File Number 4777 600W/1000W Full Bandwidth Class Amplifier

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File Number 4777 600W/1000W Full Bandwidth Class Amplifier

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HCA600ACREF
File Number
4777
600W/1000W Full Bandwidth Class Amplifier
HCA600ACREF reference design delivers 600W power into load 1000W into load. design part Intersil's Coolaudioprogram that supports customers achieve minimum time-to-market audio products. part this program, this design offered after execution licensing agreement. that time, Intersil provides licensee documentation package containing: circuit description, schematics, test manufacturing information, bill materials with vendors vendor part numbers, Intersil's engineering support contacts, evaluation unit. more information, visit page http://www.intersil.com. technical assistance, call Central Applications 1-800-442-7747, email centapp@intersil.com.
Features
600W Power into 1000W Power into <0.02% 1kHz 450W into >110dB Relative Full Power Output Noise <200µV Constant Group Delay 80kHz Small Signal Bandwidth Power Bandwidth .28kHz Slew Rate 18V/µs Efficiency >90% 500W into Meets EN55013 Requirements Based Intersil HCA8001, Audio Specific Differential Single Ended Input Over-Current, Over-Voltage Thermal Protection Soft Clipping Bridgeable 4000W
Licensing Information
Contacts licensing details, reference design evaluation, general questions follows: Continental East, Email cfelic@ca.mbn.or.jp Intersil Cool Audio, Email coolaud@intersil.com
Applications
Sound Reinforcement Professional Commercial Sound Systems Powered Speakers Hi-Fi Stereo
Reference Design Block Diagram
SOURCE SOURCE PRE-AMPLIFIER HCA600ACREF POWER DISTRIBUTION HCA600ACREF HCA600ACREF HCA600ACREF HCA600ACREF (3.08") 27.9MM (1.1") HCA600ACREF 220MM (8.7")
HCA8001 POWER SUPPLY
HEATSINK SHIELD FETS DIODES HCA8001
NOTE: HCA600ACREF used many different commercial professional applications including movie theater surround sound systems depicted this reference design block diagram.
CAUTION: These devices sensitive electrostatic discharge; follow proper Handling Procedures. 1-888-INTERSIL 407-727-9207 Copyright Intersil Corporation 1999 Coolaudiois trademark Intersil Corporation.
HCA600ACREF
Absolute Maximum Ratings
Voltage, VBUS ±130V (Note +/-12V +/-15V 12VFLT. -Bus +15V Audio Inputs Differential Peak Peak Voltage NOTE:
Operating Conditions
Voltage, VBUS ±110V +/-12V +/-12V 12VFLT -Bus +12V Ambient Temperature Range 50oC
WARNING: voltages inside shield, edge connector, speaker cables potentially deadly. Extreme caution required.
CAUTION: Stresses above those listed "Absolute Maximum Ratings" cause permanent damage device. This stress only rating operation device these other conditions above those indicated operational sections this specification implied.
Electrical Specifications
RLOAD VBUS ±110V, Supply Source Resistance 2.5, Storage Capacitor 12,000µF, 12VFLT 12V, +/-12V +/-12V 25oC
PARAMETER SUPPLY SPECIFICATION Minimum Voltage ±VBUS Current ±VBUS Current ±VBUS,Q Average Current Float Current Minimum +/-12V ±12V Current Rising Under Voltage Lock Voltage Falling Under Voltage Lock Voltage ENABLE Threshold Voltage ENABLE Threshold Voltage ENABLE Internal Source Current OUTPUT POWER EFFICIENCY Maximum Output Power (Note Maximum Output Power (Note Maximum Output Power (Note Maximum Output Power (Note Efficiency
SYMBOL
TEST CONDITIONS
UNITS
VBUS IVBUSQ 12VFLTBIAS VBIASmin I+/-15V Rising Falling VENABLE1 VENABLE2 ENABLE
600W into 1kHz Sine Wave, Full Output Power load) 1kHz Sine Wave, Full Output Power load) Quiescent Current, Signal Current supplied power output gate driver circuitry 1kHz Sine Wave, Full Output Power load) input signal voltage that activates amplifier voltage that shuts down amplifier Amplifier starts this voltage, input amplifier muted Input amplifiers active entire amplifier active Internal "Pull Current
