IRAUDAMP7D 25W-500W Scalable Output Power Class D Audio Power Amplifier Reference Design Using the IRS2092 Protected Digital Audio Driver By Jun Honda, Manuel Rodríguez, Wenduo Liu CAUTION: International Rectifier suggests the following guidelines for safe operation and handling of IRAUDAMP7D Demo Board: • Always wear safety glasses whenever operating Demo Board • Avoid personal contact with exposed metal surfaces when operating Demo Board • Turn off Demo Board when placing or removing measurement probes www.irf.com IRAUDAMP7D REV 2.8 Page 1 of 42 Item Table of Contents Page 1 Introduction of scalable design ………………………………………………….. 3 2 Power table values for each power model……………………………………… 4 3 Specifications……………………………………………………………………… 4-5 4 Connection setup…………………………………………………………………. 6 5 Test procedure…………………………………………………………………..… 7 6 Performance and test graphs………………………………………………….… 8-13 7 Clipping characteristics…………………………………………………………… 14 8 Efficiency…………………………………………………………………………… 14-16 9 Thermal considerations……………………………………………...…………… 16 10 PSRR, half bridge, full bridge……………………………………………………. 16 11 Short circuit response…………………………………………………………….. 17-18 12 IRAUDAMP7D Overview……………………………………………………….… 18-19 13 Functions Descriptions…………………………………………………………… 20-22 14 Selectable dead Time…………………………………..………………………… 22 15 Protection Features……………………………………………..………………… 22-25 16 Click and pop noise control………………………………………….…………… 25 17 Bus pumping…………………………………………………….………………… 26 18 Bridged configuration……………………………………….……..……………… 27 19 Input signal and Gain……………………………………….……………………. 28 20 Gain settings………………………………………………………………………. 29 21 Schematics………………………………………………………………………… 30-32 22 Bill of Materials………………………………………………………………..…… 33-36 23 IRAUDAMP7D models differential table………………………………………... 36 24 Hardware…………………………………………………………………………… 37-38 25 PCB specifications………………………………………………………………… 39 26 Assembly Drawings………………………………………………………….…… 40 27 Revision changes descriptions………………………………………………….. 41 www.irf.com IRAUDAMP7D REV 2.8 Page 2 of 42 Introduction The IRAUDAMP7D reference design is a two-channel Class D audio power amplifier that features output power scalability. The IRAUDAMP7D offers selectable half-bridge (stereo) and full-bridge (bridged) modes. This reference design demonstrates how to use the IRS2092 Class D audio driver IC, along with IR’s digital audio dual MOSFETs, such as IRFI4024H-117P, IRFI4019H-117P, IRFI4212H-117P and IRFI4020H-117P, on a single layer PCB. The design shows how to implement peripheral circuits on an optimum PCB layout using a single sided board. The resulting design requires a small heatsink for normal operation (one-eighth of continuous rated power). The reference design provides all the required housekeeping power supplies and protections. Unless otherwise noted, this user’s manual is based on 150V model, IRAUDAMP7D-150,. Other output power versions can be configured by replacing components given in the component selection of Table 5 on page 36 Applications • • • • • • • AV receivers Home theater systems Mini component stereos Powered speakers Sub-woofers Musical Instrument amplifiers Automotive after market amplifiers Features Output Power: Residual Noise: Distortion: Efficiency: Multiple Protection Features: PWM topology: www.irf.com Scalable output power from 25W- 500W (see Table 1) 200 μV, IHF-A weighted, AES-17 filter 0.05 % THD+N @ 60W, 4 Ω 90 % @ 120W, 4 Ω, Class D stage Over-current protection (OCP), high side and low side MOSFET Over-voltage protection (OVP), Under-voltage protection (UVP), high side and low side MOSFET DC-protection (DCP), Over-temperature protection (OTP) Self-oscillating PWM, half-bridge or full-bridge topologies selectable IRAUDAMP7D REV 2.8 Page 3 of 42 Table 1 IRAUDAMP7D Specification Table Series Item IR Power FET1A, MOSFET FET1B 8Ω Half Bridge 4Ω Full Bridge 8Ω Nominal +B, -B Supply Voltage Min/Max +B, -B Supply Voltage Voltage Gv Gain AMP7D-55 Model Name AMP7D-100 AMP7D-150 AMP7D-200 IRFI4024H-117P IRFI4212H-117P IRFI4019H-117P IRFI4020H-117P 25W x 2 50W x 2 100W x 1 60W x 2 120W x 2 240W x 1 125W x 2 250W x 2 500W x 1 250W x 2 Not Supported Not Supported ±25V ±35V ±50V ±70V ±20V ~ ±28V ±28V ~ ±45V ±45V ~ ±60V ±60V ~ ±80V 20 30 36 40 Notes: • All the power ratings are at clipping power (THD+N = 1 %). To estimate power ratings at THD+N=10%, multiply them by 1.33 • See Table 5 on page 36 for the complete listing of components table. Specifications General Test Conditions for IRAUDAMP7D-150 (unless otherwise noted) Power Supply Voltages ± 50V Load Impedance 4Ω Self-Oscillating Frequency 400kHz Voltage Gain 36 Notes / Conditions Electrical Data Typical Notes / Conditions IRS2092, Protected digital audio driver IRFI4024H-117P, IRFI4019H-117P, IRFI4212H-117P, IRFI4020H117P Digital audio MOSFETs PWM Modulator Self-oscillating, second order sigma-delta modulation, analog input Power Supply Range ± 45V to ± 60V Or see table 1 above Output Power CH1-2: (1 % THD+N) 300W 1kHz Output Power CH1-2: (10 % THD+N) 400W 1kHz Rated Load Impedance 8-4Ω Resistive load Standby Supply Current +50 mA/-80 mA No input signal Total Idle Power Consumption 7W No input signal Channel Efficiency 90 % Single-channel driven, 120W IR Devices Used . www.irf.com IRAUDAMP7D REV 2.8 Page 4 of 42 Audio Performance THD+N, 1W THD+N, 10W THD+N, 60W THD+N, 100W Before Demodulator 0.09 % 0.03 % 0.03 % 0.08 % Class D Output 0.1 % 0.04 % 0.05 % 0.10 % Dynamic Range 100 dB 100 dB Residual Noise 200 μV 200 μV Damping Factor 2000 95 dB 85 dB 75 dB 170 90 dB 80 dB 65 dB ±3 dB Channel Separation Frequency Response : 20 Hz20kHz 20 Hz-35kHz Notes / Conditions 1kHz, Single-channel driven A-weighted, AES-17 filter, Single-channel operation 22 Hz – 20kHz, AES17 filter Self-oscillating frequency 400kHz 1kHz, relative to 4 Ω load 100Hz 1kHz 10kHz 1W, 4 Ω – 8 Ω Load Thermal Performance (TA=25 °C) Condition Idling 2 ch x 15W (1/8 rated power) 2 