PWM amplifier 1 - The PWM modulator design I.

Newly detected TAS5630 chip can solve my problems about the PWM amplifier. This chip have analog inputs, the package contains all required parts (A/D converter, PWM modulator), and the parallel mode is possible if less than 4 Ohm output impedance required. with this package we have one paralleled mono or one stereo poweramp with analog input.

But I have TAS5261 chips, without analog input. For this design required TAS55xx PWM modulators and analog/digital converters. These chips recommended for home DVD  players, the power supply is 3.3 volts only. I don't think that this solution is ideal for instrument amplification.

In this post, I writing about the method and simulation of analog PWM modulator.

First I need a triangle function generator. I found too much... The clock of PWM input TAS chip is 192-384 kHz, what is understandable if digital chips placed before chip. For this frequency, not too easy to find triangle signal generator with very good output.

Can be found one-chip function generators. One of them is LM566 (with this chip I found a schematic) not available here and now, or we can use XR2206 or ICL8038 chips. These chips are very simple solutions for triangle output, maybe I will try some of them. The maximum frequency on the datasheet is 0.5MHz, typical is 1MHz, but the 8038 have 300kHz maximum. I have no experiences with these function generator chips, so I don't know about the output quality. This is the reason, why I seek discreet analog function generator for triangle output. The another reason, is, function generator chips are not available on Multisim.


The first tryouts I have no success:

This function generator promised for perfect output, but the triangle with 20 kHz only is really bad. So I don't need to try this design for 200-300 kHz.

I tried more triangle generators with op-amps, but the output is not good enough. Finally I found a really good analog triangle generator with nice triangle and square outputs. This circuit can be used up to 4MHz what is more than enough.

I have good result on 300kHz:

See the simulation output, this is 235 kHz. Very easy to set the frequency and duty cycle.

I tested this discreet (but easy to set) schematic  on higher frequency. Here ate the test results:

1.3 MHz:

2MHz:

3.5 MHz:

6 MHz:

I think, if the upper schematic is good enough on 2-4 MHz, then this is good for around 300 kHz only.

The triangle output of this circuit wired to the fast comparator. the most of comparators doesn't worked on Multisim for me, but finally I found one what is very good for output simulation:
 

Example about the signals in the circuit:

The purple line is the triangle output of function generator, the green is the part of 1kHz sinus (audio) input, the red is the TTL PWM modulated square with variable duty cycle.

In this image can be seen how duty cycle modulated by the sinus input signal:

Continued the circuit simulation, the next is the comparator. This part AD8611 is good on Multisim, but I think another comparator (for example LM311) is good on real life too. The triangle signal and the audio (sinus) input have to be connected to the comparator's inputs.

The most important question is, the quality of the PWM modulated output. What I get back, if the PWM modulated square signal converted back to the original sinus wave. The quality of this method cannot seen by the quality of the PWM modulated output. See the image:

The green line is the original audio sine wave signal. I have to get back this wave from the PWM outputs. The dark-red is the (good) result if the PWM output converted back to the original sine. What is the blue line, I will tell you soon....

After the comparator chip, I put TTL logic. This logic made soft start while the triangle generator up, and disabled the input of TAS H-bridge. This method made inverted and non-inverted PWM outputs. Finally this is the "deat time" logic. The TAS5261 contains "dead time" logic, and the most if comparators have inverted and non-inverted outputs. This TTL logic required, if the output of PWM amplifier is simple MOSFETs, not H-bridge chips with internal logic what I want to use.

......the blue line (what is really wrong and distorted) is the converted output of TTL chips.

Here are the signals in this design: The sine is 20 kHz now, the blue line is the triangle signal on 235 kHz, the red line is the TTL PWM output, the tall brown line is the output of comparator. The result is much better on the comparator output.

After simulation results I have many problems.

The first question is about the precision of simulation. How about the simulation and the  reality, whats about the differences, depending on the PCB design and the quality of parts.

After these PWM modulated square waves, I have to put TAS H-bridhe chips, and I can use these outputs for audio. Maybe this method have good result, but maybe not. Maybe the TTL outputs (what is really wrong after decoding on the simulation result) good enough for discreet MOSFET drivers. Finally I have to test the DC offset of comparator inputs and outputs, and the linear frequency range of the decoded output. These solutions is on the next post.