±110 11.5
PMAX8 THD8 PMAX4 THD4 PMAXEFF PMAXEFF PMAXEFF PMAXEFF
1kHz, RLOAD 10%, 1kHz, RLOAD 1kHz, RLOAD 10%, 1kHz, RLOAD POUT 200W, POUT 500W, POUT 400W, POUT 1000W,
1000 1200
AMPLIFIER PERFORMANCE Total Harmonic Distortion Noise Signal Noise Ratio Output Noise Intermodulation Distortion PSRR (VOUT /VBUS)
THD+N
POUT 400W, RLOAD 1kHz Relative full scale output, 600W into
0.015
µV/V
VSNR PSRR
SMPTE, 60Hz 7kHz, 4:1, RLOAD Output
0.02
HCA600ACREF
Electrical Specifications
RLOAD VBUS ±110V, Supply Source Resistance 2.5, Storage Capacitor 12,000µF, 12VFLT 12V, +/-12V +/-12V (Continued) 25oC PARAMETER PSRR (VOUT /VBUS) Amplifier Output Offset Voltage Amplifier Output Impedance Damping Factor ADDITIONAL CHARACTERISTICS Cutoff Frequency, Referenced 1kHz Cutoff Frequency, Referenced 1kHz 20kHz Response, Referenced 1kHz Power Bandwidth Slew Rate Maximum Switching Ripple Output Input Gain Input Impedance, Inverting Input Input Impedance, Inverting Input Output Signal Phasing Over Temperature Shut Down Over Temperature Hysteresis Amplifier Output Current Limit Amplifier Output Current Limit Time (Note NOTES: this power level, soft clipping circuitry beginning activate. functions "round off" peaks rather than hard limit most linear amplifiers. This helps give this amplifier pleasing sound during limiting. Moreover, this feature also makes amplifier "sound louder". This time allows amplifier reproduce large, sustained peaks without shutting down, adequate protect amplifier output from shorted speaker lines. FUPPER8 FUPPER4 20kHz FPWM R-INPUT R+INPUT Phasing OTSD -3dB, RLOAD Output -3dB, RLOAD Output Output 20kHz 10W, RLOAD Maximum Frequency Full Power RLOAD Maximum rate change output voltage Full Output Power, RLOAD Either Inverting inverting input. Unused input returned analog ground Differential amplifier input, other input grounded Differential amplifier input, other input grounded Positive going signal Inverting input results negative going amplifier output Rising temperature shutdown amplifier. external thermistor Difference between rising falling temperature shut down start points Absolute Value Time amplifier must current limiting before shutdown -0.5 12.0 V/µs Degrees
SYMBOL PSRRac |VOS| ZOUT 120Hz
TEST CONDITIONS
UNITS
voltage across speaker, load Measured 1kHz Output Measured 1kHz Output
HCA600ACREF HCA600ACREF Connector Designations
DESIGNATION Analog Ground Non-Inv Input Input Analog Ground Enable FUNCTION Input Ground Audio Input Audio Input Input Ground Enable WIRE COLOR Black Gauge) Phono Phono Black Gauge) Green Gauge) capacitance delay startup pull disable amp. Optional SPECIFICATIONS COMMENTS Connect ground pre-amp connect Audio applied does invert phase signal. Input impedance differential inputs. Audio applied inverts phase signal. Input impedance 10k.
Controls drives Brown indicating over temperature Gauge) shutdown Drives indicate onset current limit Drives indicate soft clipping activated Bias Supply Bias Supply Power Ground Positive Supply Positive Supply Power Ground Negative Supply Negative Supply Floating supply (referenced -Bus) Power Ground Grey Gauge) Blue Gauge) Purple Gauge) Orange Gauge) Black Gauge) Gauge) Gauge) Black Gauge) White Gauge) White Gauge) Yellow Gauge) Black Gauge)
CL_OUT SFCL_OUT -12V +12V PGND +BUS +BUS PGND -BUS -BUS +12VFLT PGND
Optional Optional 50mA, -12V ±10% 50mA, +12V ±10% Connect Star Ground best results least 12,000µF, 160V electrolytic capacitor. Limit under load conditions 130V.
best results least 12,000µF, 160V electrolytic capacitor. Limit under load conditions 130V.