ch x 120W (Rated power) Typical TC =30 °C TPCB=37 °C TC =54 °C TPCB=67 °C TC =80 °C TPCB=106 °C Notes / Conditions No signal input OTP shutdown after 150 s Physical Specifications Dimensions Weight 6”(L) x 4”(W) x 1.25”(H) 150 mm (L) x 100 mm (W) x 35 mm(H) 0.250kgm Test Setup www.irf.com IRAUDAMP7D REV 2.8 Page 5 of 42 +B, 5A DC supply -B, 5A DC supply 4 Ohm 4 Ohm SPK1A G CNN1 SPK1B LED1 A LED1 B LED2 A S1 LED2 B S300 RCA1A RCA1B Audio Signal Fig 1 Typical Test Setup Connector Description CH1 IN CH2 IN SUPPLY CH1 OUT CH2 OUT RCA1A RCA1B CNN1 SPK1A SPK1B Analog input for CH1 Analog input for CH2 Positive and negative supply (+B / -B) Output for CH1 Output for CH2 Switches Descriptions S1 S300 Shutdown PWM Half bridge / Full bridge select Indicator Description LED1A, B LED2A,B www.irf.com PWM (presence of low side gate signal) Protection IRAUDAMP7D REV 2.8 Page 6 of 42 Test Procedures Test Setup: 1. On the unit under test (UUT), set switch S1 to OFF and S300 to Stereo positions. 2. Connect 4 Ω-200 W dummy loads to output connectors, SPKR1A and SPKR1B, as shown on Fig 1. 3. Set up a dual power supply ±50V with 5A current limit 4. Turn OFF the dual power supply before connecting to UUT. 5. Connect the dual power supply to CNN1, as shown in Fig 1. Power up: 6. Turn ON the dual power supply. The ±B supplies must be applied and removed at the same time. 7. The red LEDs (Protections) turn ON immediately and stay on as long as S1 is in OFF position. Blue LEDs stay OFF. 8. Quiescent current for the positive and negative supplies must be less than 10mA, while S1 is in OFF position. Under this condition, IRS2092 is in shutdown mode. 9. Slide S1 to ON position; after one second delay, the two blue LEDs turn ON and the red LEDs turns off. The two blue LEDs indicate that PWM oscillation is present. This transition delay time is controlled by CSD pin of IRS2092, capacitor CP3 10. Under the normal operating condition with no input signal applied, quiescent current for the positive supply must be less than 50 mA; the negative supply current must be less than 80 mA. Switching Frequency Test: 11. With an oscilloscope, monitor switching waveform at test points VS1 of VS2 and L1B of CH2. Self oscillating frequency must be 400kHz ± 25kHz. Note: The self-oscillating switching frequency is pre-calibrated to 400kHz by the value of R11. To change switching frequency, change the resistances of R11A and R11B for CH1 and CH2 respectively. Audio Functionality Tests: 12. Set the signal generator to 1kHz, 20 mVRMS output. 13. Connect audio signal generators to RCA1A and RCA1B. 14. Sweep the audio signal voltage from 15 mVRMS to 1 VRMS. 15. Monitor the output signals at SPK1A/B with an oscilloscope. Waveform must be a non distorted sinusoidal signal. 16. Observe 1 VRMS input generates output voltage of 36 VRMS. The ratio, R8/(R7+R2), determines the voltage gain of IRAUDAMP7D. 17. Set switch S300 to Bridged position. 18. Observe that voltage gain doubles. www.irf.com IRAUDAMP7D REV 2.8 Page 7 of 42 Test Setup using Audio Precision (Ap): 19. Use unbalance-floating signal generator outputs. 20. Use balanced inputs taken across output terminals, SPKR1A and SPKR1B. 21. Connect Ap frame ground to GND in terminal CNN1. 22. Place AES-17 filter for all the testing except frequency response. 23. Use signal voltage sweep range from 15 mVRMS to 1 VRMS. 24. Run Ap test programs for all subsequent tests as shown in Fig 2- Fig 13 below. Test Results 10 5 2 1 0.5 0.2 % 0.1 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 W Blue = CH1, Red = CH2 ±B Supply = ±25V, 4 Ω Resistive Load Fig 2 IRAUDAMP7D-55, THD+N versus Power, Stereo, 4 Ω . www.irf.com IRAUDAMP7D REV 2.8 Page 8 of 42 10 5 2 1 0.5 0.2 % 0.1 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 200 W Blue = CH1, Pink = CH2 ±B Supply = ±35V, 4 Ω Resistive Load Fig 3 IRAUDAMP7D-100, THD+N versus Power, Stereo, 4 Ω . 10 5 2 1 0.5 0.2 % 0.1 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 200 500 W ±B Supply = ±35V, 8 Ω Resistive Load, Bridged Fig 4 IRAUDAMP7D-100, THD+N versus Power, Bridged, 8 Ω www.irf.com IRAUDAMP7D REV 2.8 Page 9 of 42 . 10 5 2 1 0.5 0.2 % 0.1 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 200 500 W Blue = CH1, Pink = CH2 ±B Supply = ±50V, 4 Ω Resistive Load Fig 5 IRAUDAMP7D-150, THD+N versus Power, Stereo, 4 Ω . 10 5 2 1 0.5 0.2 % 0.1 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 200 800 W ±B Supply = ±50V, 8 Ω Resistive Load Fig 6 IRAUDAMP7D-150, THD+N versus Power, Bridged 8 Ω . www.irf.com IRAUDAMP7D REV 2.8 Page 10 of 42 10 5 2 1 0.5 0.2 0.1 % 0.05 0.02 0.01 0.005 0.002 0.001 100m 200m 500m 1 2 5 10 20 50 100 200 500 W Blue = CH1, Red = CH2 ±B Supply = ±70V, 8 Ω Resistive Load Fig 7 IRAUDAMP7D-200, THD+N versus Power, Stereo 8 Ω . +4 +3 +2 +1 -0 -1 d B r A -2 -3 -4 -5 -6 -7 -8 -9 -10 20 50 100 200 500 1k 2k 5k 10k 20k 50k 100k 200k Hz Red Blue CH1 - 4 Ω, 2 V Output referenced CH1 - 8 Ω, 2 V Output referenced Fig 8 Frequency Response (All Models) . www.irf.com IRAUDAMP7D REV 2.8 Page 11 of 42 100 50 10 1 0.5 % 0.1 0.05 0.02 0.01 0.001 0.0001 20 50 100 200 500 1k 2k 5k 10k 20k Hz Blue Pink CH1, 10W Output CH1, 50W Output Fig 9 IRAUDAMP7D-150, THD+N versus Frequency, 4Ω . +0 -10 -20 -30 -40 d B V -50 -60 -70 -80 -90 -100 -110 20 50 100 200 500 1k 2k 5k 10k 20k Hz 1V Output Fig 10 IRAUDAMP7D-150, 1 kHz – 1 V Output Spectrum, Stereo . www.irf.com IRAUDAMP7D REV 2.8 Page 12 of 42 +0 -10 -20 -30 -40 d B V -50 -60 -70 -80 -90 -100 -110 20 50 100 200 500 1k 2k 5k 10k 20k Hz 1V Output Fig 11 IRAUDAMP7D-150, 1 kHz - 1V Output Spectrum, Bridged . +20 +0 -20 -40 d B V -60 -80 -100 -120 -140 10 20 50 100 200 500 1k 2k 5k 10k 20k Hz Red Blue CH1 - ACD, No signal, Self Oscillator @ 400kHz CH2 - ACD, No signal, Self Oscillator @ 400kHz Fig 12 IRAUDAMP7D-150 Noise Floor . www.irf.com IRAUDAMP7D REV 2.8 Page 13 of 42 . Red Trace: Total Distortion + Noise Voltage Gold Trace: Output Voltage 60 W / 4 Ω, 1 kHz, THD+N = 0.02 % 174 W / 4 Ω, 1 kHz, THD+N = 10 % Measured Output and Distortion Waveforms Fig 13 Clipping Characteristics . Efficiency Figs 14-19 show efficiency characteristics of the IRAUDAMP7D. The high efficiency is achieved by following major factors: 1) Low conduction loss due to the dual FETs offering low RDS(ON) 2) Low switching loss due to the dual FETs offering low input capacitance for fast rise and fall times 3) Secure dead-time provided by the IRS2092, avoiding cross-conduction 100% 90% Efficiency (%) 80% 70% 60% 25V-4ohms 50% 40% 30% 20% 10% 0% 0 10 20 30 40 Output power (W) 50 60 ±B Supply = ±25 V Fig 14 Efficiency versus Output Power, IRAUDAMP7D-55, 4 Ω, Stereo www.irf.com IRAUDAMP7D REV 2.8 Page 14 of 42 . 