Total solder points: 500 Difficulty level: beginner 1o 2o 3o 4o 5þ advanced HIGH-END CONTROL AMPLIFIER K8021 ILLUSTRATED ASSEMBLY MANUAL H8021IP-1 VELLEMAN KIT NV Legen Heirweg 33 9890 Gavere Belgium http://www.velleman.be Assembly hints 1. Assembly (Skipping this can lead to troubles ! ) Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully. 1.1 Make sure you have the right tools: · A good quality soldering iron (25-40W) with a small tip. · Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called `thinning' and will protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning. · Thin raisin-core solder. Do not use any flux or grease. · A diagonal cutter to trim excess wires. To avoid injury when 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 0.0 00 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 operation. Perform the assembly in the correct order as stated in this manual Position all parts on the PCB (Printed Circuit Board) as shown on the drawings. Values on the circuit diagram are subject to changes. Values in this assembly guide are correct* 3 Assembly hints Use the check-boxes to mark your progress. Please read the included information on safety and customer service * Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as `NOTE' on a separate leaflet. 1.3 Soldering Hints : 1- Mount the component against the PCB surface and carefully solder the leads 2- Make sure the solder joints are coneshaped and shiny 3- Trim excess leads as close as possible to the solder joint AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE ! REMOVE THEM FROM THE TAPE ONE AT A TIME ! 4 5% 1% COLOR= 2... 5 4K7= ( 4 - 7 - 2 - B ) 4K7= ( 4 - 7 - 0 - 1 - 1 ) I VÄRI KOODI FÄRG FARVE- FARGESCHEMA KODE KODE P E SF S DK N D GB F NL C CODICE CODIGO CODIGO O COLORE DE DE D CORES COLORE E S Musta Ruskea Punainen Röd Oranssi Gul Grøn Blå Violet Grå Hvid Silver Guld Sølv Guld Gul Grønn Blå Violet Grå Hvidt Sølv Guldl Orange Orange Orange Rød Rød Rot Orange Gelb Grün Blau Violet Grau Weiss Silber Gold Brun Brun Brun Braun Svart Sort Sort Schwarz Black Brown Red Orange Yellow Green Blue Purple Grey White Silver Gold FARB COLOUR CODIFI- KLEUR C KODE CODE CATION KODE O D DES E COUNoir Brun Rouge Orange Jaune Vert Blue Violet Gris Blanc Argent Or Zwart Bruin Rood 0 1 2 Oranje 3 Geel 4 Groen 5 Blauw 6 Paars 7 Grijs Wit Zilver Goud 8 9 A B 0 Nero Preto Negro 1 Marrone Castanho Marrón 2 Rosso Encar- Rojo 3 Aran- Laranja Naran- 4 Vihreä Sininen Blå Grön Giallo Amarelo Amarillo Keltainen Gul 5 Verde Verde Verde 6 Blu Azul Azul 7 Harmaa Valkoinen Vit Hopea Kulta Grå Viola Violeta Morado Purppura Lila 8 Grigio Cinzento Gris 9 Bianco Branco Blanco A Argento Prateado Plata Color code table B Oro Dourado Oro 5 Construction CONSTRUCTION The unit consists out of two PCB's, one is the main PCB, P8021B and the other is the left channel input section P8021L. First we will start with the small P8021L, then we assemble the P8021B. FTip: The pictures on the packaging can be used as a guideline. However, due to possible changes it is not 100% reliable. P8021L 1. Diodes (check the polarity) D... CATHODE 2. Resistors (check the color code) R... q q q q q q D1: 1N4148 D2: 1N4148 D3: 1N4148 D4: 1N4148 D5: 1N4148 D6: 1N4148 q q q q q q q q R1: 10K (1-0-3) R2: 10K (1-0-3) R3: 10K (1-0-3) R4: 10K (1-0-3) R5: 10K 1-0-3) R6: 10K (1-0-3) R7: 1K (1-0-2) R8: 330R (3-3-1) 6 Construction 3. Capacitors 6. RCA connectors. Mount them straight and against the PCB C... q q q q q q C1: 220p (221) C2: 220p (221) C3: 220p (221) C4: 220p (221) C5: 220p (221) C6: 220p (221) 4- Reed relays (check the position of the notch) q q q q q q SK1: MJ-523AG/B BLACK SK2: MJ-523AG/B BLACK SK3: MJ-523AG/B BLACK SK4: MJ-523AG/B BLACK SK5: MJ-523AG/B BLACK SK6: MJ-523AG/B BLACK 7. Pin connector. Mount it exactly as indicated RY... q q q q q q RY1: VR05051AS or eq. RY2: VR05051AS or eq RY3: VR05051AS or eq RY4: VR05051AS or eq RY5: VR05051AS or eq RY6: VR05051AS or eq. 5. transistors q SK7: HDR20/26 q q q q q q T1: BC557 T2: