, the amplifier rapidly settles and begins oscillating across the set level as soon as once more.

The second picture is the fundamental circuit diagram. The audio enter is in contrast with the suggestions sign, which generates a sign to drive the output stage to convey the output nearer to the enter. Hysteresis within the comparator causes the circuit to oscillate across the desired voltage at a frequency far too excessive for ears or audio system to reply to.

When you’ve got LTSpice, you may obtain and mess around with the .asc schematic file. Attempt altering r2 to vary the frequency and watch the circuit go loopy as you take away the snubber that damps extreme oscillation across the LC filter’s resonance level.

Even when you do not have LTSpice, learning the photographs offers you a good suggestion of how every thing works. Now let’s get to constructing.

Step Three: Construct the Energy Provide

Earlier than you begin soldering something, check out the schematic and instance format. The schematic is a SVG (vector graphic) so when you obtain it you may zoom in as a lot as you need with out dropping decision. Determine the place you’ll place every thing on the board, after which construct the facility provide. Hook up battery voltage and floor and ensure nothing will get scorching. Use a multimeter to regulate the “lm2596” board to output 12 volts and examine that the 7808 regulator is outputting eight volts.

That is it for the facility provide.

Step four: Construct the Output Stage and Gate Driver

Of your complete construct course of, that is the toughest step of all of them. Construct every thing within the “Gate driver circuit” and the “Energy stage” within the schematic, ensuring that the FETs are hooked up to the warmth sink.

Within the schematic, you will note wires that seem to go nowhere and say “vDrv”. These are referred to as labels within the schmatic and all labels with the identical textual content get related collectively. Join all the “vDrv” labeled wires to the output of the 12v regulator board.

After finishing this stage, energy this circuit up with a current-limited provide (you should utilize a resistor in collection with the facility provide) and be certain that nothing will get scorching. Attempt hooking every of the enter alerts to the gate driver to 8v from the facility provide (one after the other) and examine that the right gates are being pushed. Upon getting verified that you understand the gate drive is working.

As a result of gate drive utilizing a bootstrap circuit, you can’t check the output immediately by measuring the output voltage. Put the multimeter on diode examine and examine between every speaker terminal and every energy terminal.

  1. Optimistic to Speaker 1
  2. Optimistic to Speaker 2
  3. Damaging to Speaker 1
  4. Damaging to Speaker 2

Every ought to present partial conductivity just one manner, identical to a diode.

If every thing works, congratulations, you have simply completed the toughest part of the board. You remembered correct grounding, proper?

Step 5: Construct MOSFET Gate Drive Sign Generator

Upon getting completed the gate driver and energy stage, you might be able to construct the portion of the circuit that generates the alerts that inform the gate drivers what FETs to activate at what time.

Construct every thing within the “MOSFET driver sign generator with useless time” within the schematic, ensuring that you do not overlook any of the tiny capacitors. In case you omit them, the circuit will nonetheless check tremendous, however won’t work properly once you attempt to drive a speaker as a result of comparators parasitically oscillating.

Subsequent, check the circuit by feeding a sq. wave of some hertz into the “MOSFET driver sign generator with useless time” out of your sign generator or 555 timer circuit. Join battery voltage to “HV in” by way of a present limiting resistor.

Join an oscilloscope to the speaker outputs. It is best to get battery voltage reversing polarity a couple of occasions a second. Nothing ought to get heat and the output must be a pleasant, sharp sq. wave. A little bit overshoot is ok, so long as it is no more than 1/Three battery voltage.

If the output is producing a clear sq. wave, it signifies that every thing you might have constructed thus far is working. Just one sub-circuit left till completion.

Step 6: Comparator, Differential Amplifier, and the Second of Fact

You are actually able to construct the portion of the circuit that truly does the category D modulation.

Construct every thing within the “Comparator with hysteresis” and “Differential amplifier for suggestions” within the schematic, in addition to the 2 5k resistors that maintain the circuit secure when nothing is related to the enter.

Join energy to the circuit (however not HV in but) and examine that pins 2 and three of U6 ought to each be actually near half of Vreg (four volts).

If each of these values are appropriate, connect a subwoofer throughout the output terminals. hook up the facility and HV in to battery voltage by way of a present limiting resistor (you could possibly use a four ohm or larger subwoofer as a resistor). It is best to hear a small pop and the subwoofer mustn’t transfer come what may greater than a millimeter or so. Verify with an oscilloscope to make sure that the alerts moving into to and popping out of the NCP5181 gate drivers are clear and have round 40% obligation cycle every. If this isn’t the case, modify the 2 variable resistors till they’re. The frequency of the gate drive waves will likely be decrease than the specified 70-110 KHZ as a result of HV in not being related to the voltage booster.

If the gate drives alerts should not oscillating in any respect, attempt switching SPK1 and SPK2 going to the differential amplifier. If it nonetheless does not work, use an oscilloscope to trace down the fault. It is virtually definitely within the comparator or differential amplifier circuit.

As soon as the circuit is working, go away the speaker related and add the voltage booster module to spice up the voltage going to HV in to round 65-70 volts (bear in mind the fuse). Energy up the circuit, and guarantee that nothing will get scorching initially, particularly the MOSFETs and inductor. Proceed monitoring temperatures for about 5 minutes. It’s regular for the inductor to get heat, so long as it isn’t too scorching to the touch constantly. The MOSFETS must be not more than barely heat.

Verify the frequency and obligation cycle of the gate drive waves once more. Regulate for a 40% obligation cycle and make sure the frequency is between 70 and 110 Khz. If it isn’t, modify R10 within the schematic to appropriate the frequency. If the frequency is appropriate, you might be prepared to begin taking part in sound with the amplifier.

Step 7: Audio Enter and Remaining Testing

Now that the amplifier itself is working satisfactorily, it is time to construct the enter stage. On one other board (or the identical one you probably have area), construct the circuit in response to the schematic supplied with this step (it’s a must to obtain it), ensuring it’s shielded with a grounded piece of steel if near any noise producing elements. Connect energy and floor to the circuit from the amplifier, however do not hook up the audio sign but. Verify that the audio sign is at round four volts and adjustments barely once you flip the “DC offset modify” potentiometer. Regulate the potentiometer for four volts and solder the audio enter wire to the remainder of the circuit.

Though the schematic exhibits utilizing a headphone jack because the enter, you could possibly additionally add a bluetooth adapter with its output wired to the place the audio jack is. The bluetooth adapter could be powered by a 7805 regulator. (I had a 7806 and used a diode to drop one other zero.7 volts).

Energy up the amplifier once more, and plug in a cable to the AUX jack on the enter board. There’ll in all probability be some faint static.

If the static is just too loud there are a pair issues you may attempt:

  • Did you defend the enter stage properly? The comparators generate noise too.
  • Add a 100nf capacitor throughout the output of the transformer.
  • Add a 100nf capacitor between audio out and floor and place a 2k resistor in line earlier than the capacitor.
  • Be certain that the aux wire shouldn’t be close to the facility provide or amplifier output cables.

Slowly (over a number of minutes) flip up the amount, making certain that nothing will get too scorching or distorts. Regulate the achieve in order that the amplifier doesn’t clip until the amount is on most.

Relying on the standard of the inductor core and the scale of the warmth sink, it might be a good suggestion so as to add a small fan, powered from the 12v rail, to chill the amplifier. That is an particularly good concept if you can be placing it in a field.

Step eight: Demonstration Video

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