100% 90% Efficiency (%) 80% 70% 60% 35V-4ohms 50% 40% 30% 20% 10% 0% 0 20 40 60 80 100 120 140 160 Output power (W) ±B Supply = ±35 V Fig 15 Efficiency versus Output Power, IRAUDAMP7D-100, 4 Ω, Stereo . 100% 90% Efficiency (%) 80% 70% 60% 50% 35V-8ohms-Full bridge 40% 30% 20% 10% 0% 0 50 100 150 200 Output power (W) 250 300 ±B Supply = ±35V Fig 16 Efficiency versus Output Power, IRAUDAMP7D-100, 8 Ω, Bridged . 90% Efficiency (%) 80% 70% 60% 50V-4ohms 50% 40% 30% 20% 10% 0% 0 50 100 150 200 250 300 Output power (W) ±B Supply = ±50V Fig 17 Efficiency versus Output Power, IRAUDAMP7D-150, 4 Ω, Stereo www.irf.com IRAUDAMP7D REV 2.8 Page 15 of 42 . 100% 90% Efficiency (%) 80% 70% 60% 50% 50V-8ohms-Full bridge 40% 30% 20% 10% 0% 0 50 100 150 200 250 300 350 Output power (W) 400 450 500 550 ±B Supply = ±50V Fig 18 Efficiency versus Output Power, IRAUDAMP7D-150, 8 Ω, Bridged . 100% 90% Efficiency (%) 80% 70% 60% 70V-8ohms 50% 40% 30% 20% 10% 0% 0 50 100 150 200 Output power (W) 250 300 ±B supply = ±70V Fig 19 Efficiency versus Output Power, IRAUDAMP7D-200, 8 Ω, Stereo Thermal Considerations With this high efficiency, the IRAUDAMP7D design can handle one-eighth of the continuous rated power, which is generally considered to be a normal operating condition for safety standards, without additional heatsink or forced air-cooling. Power Supply Rejection Ratio (PSRR) The IRAUDAMP7D obtains good power supply rejection ratio of -65 dB at 1kHz shown in Fig 20. With this high PSRR, IRAUDAMP7D accepts any power supply topology as far as the supply voltages fit in the min and max range. www.irf.com IRAUDAMP7D REV 2.8 Page 16 of 42 Cyan: VAA & VSS are fed by +/-B bus Green: VAA & VSS are fed by external +/-5 V regulated power supplies. Fig 20 IRAUDAMP7D Power Supply Rejection Ratio Short Circuit Protection Response Figs 21-23 show over current protection reaction time of the IRAUDAMP7D in a short circuit event. As soon as the IRS2092 detects over current condition, it shuts down PWM. After one second, the IRS2092 tries to resume the PWM. If the short circuit persists, the IRS2092 repeats try and fail sequences until the short circuit is removed. Short Circuit in Positive and Negative Load Current CSD pin VS pin CSD pin Positive OCP VS pin Load current Load current Negative OCP Fig 21 Positive and Negative OCP Waveforms . www.irf.com IRAUDAMP7D REV 2.8 Page 17 of 42 OCP Waveforms Showing CSD Trip and Hiccup CSD pin CSD pin VS pin VS pin Load current Load current . Fig 22 OCP Response with Continuous Short Circuit . Actual Reaction Time OCP Waveforms Showing actual reaction time . Fig. 23 High and Low Side OCP current waveform reaction time IRAUDAMP7D Overview The IRAUDAMP7D features a self-oscillating type PWM modulator for the lowest component count, highest performance and robust design. This topology represents an analog version of a second-order sigma-delta modulation having a Class D switching stage inside the loop. The www.irf.com IRAUDAMP7D REV 2.8 Page 18 of 42 benefit of the sigma-delta modulation, in comparison to the carrier-signal based modulation, is that all the error in the audible frequency range is shifted to the inaudible upper-frequency range by nature of its operation. Also, sigma-delta modulation allows a designer to apply a sufficient amount of error correction. The IRAUDAMP7D self-oscillating topology consists of following essential functional blocks. • Front-end integrator • PWM comparator • Level shifters • Gate drivers and MOSFETs • Output LPF Integrator Referring to Fig 24 below, the input operational amplifier of the IRS2092 forms a front-end secondorder integrator with R7, C4, C6, and R11. The integrator that receives a rectangular feedback signal from the PWM output via R8 and audio input signal via R7 generates quadratic carrier signal in COMP pin. The analog input signal shifts the average value of the quadratic waveform such that the duty cycle varies according to the instantaneous voltage of the analog input signal. PWM Comparator The carrier signal in COMP pin is converted to PWM signal by an internal comparator that has threshold at middle point between VAA and VSS. The comparator has no hysteresis in its input threshold. Level Shifters The internal input level-shifter transfers the PWM signal down to the low-side gate driver section. The gate driver section has another level-shifter that level shifts up the high-side gate signal to the high-side gate driver section. Gate Drivers and MOSFETs The received PWM signal is sent to the dead-time generation block where a programmable amount of dead time is added into the PWM signal between the two gate output signals of LO and HO to prevent potential cross conduction across the output power MOSFETs. The high-side levelshifter shifts up the high-side gate drive signal out of the dead-time block. The IRS2092 drives two MOSFETs, high- and low-sides, in the power stage providing the amplified PWM waveform. Output LPF www.irf.com IRAUDAMP7D REV 2.8 Page 19 of 42 The amplified PWM output is reconstructed back to analog signal by the output LC LPF. Demodulation LC low-pass filter (LPF) formed by L1 and C12, filters out the Class D switching carrier