Transcript
Stereo valve power amplifier mplifier is ower valve a p h ig h a s u so that now For most of anges that, h c it k is h T e sound". . ublime "valv unaffordable s t a th y jo n an e everybody c
Total solder points: 700 Difficulty level: beginner 1 2 3 4 5 advanced
K4040 ILLUSTRATED ASSEMBLY MANUAL
H4040IP-1
Features & specifications 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. Specifications:
2 x 90Wrms in 4 or 8W. Up to 2 x 15Wrms full class A. Bandwidth: 8Hz to 80KHz (-3dB/1W). Harmonic distortion: 0.1% @ 1W/1KHz. Signal to noise ratio: >105dB (A weighted). Input sensitivity: 1Vrms. 115VAC or 230VAC / 500VA max.
modifications reserved
2
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 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
leads,
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
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* Use the check-boxes to mark your progress. Please read the included information on safety and customer service operation.
*
Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ on a separate leaflet.
3
Assembly hints 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 !
AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE !
4
Construction Assembly 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.
1. Ceramic Capacitor
3. Shielded wire connector
C ...
C1 : 47nF
(473)
2. CINCH / RCA connector 15cm LEFT GND GND P4040i
SK1 : CINCH SK2 : CINCH
RIGHT
L GND R GND
5
Construction Assembly of the main PCB P4040B: Because of the PCB dimensions, first mount the 8 large tube sockets so that the PCB can rest on a table, without the component leads being touched. When mounting the components, it is best to fold back the component leads a little before turning the PCB over to solder them. 1. Valve socket mounting Check the position of the notch in the centre of the tube socket, it must correspond to the notch in the circle printed on the PCB. Connect the leads to the corresponding isle on the PCB using a small piece of jumper wire. IMPORTANT: Make the connection exactly as shown in the figure, otherwise the small piece of wire could touch the bottom of the cabinet. 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 SW1, together with a lock washer at the solder side:
3
V...
1
4 5 8 2
7
6mm M3 BOLT
M3 LOCK WASHER
15mm M3 BOLT 15mm M3 SPACER
VALVE SOCKET
8mm SPACER
PCB
5
6
8
7
5 8 4
15mm M3 SPACER
3
4
1 2
1
3 V1: I.O. V2: I.O. V3: I.O. V4: I.O.
6
V5: I.O. V6: I.O. V7: I.O. V8: I.O.
Connect the valve socket terminals 1, 3, 4, 5, and 8 to the corresponding points at the solder side of the PCB. Use a piece of jumpwire but take care that the connection does not come above the spacer, otherwise, the wire could touch the housing later (see drawing above).
Construction
2. Jumpers.
Note that from J1 to J6, two jumper leads have to be mounted in the same hole.
TIP : In order to get nice straight wiring, without too much folding and measuring, follow these hints:
3. Jumpers for voltage selection MAINS VOLTAGE SELECTION: For 100V mains input, mount:
Mount the lead on the PCB as it is. Solder 1 end of the lead. Then carefully pull on the free end of the lead until it is straight. Now solder the other end.
A
A
For 120V mains input, mount:
B
B
For 230V mains input, mount: J1 J2 J3 J4 J5 J6
J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 J22 J23 J24 J25 J26
C (2 wires) (2 wires) (2 wires) (2 wires) (2 wires) (2 wires)
C For 240V mains input, mount:
D
D
REMARK: Strike out the NOT used mains voltage indication at the back of the housing !! e.g. cross out with a permanent black marker.
4. Diodes. Watch the polarity!
D...
CATHODE
D1 D2 D3 D4 D5 D6
: : : : : :
1N4148 1N4148 1N4007 1N4007 1N4007 1N4007
7
Construction D7 D8 D9 D10
D11 D12 D13 D14
D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 D26
: : : :
1N4007 1N4007 1N4007 1N4007
: : : :
1N5408 1N5408 1N5408 1N5408
: : : : : : : : : : : :
1N4148 1N4148 1N4007 1N4148 1N4007 1N4007 1N4007 1N4148 1N4148 1N4148 1N4148 1N4007
not on tape ! not on tape ! not on tape ! not on tape !
!
D12
5. Zener diodes. Watch the polarity!
CATHODE
ZD...
ZD1 : 3V9 ZD2 : 3V9
6. 1/4W Resistors
R...
