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Old 2nd February 2014, 03:08 PM   #1
djQUAN is offline djQUAN  Philippines
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Default Building a car amp using UcD180HG modules

I've been using the Tripath based (41Hz modules) car amps I built for several years now. Time for an upgrade.

I bought these UcD180HG modules back in May last year but never worked on it as I can't decide on which route to take on the powersupply and chassis. DIY? off the shelf? modules?

Suddenly dawned on me that an off the shelf car amp would be a good way to have most of the difficult parts already done. Looked at the bunch of car amps I got from a local repair shop for a good one and ended up with a generic one from the 90's.
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Took the bottom plate off and the four UcD180HG modules fit in it like a glove.
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Testing the powersupply and looking for the signals for DC protect, overcurrent and delayed mute signal. Which, luckily, can very easily be integrated for use with the UcD modules!
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Powersupply chopped off, cleaned and replaced stuff to handle the higher power this will be designed for. And it still fits, barely.
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Original powersupply fets are IRFZ30. Replaced them with IRF3205, changed the 220ohm gate resistors to 22ohms and changed the driver transistors for higher current. Transformer will be rewound for higher output voltage and more copper for more current.
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Original gate drive transistors were the 100mA rated C1815/A1015 transistors. Replaced them with BD139/140 pairs which have the same pinout in the PCB
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Replaced the powersupply caps with Elna/Rubycon since I didn't like the old no name caps which won't survive the expected higher rail voltages anyways.
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I'll update this thread as the project progresses. I also posted it in my site with a few more pictures too.
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Last edited by djQUAN; 2nd February 2014 at 03:11 PM.
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Old 3rd February 2014, 01:37 PM   #2
troystg is offline troystg  United States
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Very nice.. Subscribed.
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Old 3rd February 2014, 04:53 PM   #3
tiomilo is offline tiomilo  Costa Rica
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wow quite expensive toy you have ! 4 X UcD180HG modules ! =a lot respect !!
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Old 4th February 2014, 02:43 AM   #4
djQUAN is offline djQUAN  Philippines
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Thanks, I actually bought 5 modules. I wanted to keep a spare incase something bad happens. (I hope not!)

Input connectors will be mini XLR jacks. This will be driven by my DCX2496 in the car so no problem with balanced sources. (The DCX is also driven off my DIY line driver with balanced signals)

My concerns with this build is the modules are close to each other which might make interference issues. And also the bus pumping issue (which may be circumvented by running each channel pair out of phase - easily done since I have a balanced source).
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Old 7th February 2014, 04:26 PM   #5
djQUAN is offline djQUAN  Philippines
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Did a bit more work tonight...

Rewound the transformer secondary for 50V rails. Used DIY litz wire with 40 strands of #31 wire.
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Angle bracket to hold the hypex modules
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Wired up the power supply lines. I ran out of wires to connect the speaker terminals to the amp modules.
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Now I need some alu sheet to make the end plates.
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Old 7th February 2014, 05:20 PM   #6
tiomilo is offline tiomilo  Costa Rica
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epic work ! congrats ! almost done, let us know how it running when you finish it .
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Old 7th February 2014, 05:22 PM   #7
Jsixis is offline Jsixis  United States
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very nice work.
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Old 8th February 2014, 10:38 AM   #8
ishiru is offline ishiru  Indonesia
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great job, bro!
i did something like this once but i used a class A modules instead od of tripath


but they're now in my trashbin since they're totally burned from overheating (damn hot class A + hot trunk = )


i liked how you wound the toroid!.looks damn good!
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Old 8th February 2014, 11:54 AM   #9
djQUAN is offline djQUAN  Philippines
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Amp is now installed in the car. Very nice sounding except for a loud turn on pop. Other than that, my concern regarding the switching frequencies interacting with the multiple modules did not occur, it is dead silent. Just need to add an attenuator. Gain is too high for my use.

I'll post pics later once I tidy up the install
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Old 8th February 2014, 01:52 PM   #10
djQUAN is offline djQUAN  Philippines
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Here are some more pics!

Used my micro mill to cut the rectangular holes for the terminal blocks.
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End panels finished:
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And it lives!!! No fireworks!
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Here's the rats nest
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Tchernov audio speaker wires used to connect the UcD180HG modules to the terminal blocks
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Design fail. Terminal blocks ended up covering the mounting holes. Click the image to open in full size.
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Ended up drilling new mounting holes.
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Canare Star Quad cables with Neutrik XLRs, Switchcraft mini XLRs to connect the amp to the DCX2496.
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