signal leaving the audio output at the speaker load. A single stage output filter can be used with switching frequencies of 400 kHz and greater; a design with a lower switching frequency may require an additional stage of LPF. . R8 R117 +B CP4 0V IN- . GND Modulator and Shift level + Integrator HO VS VCC LP Filter LO COM -VSS -B CP6 IRS2092 R24 D3 R7 INPUT 0V VB COMP R25 FET1 IRFI4024H-117P IRFI4212H-117P IRFI4019H-117P IRFI4020H-117P 0V L1 C12 . +VCC CP5 R11 0V C6 C7 C4 +B +VAA CP2 -B R118 . Fig 24 Simplified Block Diagram of IRAUDAMP7D Class D Amplifier Functional Descriptions IRS2092 Gate Driver IC The IRAUDAMP7D uses IRS2092, a high-voltage (up to 200 V), high-speed power MOSFET driver with internal dead-time and protection functions specifically designed for Class D audio amplifier applications. These functions include OCP and UVP. The IRS2092 integrates bidirectional over current protection for both high-side and low-side MOSFETs. The dead-time can be selected for optimized performance according to the size of the MOSFET, minimizing deadtime while preventing shoot-through. As a result, there is no gate-timing adjustment required externally. Selectable dead-time through the DT pin voltage is an easy and reliable function which requires only two external resistors, R26 and R27 as shown on Fig 25 below. The IRS2092 offers the following functions. • PWM modulator www.irf.com IRAUDAMP7D REV 2.8 Page 20 of 42 • • • • Dead-time insertion Over current protection Under voltage protection Level shifters Refer to IRS2092 datasheet and AN-1138 for more details. R117 3.3k 1w R17 R22 R18 10K U1 16 22uF 2 3 GND VB 1nF R3 1nF C7 100R CP3 HO 20R 14 VS1 4 COMP VS 4 L1 22uH R24 13 5 CSD VCC 6 R13 D3 12 VSS LO 11 20R VREF COM 8 OCSET DT IRS2092S DIP 9 R30 R31 10, 1W 2.2k + CH1 - 2 R25 10 10k R12 8.7k C12 0.47uF, 400V 4.7R SPKR1 1 2 R20 -B 7 CH_OUT 3 10uF CP2 22uF R118 3.3k 1w FET1 15 C6 C4 SD D1 1nF IN- CP8 470uF,100V C13 0.1uF, 400V -B 1 3.3k 0.1uF,100V 22uF R2 10uF C11 10k CP6 270R CP1 RCA1 R11 CSH 5 R8 100k VAA D4 9.6k R19 CP4 1 +B 75k R26 R21 R23 10R 4.7K 10k R27 10k CP5 22uF LED1 Blue C14 0.1uF CP7 470uF,100V VCC -B Fig 25 System-level View of IRAUDAMP7D Self-Oscillating Frequency Self-oscillating frequency is determined by the total delay time along the control loop of the system; the propagation delay of the IRS2092, the MOSFETs switching speed, the time-constant of front-end integrator (R7, R8, R31, C4, C6, C7). Variations in +B and –B supply voltages also affect the self-oscillating frequency. The self-oscillating frequency changes with the duty ratio. The frequency is highest at idling. It drops as duty cycle varies away from 50%. Adjustments of Self-Oscillating Frequency Use R7 to set different self-oscillating frequencies. The PWM switching frequency in this type of self-oscillating switching scheme greatly impacts the audio performance, both in absolute www.irf.com IRAUDAMP7D REV 2.8 Page 21 of 42 frequency and frequency relative to the other channels. In the absolute terms, at higher frequencies distortion due to switching-time becomes significant, while at lower frequencies, the bandwidth of the amplifier suffers. In relative terms, interference between channels is most significant if the relative frequency difference is within the audible range. Normally, when adjusting the self-oscillating frequency of the different channels, it is suggested to either match the frequencies accurately, or have them separated by at least 25kHz. Under the normal operating condition with no audio input signal, the switching-frequency is set around 400kHz in the IRAUDAMP7D. Selectable Dead-time The dead-time of the IRS2092 is set based on the voltage applied to the DT pin. Fig 26 lists the suggested component value for each programmable dead-time between 25 and 105 ns. All the IRAUDAMP7D models use DT2 (45ns) dead-time. Dead-time Mode DT1 DT2 DT3 DT4 R1 <10k 5.6kΩ 8.2kΩ Open R2 Open 4.7kΩ 3.3kΩ <10k DT/SD Voltage Vcc 0.46 x Vcc 0.29 x Vcc COM Recommended Resistor Values for Dead Time Selection Dead- time IRS2092(S) 25nS >0.5mA Vcc 45nS R1 75nS DT 105nS R2 0.23xVcc 0.36xVcc 0.57xVcc Vcc VDT COM Fig 26 Dead-time Settings vs. VDT Voltage Protection System Overview The IRS2092 integrates over current protection (OCP) inside the IC. The rest of the protections, such as over-voltage protection (OVP), under-voltage protection (UVP), speaker DC offset www.irf.com IRAUDAMP7D REV 2.8 Page 22 of 42 protection (DCP) and over temperature protection (OTP), are realized externally to the IRS2092 (Fig 27). In the event that any of these external fault conditions are detected, the external shutdown circuit will disable the output by pulling down CSD pins, turning on red LEDs, and turning off blue LEDs (Fig 28). If the fault condition persists, the protection circuit stays in shutdown until the fault is removed. Once the fault is cleared, the blue LEDs turn on and red LEDs turn off. TH100 is thermally connected with Heat sink DCP R108 CH1_OUT 100k R109 Q102 2N3906 CH2_OUT 100k R110 R103 715R R101 4.7k 2N3906 R104 4.7k Q101 100k CP100 Q103 2N3906 330uF, 10V -VSS1 S1 2 +B -VSS1 OVP 1 3 4 +B Z100 *68V R111 10k Z101 *39V JW3 R112 47K UVP OTP TH100 2.2k 5 SD 6 SW DPDT R105 10k R106 10k R107 10k Q104 2N3904 Q100 2N3904 R102 10k C100 0.1uF R113 10k -VSS1 -VSS1 Fig 27 DCP, OTP, UVP and OVP Protection Circuits . . R17 D4 CSH +B + VB 1.2V BAV19 R19 R18 HO FET1 +VAA CSD VS VCC OCSET -VSS . CSD CP3 . RED PROT FET2 LP Filter OCREF 5.1V OCREF R13 LO BLUE R12 LED1 -B OCSET COM Fig 28 Simplified Functional Diagram of OCP and Associated LED Indicators www.irf.com IRAUDAMP7D REV 2.8 Page 23 of 42 Over-Current Protection (OCP) Low-Side Current Sensing The low-side current sensing feature protects the low side MOSFET from an overload condition in negative load current by measuring drain-to-source voltage across RDS(ON) during its on state. OCP shuts down the switching operation if