Power Class-D Full-bridge Amplifier - D2K PCB

Before I share PCB Layout about full-bridge class-d power amplifiers with 2000W power I will tell you a little more about class-d power amplifiers.

Class D amplifiers are known as PWM (Pulse Width Modulation) amplifiers or Switching amplifiers which are now increasingly popular in use. Replaces the class AB amplifier that has been used a lot before

Then what is the D class amplifier like? And what are the advantages?

Class AB amplifiers have a relatively large "power dissipation" (loss of power) that requires a large amount of heat sink. The greater the power (Watt) of class AB amplifiers, the greater the cooling needed. Here there is more or less a power loss of about 25 ~ 40% which turns into heat, which must be removed through the cooler.

Class D amplifiers produce almost no heat so they don't need a cooler. The efficiency achieved is close to almost 100%, only requires a little space and a few supporting components, and of course, the price becomes cheaper. Only the INDUCTOR and CAPACITOR components of filters in class D eat a lot of space.

The working principle of Class D Amplifiers

Sound signal (audio) is a signal in the form of Sinus. Class D amplifiers first convert these sound signals into "ON-OFF" pulses (such as switching) with "period length" which can change as shown below (indicated by Vo). Therefore class D is also called PWM (Pulse Width Modulation)

To change the input signal in the form of a sine to a PWM signal, a triangle oscillator is used and a comparator as shown below.

Then the PWM signal is amplified using the Gate drive amplifier and an amplifier Output using the FET (MOSFET).

The output signal in the form of PWM pulses is then converted back into a sine signal using "Low Pass Filter" (which consists of Lf + Cf) before being to the Speaker.

The following is the PCB layout of a Power Amplifier Class full D2K bridge with a double layer layout:

Part List Power Class-D Full-bridge Amplifier - D2K:

Core T157

22 uH = 2

Resistor

10 ohm (1/4 watt)=10

100 Ohm (1/4watt)=5

470 ohm (1/4 watt)= 3

1k Ohm (1/4 watt)=4

1k2 =1

3K3 (1/4watt)=2

4k7 (1/4watt)=16

6K8 (1/4 watt)=3

8k2=1

10k (1/4watt)=14

47k (1/4watt)=2

15k (1/4watt)=4

22k (1/4watt)=1

33k (1/4watt)=1

100k (1/4watt)=7

220k (1/4watt)=1

4r7 (1 watt)=2

10 ohm (2watt)=4

10K (2Watt)=1

10 ohm/5watt=1

1k /5watt=2

5k6 (5Watt)=2

0.1R (5Watt)=4

Capasitor milar/mkm/mkp

105/400v =2

105/250V=2

104/250v=4

562=1

102=4

104=13

471=4

221/2kv=4

151=2

Dioda/zener

Mur 460=7

4148=16

1N5819=4

12v=3

5v=1

Elco

470uf/16v=1

220uf/35v=3

220uf/16v=1

100uf/50v=2

47uf/25v=5

22uf/50v=2

10uf/16v=2

10uf/16v Nonpolar=4

Transistor/TR

IRFP250/P260/ IRFP4227=4

NPN(BD139)=5

PNP(BD140)=4

2N5551=7

2N5401=3

IC

IR2110=2

CD4070 /4030=1

TL071/081=1

4558/NE5532=2

TL431=1

RELAY12V.30A=1

LED

BLUE?RED/GREEN=7

Download

PCB Layout Power Amplifier CLass-D Fullbridge D2K PDF

PCB Layout Class-D D2K Fullbridge Gerber File

See Also Class-D D4K5

Power Amplifier 1000W Rocky TEF

Hello friends, this time I will share project about Power Amplifier with the name of Rocky TEF power amplifier with output power up to 1000 Watt RMS. With high power category, this amplifier is capable of controlling 12Inch speakers A total of 4 even 6 pieces with each speaker power of 300W. The following is a project of making this Rocky TEF power amplifier, starting from circuit scheme, PCB Layout, and also there is video assembly, also testing power amplifier.

