Velleman K4040, Illustrated Assembly Manual

Page 1: ...eginner 1 2 3 4 5 advanced Stereo valve power amplifier ILLUSTRATED ASSEMBLY MANUAL H4040IP 1 For most of us a high power valve amplifier is unaffordable This kit changes that so that now everybody can enjoy that sublime valve sound K4040 K4040 ...

Page 2: ...VAC 500VA max modifications reserved Features Pure valve sound with high quality EL34 valves High quality black and chrome housing Chrome valve socket covers Easy bias adjustment with LED indication Removable bottom for easy access and service High quality capacitors and components Gold plated input and speaker terminals Standby function Soft start circuit for power transformer 2 Features specific...

Page 3: ...the eyes Needle nose pliers for bending leads or to hold components in place Small blade and Phillips screwdrivers A basic range is fine For some projects a basic multi meter is required or might be handy 1 2 Assembly Hints Make sure the skill level matches your experience to avoid disappointments Follow the instructions carefully Read and understand the entire step before you perform each operati...

Page 4: ...ace and carefully solder the leads 2 Make sure the solder joints are cone shaped and shiny 3 Trim excess leads as close as possible to the solder joint REMOVE THEM FROM THE TAPE ONE AT A TIME Assembly hints AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE ...

Page 5: ...sembly of the small input PCB P4040i This PCB is used to connect the input signal via two RCA sockets via two holes at the rear of the cabinet SK1 CINCH SK2 CINCH 2 CINCH RCA connector L GND R GND 3 Shielded wire connector LEFT RIGHT GND GND P4040i 15cm ...

Page 6: ...e small piece of wire could touch the bottom of the cabinet 1 Valve socket mounting 15mm M3 SPACER 8mm SPACER PCB VALVE SOCKET 15mm M3 BOLT 2 7 1 8 5 4 3 V 2 3 4 1 3 5 7 4 6 5 8 1 8 Also mount a 15 mm spacer on the remaining holes in the PCB at the solder side use a 6 mm M3 bolt Two spacers round tube sockets V9 and V10 A spacer next to RY3 A spacer next to T2 A spacer next to R1 A spacer next to ...

Page 7: ...wires J2 2 wires J3 2 wires J4 2 wires J5 2 wires J6 2 wires J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26 2 Jumpers 3 Jumpers for voltage selection REMARK Strike out the NOT used mains voltage indication at the back of the housing e g cross out with a permanent black marker A A C C D D B B D1 1N4148 D2 1N4148 D3 1N4007 D4 1N4007 D5 1N4007 D6 1N4007 4 Diodes Watch th...

Page 8: ... B R18 820 8 2 1 B R19 180 1 8 1 B R20 1M 1 0 5 B R21 22K 2 2 3 B R22 3K9 3 9 2 B R23 820K 8 2 4 B R24 820 8 2 1 B R25 180 1 8 1 B R26 1M 1 0 5 B R27 22K 2 2 3 B R28 3K9 3 9 2 B R29 10K 1 0 3 B R30 10K 1 0 3 B R31 10K 1 0 3 B R32 10K 1 0 3 B R33 10K 1 0 3 B R34 10K 1 0 3 B R35 1K5 1 5 2 B R36 1K5 1 5 2 B R37 560 5 6 1 B R38 10K 1 0 3 B R39 220K 2 2 4 B R40 100K 1 0 4 B R41 220K 2 2 4 B R42 100K 1 ...

Page 9: ... 3 3 4 B 9 R71 330K 3 3 4 B 9 R72 330K 3 3 4 B 9 R73 330K 3 3 4 B 9 R74 330K 3 3 4 B 9 R75 330K 3 3 4 B 9 R76 330K 3 3 4 B 9 Construction R77 270 2 7 1 B R78 10K 1 0 3 B R79 10K 1 0 3 B R80 15K 1 5 3 B R81 680K 6 8 4 B R82 15K 1 5 3 B R83 47K 4 7 3 B R84 47K 4 7 3 B R85 390K 3 9 4 B R86 47K 4 7 3 B R87 47K 4 7 3 B R88 390K 3 9 4 B R89 180 1 8 1 B R90 180 1 8 1 B R91 180 1 8 1 B R92 180 1 8 1 B R93...

Page 10: ...S 4P SW3 DS 4P 15 DIP switches 1 SW Check the minimum voltage C3 100p 400V C4 100p 400V C5 22n 630V 0 022 C6 22n 630V 0 022 C7 470n 0 47 474 C8 2n2 222 2200 C9 22n 630V 0 022 C10 100p 400V C11 22n 630V 0 022 C12 22n 630V 0 022 C13 22n 630V 0 022 C14 22n 630V 0 022 C15 22n 630V 0 022 C16 2n2 222 2200 C17 470n 0 47 474 C18 100p 400V 101 C19 22n 630V 0 022 C20 22n 630V 0 022 C21 22n 630V 0 022 C22 22...

