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Construction Notes For The AV 800 Watt MOSFET Power Amplifier AV800
Construction Notes For The AV 800 Watt MOSFET Power Amplifier AV800
T1
BD1
Bridge Rectifier
+90 Volts DC
Toroidal Transformer
C1
10,000uf 100 Volt
C2
10,000uf 100 Volt
C3
10,000uf 100 Volt
R2
10k 5 watt
C4
10,000uf 100 Volt
Power GND
R1
10k 5 watt
15k
1uf
AV800 Amp
+
C
15k
C
-90 Volts DC
C1
10,000uf 100v
C2
10,000uf 100v
R1
10k 5 watt
47uf 390
15k
B
T2
1uf
Local Mains Supply
Power GND
Toroidal Transformer
C3
10,000uf 100v
Bridge Rectifier
BD3
C4
10,000uf 100v
AV800 Amp
15k
R2
10k 5 watt
-90 Volts DC
A
Title
Size
Number
Revision
B
Date:
File:
1
6-Feb-2001
C:\WINNT\..\av800psu.Sch
Sheet of
Drawn By:
6
The buffer stage devices do not need insulating from the heat sinks, but please be
aware that once the module is powered up. 90 volts DC will be present on the heat sink.
So dont go touching it, as it will give you a shock.
Pre-flight test
OK at this stage I am assuming you have populated all of the PCB except Q8 and the
main output stage devices IRFP240s and IRFP9240s
For the time been temporarily insert and solder Q8 into its position located in the
middle of the PCB.
Now we have come to the soldering in of the output devices. It is assumed at this point
that you have all ready matched the output stage devices as outlined in the
accompanying document on How to match output devices.
If this is already done then you can proceed by getting the PCB and flipping it over so
the copper side of the board is facing you.
Now identify which is the positive supply side of the PCB and start soldering the
IRFP240 devices face down on the appropriate pads so the metal tabs on the back of
the power MOSFETs are facing you.
Once all of the N-channel devices are done proceed with the IRFP9240
P-channel devices, in the same way.
After completing this task the module for the most part is completed.
The only other thing you will need to decide is wether to use PCB stakes to solder the
external wiring too or solder the cable directly into the PCB pads.
Now there is one device that requires some special attention. This is Q8 and this device
is the Vbe multiplier or bias compensation device, which needs to be mounted off board
on a strip of 10cm x 2cm x 4mm thick piece of aluminium and it is this piece of aluminium
that will clamp down the output stage. Q8 will need to be insulated with a TO-220 micawasher kit from this piece of metal and flying leads need to be soldered from the Gate,
Source and Drain pins of the IRF610 to the appropriately marked pads on the PCB shown
as Q8.
One other thing that needs to be done is to mount some 3mm high rubber feet on copper
side of the front and back of the PCB. This is to hold the PCB off the heat sink, so as
not to allow the PCB to touch the heat sink in any way.
Now having completed the power module and tested the Error, VAS and Buffer stages
and you are confident that it is working OK. Its time to bolt it down to a suitable heat
sink. Remember that all of the o/p devices must be insulated with either silicon rubber
washers or mica washers and heat sink compound. The type, size and shape of heat sink
are left up to you and the local availability of heat sinks. But be sure to have a heat sink
rated at 0.2 degrees/watt or 0.5 degrees/watt with fan cooling.
So we have come to the point where we need to do a full test on the amplifier module.
There are a few checks that need to be done first.
The Drain pins on all the o/p devices need to be checked for S/C to the heat sink.
The power supply wiring has been checked for correct polarity to the PCB.
The Multi-turn pot P1 has been turned back to 0 Ohms, so that a measurement of
approximately 4.7k is measured across the Gate and Drain pins of Q8 IRF610.
When wiring up the power supply, be sure to have 8 amp fuses inserted on each of
the supply lines.
Connect a multimeter on DC volt range to the o/p of the amplifier.
Ok now that you are happy that the module is setup correctly apply power via a VARIAC
if you have access to one, otherwise just power the amplifier up.
Looking at the voltmeter you should get from 1mv to 50mv offset voltage.
If this is not the case then power the amplifier down and check your work.