500mA, +12V ±10% This signal referenced negative rail (-Bus).
Molex Part Numbers: Header 26-60-5180, Connector 09-50-8183, Pins 08-52-0113 WARNING: Insulate wires. Accidental shorts between bias supplies will damage amplifier.
HCA600ACREF Typical Performance Curves
1.000 LOAD AMPLIFIER OUTPUT (dBr) 400W LOAD -1.000 -2.000 -3.000 -4.000 -5.000 0.001 0.0005 -6.000 FREQUENCY (Hz) FREQUENCY (Hz)
0.01
FIGURE FREQUENCY LOAD
FIGURE AMPLIFIER FREQUENCY RESPONSE LOAD
AMPLIFIER OUTPUT INPUT LOAD OUTPUT VOLTAGE (VRMS) 26.0 13.0 0.12 0.18
1012 OUTPUT POWER (WRMS)
602A DIGITIZING SIGNAL ANALYZER
1ms/DIV
INPUT VOLTAGE (VRMS)
FIGURE AMPLIFIER TRANSFER CHARACTERISTIC WITH VARIOUS SETTINGS SOFT CLIPPING RESISTOR
Soft Clipping
Figures show effects soft clipping circuitry within amplifier. Figure shows transfer characteristic amplifier various values soft clipping programming resistor. important aspect soft clipping apparent increase sound level. soft clipping reached, upper lower envelop sinewave gradually reduced. This "soft" rounding reduces higher harmonics that would result hard clipping shown Figure enabled. Soft clipping also results amplifier with more pleasing sound. Figure shows rounding output with soft clipping, while Figure shows ampler output without soft clipping.
100V/DIV
FIGURE OSCILLOSCOPE DISPLAY AMPLIFIER OUTPUT WITH SOFT CLIPPING CIRCUIT ENABLED
602A DIGITIZING SIGNAL ANALYZER
100V/DIV
1ms/DIV
FIGURE OSCILLOSCOPE DISPLAY AMPLIFIER OUTPUT WITH SOFT CLIPPING CIRCUIT DISABLED
HCA600ACREF Full Size Outline HCA600ACREF Board
HCA600ACREFC VIEW
SFCLOUT ENABLE BOARD CONNECTIONS SHOWN FROM COMPONENT SIDE
+INPUT
12VFLT
CLOUT
-INPUT
AGND
AGND
PGND
PGND
PGND
+BUS
+BUS
-BUS
-BUS
+12V
-12V
OUT76.2MM (3.08")
OUT+
(8.7")
HCA600ACREF Schematic Diagram HCA600ACREF Board Test Setup
AUDIO GENERATOR
OUTPUT HCA600ACREF OUT-
ANALYZER DISTORTION ANALYZER INPUT
OUT+
AMPLIFIER LOAD RESISTOR
MAKE SURE SUPPLY STABLE WITH CAPACITORS 12,000µF EARTH
120V
120V
12,000µF
CAUTION: Remove power when inserting removing amplifier board. Make sure power supply capacitors discharged damage amplifier result.
Board Test Equipment Test Procedure Intersil HCA600ACREF Amplifier
Equipment required evaluation Intersil HCA600ACREF Amplifier follows: bench supplies deliver rated voltage current this amplifier. Furthermore, most linear bench supplies cannot sink current. possible 1KVA transformer (92V-0-92V) rectifier should used supply main power. Figure Bench supplies used provide bias shown next page. Three 12V, 500mA Power Supplies transformer with required secondary windings available). Distortion Analyzer such Audio Precision System System equivalent. Load resistors, 500W 1000W fan. Associated connectors cables. HCA600ACREF Amplifier Board.
thermal shutdown extreme cases failure, this should avoided. Music does contain high frequency high power signals this concern real applications. WARNING: This coupled. apply input. applications, blocking required preamp between preamp amplifier. example, 2.2µF film capacitor between preamp -input will roll frequency response (10K input impedance). measurements valid filters used. interprets carrier class amplifier noise. Filters must used remove carrier. Always make sure that either 80kHz filters selected. 80kHz filter does attenuate carrier completely, selected external 80kHz filter should also used. This filter must high quality that does contribute THD. metal film resistor with 180pF polypropylene does well. carrier visible with scope reading output then including switching frequency THD+ Noise calculations. number valid. Selecting 80kHz filter using single pole external 80kHz pass filter allows 2nd, harmonics 20kHz signal observed. external filter should also used when measuring CCIF.
