IRAUDAMP8
120W x 4 Channel Class D Audio Power Amplifier
Using the IRS2093M and IRF6665
By
Jun Honda, Yasushi Nishimura and Liwei Zheng
CAUTION:
International Rectifier suggests the following guidelines for safe operation and handling of
IRAUDAMP8 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
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IRAUDAMP8 REV 1.0
Page 1 of 34
TABLE OF CONTENTS
PAGE
INTRODUCTION............................................................................................................................................... 3
SPECIFICATIONS ............................................................................................................................................ 3
CONNECTION SETUP ..................................................................................................................................... 5
CONNECTOR DESCRIPTION ......................................................................................................................... 5
TEST PROCEDURES....................................................................................................................................... 6
PERFORMANCE AND TEST GRAPHS .......................................................................................................... 7
CLIPPING CHARACTERISTICS.................................................................................................................... 10
EFFICIENCY................................................................................................................................................... 11
THERMAL CONSIDERATIONS ..................................................................................................................... 11
THERMAL INTERFACE MATERIAL’S PRESSURE CONTROL ................................................................................. 12
POWER SUPPLY REJECTION RATIO (PSRR)............................................................................................ 14
SHORT CIRCUIT PROTECTION RESPONSE .............................................................................................. 15
IRAUDAMP8 OVERVIEW .............................................................................................................................. 16
FUNCTIONAL DESCRIPTIONS..................................................................................................................... 18
IRS2093 GATE DRIVER IC ............................................................................................................................ 18
SELF-OSCILLATING FREQUENCY .................................................................................................................... 19
ADJUSTMENTS OF SELF-OSCILLATING FREQUENCY ......................................................................................... 19
SELECTABLE DEAD-TIME ................................................................................................................................ 20
PROTECTION SYSTEM OVERVIEW ............................................................................................................ 21
CLICK AND POP NOISE REDUCTION ......................................................................................................... 23
BUS PUMPING............................................................................................................................................... 23
INPUT SIGNAL AND GAIN SETTING ........................................................................................................... 25
GAIN SETTING............................................................................................................................................... 25
SCHEMATIC…………………………………………………………………………………………………………. .26
IRAUDAMP8 FABRICATION MATERIALS................................................................................................... 27
IRAUDAMP8 HARDWARE ............................................................................................................................ 30
IRAUDAMP8 PCB SPECIFICATIONS........................................................................................................... 31
REVISION CHANGES DESCRIPTIONS........................................................................................................ 34
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IRAUDAMP8 REV 1.0
Page 2 of 34
Introduction
The IRAUDAMP8 Demo board is a reference design which uses only one IC (IRS2093M) to derive
appropriate input signals, amplify the audio input, and achieve a four-channel 120 W/ch (4Ω) half-bridge
Class D audio power amplifier. The reference design demonstrates how to use the IRS2093M Class D audio
controller and gate driver IC, implement protection circuits, and design an optimum PCB layout using
IRF6665 DirectFET MOSFETs. The reference design contains all the required housekeeping power supplies
for ease of use. The four-channel design is scalable, for power and number of channels.
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 Modulator:
120W x 4 channels,
200V, IHF-A weighted, AES-17 filter
0.012% THD+N @ 60W, 4Ω
90% @ 120W, 4Ω, single-channel driven, Class D stage
Over-current protection (OCP), high side and low side
Over-voltage protection (OVP),
Under-voltage protection (UVP), high side and low side
Over-temperature protection (OTP)
Self-oscillating half-bridge topology with optional clock synchronization
Specifications
General Test Conditions (unless otherwise noted)
Supply Voltages
±35V
Load Impedance
4Ω
Self-Oscillating Frequency
400kHz
Gain Setting
26.5dB
Notes / Conditions
No input signal, Adjustable
1Vrms input yields rated power
Electrical Data
IR Devices Used
Typical
Notes / Conditions
IRS2093M Audio Controller and Gate-Driver,
IRF6665 DirectFET MOSFETs
Modulator
Self-oscillating, second order sigma-delta modulation, analog input
Power Supply Range
± 25V to ±35V
Bipolar power supply
Output Power CH1-4: (1% THD+N)
120W
1kHz
Output Power CH1-4: (10% THD+N)
170W
1kHz
Rated Load Impedance
8-4Ω
Resistive load
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IRAUDAMP8 REV 1.0
Page 3 of 34
Standby Supply Current
Total Idle Power Consumption
Channel Efficiency
±100mA
7W
90%
No input signal
No input signal
Single-channel driven,
120W, Class D stage
.