Power Amplifier Circuit Diagram:

Component List:
R1= 47K
R2, R5= 1K8/1W
R3= 33K/1W
R4= 15K
R6= 27K
R7= 1K
R8= 47K/1W
R9= 6K8
R10= 10K
R11, R12, R13, R14= 100R/1W
R15, R16 = 22R/1W
R17, R18=220R/5W or 470R/2W x2 Parallel
R19, R20= 2R2/W
R21, R22= 120R/5W or 220R/2W x 2 Parallel
R23, R24= 22R/2W
R25, R26= 10R/5W
C1= 10uF/50V
C2= 120nF
C3, C4= 220uF/80V
C5, C6= 120pF
C7, C8= 470pF
C9= 100nF/275V
D1= Diode Zener 33V
D2,D3,D4= 1N4007
Q1,Q2,Q3,Q4= MPSA92/ 2N5401
Q5,Q6,Q7,Q9= TIP31/ 2SC4793
Q8= TIP32/ 2SA1837
Q10, Q12, Q15= 2SC5200
Q11, Q13, Q14= 2SA1943
L1= 10uH
J1= Input
J2= V+ 45 - 70V DC
J3= V- 45 - 70V DC
J4= Emitter
J6= Base +
J7= Base -
SP= Speaker Output

PCB Layout Design Power Rocky TEF 1000W

PCB Size: 120mm x 80mm

Making PCB Power Amplifier Rocky TEF [VIDEO]

DIY Stereo Yiroshi Power Amplifier 1400W

This my second project for Yiroshi Power Amplifier Circuit, power amplifier circuit is indeed very super quality, many have tested the strength of this Yiroshi power amplifier. Power amplifier yiroshi is suitable for outdoor or indoor. Previously I have made this yiroshi amp circuit in the mono version. I have also tested it in the unboxed state of the box, using only 2SC2922 and 2SA1943 final transistors, this amplifier is capable of high enough power until my speakers are damaged and also my smps is damaged This power amplifier is tough enough, none of my final transistors parallels broken.

here is the circuit scheme of the stereo power amplifier yiroshi, the scheme below is still the same with the yiroshi circuit that superpower driver before, only later will replace the transistor previously used TIP3055 and TIP2955 I replace it with transistor 2SC5200 and 2SA1943. Because the previous transistor has only a maximum voltage of 60Volt with a maximum current of 15Ampere, so it is advisable to use a larger transistor maximum voltage and current. If for 2SC5200 and 2SA1943 transistors this is enough for me, maximum CE CE voltage up to 230V and maximum current up to 15 Ampere.

In the above circuit scheme is a combined stereo of two series of yiroshi power amplifiers, so to list the components to make it easier for you to buy, please just look at the previous post here Yiroshi Power Amplifier Circuit.

To make it easier for this yiroshi amplifier circuit you can use this PCB Layout design:

PCB Final Transistor Parallel for stereo amplifier yiroshi driver.

DIY PCB AND ASSEMBLING COMPONENTS STEREO YIROSHI AMPLIFIER (VIDEO)

I have made this stereo yiroshi power amplifier circuit, but this is still in the test process stage. and it turns out for PCB Layout for the driver you have to reverse the position of all transistors, so the same face with the top component layout. Later you will be able to see the location and position of the transistor, after the power amplifier is finished and ready to be produced.

For the final transistor, on this yiroshi stereo amplifier project, I do not use transistor Toshiba 2sc5200 and 2sa1943 as well as sanken transistor 2sc2922 and 2sa1216.

I am using transistor NJW0302 and NJW0281, the transistor price of NJW0302 and NJW0281 is almost same as Toshiba transistor 2sc5200 and 2sa1943.

Both transistors both have 150Watt power output, and IC 15Ampere but for VCEO and VCBO are different, a 20Volt difference is higher transistor NJW0302 and NJW0281, where the maximum voltage is 250Volt.

The following is a final transistor picture of NJW0302 which is embedded in the PCB:

And this is the final transistor image I've paralleled using the PCB Design layout above.I am using 14 pairs of NJW0302 and NJW0281 transistors and for per channel yiroshi driver I use 7 pairs of transistors.

Already tested power amplifier yiroshi I will supply with 20Ampere 60Volt Switching Mode Power Supply 

ASSEMBLING FINAL TRANSISTOR AND TEST POWER AMPLIFIER YIROSHI STEREO OUTPUT USING 14SET NJW0302 NJW2801.

Download File PCB Layout.PDF
PCB Stereo Yiroshi Amplifier
Transistor Final Top
Transistor Final Bottom

High Power Class-D Amplifier D4K5

This High Power Amplifier circuit is a class D power amplifier, which has a high enough power to generate 1000W of power at 8 Ohm impedance - and also more power up to 2000W at 4 Ohm impedance. This Power Amplifier can generate great power if given enough power supply. For example, you can use 30A transformer with 100V symmetric voltage.  Here is the circuit scheme of High Power Class-D Amplifier D4K5:

View larger schematic image here: Power Amplifier Class-D D4K5

Component List

Resistor

R1, R3, R4, R9, R13, R18, R19, R20= 1K

R2, R16, R39= 100K

R5, R6= 10R

R7, R8=6K8/2W

R10, R21, R26, R27=4K7

R11, R17=6K8

R12=100R

R14, R15=4R7

R22, R23, R24, R25, R31, R33=47R

R28, R29, R30=0,1R/2W

R36, R38=22R/2W

R40=1K5/5W

R41=10R/2W

RV1=10K Trimpot

Capacitor

C1=10uF/16V

C2=10N

C3, C4=1N

C5=470uF/16V

C6=220uF/16V

C7, C9, C11, C12, C13, C15, C16, C18, C19=100N MKP

C8=470uF/16V

C10, C14, C17=100uF/16V

C20=10uF/50V

C21, C22, C23=220N/475V

C24, C25, C26=470uF/180V

C27, C31, C33=100N/275V

C28, C29, C30=470uF/180V

C32=470N/250V

Diode

D1, D2, D5, D10, D11= 1N4148

D3, D4= ZD5V6

D6, D18, D19= MUR460

D7= LED (RED) OCP

D8= ZD5V6

D9= LED (BLUE)

D12,D13,D14,D15,D16,D17= 1N5819

Transistor

Q1= 2N5401

Q4, Q6= BD139

Q5, Q7= BD140

Q8, Q9, Q10, Q11, Q12, Q13= IRFP260

IC

U1= TL071

Q2= CD4049

Q3= IR2110

U2= NE555

U3= LM311

The Power Amplifier is using view components and this power amplifier include OCP, DCP. And using 6x N-Channel Power Mosfet. You can use IRFP260, IRFP4227, IRFP4242 and others. If you want to make this power amplifier, see the following PCB Layout Design

View larger PCB Layout Design: PCB Class-D D4K5
DOWNLOAD PCB .PDF: PCB Layout Design Class D D4K5

How to make Class D Power Amplifier [VIDEO]

Below step by step how to make yourself PCB board for this power amplifier [VIDEO]

DOWNLOAD : PCB POWER AMPLIFIER D4K5.PDF 

GERBER FILE: Gerber File Power Amplifier Class-D D4K5

Video updated Double Layer PCB from JLCPCB

PCB Layout Class-D D2K FB (Full Bridge) 2000W

Class D2k Full bridge Power Amplifier. Amplifier class D with 2000 watts of power at a 4 ohm load. and 3000 watts at a load of 2 ohms. As long as the power supply supports. Power supply voltage is 65-90vdc. It is suitable for drive the 18 "-21" Speaker, with power as explained above.

This PCB Layout is also equipped with over curret protect (protect if out short or load exceeds max amp power)

Schematic Class-D D2K Full Bridge

Download PCB Layout PDF

2Way Passive Crossover Mid - Hi

This time I will share the passive crossover (Xover) circuit used for the 2 Way system. Passive Xover is more complicated than an active crossover. And using active Xover is much easier because:

• It's hard to keep the phase angle. Or almost impossible. Passive Xover there is a phase shift. So in one sound rig, you should only use one type of Xover.
• It's very difficult to make a Xover flat. So high skills are needed
• Passive Crossover (Xove)r has many losses or losses due to series filters and bypasses. More than 30% of the power that goes into the speaker is bypassed
• Because Passive Xover has many losses or losses due to series filters and bypasses, if the component is not good or the design is not patent, the component can overheat
• Playing with active Xover is better because;1. No angle shift 2. There are no bypass losses

Below for the schematic 2Way Passive Crossover Mid - Hi:

PCB Layout Power Amplifier OCL140W

This the PCB Layout Power Amplifier OCL 140W. The power amplifier required symmetrical power supply with 25 - 45V DC 5A Current. See thr PCB Layout power amplifier OCL 140W Below:

PCB Dimension 45mm x 70mm

The Use of Silk Screen Technology in Printed Circuit Board (PCB)

What is silk-screening?

Silkscreen is a layer of ink traces used to identify components, test points, parts of the PCB, warning symbols, logos, and marks etc. This silkscreen is usually applied on the component side; however, using silkscreen on the solder side is also not uncommon. But this may increase the cost. Essentially a detailed PCB silkscreen can help both the manufacturer and the engineer to locate and identify all the components.

The ink is a non-conductive epoxy ink. The ink used for these markings is highly formulated. The standard colors we normally see are black, white and yellow. PCB software also uses standard fonts in silkscreen layers but you can choose other fonts from the system too. For traditional silk-screening you require a polyester screen stretched on aluminum frames, a laser photoplotter, spray developer and curing ovens.