New PWM power chips with analog inputs

In the previous article I thinking about the poweramps of my guitar/vocal amplifier. The power supply is ready, I have 1200VA, this is the reason why I want to include more than one guitar amp to this new design. But whats about the top of this amplifier case, where I need poweramps and preamps?

I think for the guitar amp I will use bridged TDA7293 because for 8 or 16 Ohm speakers the bridged amp solution is better. But for keyboard/vocal I wanted to use Class-D TAS chips. These chips have 125W output power for 8 Ohm, but 315W for 4 Ohm. The impedance of additional cabinet for vocal or for guitar can be 4 Ohm (or less) if required. In my previous DIY amplifier I used bridged TDA chips, and I really like it. This is the reason why I want "hybrid" solution. One analog amplifier for guitar with TDA chips, and another one for all others with PWM solution.


This is one example that the 4x200W TDA bridged solution is more than enough for clubs for guitar and vocal (but this is gym):



For the PWM solution I think about TAS5261 chips. This is small power bridge with PWM input, but PWM modulator and A/D converter required. I have no experience with these chips, and these solutions have very small size, I am not sure that I can assemble them.

This chip is 2x210W PWM power-bridge with the smaller package.

This is TAS5261 chip, 1x350W power bridge.

I like these solutions, error and speaker protections included, chips have very good efficiency, no large heatshink required. The efficiency of TDA solution is about 60%, but his PWM chip have more than 90%.

But these TAS chips offered for home theater or home DVD systems, maybe not for instrument amplification. See the datasheet:

• 315W - 4 Ohm
• 220W - 6 Ohm
• 125W - 8 Ohm

This is the reason why I don't want to use this solution for 8 Ohm guitar speakers, but maybe want to use for 4 Ohm vocal or additional cabinets.


The another thing that I don't want to use required additional circuits like A/D converters and PWM modulators. These chips have very small package, and the power is 3.3V only.

The PWM modulator:

The one pin of this chip 0.2mm width, the distance between the middle line of pins are 0.5mm. Very hard to solder and assemble these parts.


But now the TAS PWM power bridges have analog inputs. PWM modulators and A/D converters not required. The package of these new solutions have 44 pin DKD, and the new 64 pin PHD. The 44 pin DKD package is same as like the previous TAS5261 chip. The biggest version of new analog input TAS chips have 600W power output, what is really great on very small size. See the datasheet page 18.

The benefits:

• Very good efficiency (85...93%) no large heatshink (and cooler) required
• Have analog inputs, no PWM modulators and A/D converters needed
• The chip have error protection

But:

• The 600W available on on 2 Ohm cabinet (the output of chips are paralleled)
• 4 Ohm - 300W, what is not bad, but the previous chip have same feature.
• 3 Ohm - 400W (paralleled outputs)
• 6 Ohm - 210W
• 8 Ohm - 160W.

But with these output powers have distortion 10% what is not small enough. If we need better quality, max. 1% distortion, the possible power will much smaller, the chip cannot be paralleled:

• 4 Ohm - 240W. This is same as TDA bridged amplifier but on 8 Ohm impedance.
• 6 Ohm - 160W
• 8 Ohm - 125W

With smaller impedance with paralleled outputs on 1% distortion:

• 3 Ohm - 310W
• 2 Ohm - 480W

I found these solutions if I want to use PWM amplifier. The PWM chip is better than older solutions if I have speaker cabinet with 4 Ohm or less. I am not decided yet what will the poweramp on the top case of my guitar combo:

About the top of my new guitar amplifier design

This project stopped for years, but the wood case of my new guitar amplifier is ready. The rason of long time delay while I did nothing is that I used my old amplifiers. One is my previous DIY guitar amp have been disasembled, and I have a Carlsbro GLX100 amplifier with Eminence ReadCoat speaker, whats are very good solutions. This is the reason why I don't hurry with my new idea, but now I take apart my old DIY amplifier and the power supply have been moved to the new wood-case.

My old rack mounted amplifier was stereo for guitar, because I  using multieffect. I have Boss GT8, where not only the effects have stereo outputs, this is dual guitar effect, where I can use different amplifiers for left and right channels. This is the reason, why I have combo design but with two speakers for stereo solution:

After the wood case, I have metal cases for electronic circuits:

This is the back of the wood case:

....now without the middle slat because I need space to fix the speakers.