the drain-to-source voltage exceeds a preset trip level. The voltage setting on the OCSET pin programs the threshold for low-side over-current sensing. When the VS voltage during low-side conduction gets higher than the OCSET voltage, the IRS2092 turns off outputs and pulls CSD down to -VSS. High-Side Current Sensing The high-side current sensing protects the high side MOSFET from an overload condition in positive load current by measuring drain-to-source voltage across RDS(ON) during its on state. OCP shuts down the switching operation if the drain-to-source voltage exceeds a preset trip level. High-side over-current sensing monitors drain-to-source voltage of the high-side MOSFET while it is in the on state through the CSH and VS pins. The CSH pin detects the drain voltage with reference to the VS pin, which is the source of the high-side MOSFET. In contrast to the low-side current sensing, the threshold of CSH pin to trigger OC protection is internally fixed at 1.2V. An external resistive divider R19, R18 and R17 are used to program a threshold as shown in Fig 26. An external reverse blocking diode D4 is required to block high voltage feeding into the CSH pin during low-side conduction. By subtracting a forward voltage drop of 0.6V at D4, the minimum threshold which can be set for the high-side is 0.6V across the drain-to-source. Table 2 Actual OCP table setting thresholds Function OCSET Device R12A R12B Tested OCP current 25oC CSH R18A R18B Tested OCP current 25oC Peak load current at rated power Amp7-55 Amp7-100 Amp7-150 Amp7-200 1.3K 3.9K 7.5K 5.2K 23A 30A 23A 4.7K 9.6K 8.2K 23A 29A 23A 8.7A 12.2A 8.9A 0.0 6.0A Over-Voltage Protection (OVP) OVP is provided externally to the IRS2092. OVP shuts down the amplifier if the bus voltage between GND and +B exceeds 75V. The threshold is determined by a Zener diode Z100. OVP www.irf.com IRAUDAMP7D REV 2.8 Page 24 of 42 protects the board from harmful excessive supply voltages, such as due to bus pumping at very low frequency continuous output in stereo mode. Under-Voltage Protection (UVP) UVP is provided externally to the IRS2092. UVP prevents unwanted audible noise output from unstable PWM operation during power up and down. UVP shuts down the amplifier if the bus voltage between GND and +B falls below a voltage set by Zener diode Z101. Speaker DC-Voltage Protection (DCP) DCP protects speakers against DC output current feeding to its voice coil. DC offset detection detects abnormal DC offset and shuts down PWM. If this abnormal condition is caused by a MOSFET failure because one of the high-side or low-side MOSFETs short circuited and remained in the on state, the power supply needs to be cut off in order to protect the speakers. Output DC offset greater than ±4V triggers DCP. Offset Null (DC Offset) Adjustment The IRAUDAMP7D requires no output-offset adjustment. DC offsets are tested to be less than ±20 mV. Over-Temperature Protection (OTP) A NTC resistor, TH100 in Fig 25, is placed in close proximity to two dual MOSFETs on a heatsink to monitor heatsink temperature. If the heatsink temperature rises above 100 °C, the OTP shuts down both channels by pulling down CSD pins of the IRS2092. OTP recovers once the temperature has cooled down. ON-OFF Switch OFF position of S1 forces the IRAUDAMP7D to stay in shutdown mode by pulling down the CSD pin. During the shutdown mode the output MOSFETs are kept off. Click and POP Noise Reduction Thanks to the click and pop elimination function built into the IRS2092, IRAUDAMP7D does not use any additional components for this function. www.irf.com IRAUDAMP7D REV 2.8 Page 25 of 42 Power Supply Requirements For convenience, the IRAUDAMP7D has all the necessary housekeeping power supplies onboard and only requires a pair of symmetric power supplies. Power supply voltage depends on the model and is shown in the power selection in Table 1. House Keeping Power Supply The internally-generated housekeeping power supplies include ±5.6V for analog signal processing, and +12V supply (VCC) referred to negative supply rail -B for MOSFET gate drive. The VAA and VSS supplying floating input section are fed from +B and -B power stage bus supplies via R117 and R118, respectively. Gate driver section of IRS2092 uses VCC to drive gates of MOSFETs. The VCC is referenced to –B (negative power supply). D3 and CP6 form a bootstrap floating supply for the HO gate driver. Bus Pumping When the IRAUDAMP7D is running in the stereo mode, bus pumping effect takes place with low frequency high output. Since the energy flowing in the Class D switching stage is bi-directional, there is a period where the Class D amplifier feeds energy back to the power supply. The majority of the energy flowing back to the supply is from the energy stored in the inductor in the output LPF. Usually, the power supply has no way to absorb the energy coming back from the load. Consequently the bus voltage is pumped up, creating bus voltage fluctuations. Following conditions make bus pumping worse: 1. Lower output frequencies (bus-pumping duration is longer per half cycle) 2. Higher power output voltage and/or lower load impedance (more energy transfers between supplies) 3. Smaller bus capacitance (the same energy will cause a larger voltage increase) The OVP protects IRAUDAMP7D from failure in case of excessive bus pumping. One of the easiest counter measures of bus pumping is to drive both of the channels in a stereo configuration out-of-phase so that one channel consumes the energy flow from the other and does not return it to the power supply. Bus voltage detection monitors only +B supply, assuming the bus pumping on the supplies is symmetric in +B and -B supplies. There is no bus pumping effect in full bridge mode. www.irf.com IRAUDAMP7D REV 2.8 Page 26 of 42 Cyan: Positive Rail voltage (+B), Green: Speaker Output, Pink: Negative Rail voltage (-B) Fig 29 Bus Pumping in Half Bridge Mode Bridged