Page 11: ...p SK6 3p SK7 3p SK8 3p 18 PCB connectors 19 Valve sockets 5 9 8 7 4 3 2 V 6 1 The various relays have leads that correspond to the printing on the PCB RY3 VR5V122C RY4 VR10V121C RY5 VR10V121C 20 Power relays RY RY F1 Insert a 5A fuse for 115V Insert a 2 5A fuse for 230V Fit the protective cap to the fuse holder 21 Fuse holder fuse F TR1 12VAC 22 Transformer TRAFO Construction ...

Page 12: ...C38 100µF 400V C39 220µF 450V C40 220µF 450V C41 220µF 450V C42 220µF 450V 23 Electrolytic capacitors check the polarity C Mount him as square as possible against the PCB also solder the metal support SW1 3P ON ON ON SW 24 Switch SIDE VIEW IMPORTANT Don t leave a gap between the SWITCH and the PCB IC1 LM3914 25 IC Watch the position of the notch ...

Page 13: ...ng VIEWED FROM SOLDERSIDE 3 4 5 4 3 5 6 V8 8 1 2 7 1 8 8 1 V5 8 1 7 2 6 5 4 5 3 3 4 4 3 3 4 5 5 6 V7 1 8 2 1 8 7 8 1 8 1 7 5 6 4 5 V6 2 3 3 4 f2 6 3VAC f2 f1 f1 5 3 4 4 5 3 1 2 8 V4 6 7 1 8 2 8 8 1 1 6 7 5 4 V1 3 3 5 4 6 3VAC 5 3 4 4 5 3 2 1 8 1 6 V3 7 8 f2 f2 8 8 1 6 7 5 4 1 V2 2 3 3 5 4 f1 f1 Again thoroughly check all the components for miss mounting polarity including soldering errors Valve wi...

Page 14: ...o that one of the sup porting bushes can make contact with the cabinet Mount the chrome feet at the four corners of the cabinet using an M4 bolt A piece of felt can be sticked under each foot Mount the loudspeaker terminals repeat twice Mount the three loudspeaker terminals on the triangular PCB plate see figure the connecting eyes should not be used 27 Assembly into the unit CLICK INTO HOLE Fig 1...

Page 15: ...m length to the middle terminal of the mains connector Slide a 1 5 cm length of insulating heat shrink sleeve over each terminal all the way up the con nector This can be shrunken by hot air e g with a hair dryer IMPORTANT Stick a piece of insulating foil on the connector see figure 4 0 This will later be used to prevent the connector piercing through the transformer Also stick a piece of insulati...

Page 16: ...ow wire to the 4 Ohm loudspeaker terminal Solder the red wire to the 0 loudspeaker terminal Solder the blue wire to the 8 Ohm loudspeaker terminal IMPORTANT Heat the terminals up until the solder melts easily Then slide the insulating heat shrink sleeve over the leads PLATE RUBBER WASHER TRANSFORMER RUBBER WASHER METAL CASE BOLT Fig 5 0 Cut 4 x 4 cm OUTPUT TRANSFORMER ZD043 TRANSFORMER 8D002 POWER...

Page 17: ...ds to the output terminals see figure 7 Do not forget to slide a 3 cm length of insulating heat shrink sleeve over the wires Solder the double yellow wire to the 4 Ohm loudspeaker terminal Solder the red wire to the 0 loudspeaker terminal Solder the blue wire to the 8 Ohm loudspeaker terminal IMPORTANT Heat the terminals until the solder melts easily Then slide the insulating heat shrink sleeve ov...

Page 18: ...ck green wires should be connected in the same way to the 6 3V connection of the right hand amplifier PCB Connect the screened cable from the input PCB to the L connection left channel and the screen to the GND connection Do the same for the right channel R 28 Assembly and wiring Assembly and wiring IMPORTANT The connector leads of the transformer may not be shortened If there is more than one wir...

Page 19: ... 3V should also be found at connectors 2 and 7 of the tube sockets V1 to V8 Fit the small tubes V9 and V10 type ECC83 or 12AX7 CV492 V11 type ECC82 or 12AU7 CV491 Again connect the amplifier to the mains and set the mains switch to ON fully up Wait until the green LED is lit continuously Now check the voltages on the PCB measure the voltages with respect to earth Earth can be taken from lead J26 n...