Test Procedure Evaluation HCA600ACREF
power supply sequencing critical with exception. -12V must applied same time before +12V. not, start. Frequency sweeps should limited between 80kHz high powers. Amplitude frequency sweeps full power will damage amplifier. Nevertheless, high frequency (>10kHz) high power continuous sine wave testing result
HCA600ACREF Block Diagram HCA600ACREF Test Setup
AUDIO PRECISION OTHER DISTORTION ANALYZER AUDIO PRECISION UNBALANCED GROUNDED LOAD RESISTOR
+12V
+12V
200mA
-12V
+12V
200mA
12VFLT
+12V
500mA
+BUS (125V)
-BUS (-125V) PGND 1kVA POWER SUPPLY (SEE BELOW)
CAUTION: Remove power discharge capacitors before removing inserting amplifier. Failure damage module.
NOTES: Differential input. input signal INPUT INPUT returned analog ground. When using INPUT, return INPUT analog ground. Enable left open since 25µA pull current will enable fan, SFCL also left open.
HCA600ACREF Power Supply HCA600ACREF
12,000µF 160V PINS PGND +12V -12V 100µF 12VFLT PINS AGND 100µF -12V +12V
125V LOAD 1kVA TRANSFORMER 92VAC 92VAC -125V LOAD 12,000µF 160V
PINS +BUS PINS -BUS
INPUT
STAR GROUND LOAD 13.6VAC 13.6VAC LOAD 470µF 470µF -12V
13.6VAC LOAD 1,000µF
12VFLT
100µF
WARNING: High voltage secondary.
NOTES: 200V, diodes. These will blow both fuses either MOSFET power amplifier fails short. 200V, diodes that return energy supply fuse blows. FIGURE
Power Supply Specifications
+Bus -Bus
voltage necessary achieve full power ±110V. unregulated supply, load voltage will significantly higher. MOSFETs used amplifier support differential voltage between buses. That +/-Bus 125V, then each MOSFET support 250V. breakdown MOSFETS 275V. Care must take ensure that under load, high line conditions this breakdown voltage exceeded. Doing damage amplifier. This limitation makes difficult achieve full power from unregulated power supply. output impedance transformer very size bulk capacitance must large. better solution switching power supply. This allows amplifier used full potential. With unregulated power supply, 500W maximum power. amplifier will still able provide 600W transient power. While shown power supply diagram, high frequency ceramic caps (0.1µF) should placed parallel with electrolytic capacitors +/-12V bias 12VFLT. This additional filtering will improve performance amplifier.
+12V -12V
Each supply draws approximately 40mA. Regulation required. best results make sure that rectified secondary voltage minimum line voltage greater than dropout voltage regulator. 100mA, 12V, linear regulator used.
12VFLT
This voltage needed drive gates MOSFETs. current required order 400mA. This voltage should also regulated. current high enough that regulator with heatsinking required. This supply referenced -Bus. reference this supply ground will damaged.
NOTE: applications that multiple modules, power supplies shared long currents each supply scaled accordingly.
voltages +/-Bus dangerous. careful. touch components inside shield when power applied. Make sure bulk capacitance power supply discharged before disconnecting connecting edge connector. Don't touch uninsulated speaker wires when running high powers. Diodes required safety. them.
HCA600ACREF
Heat Sinking
HCA600ACREF heat sink must supplemented achieve full power. amount additional heatsinking depends airflow. bench testing, small within inches board blowing across shield sufficient full power testing. resistors used test board will also likely require fan. applications, internal thermal transfer plate should bolted chassis. This accomplished either placing board horizontally that shield thermal contact with bottom side chassis using bracket which mounts both chassis thermal plate. shield will make good thermal contact with thermal transfer plate unless stiff piece aluminum bolted transfer plate from outside shield. reference design uses aluminum bars this purpose. chassis bracket also serve same purpose, allowing aluminum bars discarded. aluminum shield necessary compliance. remove ensure long reliable life, heatsinking should designed that module typically runs 70oC less. Higher operating temperatures will reduce lifetime module. also important high temperature fiber washers when mounting FETs transfer plate. Teflonand plastic washers will flow high temperatures causing FETs loose contact with transfer plate fail. third power into (333W) efficiency 85%. amplifier shuts down when heat sink temperature 100oC. Allowing temperature rise degrees above ambient, thermal resistance heat sink must approximately watt. highly recommended. With small fan, existing heat sink bolted chassis more than adequate.