Assuming all is well then power the amplifier down and find a small flat blade
screwdriver so you can be ready to adjust P1 for the biasing of the o/p stage.
But first connect the voltmeter across one of the o/p stage Source resistors using
Alligator leads.
Now reapply power to the amplifier and slowly adjust P1 while watching the voltmeter,
for a reading of 18mv.
Now check across the rest of the Source resistors and find the one, which has the
highest reading, and adjust P1 till 18mv is read.
Now connect a load and signal source to the amplifier and with a CRO if you have access
to one observe that the waveform is clean and free from noise and distortion.
If you dont have a CRO and Signal generator, connect a pre-amp and loudspeaker and
have a good listen. The sound should be very clean and dynamic.
Congratulations, the amplifier is complete.
Best Regards
Anthony Eric Holton
8th February 2001
www.aussieamplifiers.com
Component Value
100uf 160v RB
10PF Ceramic
47UF/100V RB
47UF/100V RB
47UF/100V RB
47UF/100V RB
47UF/100V RB
47UF/100V RB
10pf Ceramic
1uf MKT
2n2 MKT
68pf Ceramic
2n2 MKT
220uf 25v RB
47uf Bipolar
100nf MKT
100nf MKT
47uf Bipolar
47uf 25v RB
47UF 100V RB
47UF 100V RB
47UF 100V RB
47UF 100V RB
47UF 100V RB
47UF 100V RB
100uf 160v RB
100nf-x2/250vac Mains Rated
1N4007 1 amp diode
1N4007 1 amp diode
1 inch pitch, Min 10 Degrees/Watt
1 inch pitch, Min 10 Degrees/Watt
LED any colour
LED any colour
5K POT Multi turn or 10 turn
2SC2240 TO-220
2SC2240 TO-92A
2SA1306 TO-220
2SA1306 TO-220
IRF610 TO-220
BC546 TO-92
BC546 TO-92
IRF610 TO-220
IRFP240 TO-3P
IRFP240 TO-3P
IRFP240 TO-3P
IRFP240 TO-3P
IRFP240 TO-3P
IRFP240 TO-3P
IRFP240 TO-3P
IRFP9240 TO-3P
IRFP9240 TO-3P
IRFP9240 TO-3P
IRFP9240 TO-3P
IRFP9240 TO-3P
Q21
Q22
Designators
Q23
Q24
Q25
Q26
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
R33
R34
R35
R36
R37
R38
R39
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
IRFP9240 TO-3P
IRFP9240 TO-3P
Component Value
BD681 TO-126
2SC3298 TO-220
2SC3298 TO-220
IRF9610 TO-220
2k2
2k2
120
100
Wire LINK2
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
10k 1watt
470
470
470
470
470
470
470
47K
100
Wire LINK4
100
4k7
4k7
4k7
47
47
4k7
4k3
10 Ohm 1watt
1k
100
470
390
15k
330
470
10k 1 Watt
Wire LINK3
10k 1watt
100
100
Wire LINK5
470
470
470
470
470
470
470
470
R54
R55
10k
100
Designators
Component Value
R56
R57
R58
R59
R60
R61
R62
R63
R64
R65
ZD1
ZD2
100
100
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
0.22 3 WATT
10 OHM 5 WATT
15v 1watt Zener Diode
15v 1watt Zener Diode
10
Component Value
Misc
1 Inch pitch 10 Degree/watt heat sink
Wire Links
Quantity
2
4
Resistors
0.22 Ohm 3 Watt Resistor
100 Ohm Resistors