R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
8
R11 R12 R13 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 R56 R57 R58
: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
12K 33K 33K 12K 820K 820 180 1M 22K 3K9 820K 820 180 1M 22K 3K9 10K 10K 10K 10K 10K 10K 1K5 1K5 560 10K 220K 100K 220K 100K 220K 100K 220K 100K 1K5 33K 12K 220K 10K 100K 220K 100K 220K 100K 220K 100K
(1 - 2 - 3 - B) (3 - 3 - 3 - B) (3 - 3 - 3 - B) (1 - 2 - 3 - B) (8 - 2 - 4 - B) (8 - 2 - 1 - B) (1 - 8 - 1 - B) (1 - 0 - 5 - B) (2 - 2 - 3 - B) (3 - 9 - 2 - B) (8 - 2 - 4 - B) (8 - 2 - 1 - B) (1 - 8 - 1 - B) (1 - 0 - 5 - B) (2 - 2 - 3 - B) (3 - 9 - 2 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 5 - 2 - B) (1 - 5 - 2 - B) (5 - 6 - 1 - B) (1 - 0 - 3 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (1 - 5 - 2 - B) (3 - 3 - 3 - B) (1 - 2 - 3 - B) (2 - 2 - 4 - B) (1 - 0 - 3 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B) (2 - 2 - 4 - B) (1 - 0 - 4 - B)
7. Metal film resistors (1/2W) : : : : : : : : : :
1K 1K 470 1K 22K 220K 2K2 2K2 220K 22K
(1 - 0 - 2 - B) (1 - 0 - 2 - B) (4 - 7 - 1 - B) (1 - 0 - 2 - B) (2 - 2 - 3 - B) (2 - 2 - 4 - B) (2 - 2 - 2 - B) (2 - 2 - 2 - B) (2 - 2 - 4 - B) (2 - 2 - 3 - B)
R...
R59 : 100K R60 : 100K R61 : 47K
(1 - 0 - 4 - B - 9) (1 - 0 - 4 - B - 9) (4 - 7 - 3 - B - 9)
Construction R63 R64 R65 R66 R67 R68 R69 R70 R71 R72 R73 R74 R75 R76
R62 : 220 : 220 : 820 : 220 : 220 : 820 : 330K : 330K : 330K : 330K : 330K : 330K : 330K : 330K
: 47K (4 - 7 - 3 - B - 9) (2 - 2 - 1 - B - 9) (2 - 2 - 1 - B - 9) (8 - 2 - 1 - B - 9) (2 - 2 - 1 - B - 9) (2 - 2 - 1 - B - 9) (8 - 2 - 1 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9) (3 - 3 - 4 - B - 9)
9. LEDs. Watch the polarity!
LD...
CATHODE
LD1 : 5mm Red blinking LD2 : 3mm Bicolour
Carefully check the assembly of this LED :
8. 1W resistors R...
3 1
2
1
3
2mm
R77 R78 R79 R80 R81 R82 R83 R84 R85 R86 R87 R88 R89 R90 R91 R92 R93 R94 R95 R96 R97 R98 R99 R100 R101 R102 R103 R104
2
: 270 : 10K : 10K : 15K : 680K : 15K : 47K : 47K : 390K : 47K : 47K : 390K : 180 : 180 : 180 : 180 : 180 : 180 : 180 : 180 : 10 : 10 : 10 : 10 : 10 : 10 : 10 : 10
(2 - 7 - 1 - B) (1 - 0 - 3 - B) (1 - 0 - 3 - B) (1 - 5 - 3 - B) (6 - 8 - 4 - B) (1 - 5 - 3 - B) (4 - 7 - 3 - B) (4 - 7 - 3 - B) (3 - 9 - 4 - B) (4 - 7 - 3 - B) (4 - 7 - 3 - B) (3 - 9 - 4 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 8 - 1 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B) (1 - 0 - 0 - B)
LD...
5mm
5mm
LD3 LD4 LD5 LD6 LD7 LD8 LD9 LD10 LD11 LD12
: : : : : : : : : :
3mm 3mm 3mm 3mm 3mm 3mm 3mm 3mm 3mm 3mm
RED RED RED RED GREEN GREEN RED RED RED RED
10. IC socket. Watch the position of the notch!
IC1 : 18p
9
Construction
11. REED relays. Check the position of the notch!
15. DIP switches
RY...
SW...
1
1
PIN 1
Check that switch 1 corresponds to pin 1.
RY1 : VR05R121 RY2 : VR05R121
SW2 SW3
12. Resistors trimmers (vertical type)
16. Capacitors
RV1 RV2 RV3 RV4 RV5 RV6 RV7 RV8
: : : : : : : :
100K 100K 100K 100K 100K 100K 100K 100K
: : : :
DS-4P DS-4P
C... RV...
Check the minimum voltage !
13. Transistors T1 T2 T3 T4
: :
BC547C BC547C BC547C BC516
14. 5W resistors R...