 The power supply built to the bottom of wood-case. I know that all other industrial solution have same case with other circuits on the top, but now I have more space on the top for amplifiers and equalizers. I think the larger distance between transformer and circuits have benefits:

The design of wood case was realy good, I made model of paper, and got to the professional carpenter, who manufactured and assembled:

The bottom of this amplifier is done, this is the power supply. From the power supply the required voltages wired to the top of amplifier case:

Here I have +/- 40V for poweramps, +/-18V for preamps, +24V for LED-s relays, and coolers.

But the most important question is what I have on the top

Because the power supply built to the bottom, I have more space on the top. The power of toroid transformer is 1200VA. I want to place guitar preamplifiers and amplifier (stereo for multieffect), and one more stereo poweramp for additional cabinets for vocal or keyboards. I need parametric equalizer, if I have enough space on the top-case, separated for left and right channels. I need audio mixer with mic preamps for vocal or another audio sources with headphone and line outputs.


But the most important question is, what will be the power amplifier on the top case. On this time, I want to build some digital class-D poweramp maybe for vocal only not for guitar. I have PWM power bridges, what is 1x315W, and I have 2x210W TAS chips:

1x350W with TAS5261 is would be enough for guitar, but this power available for 4 Ohm only. The guitar speakers are 8 or 16 Ohms. On 8 Ohm this chip have 125W output power. Now I think, for guitar (where the speaker is 8 Ohm) I will use bridged TDA7293 chips, where I got 200-220W for 8 Ohm speakers. This chip is very popular on guitar amplifier market, Marshall, Carlsbro using this solution. And for example the Crate Powerblock is PWM poweramp.


Because the vocal or additional guitar speakers have less than 8 Ohm impedance, the PWM chip is good solution. The benefit of PWM chip is the very high efficiency. But the disadvantage is the very small size of chip, TAS5261 have digital PWM inputs only, so I need PWM modulator like TAS5028 for example. TAS5028 is more small than TAS5261, so more harder to build the PCB. Finally the PWM modulators have digital inputs, so I need A/D converter for analog input devices.

I'm not sure that I can build complex design with these very small chips. The another detriment is that the PWM modulator and the A/D converter need 3.3V only, what is used for DVD players orfor computer soundcards. I don't think that the vocal or guitar amplifier design is same as like the home theater systems. The power stage of this idea need only non-symmetrical power voltage, +50V. I have +/-40V for TDA bridged solution, what is much better. I can bridged the TDA chips, but I can't bridge TAS power chips, because this is already internally bridged. At he moment I think the bridged TDA circuits are better and easier to build for guitar and vocal.

Failure in the official datasheet of TDA7293

The original datasheet of TDA7293 is not correct. The 10th page for parallel module is wrong on the first version created at 1999. If you seek the datasheet by google, you may find this older version first. You have to use new datasheet created at 2003. Here is an article about this problem (and my own paralleled TDA amplifier by the datasheet 1999 was wrong like in the article):

"Make sure to use the schematic from the datasheet from 2003. Slave mode is activated by pulling IN+, IN- and SGND to -Vs, the negative supply! In older versions of the schematic slave mode is NOT activated properly, which may lead according to reports on the internet to the destruction of the chip."

About these datasheets:

On the first version created at 1999 the inputs of slave chip is grounded:


In the new datasheet from 2003 this is changed to "-" power voltage:


This change is very important for parallel design. Against chip destruction and high value of distortion use the second version of the official datasheet.

See also:

• TDA7293 for more than 300W
• New PWM Fan controller with speaker protection
• Modular TDA7293 bridge/parallel amplifier
• PDF manual for TDA7293 amplifiers
  

TDA7293 for more than 300W (500-600-700W)

My previous post, where I wrote about the TDA7294 and 7293 modular amplifier design, I uploaded a table about the output powers:



By this table, for the maximum 300W amplifier required:

• 1 Main module
  
• 2 Parallel module
  
• 1 Bridge module
  
• 2 Parallel module
  
• Speaker protection with FAN controller
  

This amplifier required 6 pcs TDA7293, but for stereo device 12 pcs needed. The "chip" is really low cost, not too much for 300W amplifier.

But not only 2 parallel chips can be inserted after the main and bridged module. Schematics with 3 parallel modules (after main and bridged modules too) may possible. If the possible output current of one chip is 2.5A, with 4 chips (one main or bridged, and 3-3 paralleled modules after main and bridge circuits) is 4x2.5=10A. With +-40V (80V) the result is 800W like in this schematic. But this is not true. One chip is 75W, 8x75=600W maximum output power.

