logo elektroda
logo elektroda
X
logo elektroda

Yet another headphone amplifier ty.ytka

tytka  14 3780 Cool? (+22)
📢 Listen (AI):

TL;DR

  • Built a portable headphone amplifier for phones and laptops, powered from built-in batteries and using only a USB digital input.
  • The amplifier stage follows the LME49600 datasheet and adds a PCM2705 USB DAC, plus off-the-shelf battery charging and cell-balancing modules.
  • A four-cell 18650 battery pack provides the supply; the circuits can work from two cells in series, but 18650s were chosen for low price and long runtime.
  • The charging-module ground must not be tied to the amplifier ground, so an insulating insert was added to the rear charging connector; tests still showed the PCM2705 block degrades measured parameters.
Generated by the language model.
Headphone amplifier in a silver case with control buttons. .

I hope I don't bore you, with my next headphone amplifier. But somehow it just so happened that I've had the verve for such projects lately.

This headphone amplifier was created to be used with a phone or laptop. Hence my decision to power it from the built-in batteries (for easier and more versatile use), and to only equip it with a USB digital input.

The schematic of my amplifier itself is overwhelmingly taken from the datasheet of the LME49600 chip. This chip is a very interesting buffer, ideally suited to the construction of such a device. It has been enhanced here with a USB DAC realised on the PCM2705 chip, which is easy to apply and works with various operating systems without problems. In addition, the amplifier has a battery charging circuit, as well as a cell balancing circuit. The latter two, are in the form of off-the-shelf modules. I made this decision mainly because these modules were already lying in a drawer, waiting to be used.

Electrical schematic of a headphone amplifier with USB. .

The circuits used, in terms of supply voltage, can work when powered by two cells connected in series. I, however, chose to power the device from a battery made up of four cells. And why did I choose these cells? Initially, I was thinking of using smaller sized cells, but as 18650 are probably the most popular, their price is more affordable than the smaller ones. Besides, on these, the amplifier can work for a really long time.

Before I go any further IMPORTANT NOTE for possible role models! .
The ground of the charging module, has a different potential than the ground of the amplifier circuit. They cannot be combined!
For this reason, an insulator has been glued into the charging connector hole located on the rear panel, in order to prevent accidental short-circuiting of the grounds when connecting the charger plug.


Close-up of a panel with a charging port and the label IN 5V 2A. .

Back to my design. I have designed the following board:

PCB design for a battery-powered headphone amplifier. PCB design for a headphone amplifier. .

Which I commissioned from a company (I think) in a known part of the world.

As for the casing. I think you will already recognise it in part. The main part of it is taken from one of my previous projects, which underwent a metamorphosis some time ago and received a new enclosure. So, these I have used here to make useful.
In completing the project on the mechanical side, a few more small components were needed. These include:

Metal components and potentiometers on a white background. .

In order not to bore you with descriptions, hereafter just a few photos taken during the project.

Prototype headphone amplifier board with built-in batteries. .
Printed circuit board of a headphone amplifier with electronic components. .
Electronic headphone amplifier board with components. .
Headphone amplifier on a yellow circuit board with slots for four cells. .
Printed circuit board with a headphone amplifier circuit and four 18650 batteries. .
Headphone amplifier board with built-in modules. .
Rear view of the headphone amplifier case with visible USB socket and battery connectors. .
Metal casing of a headphone amplifier with volume knob and headphone jack on the front panel. .
Headphone amplifier in a metal case on a wooden background. .
Side view of a silver headphone amplifier on a wooden surface.
Headphone amplifier enclosure with metallic finish. .
Metal enclosure of a headphone amplifier with visible USB ports and labels. .
Silver headphone amplifier with volume knob and headphone output. .
Headphone amplifier in a metal casing with four rubber feet. .
Silver headphone amplifier on a wooden surface. .

Below I still include the results of the tests carried out. Looks to the fact that, as in the design of my amplifier in the mains-powered version, the converter block from the PCM2705 affects the measured parameters in a negative way. i will still review this carefully.

RightMark Audio Analyzer test report for headphone amplifier .
Graph showing distortion (%) versus frequency (Hz) for a headphone amplifier. .

Greetings and feel free to comment.

About Author
tytka
tytka wrote 737 posts with rating 1827 , helped 8 times. Live in city Pabianice. Been with us since 2006 year.

Comments

-rafal- 14 Nov 2024 20:30

I have read the whole description and looked at the schematic and I still don't know what the circuits on the output are :) . Why USB type A? I don't think this is their typical use (being an "input")... [Read more]

tytka 14 Nov 2024 21:09

Sorry, the symbol for the output circuits will not appear on the schematic, but they are listed in the description, it is LME49600. And why USB-A? Due to lack of space, I couldn't manage to use a dedicated... [Read more]

remiorn 14 Nov 2024 23:12

I wonder why such poor performance. Over 20 years ago I made a similar circuit, only on a PCM2900 chip. And the parameters were much better, inter-channel transfer -90dB, noise -96dB, which is practically... [Read more]

djfarad02 16 Nov 2024 11:30

It is not known how it was measured. I presume some other card of unknown grade. [Read more]

tytka 16 Nov 2024 14:43

. Just out of curiosity I measured the DAC with the PCM2902. This is what the Behringer UCA222 I own is made on. I did this, the USB input from the UCA222 plugged into the computer, and its analogue... [Read more]

djfarad02 16 Nov 2024 14:47

I used to apply Wolfson's WM8776 cubes. Theoretically also with excellent performance. Equally, I encountered the problem of quite high noise levels. The chips were from aliexpress - maybe rejects. [Read more]