Audio Performance
*Before
Demodula
tor
Class D
Output
THD+N, 1W
THD+N, 10W
THD+N, 60W
THD+N, 100W
0.015%
0.006%
0.005%
0.015%
0.015%
0.008%
0.012%
0.02%
Dynamic Range
101dB
101dB
Residual Noise, 22Hz - 20kHzAES17
200V
200V
Damping Factor
Channel Separation
2000
85dB
85dB
75dB
N/A
48
78dB
77dB
70dB
±1dB
±3dB
Frequency Response : 20Hz-20kHz
: 20Hz-35kHz
Thermal Performance
Idling
4ch x 15W (1/8 rated power)
4ch x 120W (Rated power)
Physical Specifications
Dimensions
Typical
TC =30C
TPCB=42C
TC =54C
TPCB=71C
TC =80C
TPCB=106C
Notes / Conditions
1kHz, Single-channel driven
A-weighted, AES-17 filter,
Single-channel operation
Self-oscillating – 400kHz
1kHz, relative to 4Ω load
100Hz
1kHz
10kHz
1W, 4Ω - 8Ω Load
Notes / Conditions
No signal input, TA=25C
Continuous, TA=25C
At OTP shutdown @ 150 sec,
TA=25C
Weight
3.94”(L) x 2.83”(W) x 0.85”(H)
100 mm (L) x 72 mm (W) x 21.5 mm(H)
0.140kgm
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IRAUDAMP8 REV 1.0
Page 4 of 34
Connection Setup
Audio Signal Generator
CH1 CH2 CH3 CH4
Input
Frequency adjustor
VR1
DS1
,VCC INDICATOR
IRS2093
IRF6665
Output
Output
CH2 CH1 +B GND -B CH4 CH3
G
35 V, 10 A DC supply
250W,4ΩNon-inductive
35 V, 10 A DC supply
Fig 1 Typical Test Setup
Connector Description
CH1 IN
CH2 IN
CH3 IN
CH4 IN
SUPPLY
CH1 OUT
CH2 OUT
CH3 OUT
CH4 OUT
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CN1
CN1
CN1
CN1
P1
P2
P2
P3
P3
Analog input for CH1
Analog input for CH2
Analog input for CH3
Analog input for CH4
Positive and negative supply (+B / -B)
Output for CH1
Output for CH2
Output for CH3
Output for CH4
IRAUDAMP8 REV 1.0
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Test Procedures
Test Setup:
1. Connect 4-200 W dummy loads to 4 output connectors (P2 and P3 as shown on Fig 1)
and an Audio Precision analyzer (AP).
2. Connect the Audio Signal Generator to CN2 for CH1~CH4 respectively (AP).
3. Set up the dual power supply with voltages of ±35V; current limit to 10A.
4. TURN OFF the dual power supply before connecting to On of the unit under test (UUT).
5. Connect the dual power supply to P1. as shown on 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 Blue LED should turn ON immediately and stay ON
8. Quiescent current for the positive supply should be 100mA 10mA at +35V.
9. Quiescent current for the negative supply should be 115mA 10mA at –35V.
Switching Frequency test
10. With an Oscilloscope, monitor the switching waveform at test points VS1~VS4. Adjust VR1
to set the self oscillating frequency to 400 kHz 25 kHz.
Functionality Audio Tests:
11. Set the signal generator to 1kHz, 20 mVRMS output.
12. Connect the audio signal generator to CN2(Input of CH1,CH2,CH3,CH4)
13. Sweep the audio signal voltage from 15 mVRMS to 1 VRMS.
14. Monitor the output signals at P2/P3 with an oscilloscope. The waveform must be a non
distorted sinusoidal signal.
15. Observe that a 1 VRMS input generates an output voltage of 21.2 VRMS. The ratio,
R4A/(R3A), determines the voltage gain of IRAUDAMP8.
