DIY 5.1 Home Theater System 700watt RMS

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Make you own high quality 5.1 Home Theater System which is 700 watts RMS. 5+1 channel. 5 channels are 100 watts each and subwoofer is 200 watts ((5*100w)+(1*200w)=700w) (Front- left, Front- right, Center, Surround- left, Surround- right, Subwoofer). It is remote controlled. It has 4 - L/R inputs(Stereo) and one 6 channel input. Among four inputs one is for USB/MP3 player with built in Bluetooth. It also has SD card slot, USB slot, Aux input and listen songs from your mobile through Bluetooth. I am not able to find any suitable cabinet for this amplifier. I purchased locally available metal box and I cut and installed all the components as per requirement.

Enjoy making it.

Step 1: Requirements

  • 5.1 remote control kit
  • Cabinet
  • 22-0-22 or 24-0-24 5 amps Transformer
  • 12-0-12 1 amp Transformer
  • 0-12 500ma Transformer
  • Mains cord
  • USB/MP3 player with built in bluetooth
  • Large Heatsink's
  • Cooling fans
  • ON/OFF rocker switch
  • 4 Way Spring Loaded Terminal Connector
  • PCB plastic spacers

  • RCA female connectors

  • 1*10" subwoofer
  • 2*3" tweeters
  • 2*4" subwoofers
  • 6*4" Mid speakers

For electronics components please view the circuit diagrams.

Step 2: 5 Channel PCB

I designed PCB in Diptrace. File attached.

Step 3: Subwoofer

I have two circuits. One is with TDA 7294 and another is TIP 142 and TIP 147 Transistors. Both work very well. I preferred TDA IC because all the remaining channels are with TDA and distortion will be less. In this two Ic's are combined as a bridge. I provided transistor circuit and also PCB. Use bigger heatsink and cooling fan for TDA circuit.

Differences --------------- TDA 7294 ----------------- Transistor Circuit

Quality ------------------------Good ---------------------Better than TDA 7294

Voltage range --------------(+/-35 v) ----------------------(+/-54 v) (Checked)

Heat dissipation -------------More --------------------------Very less

Distortion-------------------Very less----------------------------less

Step 4: Alternate Amplifier Board

If you are new in making PCB's , better to buy assembled boards. Visit the link : TPA 3116 Amplifier Board .

It is a class D amplifier with two channels and 50w each. In order to make 6 channels we need three boards. Total 300w RMS. Voltage range is 12-24v DC Single power supply. For separate 100w subwoofer amplifier please visit TPA 3116 subwoofer 100w . The sound quality is good and these boards are very cheap. In order to work with these boards we have to remove the volume controls that are soldered to the PCB.

Step 5: Power Supply

Here I used 3 transformers. One is 22-0-22 5 amps which gives +/- 35 v DC. I used 4 10000MFD 63v capacitors. This is for the amplifier. It is better to use 10 amps transformer if you want to utilize full power. Another is 12-0-12 1 amp for remote control kit. and 0-12v 500ma for cooling fans. I used two cooling fans. Designed PCB attached. Please open in Diptrace software.

Step 6: Remote Control

I purchased this remote kit from this site.

http://imranicsworld.blogspot.in/2014/

The sound quality is amazing. The subwoofer filter does not sound good, so I found another best circuit from Internet. I have provided the PCB in next step. After replacing the subwoofer filter it sounded amazing. We have to power this kit with separate 12-0-12, 1 amp Transformer. For remaining details please visit the website.

System Features:

  • External usb board control fuction is also provided for usb control.
  • It has a rotary ENCODER which is also used to control all its function adjustments.
  • This kit gives u a true pro-logic effect on rear channels with a best quality of sound.
  • Digital gain option is provided for individual channel corrections and input gain correction.
  • Each input gain and individual output channels gain can be adjusted using remote control.
  • Memory function is provided for audio levels and also audio inputs.
  • Low pass filter circuit is provided as a separate unit for user adjustments and can be modified.
  • Soft mute fuction is used for audio mute.
  • 2 band tone control (BASS/TREBLE).
  • Display software is modified to give a bigger size numbers for audio level for user visibility.