Configuration By selecting S300 to Bridged position, the IRAUDAMP7D realizes full bridge mode, also known as bridge-tied-load, or BTL configuration. Full bridge operation is achieved by feeding out-of-phase audio input signals to the two input channels as shown in the Fig 30 below. In bridged mode, IRAUDAMP7D receives audio input signal from channel A only. The on-board inverter feed out-of-phase signal to Channel B. The speaker output must be connected between (+) of Channel A and (+) of Channel B in bridged mode. In bridged mode, nominal load impedance is 8 Ω. (See power table in Table 1) . C300 From Ch A RCA1 JW8 R300 22k Bridged R302 +VAA 0.1uF 1 100 7 R301 22k 8 CP1B+ S300 1 U300 TL072CP 2 From Ch B RCA2 3 2 4 6 5 3 6 SW DPDT 4 5 C301 Steereo R303 -VSS 0.1uF 100 Fig 30 Bridged Configuration (BTL) www.irf.com IRAUDAMP7D REV 2.8 Page 27 of 42 Load Impedance Each channel is optimized for a 4 Ω speaker load in half bridge and 8 Ω load in full bridge. Output Filter Selection Since the output filter is not included in the control loop of the IRAUDAMP7D, the control loop has no ability to compensate performance deterioration caused by the output filter. Therefore, it is necessary to understand what characteristics are preferable when designing the output filter. 1) The DC resistance of the inductor should be minimized to 20 mΩ or less. 2) The linearity of the output inductor and capacitor should be high with output current and voltage. Fig 31 demonstrates THD performance difference with various inductors. 100 T T 10 1 % 0.1 0.01 0.001 0.0001 100m 200m 500m 1 2 5 10 20 50 100 200 W Fig 31 THD+N vs. Output Power with Different kind of Output Inductors www.irf.com IRAUDAMP7D REV 2.8 Page 28 of 42 Input Signal and Gain Setting A proper input signal is an analog signal ranging from 20Hz to 20kHz with up to 3 VRMS amplitude with a source impedance of no more than 600 Ω. Input signal with frequencies from 30kHz to 60kHz may cause LC resonance in the output LPF, causing a large reactive current flowing through the switching stage, especially with greater than 8 Ω load impedances, and the LC resonance can activate OCP. The IRAUDAMP7D has an RC network called Zobel network (R30 and C13) to damp the resonance and prevent peaking frequency response with light loading impedance. (Fig 32) The Zobel network is not thermally rated to handle continuous supersonic frequencies above 20kHz. These supersonic input frequencies can be filtered out by adding R2 and C2 as shown on main schematic Fig 33 and Fig 34. This RC filter works also as an input RF filter to prevent potential radio frequency interferences. . 0V LP Filter 0V L1 C12 . R30 . C13 . Fig 32 Output Low Pass Filter and Zobel Network Gain Setting The ratio of resistors R8/R2 in Fig 23 sets voltage gain. The IRAUDAMP7D has no on board volume control. To change the voltage gain, change the input resistor term R2. Changing R8 affects PWM control loop design and may result poor audio performance. www.irf.com IRAUDAMP7D REV 2.8 Page 29 of 42 Feedback *47k R18A U1A 1 CP4A 22uF VAA CSH GND VB 16 10k CP6A R11A 2 15 *300R 22uF 3 BS250P Prot A 3 FET2A 1 R14A C7A 1nF 1nF R3A C4A 5 100R -VSS1 Z104A 5.6V CP3A 10uF CP2A 22uF R118A *3.3k 1w HO COMP VS 13 15V 12 D3A R20A C6A SD D1A IN- R13A 6 CSD VCC VSS LO VREF COM OCSET DT R26A R23A 10R 10k 10k R27A 10k CP5A 22uF VCC1 3 C11A 0.1uF,100V VS1 C12A 0.47uF, 400V C8A Heat sink Note: Components values marked on red or * are according to power table IRAUDAMP7-55, +B,-B are +/-25V with FET1 as IRFI4024H-117P IRAUDAMP7-100, +B,-B are +/-35Vwith FET1 as IRFI4212H-117P IRAUDAMP7-150, +B,-B are +/-50Vwith FET1 as IRFI4019H-117P IRAUDAMP7-200, +B,-B are +/-70Vwith FET1 as IRFI4020H-117P 22uF 0.1uF,100V CP7A -B *470uF, 100V Blue LED 2 R114A CP101A Fig 33 Amplifier Schematic, Channel 1 . www.irf.com IRAUDAMP7D REV 2.8 Page 30 of 42 R30A 10, 1W D6A -B *15k 15V -B SPKR1A D5A C13A 0.1uF, 400V C14A LED1A CHA, OUT CH1_OUT 1 2 *1k 1w TIP31C R115A Q105A Z102A CP8A *470uF, 100V +B L1A 22uH 1 IRS2092PbF 9 2 R25A JW2A 10 R21A 8 R24A 20R -B 7 HS1 4 3 4.7R 11 10k R12A *7.5k 20R 14 Z1A 4 Red LED 2 4.7k 1nF FET1A *IRFI4019H-117P 5 Z103A 5.6V D4A *9.1k R19A +VAA1 -B CONN1 +B C10A 0.1uF, 400V 10k R29A R1A 100k R22A CHA open *3.01k 1% C2A 1nF 1 2 3 +B JW1A R28A 330 +B 10R R7A C9A open 22uF R2A 150pF,250V RCA1 CP1A *3.3k 1w R17A 1 RCA1A +B R117A R8A *120k 1% IRAUDAMP7 Rev 2.2 R31A 2.2k + CHA - Feedback R117B *47k R18B GND VB IN- HO 15 22uF 3 Prot B Red LED 1nF C7B 1nF 1nF BS250P R3B C4B 2 4.7k 3 FET2B 1 D1B Z1B 4 5 100R -VSS2 Z104B 5.6V CP3B 10uF CP2B 22uF R118B *3.3k 1w COMP VS 15V 13 C6B SD R13B 6 CSD VCC VSS LO 4.7R 11 VREF COM 20R OCSET 9 R23B R26B 10k 10R 10k R27B 10k CP5B 22uF VCC2 3 L1B 22uH VS2 C12B 0.47uF, 400V C8B LED1B Heat sink *470uF, 100V Blue LED 2 R114B *1k 1w TIP31C R115B Q105B Z102B *15k 15V -B Note: Components values marked on red or * are according to power table IRAUDAMP7-55, +B,-B are +/-25V with FET1 as IRFI4024H-117P IRAUDAMP7-100, +B,-B are +/-35Vwith FET1 as IRFI4212H-117P IRAUDAMP7-150, +B,-B are +/-50Vwith FET1 as IRFI4019H-117P IRAUDAMP7-200, +B,-B are +/-70Vwith FET1 as IRFI4020H-117P 22uF CP101B Fig 34 Amplifier Schematic, Channel 2 . www.irf.com IRAUDAMP7D REV 2.8 Page 31 of 42 D5B IRAUDAMP7 Rev 2.2 SPKR1B 1 2 R30B 10, 1W D6B -B CP7B -B CHB, OUT CH2_OUT C13B 0.1uF, 400V 1 IRS2092PbF DT 2 R25B JW2B 10 R21A 8 C10B 0.1uF, 400V 3 -B 7 R24B CP8B *470uF, 100V +B 4 D3B R20B 12 10k R12B *7.5k 20R 14 0.1uF,100V 0.1uF,100V C14B 2 *300R R14B FET1B *IRFI4019H-117P 10k CP6B R11B C11B R29B CSH 16 5 CP4B 22uF VAA D4B *9.1k R19B +VAA2 Z103B 5.6V +B C9B 10k U1B 1 +B JW1B open R1B 100k CHB +B R28B *3.01k 1% C2B 1nF R22B open 330 22uF *3.3k 1w R17B R7B R2B 150pF,250V RCA1 CP1B 1 RCA1B 10R R8B *120k 1% R31B 2.2k + CHB - SD +B -B JW20 JW5 JW6 JW7 VCC2 TH100 is thermally connected with Heat sink VCC2 DCP R108 SD CH1_OUT +B TH100 2.2k OTP -B 100k R109 Q102 2N3906 VCC2 JW21 CH2_OUT 