Article
Cool Power with D-Watt
A high-performance amplifier with lots of output power
Elektor has a long history and a good reputation with high-end yet DIY, audio projects. This time we proudly present a new power amplifier aimed at all audio enthusiasts, built around a digital audio driver IC and operating in class-D. This has the advantage that the amplifier can deliver a lot of output power (like 200 watts into 8 ohms) with very low heat dissipation. Say goodbye to big heatsinks!
Gerber file
CAM/CAD data for the PCB referred to in this article is available as a Gerber file. Elektor GREEN and GOLD members can exclusively download these files for free as part of their membership. Gerber files allow a PCB to be produced on an appropriate device available locally, or through an online PCB manufacturing service.
Elektor recommends the Elektor PCB Service service from its business partner Eurocircuits or AISLER as the best services for its own prototypes and volume production.
The use of our Gerber files is provided under a modified Creative Commons license. Creative Commons offers authors, scientists, educators and other creatives the freedom to handle their copyright in a more free way without losing their ownership.
PCB
Component list
Component List
Resistors
Default: 5%, 0.25W
R1,R8 = 1kOhm
R2,R23,R24,R30,R34,R36,R37,R46,R50,R54 = 10kOhm
R3,R20 = not mounted
R4 = 2kOhm 1%
R5 = 330Ohm
R6,R18 = 3kOhm 1%
R7,R52 = 120kOhm
R9 = 470Ohm
R10,R11,R15,R31 = 10Ohm
R12,R13 = 1.8kOhm, 2W
R14 = 2.2kOhm
R16 = 4.7Ohm
R17,R35 = 6.8kOhm
R19 = 5.6kOhm
R21 = 33kOhm
R22 = 8.2kOhm
R25,R26 = 18Ohm
R27 = 1Ohm, 1 W
R28 = 10Ohm 1W
R29 = 2.2kOhm, 2W
R32,R40 = 4.7kOhm
R33,R43 = 15kOhm
R38,R39,R45,R48,R51 = 22kOhm
R41 = 1MOhm
R42 = 10MOhm
R44 = 2.7kOhm
R47 = 150kOhm
R49 = 820kOhm
R53 = 47kOhm
P1 = 1kOhm trimpot, top screw adjustment
Capacitors
C1,C5,C7,C8,C9 = 1nF 1%, 63V, polystyrene, 7.18mm pitch (LCR Components type EXFS/HR 1000pF ±1%)
C2,C3,C11,C13,C16,C18,C31 = 100nF 10%, 50V, X7R, 0.2’’ pitch
C4 = 10µF 10%, 63V, MKT, 15mm pitch
C6 = 150pF 5%, 500V, silver mica, 5.9mm pitch (Cornell Dubilier type CD15FD151JO3F)
C10,C12,C14,C20,C32 = 10µF 20%, 50V, 5x11 mm, 2mm pitch
C15 = 10nF 10% 100V, X7R, 0.2’’ pitch
C17,C19,C33 = 1µF 20%, 50V, 5x11 mm, 2mm pitch
C21 = 22µF 20%, 50V, 5x11 mm, 2mm pitch
C22,C24 = 100nF 10%, 250V, MKT, 4x10 mm, 7.5mm pitch (TDK type B32520C3104K000)
C23,C25 = 680µF 20%, 100V, 28mOhm @ 2.57A, 18x40 mm, 7.5mm pitch (Rubycon type 100ZL680MEFC18X40)
C26 = 100nF 10%, 200V, X7R, 0.2’’ pitch (Kemet type C330C104K2R5TA)
C27,C28,C30 = 100nF 5%, 400V, polypropylene, 15mm pitch (TDK type B32652A4104J000)
C29 = 470nF 5%, 400V, polypropylene, 15mm pitch (TDK type B32652A4474J000)
C34 = 100µF 20%, 10V, bipolar, 2.5mm or 3.5mm pitch, diam. 8mm max.