The official guitar amplifiers (Marshall, Carlsbro, ...) using one TDA729x chips always says 100W output powers what is not true. But for high output power around 550...600W not impossible. For this amplifier required good speaker protection and fan controller and very good power supply with kW-s of transformer and high values of capacitors.

See also:

• Failure in the official datasheet of TDA7293
• New PWM Fan controller with speaker protection
• Modular TDA7293 bridge/parallel amplifier
• PDF manual for TDA7293 amplifiers

PCB sales of this project Module name Size (mm) Area (cm2) PDF SCH PCB image Tested Price (US$) Des. Sim.1 Full2 Sim.1 Full2 Man3 TDA 7293 main module 59x65 38 Yes Yes Yes - - No 7 15 Ask TDA 7293 bridge module 44x50 22 Yes Yes Yes - - No 5 12 Ask TDA 7293 parallel module 41x47 19 Yes Yes Yes - - No 5 12 Ask Dual speaker protection 51x42 21 Yes Yes Yes - - No 5 12 Ask PWM Fan controller V:1 70x57 40 Yes Yes Yes - - No 7 15 Ask PWM Fan controller V:2 56x57 32 Yes Yes Yes - - No 6 14 Ask Stereo bridged TDA7294 amp (2x200W + speaker protection) 77x184 142 Yes Yes Yes Yes - Yes 21 - Ask Power supply for poweramps 135x98 132 Yes Yes Yes Yes - Yes 19 - Ask Soft start for toroid transformers 67x67 45 Yes Yes Yes Yes - Yes 8 - Ask How to order? Please read the rules carefully!

New PWM FAN controlers with speaker protection module

On the previous post I wrote about modular amplifier, can be connected to single, parallelled, and bridged mode (here is the PDF manual). The single amplifier is about 75-100W, bit with parallel and bridged mode the full poweramp maybe 700-800W (with bridged mode, but with 3 paralleled module). The original design contains one module for speaker protection with UPC1237 chip, which is very cheap and good solution. But the FAN controller for thermal protection is missing.

The thermal protection included to all TDA7293 chip, but no fan controller. The benefit of PWM FAN controller is the control sign is depend on the heatsink heat. I re-designed the PCB of speaker protection with PWM Fan controll circuit, but I made two versions. The first working with 4 OpAmps, and controls 3 fans with 10A output current:



The fan controller starts with 12V regulator, and the end of this circuit the 200V 10A MOSFET before fans. Paralleled with fans I have LED to display the "heat" of the system because the LED controlled with same same output like the fans.

Here is the PCB for this new module which compatible with the original speaker protection module:


This have PCB 7cm width, which is too much, so I looking for smaller and simpler fan controller circuit. Lot of solutions available on the NET with 555 and 556 timer IC, but I made something with MIC502 fan controller circuit. This circuit is simple and "vintage" DIL8 package, not the cheapest solution, but small, and not too much other parts required. The benefit of this solution, that the "sleep mode" setting. This is the threshold while the FANs not working (if not required).



with this simplest circuit I can design smaller PCB:


The width of this PCB is 55 mm instead of 70, what is good result. The speaker protection without PWM fan controller is 51 mm. This module now 4 mm wider.

I have one more choice to made PWM controller. The AMC6821 chip is really good solution. The chip made for computer mainboards, so the size is really small which is not really good for home designers, but maybe more smaller solution is good news for industrial designs.

The AMC6821 PWM Temp monitor and FAN controller chip:


The application of this is really easy and simple. The original module, contains speaker protection only is available if the single version of TDA729x modular amplifier required. But if using more modules for paralleled and bridged application, maybe for real instrument amplifications, the good heating system with temperature monitored FAN controller required.

See also:

• Failure in the official datasheet of TDA7293
• TDA7293 for more than 300W
• Modular TDA7293 bridge/parallel amplifier
• PDF manual for TDA7293 amplifiers

PCB sales of this project Module name Size (mm) Area (cm2) PDF SCH PCB image Tested Price (US$) Des. Sim.1 Full2 Sim.1 Full2 Man3 PWM Fan controller V:1 70x57 40 Yes Yes Yes - - No 7 15 Ask PWM Fan controller V:2 56x57 32 Yes Yes Yes - - No 6 14 Ask How to order? Please read the rules carefully!