Test Setup using Audio Precision (Ap):
16. Use an unbalanced-floating signal from the generator outputs.
17. Use balanced inputs taken across output terminals, P2 and P3.
18. Connect Ap frame ground to GND at terminal P1.
19. Select the AES-17 filter(pull-down menu) for all the testing except frequency response.
20. Use a signal voltage sweep range from 15 mVRMS to 1 VRMS.
21. Run Ap test programs for all subsequent tests as shown in Fig 2- Fig 7below.
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IRAUDAMP8 REV 1.0
Page 6 of 34
Performance and test graphs
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
CH1-Blue; CH2-Yellow; CH3-Red; CH4-Cyan
±B Supply = ±35V, 4 Ω Resistive Load
Fig 2 IRAUDAMP8, THD+N versus Power, Stereo, 4 Ω
.
+4
T
+3
+2
+1
-0
-1
d
B
r
-2
A
-4
-3
-5
-6
-7
-8
-9
-10
20
50
100
200
500
1k
2k
5k
10k
20k
50k
100k 200k
Hz
CH1-Blue; CH2-Yellow; CH3-Red; CH4-Cyan
±B Supply = ±35V, 4 Ω Resistive Load
Fig 3 IRAUDAMP8, Frequency response
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IRAUDAMP8 REV 1.0
Page 7 of 34
100
50
20
10
5
2
1
0.5
%
0.2
0.1
0.05
0.02
0.01
0.005
0.002
0.001
0.0005
0.0002
0.0001
20
50
100
200
500
1k
2k
5k
10k
20k
Hz
Red
Blue
CH1, 10W Output
CH1, 50W Output
Fig 4 THD+N Ratio vs. Frequency
CH1-Blue; CH2-Yellow; CH3-Red; CH4-Cyan
Fig 5, 1V output Frequency Spectrum
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IRAUDAMP8 REV 1.0
Page 8 of 34
CH1-Blue; CH2-Yellow; CH3-Red; CH4-Cyan
No signal, Self Oscillator @ 400kHz
Fig 6, IRAUDAMP8 Noise Floor
.
+0
-10
-20
-30
-40
-50
d
B
-60
-70
-80
-90
-100
-110
-120
20
50
100
200
500
1k
2k
5k
10k
20k
Hz
Red
Blue
CH1 – CH2, 60W
CH2 – CH1, 60W
Fig 7, Channel separation vs. frequency
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IRAUDAMP8 REV 1.0
Page 9 of 34
Clipping characteristics
Red Trace: Total Distortion + Noise Voltage
Green Trace: Output Voltage
60W / 4, 1kHz, THD+N=0.012%
174W / 4, 1kHz, THD+N=10%
Measured Output and Distortion Waveforms
Fig 8 Clipping Characteristics
.
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IRAUDAMP8 REV 1.0
Page 10 of 34
Efficiency
Fig 9 shows efficiency characteristics of the IRAUDAMP8. The high efficiency is achieved by
following major factors:
1) Low conduction loss due to the DirectFETs offering low RDS(ON)
2) Low switching loss due to the DirectFETs offering low input capacitance for fast rise and
fall times
Secure dead-time provided by the IRS2093, avoiding cross-conduction
100%
90%
Efficiency (%)
80%
70%
60%
AMP8 35V 4ohms
50%
40%
30%
20%
10%
0%
0
50
100
150
Output power (W)
Fig 9, IRAUDAMP8 4 ohms load Stereo, ±B supply = ±35V
Thermal Considerations
With this high efficiency, the IRAUDAMP8 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 heatsinks or forced air-cooling.
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IRAUDAMP8 REV 1.0
Page 11 of 34
Thermal Interface Material’s Pressure Control
The pressure between DirectFET & TIM (Thermal Interface Material) is controlled by depth of Heat
Spreader’s groove. Choose TIM which is recommended by IR. (Refer to AN-1035 for more
details). TIM’s manufacturer thickness, conductivity, & etc. determine pressure requirement.
Below shows selection options recommended:
Fig 10 TIM Information
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IRAUDAMP8 REV 1.0
Page 12 of 34
Check the TIM’s compression deflection with constant rate of strain (example as Fig.11) base on
manufacturer’s datasheet. According to the stress requirement, find strain range for the TIM. Then,
calculate heat spreader groove depth as below:
Groove Depth=DirectFET’s Height +TIM’s Thickness*strain
**DirectFET’s height should be measured from PCB to the top of DirectFET after reflow. The
average height of IRF6665 is 0.6mm.