100 Ohm Resistors
10k Ohm Resistor
10k Ohm 1watt Resistor
10 Ohm 1watt Resistor
120 Ohm Resistor
15k Ohm Resistor
1k Ohm Resistor
2k2 Ohm Resistor
330 Ohm Resistor
390 Ohm Resistor
47 Ohm Resistor
470 Ohm Resistor
47K Ohm Resistor
4k3 Ohm Resistor
4k7 Ohm Resistor
10 Ohm 5 Watt Resistor
5K multi turn POT
14
8
1
1
3
1
1
1
1
2
1
1
2
17
1
1
4
1
1
Capacitors
10PF Capacitor
10pf Capacitor
100nf MKT Capacitor
100nf MKT Capacitor
100nfx2 250vac Capacitor
100uf 160v Capacitor
1uf MKT Capacitor
220uf 25v Capacitor
2n2 MKT Capacitor
47UF 100V Capacitor
47uf 25v Capacitor
47uf BP Capacitor
68pf Capacitor
1
1
1
1
1
2
1
1
2
12
1
2
1
Semiconductors
15v 1watt Zener Diode
15v 1watt Zener Diode
1N4007 1 amp Diode
2SA1306 Transistor
2SC2240 Transistor
2SC3298 Transistor
BC546 Transistor
BD681 Transistor
IRF610 Transistor
IRF9610 Transistor
IRFP240 Transistor
IRFP9240 Transistor
Light Emitting Diodes
1
1
2
2
2
2
2
1
2
1
7
7
2
11
+15 VOLTSVCC
DRAIN
C
Q2
P-channel MOSFET
R1
150 Ohm 1 watt
M1
DC VOLTMETER
GND
GATE
SOURCE
DRAIN
GATE
Q1
N-channel MOSFET
R1
150 Ohm 1 watt
M1
DC VOLTMETER
SOURCE
B
GND
VCC
+15 VOLTS
A
Title
Size
Number
Revision
B
Date:
File:
1
6-Feb-2001
C:\WINNT\..\FET_MATCH.Sch
Sheet of
Drawn By:
6
12
C3
C1
220uf 100v
100
R1
2k2
R13
10k 1 Watt
R2
2k2
47uf 100v
D1
R4
C4
47uf 100v
C5
47uf 100v
C6
C7
47uf 100v
C8
47uf 100v
+ 92V
47uf 100v
1N4007
R3
100
R20
470
Q1
2SC2240
C9
10pf
Q2
2SC2240
Q3
2SA1306
Q15
IRFP240
Q4
2SA1306
Q14
IRFP240
R19
C2
10pf
470
Q13
IRFP240
R18
C-mount1
470
D6
1N4936 (Opti onal)
68pf
Q6
BC546B
Con?
C15
SOCKET
33uf
R35
R26
470
4k7
ZD1
1N4744
Q12
IRFP240
R17
Q7
BC546B
470
Q11
IRFP240
R16
R27
4k7
C11
470
R28
100
R29
100
Q5
IFR610
2n2
Q10
IRFP240
R15
470
R24
100
R22
ZD3
1N4737
C13
2n2
P1
Con?
C18
SOCKET
33uf
R39
R30
470
4k7
C16
100nf
R40
10k 1 Watt
C10
1uf MKT
5k
10k 1 Watt
C19
47uf
ZD2
1N4744
R54
10k
IRF610
R7
0.22
R8
0.22
R9
0.22
R10
0.22
R11
0.22
R34
100
100
SOCKET
R58
0.22
R44
ZD4
1N4737
100
R59
0.22
R60
0.22
R61
0.22
R62
0.22
R63
0.22
R47
470
68pf
R48
IRF9610
R37
R49
Q19
IRFP9240
470
R51
Q18
IRFP9240
470
R52
Q17
IRFP9240
470
R54
100
D5
1N4936 (Opti onal)
R50
Q25
2SC3298
C27
100nf MKP x2
Q20
IRFP9240
470
15k
R36
390
R64
0.22
Q21
IRFP9240
470
Feed b ack
R65
5.6 Ohm 5 Watt
Q22
IRFP9240
Q26
Q24
2SC3298
Feed b ack
Con?
ZD6
6.8 volts
R43
C12
C17
C14
100nf MKT
220uf
R12
0.22
D4
DIODE
R33
1K
R31
C-mount2 4k3
68pf
R6
0.22
D3
DIODE
R38
330
Q23
BD681
R42
470
ZD5
6.8 Volt
Q8
Q9
IRFP240
R14
100
R25
4k7
R55
100
R53
470
R57
100
Q16
IRFP9240
D2
1N4007
C26
220uf 100v
C20
47uf 100v
C21
47uf 100v
C22
47uf 100v
C23
C24
47uf 100v
C25
47uf 100v
Title
S iz e
47uf 100v
- 92V
Revision
C
Dat e:
File:
1
S h eet of
Dr aw n By:Anthony E Holton
6