OUTPUT PORTS FOR EXTERNAL HARDWARE CONTROL:

  • 4 output lines for external usb board (CHINA USB BOARD ) control for its basic operations such asPLAY /PAUSE , MODE (usb/fm), TRACK PERV << and >> TRACK NEXT.
  • 1 MUTE signal line out.
  • 1 STAND-BY signal line out.
  • 1 USB +5V output signal.

ROTARY ENCODER FUNCTIONS:

  • Volume up/dwn for master control and front ,rear, centre ,subwoofer volume adjustments.
  • Bass/Treble adjustments.
  • Input selection.

AUDIO PROCESSOR FEATURES:

  • 6 channels independent electronic volume (0 to –99dB/1dBstep, –∞dB)
  • 6 channels independent gain control (0 to +14dB/ 2dB step)
  • L/R channel 4 input selector (Input gain: 0 to +14dB/ 2dB step)
  • Multi channel input: 6 channels input
  • Tone control Bass: –14 to + 14dB(2dB step),Treble: –14 to + 14dB(2dB step)
  • Can use 1 input for REC output (REC output gain: 0, +2, +4, +6dB)
  • Built-in ADC output (Input Att: 0/ –6/ –12/ –18dB)
  • Built-in L+R/ L–R block
  • Built-in digital power supply

These features and functions are taken from the website.

Step 7: Subwoofer Filter

This subwoofer filter is based on NE5532 IC. I modified the circuit by replacing 47k presets with 1ohm resistors. The sound quality is amazing. I attached the circuit and PCB layout.

Step 8: USB/Mp3 Player

Better use USB/MP3 with built in bluetooth module. If not use an external bluetooth receiver.

Step 9: Wiring

Connect according to the block diagram.

Step 10: Speaker Enclosures

I have made these enclosures with 12mm MDF. Measurements given in pictures. Subwoofer enclosure is old one.

Step 11: Paint Job

Applied primer and painted with blue color. Installed all the speakers.

Step 12: Final Step

Label the cabinet.

Enjoy the music...

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    23 Discussions

    0
    None
    sriegam

    Question 11 days ago on Introduction

    Hi anisetty,
    you have done a great job. Can u mention what was the total cost to prepare this model ?
    and one more Ques. I'm from Hyderabad. So usually where can i buy these parts ? I'm new for this types of jobs. I'm interested in DIY.

    Where did you hail from (Which state) ? and is it possible to you to make a 2.1 soundbar with sub woofer ? and is it possible to you to deliver to my location. (so sorry to ask you about this)

    1 more answer
    0
    None
    sandilya.anisettysriegam

    Answer 7 days ago

    Hi,
    Thank you for the comment. I'm from hyderabad. I purchased maximum of spares from Aliexpress.com. Total cost is between12 to 14k. I am out of city for the purpose of my job and I'm not able to do any project.

    0
    None
    StefanS32

    7 days ago

    How did you connect the three amplifiers, and how did you remove the volume knob, and what did you do with those connections

    1 reply
    0
    None
    sandilya.anisettyStefanS32

    Reply 7 days ago

    All the amplifiers are connected to Audio processor board and volume is controlled by the same board.

    0
    None
    Ramuswati

    Question 2 months ago on Step 5

    Hi, I need help. I want to give dc power supply of -24 0 +24 and 24-0 v both for amplifier as well as 5.1 board so can you please suggest me how to make

    0
    None
    KrisS107

    3 months ago

    Thumbs up this is a pretty nice job, Pls in this subfilter circuit, this 6 pins terminal (HDR-1x6TH/2), pls kindly tell us where each of the pin will be connected to in the circuit diagram, am happily waiting for your response soon.

    Warm regards!

    0
    None
    anand_ivy

    11 months ago

    Nice Job got some more idea about the Sub PRE!!!

    thank you!!

    4 replies
    0
    None
    anand_ivysandilya.anisetty

    Reply 10 months ago

    Can you design me a PCB with STBY/MUTE? or shall I get sch of the above posted PCB's?

    0
    None
    anand_ivysandilya.anisetty

    Reply 10 months ago

    Yes of course but it doesn't standby/mute the amp it just standby/mute the input alone....
    What I need is to turn off (standby/mute) the amp...

    0
    None
    jacob_1

    1 year ago

    A lot of job done.
    Did you think about using build in raspberry pi (with eg. Kodi) or some android or some nettop with Windows in order to make it real multimedia? You will have one device with YouTube, Netflix, Spotify, internet, dlna etc