Fig 11 compression deflection with constant rate of strain
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IRAUDAMP8 REV 1.0
Page 13 of 34
Power Supply Rejection Ratio (PSRR)
The IRAUDAMP8 obtains good power supply rejection ratio of -68 dB at 1kHz shown in Fig 12.
With this high PSRR, IRAUDAMP8 accepts any power supply topology when the supply voltages
fit between the min and max range.
+0
-10
-20
-30
d
B
V
-40
-50
-60
-70
-80
-90
20
50
100
200
500
1k
2k
5k
10k
20k
40k
Hz
Sweep
Trace
Color
Line Style
Thick
Data
Axis
1
1
Red
Solid
2
Anlr.Ampl
Left
Comment
Fig 12 Amp8 Power Supply Rejection Ratio (PSRR)
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IRAUDAMP8 REV 1.0
Page 14 of 34
Short Circuit Protection Response
Figs 13-14 show over current protection reaction time of the IRAUDAMP8 in a short circuit event.
As soon as the IRS2093 detects an over current condition, it shuts down PWM. After one second,
the IRS2093 tries to resume the PWM. If the short circuit persists, the IRS2093 repeats try and fail
sequences until the short circuit is removed.
Short Circuit in Positive and Negative Load Current
CSD pin
CSD pin
VS pin
VS pin
Load current
Load current
Positive OCP
Negative OCP
Fig 13 Positive and Negative OCP Waveforms
.
OCP Waveforms Showing CSD Trip and Hiccup
CSD pin
CSD pin
VS pin
VS pin
Load current
Load current
Fig 14 OCP Response with Continuous Short Circuit
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IRAUDAMP8 REV 1.0
Page 15 of 34
IRAUDAMP8 Overview
The IRAUDAMP8 features a 4CH self-oscillating type PWM modulator for the smallest space,
highest performance and robust design. This topology represents an analog version of a secondorder sigma-delta modulation having a Class D switching stage inside the loop. The 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 IRAUDAMP8 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 15 below, the input operational amplifier of the IRS2093 forms a front-end secondorder integrator with R3, C2, C3, and R2. The integrator that receives a rectangular feedback
signal from the PWM output via R4 and audio input signal via R3 generates a quadratic carrier
signal at the 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 at the COMP pin is converted to a PWM signal by an internal comparator that
has a 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.
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IRAUDAMP8 REV 1.0
Page 16 of 34
Gate Drivers and DirectFETs
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 DirectFETs. The high-side levelshifter shifts up the high-side gate drive signal out of the dead-time block.
Each channel of the IRS2093’s drives two DirectFETs, high- and low-sides, in the power stage
providing the amplified PWM waveform.
Output LPF
The amplified PWM output is reconstructed back to an analog signal by the output LC LPF.
Demodulation LC low-pass filter (LPF) formed by L1 and C13, 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.
Fig 15 Simplified Block Diagram of IRAUDAMP8 Class D Amplifier
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IRAUDAMP8 REV 1.0
Page 17 of 34
Functional Descriptions
IRS2093 Gate Driver IC
The IRAUDAMP8 uses the IRS2093, a 4 Channel 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 IRS2093 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, R12 and R13 as shown on Fig 16 or Fig 22 below.
The IRS2093 offers the following functions.
PWM modulator
Dead-time insertion
Over current protection
Under voltage protection
Level shifters
Refer to IRS2093 datasheet and AN-1146 for more details.
Fig 16 System-level View of IRAUDAMP8
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IRAUDAMP8 REV 1.0
Page 18 of 34
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 IRS2093, the DirectFETs switching speed, the time-constant
of front-end integrator (R2, R3, R4, C2, C3 ). 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 R2 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
frequency and frequency relative to the other channels. In 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 IRAUDAMP8.
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Page 19 of 34
Selectable Dead-time
The dead-time of the IRS2093 is set based on the voltage applied to the DT pin. Fig 17 lists the
suggested component value for each programmable dead-time between 45 and 105 ns.
All the IRAUDAMP8 models use DT1 (45ns) dead-time.
Dead-time Mode
DT1
DT2
DT3
DT4
R1
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