C35 = 2.2µF, 50V, 5x11 mm, 2mm pitch
Inductor
L1 = 22µH, Micrometals type T130-2 ring core, max. 20x40mm. Wire: 200cm of 1.5mm/AWG15 enameled copper
Semiconductors
D1,D2,D11,D13,D14,D17 = 1N4148
D3,D8,D9 = 1N4007
D4,D5,D10 = BZX85C18 SB00018/E1, 18V/1.3W zener diode
D15,D16 = BZX55C68-TR, 68V/0.5W zener diode (alternatively, NXP type BZX79-C68)
D6 = MUR120G (200V, 1A)
D7 = BAV21 (250V, 250mA)
D12 = LED, green, 3mm
T1 = IRFI4020H-117P
T2 = TIP122G
T3,T4,T6,T7,T9,T10,T11,T12 = BC547C
T5 = BC557C
T8 = IRFD210PBF
IC1 = AD8031ANZ
IC2 = IRS2092PBF
IC3 = MC7805CTG
IC4 = MC7905ACTG
IC5 = MC7812CTG
Miscellaneous
K1,K2,K3,K4,K5 = Faston spade connector, PCB mount, dim. 6.35x0.81 mm, 0.2’’ pitch
JP1,JP2 = 3-pin pinheader, 0.1’’ pitch, with jumpers
RE1 = relay, PCB mount, SPCO, 16A, 48V/5.52kOhm (TE Connectivity/Schrack type RT314048)
HS1 = heatsink, PCB mount, 2.6K/W, mounting pins spaced 1 inch (Aavid Thermalloy type 530002B02500G)
Heatsink for IC4/IC5/T2: 27x90 mm aluminum sheet, 2mm thick
Heatsink for IC3: 30 x 30 mm aluminum sheet, 1mm or 2mm thick
Isolation materials for T2,IC3,IC4,IC5 (TO-220 thermal pad + TO-220 bush)
6 pcs solder pin, 1.3mm diam.
1 pc DIP-16 IC socket
1 pc DIP-8 IC socket
Kit of parts incl. PCB 150115-1 (mono), excl. supply: Elektor Store # 150115-71
PCB # 150115-1, available separately and optionally
Ancillaries for Hypex SMPS400A400 PSU connection
1 pc JST VHR series 5-way straight case for PCB connector, 3.96mm pitch (RS Components # 820-1188, set of 5 pcs)
1 x JST VHR series 3-way straight case for PCB connector, 3.96mm pitch (RS Components # 820-1175, set of 5 pcs)
5 x JST cable set with crimp connectors at both sides (RS Components # 820-1135, set of 5 pcs)
3 pcs isolated Faston connector, female, 0.25’’ pitch
Resistors
Default: 5%, 0.25W
R1,R8 = 1kOhm
R2,R23,R24,R30,R34,R36,R37,R46,R50,R54 = 10kOhm
R3,R20 = not mounted
R4 = 2kOhm 1%
R5 = 330Ohm
R6,R18 = 3kOhm 1%
R7,R52 = 120kOhm
R9 = 470Ohm
R10,R11,R15,R31 = 10Ohm
R12,R13 = 1.8kOhm, 2W
R14 = 2.2kOhm
R16 = 4.7Ohm
R17,R35 = 6.8kOhm
R19 = 5.6kOhm
R21 = 33kOhm
R22 = 8.2kOhm
R25,R26 = 18Ohm
R27 = 1Ohm, 1 W
R28 = 10Ohm 1W
R29 = 2.2kOhm, 2W
R32,R40 = 4.7kOhm
R33,R43 = 15kOhm
R38,R39,R45,R48,R51 = 22kOhm
R41 = 1MOhm
R42 = 10MOhm
R44 = 2.7kOhm
R47 = 150kOhm
R49 = 820kOhm
R53 = 47kOhm
P1 = 1kOhm trimpot, top screw adjustment
Capacitors
C1,C5,C7,C8,C9 = 1nF 1%, 63V, polystyrene, 7.18mm pitch (LCR Components type EXFS/HR 1000pF ±1%)
C2,C3,C11,C13,C16,C18,C31 = 100nF 10%, 50V, X7R, 0.2’’ pitch
C4 = 10µF 10%, 63V, MKT, 15mm pitch
