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Old 11th October 2005, 04:02 PM   #1
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Default Making of Lightforce 1 Class D Powerbriefcase

Here is a project about building a fully operational 2 x 200 Watt RMS power amplifier into a small aluminium Poker briefcase.

You can buy the briefcase in any supermarket or hardware store for something like 10$. (It's the small one with 200 chips )

As you can see on the picture below, it looks very nice, and including all parts for the amplifier it weights just around 1500 grams. Not exactly 'heavy hifi'.
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Old 11th October 2005, 04:12 PM   #2
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To keep weight and size down, a small but powerful switchmode power supply is used. (Schematic will be posted later).

The use of a switchmode power supply means the power can be easily upgraded. Since power output is mainly limited by the voltage of the power caps. (63V). You can use 80V caps, and put a few extra windings on the transformer to get 350 Watts per channel. (in 8 Ohms). No problem. I just thought 200 W per channel is more than adequate for my 3rd story downtown appartment with neighbors.

I made the switchmode transformer myself, and it is wound with 15 windings on the primary side, and 6 on the secondary side. In between glass wick tape, to get a good safety distance.
But quite easy to build!

It's running 250 kHz, on a ETD14 core. This means it can transfer around 1.2 kW before it is thermally overloaded.

The amplifier modules are ZAPpulse 2.3SE's. That's why i call it Lightforce 1, i plan to upgrade it to Lightforce 2, when new modules are available.

More to come....
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Old 12th October 2005, 03:28 AM   #3
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This is a dream come true.
Portable lightweight hi-fi power.
I can't wait to see the details on the SMPS.
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Old 12th October 2005, 06:12 AM   #4
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Hi lars Clausen,

Congratulations to you for your new "LIGHTFORCE" project....

Its a very brilliant idea to run the Class-D with SMPS...lots of high efficiencies from both sides.....combined together!

Keep up the good work...
Every body would be able to learn from it....
Cheers,
K a n w a r
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Old 13th October 2005, 12:37 AM   #5
kartino is offline kartino  Indonesia
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Default Hand made SMPS please!

Hi Lars,

I am very interested with your DIY SMPS, looks very simple. I am waiting the schematic.
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Old 18th October 2005, 03:39 PM   #6
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The heat dissipation of the zappulse is well documented. How about the SMPS? I donít see that youíve added a heat sink plate for it?
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Old 18th October 2005, 03:51 PM   #7
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Raintalk: It dissipates some 25W at full power (500VA). So i am using one sheet of aluminium 2 mm thick, 16 by 20 cm for both smps and modules together.

Best regards

Lars
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Old 18th October 2005, 07:17 PM   #8
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Lars, I like the look of that SPMS. I'd love to use something like that to drive 5 channels of class-d for a work-related project (quality PC audio...)

Would love to see your schematic
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Old 19th October 2005, 01:40 PM   #9
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Yves: I will post it here shortly, i just need to make one small adjustment to the gate drivers, to optimize the efficiency.

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Old 19th October 2005, 02:48 PM   #10
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Fantastic Lars, I just hope you don't mind me using it with the competing-product-I-won't-mention-in-this-thread
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