Page 20: ...ond or third LED lights up Complete the adjustment for all tubes of the left hand channel Adjustment of the right hand channel Ensure that all switches of the left hand channel are OFF up Switch the first switch of SW3 right DIP switch ON down Carefully adjust RV5 until the second or third LED lights up LD4 or LD5 Switch OFF the first switch up Switch ON the second switch down Carefully adjust RV6...

Page 21: ...est to place a small loudspeaker close to the amplifier such that you can turn and listen for the best result Before fitting the covers check the supply and amplifier PCBs to see that no components have been mounted too high Mount the cover on the base set the cabinet on its side using black Allen bolts Make a loop of the three earth connections in the cabinet via the spade plugs and the length of...

Page 22: ...ed by first fitting the covers for the supply transformers Mount the front panel to the cabinet use the support brackets supplied together with M3 and M4 Allen bolts Check the position of the switch and the LED see figure 13 If it all fits together well then all bolts can be fully tightened Fig 13 Final assembly of the cabinet ...

Page 23: ...ezo tweeter a 10 Ohm resistor must be placed in series with the tweeter Increase R65 and R68 in value e g 1k or 1K5 the input sensitivity will then be somewhat higher NOTES As tubes are very sensitive to shocks do NOT move the unit when the tubes are hot Should a tube nevertheless fail then this can be seen by the sudden bright red glow of the lamp In the event of the lamp discharging then the ass...

Page 24: ...6 220K BC516 T4 C24 100u GREEN R35 1K5 R37 560 LD1 L 56BHD D19 1N4007 ZD2 C23 4u7 C25 470u D18 1N4148 R9 220K D17 1N4007 D16 1N4148 R7 2K2 0 475 0 425 LD11 RED LD10 RED LD9 RED 0 375 0 325 LD5 RED LD6 RED LD7 GREEN LD8 GREEN LD12 RED 3 R48 33K 1 R74 330K 0 5W 2 3 R73 330K 0 5W R75 330K 0 5W 4 2 3 R71 330K 0 5W R72 330K 0 5W R69 330K 0 5W NC 0 4 LM3914 RHI RLO 6 REF 7 0 35 16 17 0 3 14 15 SIG 5 MOD...

Page 25: ...C82 RIGHT INPUT R2 1K IN RV5 100K RV6 100K R88 390K 1W R60 100K 5W R28 3K9 C5 22n 630V 2 1 V10 R27 22K 7 ECC83 R62 47K 5W C18 100p 400V V3R R86 47K 1W C15 22n 2 1 6 C19 22n 630V R54 100K C20 22n 630V R52 100K VR VIOLET GREEN BLACK BIAS7 R95 180 1W R96 180 1W 4 5 3 1 f1 EL34 V8 2 R104 10 1W f2 8 7 3 4 5 1 f1 f2 EL34 V7 2 7 R102 10 1W BIAS8 8 GND LS GND RED BLACK BROWN ORANGE BIAS5 R94 180 1W 8 f1 2...

Page 26: ...CC82 LEFT INPUT R1 1K IN RV1 100K RV2 100K R85 390K 1W R59 100K 5W R22 3K9 C9 22n 630V 7 6 V9 R21 22K 7 ECC83 R61 47K 5W C10 100p 400V V3L R83 47K 1W C6 22n 2 6 1 C11 22n 630V R42 100K C12 22n 630V R40 100K VL VIOLET GREEN BLACK BIAS3 R92 180 1W 4 5 3 1 f1 EL34 V4 2 R100 10 1W f2 8 7 R91 180 1W 3 4 5 1 f1 f2 EL34 V3 2 7 R98 10 1W BIAS4 8 GND LS GND RED BLACK BROWN ORANGE BIAS1 8 f1 2 R99 10 1W f2 ...

Page 27: ... R88 R28 J6 R23 1 B 120VAC A 100VAC R106 R108 2 5A SLOW AT 230 245VAC EARTH MAINS 5A SLOW AT 100 120VAC R107 F1 YELLOW LS RED LS D5 D6 12VDC D4 D3 T1 SK5 J7 L N R105 R4 ZD1 D1 RY3 R3 D13 D14 R79 YELLOW BLACK BROWN GRAY 6 3VAC C37 D7 R5 C28 J8 R63 f1 GRAY C29 245V C27 D2 RY4 50VDC TRANSFORMER 12VAC 120V 0 R64 f2 415VDC J1 C39 D12 D11 C30 R80 R78 D8 D9 D10 SK7 RY5 VIOLET ORANGE BLUE YELLOW RED R77 T...

Page 28: ...Modifications and typographical errors reserved Velleman Kit nv H4040IP 1 2014 rev 3 0 5 4 1 0 3 2 9 3 1 9 1 8 2 VELLEMAN NV Legen Heirweg 33 B 9890 GAVERE Belgium Europe ...