C6 = 150pF 5%, 500V, silver mica, 5.9mm pitch (Cornell Dubilier type CD15FD151JO3F)
C10,C12,C14,C20,C32 = 10µF 20%, 50V, 5x11 mm, 2mm pitch
C15 = 10nF 10% 100V, X7R, 0.2’’ pitch
C17,C19,C33 = 1µF 20%, 50V, 5x11 mm, 2mm pitch
C21 = 22µF 20%, 50V, 5x11 mm, 2mm pitch
C22,C24 = 100nF 10%, 250V, MKT, 4x10 mm, 7.5mm pitch (TDK type B32520C3104K000)
C23,C25 = 680µF 20%, 100V, 28mOhm @ 2.57A, 18x40 mm, 7.5mm pitch (Rubycon type 100ZL680MEFC18X40)
C26 = 100nF 10%, 200V, X7R, 0.2’’ pitch (Kemet type C330C104K2R5TA)
C27,C28,C30 = 100nF 5%, 400V, polypropylene, 15mm pitch (TDK type B32652A4104J000)
C29 = 470nF 5%, 400V, polypropylene, 15mm pitch (TDK type B32652A4474J000)
C34 = 100µF 20%, 10V, bipolar, 2.5mm or 3.5mm pitch, diam. 8mm max.
C35 = 2.2µF, 50V, 5x11 mm, 2mm pitch
Inductor
L1 = 22µH, Micrometals type T130-2 ring core, max. 20x40mm. Wire: 200cm of 1.5mm/AWG15 enameled copper
Semiconductors
D1,D2,D11,D13,D14,D17 = 1N4148
D3,D8,D9 = 1N4007
D4,D5,D10 = BZX85C18 SB00018/E1, 18V/1.3W zener diode
D15,D16 = BZX55C68-TR, 68V/0.5W zener diode (alternatively, NXP type BZX79-C68)
D6 = MUR120G (200V, 1A)
D7 = BAV21 (250V, 250mA)
D12 = LED, green, 3mm
T1 = IRFI4020H-117P
T2 = TIP122G
T3,T4,T6,T7,T9,T10,T11,T12 = BC547C
T5 = BC557C
T8 = IRFD210PBF
IC1 = AD8031ANZ
IC2 = IRS2092PBF
IC3 = MC7805CTG
IC4 = MC7905ACTG
IC5 = MC7812CTG
Miscellaneous
K1,K2,K3,K4,K5 = Faston spade connector, PCB mount, dim. 6.35x0.81 mm, 0.2’’ pitch
JP1,JP2 = 3-pin pinheader, 0.1’’ pitch, with jumpers
RE1 = relay, PCB mount, SPCO, 16A, 48V/5.52kOhm (TE Connectivity/Schrack type RT314048)
HS1 = heatsink, PCB mount, 2.6K/W, mounting pins spaced 1 inch (Aavid Thermalloy type 530002B02500G)
Heatsink for IC4/IC5/T2: 27x90 mm aluminum sheet, 2mm thick
Heatsink for IC3: 30 x 30 mm aluminum sheet, 1mm or 2mm thick
Isolation materials for T2,IC3,IC4,IC5 (TO-220 thermal pad + TO-220 bush)
6 pcs solder pin, 1.3mm diam.
1 pc DIP-16 IC socket
1 pc DIP-8 IC socket
Kit of parts incl. PCB 150115-1 (mono), excl. supply: Elektor Store # 150115-71
PCB # 150115-1, available separately and optionally
Ancillaries for Hypex SMPS400A400 PSU connection
1 pc JST VHR series 5-way straight case for PCB connector, 3.96mm pitch (RS Components # 820-1188, set of 5 pcs)
1 x JST VHR series 3-way straight case for PCB connector, 3.96mm pitch (RS Components # 820-1175, set of 5 pcs)
5 x JST cable set with crimp connectors at both sides (RS Components # 820-1135, set of 5 pcs)
3 pcs isolated Faston connector, female, 0.25’’ pitch
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