Method of Silk-screening:

There are three basic ways to apply silkscreen.

1: Manual Screen-printing:

Manual screen-printing is done when the line widths are greater than 7 mil (0.007”) and the registration tolerance is 5 mil. For this method, you require a stencil of the text and traces made of nylon. The ink is pushed through the stencil onto the laminate. Next, the board is baked in a curing oven for the ink to cure. The application and set up is easy but the result is least precise.

2: Liquid Photo Imaging (LPI):

This method is used when the line widths are greater than 4 mil. Liquid Photo Imaging is quite similar to the process used for the application of solder mask. In this, a liquid photoimageable epoxy is coated on to the laminate and then exposed with UV light. After this, the board is developed and cured. It is much more accurate than manual screening

3: Direct Legend Printing (DLP):

DLP is the most accurate of all these processes but is more expensive. In this process, an inkjet projector is used with acrylic ink that is applied to the raw PCB directly from the CAD data. The ink is cured with UV light as it is printed. It should be noted though that the acrylic ink does not cure on boards with silver finishes.

Importance of Silk-Screen:

A properly designed silk-screen can prove to be highly useful as it can reduce the chance of error and can reduce the time taken to spot the error. The silkscreen can easily label the passive components of the PCB no matter how packed the board may be.

There are a few things you should keep in mind regarding silk-screening. For example, the silkscreen epoxy should not be printed over pads or land PCBs that will be soldered as it will melt into the solder joint. This is why it should be applied over the solder mask. While designing you should keep the component outlines away from the pins (almost at a distance of 0.25 mm). Also you should check to see if the width of the silkscreen graphics is suitable to the design. Try to keep the line widths no less than 6 mil.

Knowing more about PCB and silk-screening can help you to reduce your PCB costs. For example, applying silk screen on only one side and choosing the standard colors will give you better overall pricing and give you the same benefits.

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5.1 Home theater Power Amplifier with Gainclone LM1875 + LM3886

At this time I will share about the power amplifier which is devoted to the use of a home theater that has a 5.1 / 6 channel amplifier that is, front right. front left, rear right, rear left, center, and subwoofer. For each channel, I use the LM1875 gainclone amplifier and specifically for the subwoofer channel I use the IC gainclone LM3886 which I BTL has to be more powerful to move the subwoofer speaker.

Why am I using a gainclone amplifier? because this gainclone amplifier has a very clear output due to very low noise and very low distortion. But the power output is'nt big, for the LM1875 it has a power output of around 20W and the LM3886 has a power of around 68W.

Here's the 5.1 power amplifier circuit with Gainclone:

Download Schematic.PDF for more detail and part list in BoM file at the end of post

The 5.1 Home theater power amplifier scheme above is equipped with a power supply circuit, preamplifier, subwoofer preamplifier, and also a 15V power supply regulator circuit for the preamplifier. This power amplifier is not equipped with a 5.1 sound processor, so to get a more 3D sound you can add 5.1 sound processor. Or you can take input from a soundcard that already has 5.1 audio output system. And this amplifier required analog audio input.

Power supply specifications:

Minimum power supply: 15VAC 5A

Maximum power supply: 24VAC 10A

PCB Layout 5.1 Home theater Power Amplifier with Gainclone LM1875 + LM3886

Check this building video 5.1 Home theater Power Amplifier with Gainclone LM1875 + LM3886

Download
Schematic Power Amplifier 5.1 with Gainclone LM1875 + LM3886
BoM (Part List) Power Amplifier 5.1 with Gainclone LM1875 + LM3886
Gerber File (PCB Production) Power Amplifier 5.1 with Gainclone LM1875 + LM3886

CLASS-D Power Amplifier D900 IR2110 - SMD

On this occasion I will share a very good and simple D-class power amplifier scheme with 900W RMS power, this scheme I design in Easyeda. This scheme originally is made by Mr.Kartino Surodipo.  This D900 new design have 2 features that is New Feedback design and Input Comparator. here is the power amplifier scheme:

Downlaod Schematic .PDF for more detail: Schematic Class-D Power Amplifier D900 IR2110 SMD

I design the pcb layout using the SMD component, and you can see the component list via .xls file download here: BoM CLASS-D Power Amplifier D900 IR2110 - SMD

Recommended Power Supply that using for this class-d amplifier: 50VDC - 90VDC with current minimum 10A.

PCB LAYOUT DESIGN TOP BOTTOM COPPER

Downlaod Gerber File: CLASS-D Power Amplifier D900 IR2110 - SMD

ASSEMBLING CLASS-D 900W IR2110 AMPLIFIER