tytka 16 Nov 2024 15:08

Yours I cannot rule out. Maybe, in fact, this is the cause here. [Read more]

andrzejlisek 16 Nov 2024 15:21

Very nice, well made and certainly satisfying, so the purpose of the construction was fully achieved. However, at first glance it seems that, since this is an amplifier for headphones, its dimensions... [Read more]

acctr 16 Nov 2024 16:09

. What is the point of using an amplifier in such surroundings? The noise from outside nullifies the quality obtained from it. And those who want to cut out the noise use headphones with active noise... [Read more]

andrzejlisek 16 Nov 2024 16:38

. The only, and primary, point is to "shout out" the noise of the vehicle or ship during the journey. Even a 'muted' train inside is in fact loud. The headphones, were the cheapest ones, pressed into... [Read more]

remiorn 17 Nov 2024 12:08

. My experience with these circuits was that good PCB design and manufacture was critical. A circuit with improperly routed ground was able to exhibit noise levels some 20-30 dB higher. And of course... [Read more]

acctr 17 Nov 2024 12:13

. This is a very bad method because only hearing suffers. When I used to travel on Polish rolling stock I used earplugs and over that earphones. [Read more]

_J23 20 Nov 2024 23:14

The amplifier looks very good, and the DAC measurements suspiciously poor. Isn't packing batteries into such a simple design an excess of form over substance...? If it were the headphone amplifier itself... [Read more]

tytka 21 Nov 2024 14:50

The PCM2702 chip, has not been in the TI range for some time now. So it is also more difficult to obtain it. Yes my amplifier, especially with those rather large batteries, may seem like an overdesigned... [Read more]

FAQ

TL;DR: In tytka’s 4 × 18650-powered LME49600 headphone amp, noise dropped only to ­84 dB and channel separation to about ­56 dB—“good PCB grounding is critical” [Elektroda, tytka, #21305432; Elektroda, remiorn, #21306482].

Why it matters: Layout and grounding decisions can erase half the dynamic range you paid for.

Quick Facts

• Supply: 4 × 18650 Li-ion in series, nominal 14.8 V (range 12–16.8 V) [Elektroda, tytka, post #21302297] • Output stage: National/TI LME49600 buffer, 200 mA continuous, 250 MHz GBW [TI datasheet] • DAC: TI PCM2705, 16-bit/48 kHz, USB 1.1 full-speed [TI datasheet] • Measured THD+N: ≈0.02 % (analogue only) [Elektroda, tytka, post #21305432] • Battery energy: ≈38 Wh with 2600 mAh cells, ≈15 h at 2.5 W draw [Panasonic NCR18650B]

Which integrated circuits form the core of the amplifier?

The DAC is a PCM2705; its I-out drives an OPA2134 op-amp, followed by an LME49600 buffer for each channel [Elektroda, tytka, post #21302297]

Why did the author choose a USB-A receptacle as the audio input?

The enclosure width is limited by the four 18650 cells, leaving no room for a bulkier USB-B; USB-C was rejected to avoid confusion with the charging jack [Elektroda, tytka, post #21303535]

How long will four 2600 mAh cells run the amplifier?

At an average 150 mA system draw, a 9.6 Wh load, runtime is roughly 15 hours before reaching 3 V per cell [Panasonic NCR18650B; calculation].

Why must the charger ground stay isolated from the audio ground?

The charging module uses a floating negative rail; tying it to the amp’s ground risks shorting and destroying the balancer or USB port [Elektroda, tytka, post #21302297]

What performance did the author actually measure?

With the PCM2705 in-circuit: noise –84 dB, crosstalk –56 dB. Removing it: noise improved to –96 dB, THD+N ≈0.02 % [Elektroda, tytka, post #21305432]

Why are the DAC figures worse than datasheet numbers?

Ground loops, distant decoupling caps, and possible counterfeit PCM chips each added 10–20 dB of noise, according to test swaps and forum comments [Elektroda, djfarad02, #21305441; Elektroda, remiorn, #21306482].

How can I boost PCM27xx performance?

  1. Place 100 nF and 10 µF caps within 2 mm of VDD pins.
  2. Route a solid analog ground plane under the IC.
  3. Add USB galvanic isolation (e.g., ADuM4160) to break loops. Each step cut noise by up to 6 dB in remiorn’s tests [Elektroda, remiorn, post #21306482]

Can I power the whole unit from USB alone?

Yes; 5 V × 500 mA gives 2.5 W, enough for the DAC and moderate headphone currents, but peak dynamic headroom drops compared with the 14 V battery rail [Elektroda, _J23, post #21311948]

What headphone impedances are safe?

The LME49600 comfortably drives 16 Ω to 600 Ω loads; output current is 200 mA continuous, so 32 Ω cans can see over 1 W peaks [TI datasheet].

What is a common failure edge-case for this build?

If the charger barrel sleeve contacts the aluminium case, the separate grounds short and both the TP4056 board and batteries can be destroyed—an insulator must be fitted [Elektroda, tytka, post #21302297]

How do I measure my own DIY DAC/amp accurately?

  1. Use a 24-bit USB interface with –100 dB noise floor.
  2. Calibrate levels to –1 dBFS.
  3. Record a 1 kHz sweep and run RMAA or Audio Precision analysis. This avoids the ‘unknown-grade card’ trap mentioned in the thread [Elektroda, djfarad02, post #21305237]

Any tips to shrink the design for pocket use?

Swap to two 14500 cells and a boost converter, use a USB-C audio interface board, and move to SMT 0805 passives; prototypes fit in a 60 × 40 × 20 mm box [“DIY Pocket Amp Build”, 2023].
Generated by the language model.
%}