BC557 T3: BC557 T4: BC557 T5: BC557 T6: BC557 7 Construction P8021B Assembly 8 Construction 1. Jump wires 3. Zener diode (check the polarity) ZD... CATHODE q ZD1: 20V / 0.6W q J1... J25 4. Resistors (check the color code) 2. Diodes (check the polarity) D... CATHODE R... q q q q q q q q q q q q q q q q D1: 1N4148 D2: 1N4148 D3: 1N4148 D4: 1N4148 D5: 1N4148 D6: 1N4148 D7: 1N4148 D8: 1N4148 D9: 1N4007 D10: 1N4007 D11: 1N4007 D12: 1N4007 D13: 1N4007 D14: 1N4007 D15: 1N4007 D16: 1N4007 q q q q q q q q q q q q q q q q q q q q q R1: 10K (1-0-3) R2: 10K (1-0-3) R3: 10K (1-0-3) R4: 10K (1-0-3) R5: 10K (1-0-3) R6: 10K (1-0-3) R7: 10K (1-0-3) R8: 10K (1-0-3) R9: 47K (4-7-3) R10: 470R (4-7-1) R11: 620R/1% (6-2-0-0) R12: 33R (3-3-0) R13: 33R (3-3-0) R14: 390K/1% (3-9-0-3) R15: 33K/1% (3-3-0-2) R16: 1K (1-0-2) R17: 47K (4-7-3) R18: 470R (4-7-1) R19: 620R/1% (6-2-0-0) R20: 390K/1% (3-9-0-3) R21: 33K/1% (3-3-0-2) 9 Construction q R22: 1K (1-0-2) q R23: 560R/1% (5-6-0-0) q R24: 1K8/1% (1-8-0-1) q R25A or R25B: 1K5 (1-5-0-1) (*) q R26: 1K5 (1-5-2) q R27: 560R/1% (5-6-0-0) q R28A or R28B: 1K5 (1-5-2) (*) * The position of R25 and R28 depends on the supplied IC for IC2 and IC3: Mount R25B and R28B if type OPA134 is supplied. Mount R25A and R28A. If types OPA604 or TLE2071 are supplied. q q q q q q q q q q q q q q q q q q q q q q q q q R29: 1K8/1% (1-8-0-1) R30: 1K5 (1-5-2) R31: 56R (5-6-0) R32: 56R (5-6-0) R33: 1K (1-0-2) R34: 330R (3-3-1) R35: 1R (1-0-0) R36: 1R (1-0-0) R37: 1R (1-0-0) R38: 1R (1-0-0) R39: 1K/1% (1-0-0-1) R40: 1K/1% (1-0-0-1) R41: 1K (1-0-2) R42: 1K (1-0-2) R43: 1K (1-0-2) R44: 1K (1-0-2) R45: 10K (1-0-3) R46: 10K (1-0-3) R47: 10K (1-0-3) R48: 10K (1-0-3) R49: 10K (1-0-3) R50: 4K7 (4-7-2) R51: 1R (1-0-0) R52: 470R (4-7-1) R53: 1K5 (1-5-2) 5. Choke L... L... q L1: 1uH (1-0) q L2: 1uH (1-0) 6. IC sockets q q q q IC1: 8P IC2: 8P IC3: 8P IC4: 18P 7. Female header SK.. J... q SK7: 20P (type 96120205) 10 Construction 8. Capacitors 9. Reed relays (check the position of the notch) C... RY... q q q q q q q q RY1: VR05051AS or eq. RY2: VR05051AS or eq RY3: VR05051AS or eq RY4: VR05051AS or eq RY5: VR05051AS or eq RY6: VR05051AS or eq. RY7: VR05051AS or eq. RY8: VR05051AS or eq. q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q C1: 220p (221) C2: 220p (221) C3: 220p (221) C4: 220p (221) C5: 220p (221) C6: 220p (221) C7: 220p (221) C8: 220p (221) C9: 220p (221) C10: 2n2 (222, 2200) C11: 2n2 (222, 2200) C12: 8n2 (822, 8200) C13: 8n2 (822, 8200) C14: 100n (104, 0.1, u1) C15: 100n (104, 0.1, u1) C16: 100n (104, 0.1, u1) C17: 100n (104, 0.1, u1) C18: 100n (104, 0.1, u1) C19: 100n (104, 0.1, u1) C20: 100n (104, 0.1, u1) C21: 100n (104, 0.1, u1) C22: 100n (104, 0.1, u1) C23: 100n (104, 0.1, u1) C24: 100n (104, 0.1, u1) C25: 100n (104, 0.1, u1) C26: 100n (104, 0.1, u1) C27: 100n (104, 0.1, u1) C28: 100n (104, 0.1, u1) C29: 100n (104, 0.1, u1) C30: 2.2uF C31: 2.2uF 10. Pin header connector, cut at the indicated 5 pins 5 q SK8: 5P q SK9: 5P 11 Construction 11. transistors 13. Push button Mount them straight against the PCB surface ! q q q q q q q q T1: BC557 T2: BC557 T3: BC557 T4: BC557 T5: BC557 T6: BC557 T7: BC557 T8: BC557 q q q q q SW1: TS-04PV SW2: TS-04PV SW3: TS-04PV SW4: TS-04PV SW5: TS-04PV Remark: The metal part of these buttons are used as jump wire. Be sure not to test or use the unit without soldering these push buttons. 12. Trim potentiometer 14. Phone jack. Mount him straight against the PCB surface ! L' SK.. q RV1: 100K q RV2: 100K J... R R' L q SK13: JCF3.5 (3.5mm jack) 12 Construction 15. RCA connectors. Mount them straight and against the PCB 17. Voltage regulator. The back side corresponds to the thick line. VR... q q q q q q SK1: MJ-523AG/R RED SK2: MJ-523AG/R RED SK3: MJ-523AG/R RED SK4: MJ-523AG/R RED SK5: MJ-523AG/R RED SK6: MJ-523AG/R RED q VR1 UA7815 q VR2 UA7915 q VR3 UA7805 16. Electrolytic capacitors. Check the polarity ! 