100k R110 R103 715R R104 4.7k Q101 R101 4.7k 2N3906 VCC1 100k CP100 Q103 2N3906 330uF, 10V -VSS1 S1 2 +B +B 1 3 -VSS1 Z100 *68V 4 R111 10k Z101 *39V JW3 R112 47K R105 10k R106 10k R107 10k Q104 2N3904 Q100 2N3904 R102 10k UVP 6 SW DPDT SD OVP 5 C100 0.1uF R113 10k -VSS1 -VSS1 Note: Components values marked on red or * are according to power table Fig 35 Protection Schematic . Bridged S300 CP1B+ 3 4 SW DPDT 5 C300 FromCHA, RCA input RCA1 R300 JW8 22k 0.1uF 1 JW9 Steereo 6 +VAA2 100 7 R301 22k R302 2 1 8 U300 TL071CP 2 6 3 4 5 C301 R303 -VSS2 0.1uF 100 Fig 36 Bridge Preamp Schematic www.irf.com IRAUDAMP7D REV 2.8 Page 32 of 42 FromCH2, RCA input RCA2 IRAUDAMP7D-150 Fabrication Materials Table 3 IRAUDAMP7D-150 Electrical Bill of Materials Quantit y Value Description Designator Digikey P/N Vendor 8 1nF, 50V CAP 1nF 50V POLYESTER 5% C2A, C2B, C4A, C4B, C6A, C6B, C7A, C7B P4551-ND Panasonic ECG 2 150 pF, 250V C8A, C8B P11413TB-ND Panasonic ECG 2 Open C9A, C9B P11413TB-ND Panasonic ECG 4 0.1uF, 400V C10A, C10B, C13A, C13B 495-1311-ND EPCOS Inc 4 0.1uF 100V C11A, C11B, C14A, C14B 495-1147-ND EPCOS Inc 2 0.47uF, 400V C12A, C12B 495-1315-ND EPCOS Inc 3 0.1uF 100V C100, C300, C301 495-1147-ND EPCOS Inc 1 ED365/3 CONN1 ED2355-ND On Shore Technology CP1A, CP1B, CP2A, CP2B, CP4A, CP4B, CP5A, CP5B, CP6A, CP6B, CP101A, CP101B 493-1058-ND Nichicon CP3A, CP3B P966-ND Panasonic ECG CP7A, CP7B, CP8A, CP8B 493-1985-ND Nichicon CP100 P5125-ND Panasonic ECG D1A, D1B 1N4148T-73CT-ND Rohm 12 22uF 2 10uF, 16V 4 470uF/100V CERAMIC CAP 150PF 250 VAC CERAMIC 10 % CERAMIC CAP 150PF 250 VAC CERAMIC 10% CAP .10UF 400V METAL POLYPROPYLANE CAP .10UF 100V METAL POLYESTER CAP .47UF 400V METAL POLYPROPYLANE CAP .10UF 100V METAL POLYESTER TERMINAL BLOCK 7.50MM 3POS PCB CAP 22UF 25V ELECT VR RADIAL CAP ELECT 10UF 16V KS RADIAL CAP 470UF 100V ELECT PW RADIAL CAP 330UF 10V ALUM LYTIC RADIAL DIODE SWITCH 100V 150MA DO-35 1 330uF, 10V 2 1N4148T-73 4 MUR120RLG DIODE ULTRA FAST 1A 200V AXIAL DO-41 D3A, D3B, D4A, D4B MUR120RLGOSCT -ND 4 1N4003 DIODE GEN PURPOSE 200V 1A DO41 D5A, D5B, D6A, D6B 1N4003FSCT-ND 2 *IRFI4019H117P FET1A, FET1B IR's Part No. 2 BS250P FET2A, FET2B BS250P-ND Zetex Inc Aluminum heat spreader HS1 Drawing IRHS_Amp1 Custom made AXIAL JUMPER RES 0.0 OHM AXIAL JUMPER RES 0.0 OHM Wire Jumper #20 AWG insulated Wire Jumper #20 AWG insulated Wire Jumper #20 AWG insulated Wire Jumper #20 AWG insulated Wire Jumper #20 AWG insulated Class D Inductor, 22UH JW1A, JW1B, JW2A, JW2B P0.0BACT-ND JW3 P0.0BACT-ND JW5 Custom Custom JW6, JW7 Custom Custom JW8 Custom Custom JW9 Custom Custom JW20, JW21 Custom Custom L1A, L1B 'Sagami 7G17A- 'Inductors, 1 Heat sink 4 Wire 0.400" 1 Wire 0.300" 1 Wire 1.640" 2 Wire 1.800" 1 Wire 1.240" 1 Wire 1.200" 2 Wire 0.800" 2 22uH, 13A www.irf.com IRFI4019H-117P, Dual MOSFET TO-220-5 MOSFET P-CH 45V 230MA TO-92 IRAUDAMP7D REV 2.8 ON Semiconducto r Fairchild Semiconducto r International Rectifier Panasonic ECG Panasonic ECG Page 33 of 42 13A LED 3MM DUAL FLANGE BLUE CLEAR LED 3MM HI-EFF RED TRANSPARENT 220M-R or IN09063 Inc. or ICE Components, Inc. LED1A, LED1B 160-1600-ND LITE-ON INC Prot A, Prot B 160-1140-ND LITE-ON INC 2 Blue LED 2 Red LED 2 2N3904-AP TRANSISTOR NPN GP 40V TO92 Q100, Q104 2N3904-APCT-ND 3 2N3906-AP TRANSISTOR PNP GP 40V TO92 Q101, Q102, Q103 2N3906-APCT-ND 2 TIP31C TRANS NPN EPITAX 100V 3A TO-220 Q105A, Q105B TIP31CFS-ND 4 100k R1A, R1B, R108, R110 P100KBACT-ND Panasonic ECG 2 330 R2A, R2B P330BACT-ND Panasonic ECG 2 100 Ohms R3A, R3B P100BACT-ND Panasonic ECG 2 3k 1% R7A, R7B P3.00KCACT-ND Panasonic ECG 2 120k 1% R8A, R8B P120KCACT-ND Panasonic ECG 2 300 Ohms R11A, R11B P300BACT-ND P300BACTND 2 7.5k R12A, R12B P7.5KBACT-ND Yageo R13A, R13B, R19A, R19B, R22A, R22B, R23A, R23B, R26A, R26B, R27A, R27B, R102, R105, R106, R107, R111, R113 P10KBACT-ND Panasonic ECG R14A, R14B, R101, R104 P4.7KBACT-ND Panasonic ECG R17A, R17B P47KBACT-ND Panasonic ECG R18A, R18B P9.1KBACT-ND Panasonic ECG R20A, R20B P4.7BACT-ND Panasonic ECG R21A, R28A, R28B PPC10.0XCT-ND Vishay/BC Components R24A, R24B, R25A, R25B PPC20.0XCT-ND Vishay/BC Components R29A, R29B PPC10.0XCT-ND Vishay/BC Components R30A, R30B 10W-1-ND Yageo 18 10k 4 4.7k 2 47k 2 9.1k 2 4.7 Ohms 3 10 Ohms 4 20R 2 open 2 2.2k 1W www.irf.com RES 100K OHM CARBON FILM 1/4W 5% AXIAL RES 330 OHM CARBON FILM 1/4W 5% AXIAL RES 100 OHM CARBON FILM 1/4W 5% AXIAL RES METAL FILM 3.00K OHM 1/4W 1% AXIAL RES METAL FILM 120K OHM 1/4W 1% AXIAL RES 300 OHM CARBON FILM 1/4W 5% AXIAL RES 7.5K OHM CARBON FILM 1/4W 5% AXIAL RES 10k OHM CARBON FILM 1/4W 5% AXIAL RES 4.7K OHM CARBON FILM 1/4W 5% AXIAL RES 47K OHM CARBON FILM 1/4W 5% AXIAL RES 9.1K OHM CARBON FILM 1/4W 5% AXIAL RES 4.7 OHM CARBON FILM 1/4W 5% AXIAL RES METAL FILM 10.0 OHM 1/2W 1% AXIAL RES METAL FILM 20.0 OHM 1/2W 1% AXIAL RES METAL FILM 10.0 OHM 1/2W 1% AXIAL RES 10 OHM 1W 5% METAL OXIDE IRAUDAMP7D REV 2.8 Micro Commercial Co. Micro Commercial Co. Fairchild Semiconducto r Page 34 of 42 2 2.2k 1W 1 715 1% 1 100k 1 47k 2 1k 1W 2 15k 4 3.3k 1W 2 22k 2 100 Ohms 1 1 RCJ-013 (White CH2) RCJ-012 (Red CH1) AXIAL RES 2.2K OHM 1W 5% METAL OXIDE AXIAL RES 715 OHM 1% 50PPM 1/4W RES 100K OHM CARBON FILM 1/4W 5% AXIAL RES 47K OHM CARBON FILM 1/4W 5% AXIAL RES 1.0K OHM 1W 5% METAL OXIDE AXIAL RES 15k OHM CARBON FILM 1/4W 5% AXIAL RES 3.3K OHM 1W 5% METAL OXIDE AXIAL RES 22K OHM CARBON FILM 1/4W 5% AXIAL RES 100 OHM CARBON FILM 1/4W 5% CONN RCA JACK METAL R/A WHT PCB CONN RCA JACK METAL R/A WHT PCB SWITCH SLIDE DPDT 12V .1A L=4 TERMINAL BLOCK 7.50MM 2POS PCB THERMISTOR NTC 2.2K OHM LEADED Class D Controller, IRS2092PbF DIP-16, Class D Controller, IRS2092PbFDIP-16 IC LN JFET-IN GP OP AMP 8-DIP R31A, R31B 2.2KW-1-ND Yageo R103 CMF715QFCT-ND Vishay/Dale R109 P100KBACT-ND Panasonic ECG R112 P47KBACT-ND Panasonic ECG R114A, R114B 1.0KW-1-ND Yageo R115A, R115B P15KBACT-ND Panasonic ECG R117A, R117B, R118A, R118B 3.3KW-1-ND Yageo R300, R301 P22KBACT-ND Panasonic