Velleman-Kit HIGH-Q K8040, Assembly Manual

Page 1: ...Total solder points 299 Difficulty level beginner 1 2 3 4 5 advanced HIGH END MONO MOSFET POWER AMPLIFIER ILLUSTRATED ASSEMBLY MANUAL H8040IP 2 K8040 K8040 ...

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Page 3: ...ifiers double overheating protection with LED indication high grade speaker and input connections overload protection Specifications input input sensitivity for maximum output 0dBm 0 775Vrms input impedance 15Kohm minimum auto switch on voltage 5mVrms output maximum RMS output power 4ohm 90W maximum RMS output power 8ohm 70W dynamic RMS output power in 4ohm 125W minimum load impedance 4 ohm dampin...

Page 4: ...en cutting excess leads hold the lead so they cannot fly towards 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 Re...

Page 5: ...t 1 3 Soldering Hints 1 Mount the component against the PCB surface 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 6: ... 2 R5 470R 4 7 1 R6 100R 1 0 1 R7 15K 1 5 3 R8 15K 1 5 3 R9 15K 1 5 3 R10 15K 1 5 3 R11 470R 4 7 1 R12 15K 1 5 3 R13 15K 1 5 3 R14 100R 1 0 1 R15 15K 1 5 3 R16 2K2 0 6W 2 2 2 9 R17 100R 1 0 1 R18 1K 1 0 2 R19 470R 4 7 1 R20 2K2 0 6W 2 2 2 9 R21 1M 1 0 5 R22 470R 4 7 1 R23 1K 1 0 2 R24 470K 4 7 4 R25 470K 4 7 4 R26 470K 4 7 4 R27 100K 1 0 4 4 Resistors check the color code R ZD1 20V 1 3W Mount 5mm ...

Page 7: ...pre amplifier can drive low impedance Our K8021 is OK for low impedance Our K8020 is not suited for low impedance driving Rx is normally left open C1 100nF 104 C2 100nF 104 C3 100nF 104 C4 100nF 104 C5 100nF 104 C6 100nF 104 C7 100nF 104 C8 100nF 104 5 Capacitors c IC1 8p IC2 8p IC3 6p 6 IC sockets Watch the position of the notch 7 10W resistor R 5mm R40 4R7 4 7 4R7 C9 2n2 222 C10 220n 224 C11 1uF...

Page 8: ...plifier can be built with red connectors right amp and one with the black connectors 10 RCA connectors Mount them straight and against the PCB SK3 3p Mains in SK4 3p Mains transformer SK5 SK6 2x 2 pole Transformer output First slide these two connectors in each other 12 Terminal blocks Check that the position corresponds with the PCB silk printing SK7 2 pole Temp sensor SK8 2 pole Power meter SK9 ...

Page 9: ...ering L1 8 Turns dia 8mm 14 Coil L VR1 UA7805 16 Voltage regulator The back side corresponds to the thick line C17 10µF C18 10µF C19 10µF C20 10µF C21 10µF C23 1µF C24 10µF C25 47µF 63V C26 47µF 63V C27 47µF 63V C28 47µF 63V C29 220µF 63V C30 220µF 63V 15 Electrolytic capacitors Check the polarity C VR TR1 TIC246 or eq 17 Triac The back side corresponds to the thick line TR construction LD1 LED3RL...

Page 10: ...ring Last Solder the second connection LD4 L 424YDT LD5 L 424YDT LD6 L 424YDT LD7 L 424YDT Meter backlight LD8 is a white LED serving as backlight for the power meter LD8 L5WD 5mm white 22 Mounting front LED s Check the polarity Short lead Cathode or 7mm C 12m m IMPORTANT Mount these LED s exactly like in the drawing otherwise some LED s will not fit correctly in the front panel Please also use th...

Page 11: ...ator A ATTENTION The bolt should be inserted on the side of the IC holder with the countersunk opening B DO NOT TIGHTEN THE NUT YET 1 Position the IC onto the PCB 2 Make sure that the support plate is touching the PCB surface 3 Tighten the support nut 4 Check again that the plate is touching the PCB surface 5 Solder the IC connections 23 Mounting the Power IC A Drop of heat conductive compound A B...