BARS SHIELD
large inductor should glued shield board, that anchored securely. Thermal grease between transfer plate shield required. Place small washers under heatsink lift board. washer next requires thermal grease both sides that thermistor used sense temperature thermal transfer plate will thermal contact. GROUNDING audio amplifiers, grounding important. module ground planes, power analog. These connected board zero jumper, R31. most applications, this jumper should removed, analog ground should make only connection with power ground, (star ground) Figure power supply transformer. AUTOMATIC RESTART INTO SHORT amplifier capable distinguishing impedance load from dead short. output shorted with impedance, will deliver 50ms then shut down. impedance very short), amplifier will deliver short burst then shut down. either case, power must cycled user restart amplifier. will shut down impedance loudspeaker dips, speakers momentarily shorted. this case, amplifier limits current supplied loudspeaker. amplifier designed with speakers. stable into loads, magnetics heatsinking designed impedance speakers multiple speakers parallel. auto restart into dead short absolutely required, then populate with resistor, change 0.1µF, 10V, 1206 capacitor. current limit time will 5ms, amplifier will always restart after dead short more times. safety reliability issues, current ramps more than start attempt, amplifier will shut down power will need cycled. this mode, unless short removed quickly fuses power supply will blow. After short removed fuses replaced will restart. Most users should auto restart, easier customer cycle power than replace fuse. COMPLIANCE POWER SUPPLY WIRING
TRANSFER PLATE
BOARD
FIGURE
Assembly
Make sure FETs secure, thermal grease both sides aluminum oxide spacers. Glue inductors down ensure that coils output choke against shield. This, cause short.
with Harris reference designs amplifier meets both requirements when placed suitable chassis with appropriate by-pass capacitance. audio input requires 1000pF capacitor chassis, +speaker cable requires 0.047µF 200V capacitor. negative audio input speaker return should grounded chassis. power line filter also required meet conducted emission specifications.
Teflonis trademark Pont Nemours Company.
HCA600ACREF
Power supply wiring important. wires +/-Bus must kept close their return (power ground). Twisting cables recommended. bias supplies should also kept close their returns (AGND). Twisting recommended. return 12VFLT -Bus. primary wires transformer should twisted should secondary wires rectifiers. When twisting possible, wraps. frequency issues usually radiation from bridge rectifiers board itself compliant.
Authorized Intersil Licensing Agents
Asia
Continental East, Inc. 3-1-5 Azabudai, Minato-ku Tokyo 106, Japan Tel: 03-3584-0339 FAX: 03-3588-0930
Intersil semiconductor products manufactured, assembled tested under ISO9000 quality systems certification.
Intersil semiconductor products sold description only. Intersil Corporation reserves right make changes circuit design and/or specifications time without notice. Accordingly, reader cautioned verify that data sheets current before placing orders. Information furnished Intersil believed accurate reliable. However, responsibility assumed Intersil subsidiaries use; infringements patents other rights third parties which result from use. license granted implication otherwise under patent patent rights Intersil subsidiaries. information regarding Intersil Corporation products, site www.intersil.com
Sales Office Headquarters
NORTH AMERICA Intersil Corporation 883, Mail Stop 53-204 Melbourne, 32902 TEL: (407) 724-7000 FAX: (407) 724-7240 EUROPE Intersil Mercure Center 100, Fusee 1130 Brussels, Belgium TEL: (32) 2.724.2111 FAX: (32) 2.724.22.05 ASIA Intersil (Taiwan) Ltd. 7F-6, Hsing North Road Taipei, Taiwan Republic China TEL: (886) 2716 9310 FAX: (886) 2715 3029

File Number 4777 600W/1000W Full Bandwidth Class Amplifier

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