ECG R302, R303 P100BACT-ND Panasonic ECG RCA1A CP-1402-ND (White) CUI Inc RCA1B CP-1401-ND (Red) CUI Inc S1, S300 EG1908-ND E-Switch SPKR1A, SPKR1B ED2354-ND TH100 BC2304-ND U1A, U1B IR's P/N U300 296-7186-5-ND 2 EG2209A 2 ED365/2 1 2.2k at 25C 2 IRS2092PbF 1 TL071CP 4 15V DIODE Zener 500MW 15V DO35 Z1A, Z1B, Z102A, Z102B 1N5245B-TPCTND 1 68V DIODE Zener 500MW 68V DO35 Z100 1N5266B-TPCTND 1 39V DIODE Zener 500MW 39V DO35 Z101 1N5259BDICT-ND 4 5.6V DIODE Zener 500MW 5.6V DO35 Z103A, Z103B, Z104A, Z104B 1N5232B-TPCTND On Shore Technology Vishay/BC Components International Rectifier Texas Instruments Micro Commercial Co. Micro Commercial Co. Micro Commercial Co. Micro Commercial Co. Note all ½ W and 1W resistors are flame proof part numbers Table 4 IRAUDAMP7D Mechanical Bill of Materials Quantit y Value Description Designator Digikey P/N Vendor 1 16-DIP Socket 16 PIN SOLDER TAIL DIP SOCKET IC Socket 1 A402AE -ND Aries Electronics 5 Washer #4 SS WASHER LOCK INTERNAL #4 SS Lock washer 1, Lock washer 2, Lock washer 3, Lock washer 4, Lock washer 5 H729ND Building Fasteners 1 PCB Print Circuit Board IRAUDAMP7D_Rev PCB 1 www.irf.com IRAUDAMP7D REV 2.8 Custom Page 35 of 42 2.2 .PCB 12 Screw 440X5/16 SCREW MACHINE PHILLIPS 4-40X5/16 Screw 1, Screw 2, Screw 3, Screw 4, Screw 5, Screw 6, Screw 7, Screw 8, Screw 9, Screw 10, Screw 11, Screw 12 H343ND 4 Stand off 0.5" STANDOFF HEX 440THR .500"L ALUM Stand Off 1, Stand Off 2, Stand Off 3, Stand Off 4 1893KND 1 Stand off 0.5" STANDOFF HEX M/F 440 .500" ALUM, Chassis GND Stand Off 5 8401KND AAVID 4880G Thermalloy TO-220 mounting kit with screw TO-220 mounting kit 1 Newuar k 82K609 6 1 Building Fasteners Keystone Electronics Keystone Electronics Thermalloy Table 5 IRAUDAMP7D Models Differential Table Model Name Item IR Power MOSFETS Half Bridge Output Full Bridge Output Power Supply Audio Gain Feedback +VAA -VSS VCC OCSET CSH Oscillation Frequency VB AMP7D-55 AMP7D-100 AMP7D-150 125 W x 2 AMP7D-200 IRFI4020H117P 250 W x 2 FET1 IRFI4024H-117P IRFI4212H-117P IRFI4019H-117P 8Ω 25 W x 2 60 W x 2 4Ω 50 W x 2 8Ω Stereo 120 W x 2 250 W x 2 N/A Stereo 100 W x 1 240 W x 1 500 W x 1 N/A Bridged +B, -B ±B Voltage Range Gain ±25 V ±35 V ±50 V ±70 V ±3 V 20 ±5 V 30 ±8 V 36 ±10 V 40 R8A,R8B R117A* R117B* R118A* R118B* R114A* R114B* R115A R115B R12A R12B R18A R18B R11A R11B R17A R17B 68k 100k 120k 130 k 1 k, 1 W 2.2 k, 1 W 3.3 k, 1 W 5.1 k, 1 W 1 k, 1 W 2.2 k, 1 W 3.3 k, 1 W 5.1 k, 1 W 100,1 W 220, 1 W 1 k, 1 W 2.2 k 1 W 4.7 k 10 k 15 k 20 k 1.3 k (20 A) 0.0 (20A) 3.9 k (23 A) 4.7 k (23A) 7.5 k (30 A) 9.1 k (29A) 5.2 k (23 A) 8.2 k (23 A) (Trip level) (Trip level) 270 270 300 360 400kHz 20 k 33 k 47 k 75 24 V 1N5252BDICTND 12 V 1N5242B-TPCTND 47 V 1N5261BDICTND 30 V 1N5256BDICTND 68 V 1N5266B-TPCTND 39 V 1N5259BDICTND 91 V 1N5270BTPCT-ND 51 V 1N5262BTPCT-ND IN4002 IN4002 IN4002 N/A OVP Z100 UVP Z101 Clamping Diode D5A D5B D6A D6B Notes Zener Digikey P/N Zener Digikey P/N * Marked components are axial, ±5 %, ¼ w, and flame proof type. www.irf.com IRAUDAMP7D REV 2.8 Page 36 of 42 IRAUDAMP7D Hardware Put silicone grease between the heat spreader and TO-220-5 Heat sink Heatsink threaded Screw Lock washer Flat Washer #4 Dual FET TO-220-5 Heatsink threaded PCB Lock washer Screws H343-ND Screw Lock washers H729-ND Fig 37 Dual MOSFET Mounting TO-220 Pad insulator Heat Sink Shoulder Washer Heatsink threaded Screw Lock washer Flat Washer #4 TO-220 Heatsink threaded PCB Lock washer Lock washers H729-ND Screw Screws H343-ND Fig 38 +VCC Regulator TO-220 Mounting www.irf.com IRAUDAMP7D REV 2.8 Page 37 of 42 Fig 39 Heat Spreader . Screw H343-ND Screw H343-ND Lock washer Screw H343-ND Lock washer Lock washer incert thermistor into this hole and put silicone grease Screw H343-ND Stand Off 3 1893K-ND Lock washer Stand Off 2 1893K-ND Lock washer Lock washer Screw Stand Off 4 1893K-ND Lock washers H729-ND GND Standoff Screw Stand Off 5 8401K-ND Stand Off 1 1893K-ND Screws H343-ND Fig 40 Hardware Assemblies www.irf.com IRAUDAMP7D REV 2.8 Page 38 of 42 IRAUDAMP7D PCB Specifications PCB: 1. 2. 3. 4. 5. 6. Single Layers SMT PCB with through holes 1/16 thickness 2/0 OZ Cu FR4 material 10 mil lines and spaces Solder Mask two sides to be Green enamel EMP110 DBG (CARAPACE) or Enthone Endplate DSR-3241or equivalent. 7. Top Silk Screen to be white epoxy non conductive per IPC–RB 276 Standard. 8. All exposed copper must finished with TIN-LEAD Sn 60 or 63 for 100u inches thick. 9. Tolerance of PCB size shall be 0.010 –0.000 inches 10. Tolerance of all Holes is -.000 + 0.003” 11. PCB acceptance criteria as defined for class II PCB’S standards. Gerber Files Apertures Description: All Gerber files stored in the attached CD-ROM were generated from Protel Altium Designer Altium Designer 6. Each file name extension means the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. .gbl .gto .gbs .gko .gm1 .gd1 .gg1 .txt .apr Bottom copper, bottom side Top silk screen Bottom Solder Mask Keep Out, Mechanical Drill Drawing Drill locations CNC data Apertures data Additional files for assembly that may not be related with Gerber files: 10. .pcb 11. .bom 12. .cpl 13. .sch 14. .csv 15. .net 16. .bak 17. .lib www.irf.com PCB file Bill of materials Components locations Schematic Pick and Place Components Net List Back up files PCB libraries IRAUDAMP7D REV 2.8 Page 39 of 42 Fig 41 IRAUDAMP7D PCB Top Overlay (Top View) Fig 42 IRAUDAMP7D PCB Bottom Layer (Top View) www.irf.com IRAUDAMP7D REV 2.8 Page 40 of 42 Revision changes descriptions Revision Rev 2.7 Rev 2.8 Rev 2.9 www.irf.com Changes description Released Deleted Author and e-mail on schematics BOM updated :Ice Components as a second vender of the inductor IRAUDAMP7D REV 2.8 Date August, 26 2008 October 22, 2009 October 28, 2009 Page 41 of 42 WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 Data and specifications subject to change without notice. 08/26/2008 www.irf.com IRAUDAMP7D REV 2.8 Page 42 of 42