18. Transformer. C... q q q q q q q q q q q q q q q q C32: 47µ C33: 47µ C34: 100µ C35: 100µ C36: 100µ C37: 470µ C38: 470µ C39: 470µ C40: 470µ C41: 470µ C42: 1000µ C43: 1000µ C44: 1000µ C45: 1000µ C46: 1000µ C47: 1000µ TRANSFORMER q TR1: TR8021, 9V-2x18V/ 6VA 13 Construction 19. Volume potentiometer. 20. Mains voltage selection RV... q RV3: STRK27103 (2x50K ALPS) CAUTION: This is a high quality potentiometer, handle it with care. Follow the mounting instructions exactly and in order! 1.Mount the support bracket onto the potentiometer. Tighten the nut carefully. 2.Mount the potentiometer onto the PCB, using two 6mm (0.23") screws and M3 nut. Only slightly tighten the nuts ! Do not solder the potentiometer connections yet ! Use a piece of isolated brown wire to select the mains (outlet) voltage, as indicated on the PC board. q For 115Vac (100 to 120Vac) A jumper between A-B, and a jumper between C-D. A B C D q For 230Vac (220 to 240Vac) A jumper between B-C. B C Using a black marker, erase the not used voltage at the back of the unit. 21. Mains voltage connection preparation q Connect a 10cm blue wire to the point N of SK12. q Connect a 10cm brown wire to the point L of SK12. q Connect a 10cm yellow/green wire to the earth point of SK12. Later these connection will be soldered to the mains connector. 14 Construction 22. Mounting the LED's. Check the polarity ! Short lead = Cathode or-- ! LD... CATHODE CAUTION: After bending the leads the long appearing lead will be the cathode! IMPORTANT Mount these LED's exactly like in the Next: Solder one lead, and check the drawing, otherwise some LED's will position, if necessary correct by heat- not fit correctly in the front panel. ing the soldering. Please also use the front panel as a positioning reference. Last: Solder the second connection. First: Bend the leads exactly like the drawing. q LD7 L-424YDT 3mm C q q q q q q LD1 L-424YDT LD2 L-424YDT LD3 L-424YDT LD4 L-424YDT LD5 L-424YDT LD6 L-424YDT C FIG. 1 3mm 12mm FIG. 2 7mm q LD8 L-424YDT FIG. 3 15 Construction 23. Mounting the sub PCB support q Mount four 2cm (0.8") M3 spacers at the indicated positions using four 6mm (0.23") M3 screws. 16 Enclosure preparation 24. Enclosure preparation q Cut the thread in the holes for the enclosure feet in one of the aluminum profiles, using the supplied special M4 screw as a tap. q Mount the Feet on the aluminum profile, using two M4 hexagonal Allen screws. Use the supplied Allen wrench. It is advisable to stick the protection adhesive onto the feet. FIG. 1 FIG. 2 q Cut the thread in the front and back of the aluminum profiles, using the supplied special M4 screw (4 holes per piece) FIG. 3 q Cut the thread in the back panel phono ground screw position, using the supplied special M3 screw. FIG. 4 17 Enclosure preparation q Position the main PCB in the aluminum profile that is prepared with the feet. The potentiometer must be at the same side of the feet. FIG. 5 Align pcb with profile ! q Mark the center position of the three fixation holes on the aluminum. 18 Enclosure preparation q Remove the pcb and use a knife or a screwdriver to scratch the paint from the aluminum fixation, from the hole closest to the back end. This fixation will be used later to connect the ground and earth. FIG. 6 q Mount the 3, 5mm (0.14") spacers like FIG. 7 in the drawing. Using three hexagonal screws and a 5mm M3 spacer washer. Do not tighten the spacers yet. M3 hex. nut Washer q 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. FIG. 8 0.0 00 q Using an ohmmeter, measure between the edge of the aluminum profile and the back spacer, if there is a good electric contact (0 ohm). If not, repeat the above step to remove the paint under the spacer. 19 Final assembly 25. Potentiometer assembly and final PCB mount q Mount the PCB into the enclosure like before. Tip: Check if the pcb does not have to much play at the potentiometer posiPlay? tion. If there is too much play, put a piece of tape round the edge of the pcb to remove FIG. 1 the slack. q Fix the pcb using a 5mm spacers next to C36. FIG. 2 q Mount the knob onto the potentiometer. (check the notch position) ...