Page 12: ...he wires For 230V 220V to 240V edge orange then brown and black For 115V 110V to 120V edge brown then orange and black Using a black marker erase the not used voltage on the rear panel of the unit Secondary windings connection Connect the Red Yellow Blue and Grey wire to the SK5 SK6 connector check the colors on the PCB 24 Mounting the power transformer and mains voltage selection Construction 230...

Page 13: ...e feet on the aluminum profile using two M4 hexagonal Allen screws Use the supplied Allen wrench It is advis able to stick the protection adhesive onto the feet Cut the thread in the front and back of the aluminum profiles using the supplied special M4 screw 4 holes per piece 25 Enclosure preparation Enclosure preparation FIG 1 FIG 2 FIG 3 ...

Page 14: ...nt from the aluminum fixation from the hole closest to the back end This fixation will be used later to connect the ground and earth Mount the three 5mm 0 14 spacers as shown in the drawing Use three hexagonal screws and 3 washer Do not tighten the spacers yet Position the PCB in the enclosure and check if the position of the spacers is correct if so remove the PCB and tighten the spacers Enclosur...

Page 15: ...two M3 nuts and two hexagonal bolts into the profile the nuts will be used for the temperature sensor the bolts will be used for the IC support plate Mount the temperature sensor check the exact position Make sure there is silicone compound between the sensor and the enclosure Solder the wires of the supplied two pole connector onto the sensor There is no polarity Enclosure preparation 0 000 FIG 7...

Page 16: ...xagonal bolts Make sure there is silicone compound between the IC support and the enclosure Glue the included insert C between the transformer and housing Make sure the PCB is aligned with the back of the enclosure IMPORTANT FIRST fix the IC support THEN fix the pcb using three 5mm spacers washer DO NOT TIGHTEN THESE FIXATIONS YET Note Not all components are visible on the drawing 26 final PCB mou...

Page 17: ...eutral Brown for Live Yellow green for earth Use 3 pieces of about 10cm for later connection to the PCB mains connector Mount the speaker connectors onto the rear panel black negative Take care of the isolation washers there are two different types See picture Make sure the connectors are very tight fit and do not make electrical contact with the panel check using ohm meter 27 Speaker and mains co...

Page 18: ...nk tube to isolate the connection Solder a spade terminal to the other end do not forget the terminal isolation Mount insert the mains connector onto the rear panel Insert a 2A fuse into the connector there is also room for a spare fuse 28 Final assembly and connection Final assembly 15cm ...

Page 19: ...ower meter onto the front panel Fix the meter using a piece of transparent adhesive tape four sides Make sure the meter is positioned straight Connect the meter to the PCB SK8 Mount the front panel onto the front using two M4 Allen screws Check the position of the LED s and check if the button is working correctly It could be that paint covering the holes is preventing the buttons from smooth oper...

Page 20: ...Connect a 60W light bulb in series with the Live Brown wire and the Live connection on the PCB Mount both the fuse and the spare fuse in the fuse holder CAUTION Some points on the PCB are connected to the dangerous mains voltage Connect the mains AC voltage to the mains See also the user manual about the power cord Normally after switching ON the amplifier the light bulb should briefly light up If...

Page 21: ...posed live parts Disconnect the mains plug Now the brown Live wire can be connected directly to the connector SK3 Check the user manual to test all functions and operation of the unit Finally the cover can be mounted Please note that the user manual is also used for the assembled version some remarks may not apply to the kit version Test ...

Page 22: ... R19 470R R18 1K C8 100n C1 100n R24 470K R27 100K C34 10 000uF 50V C33 10 000uF 50V C32 10 000uF 50V C31 10 000uF 50V C18 10µ C17 10µ ZD1 20V 1 3W C25 47µ 63V C26 47µ 63V C7 100n C6 100n R30 0R R34 0R R10 15K D3 1N4148 D4 1N4148 D5 1N4148 D6 1N4148 C3 100n C4 100n R22 470R C29 220µ 63V C30 220µ 63V R20 2K2 0 6W C2 100n C5 100n 5V 5V 5V 5V 5V LD7 L 424YDT R5 470R 5V Stby ON Stby ON Auto on Clip de...

Page 23: ...23 32 PCB PCB ...

Page 24: ...VELLEMAN KIT NV Legen Heirweg 33 9890 Gavere Belgium Europe Info http www velleman be Modifications and typographical errors reserved Velleman Kit nv H8040IP 2009 ED2 5 4 1 0 3 2 9 4 1 6 7 7 5 ...