C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22
: : : : : : : : : : : : : : : : : : : :
100p/400V 100p/400V 22n/630V 22n/630V 470n 2n2 22n/630V 100p/400V 22n/630V 22n/630V 22n/630V 22n/630V 22n/630V 2n2 470n 100p/400V 22n/630V 22n/630V 22n/630V 22n/630V
(0.022) (0.022) (0.47, 474) (222, 2200) (0.022) (0.022) (0.022) (0.022) (0.022) (0.022) (222, 2200) (0.47, 474) (101) (0.022) (0.022) (0.022) (0.022)
17. Electrolytic capacitors (check the polarity) 2mm
REMARK: You will have two 8.2 Ohm 5W resistors left over for later use.
R105 R106 R107 R108
10
: : : :
15 15 15 15
C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34
: : : : : : : : : : : :
4µ7 100µF 470µF 470µF 470µF 470µF 47µF 100µF 47µF 47µF 47µF 100µF
/ 25V / 25V / 25V / 25V / 25V / 100V / 100V / 100V / 25V / 25V / 25V
C...
Construction
18. PCB connectors
20. Power relays
The various relays have leads that correspond to
With the holes facing the PCB edge !
the printing on the PCB:
RY3
SK3 SK4
SK9 SK10 SK11 SK12 SK13 SK14 SK15 SK16
: VR5V122C
RY...
: 2p : 2p : : : : : : : :
2p 2p 2p 2p 2p 2p 2p 2p
RY4 RY5
: VR10V121C : VR10V121C
RY...
SK5 SK6 SK7 SK8
21. Fuse holder + fuse : : : :
F1
3p 3p 3p 3p
F...
19. Valve sockets
V...
1
6
2
7
Insert a 5A fuse for 115V Insert a 2.5A fuse for 230V
3
8 5
9
4
Fit the protective cap to the fuse holder.
22. Transformer
Mount them square against the PCB! V9 V10 V11
TRAFO...
: B9A : B9A : B9A
TR1 : 12VAC
11
Construction
23. Electrolytic capacitors (check the polarity)
Generally these capacitors are from the snap-in type and cannot be mounted incorrectly.
C35 C36 C37 C38 C39 C40 C41 C42
: : : : : : : :
22µF/350V 22µF/350V 100µF/400V 100µF/400V 220µF/450V 220µF/450V 220µF/450V 220µF/450V
C...
24. Switch IMPORTANT: Don't leave a gap between the SWITCH and the PCB!
SW...
SIDE VIEW
Mount him as square as possible against the PCB, also solder the metal support.
SW1 : 3P ON-ON-ON
25. IC. Watch the position of the notch!
IC1
12
: LM3914
Valve wiring
26. 6,3V Valve wiring Wiring for the 8 tube sockets V1 to V8. Use twisted brown wire for each one. For safety, it is advisable to check with an ohmmeter that the two 6.3V terminals are not short circuited.
f2
f1
f2
f1
f2
6.3VAC f2
V6
V7 5
6
7
8
1
3
4
1 8
6
8
4 7
6
1
3
4
1
8
5
3
2
5
8 1
2
V2 7
4 5
3
5
4
1
8
f1
V3
3
2
5
4
f1 6.3VAC
1
4
8 5
4
3
1
2
8
7
5
6
3
3
VIEWED FROM SOLDERSIDE V5 3
V8 5
6
7
8
1
2
5 4
3
4
1
8 1 3
3
2
8
7
6
5
2
1
3
4
1
8 4
7
8
5
8 1
6
4 5
4
V1 3
V4 5
1
4
8 5
4
3
2
1
8
7
5
6
3
Again thoroughly check all the components for miss mounting (polarity!) , including soldering errors !!
13
Assembly into the unit
27. Assembly into the unit Mount the cage nuts into the square holes concerned, from the inside to the outside, (with the nut along the inside). These nuts are used to fasten the covers down, and there are 7 of them in the cabinet base.
CLICK INTO HOLE Fig. 1.0
M3 NUT M3 LOCK WASHER
5mm SPACER
Mount the input PCB on the right-hand side of the housing as shown in the figure. It is possible that a masking sticker from the cabinet will have to be removed, so that one of the supporting bushes can make contact with the cabinet.
16mm M3 BUTTON HEAD BOLT
Fig. 2.0
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.
16mm M3 BUTTON HEAD BOLT
Fig. 3.0 HOUSING (REAR)
LS TERMINAL
PCB SUPPORT M3 LOCK WASHER M3 NUT
NUT LS TERMINAL NUT LS TERMINAL
14
Check that the solder side of the PCB, is along the side of the nuts.
Assembly into the unit
Solder a 35 cm length of yellow wire to the 4 Ohm connection (YEL). Solder a 35 cm length of red wire to the 0 connection (RED).
HINT: In order to tighten the nuts well, immobilise the loudspeaker terminal by inserting a screwdriver through the hole for the loudspeaker lead.
Fit the unit onto the housing with three black Allen bolts, fix with a shakeproof washer and nut.
IMPORTANT: The loudspeaker terminals must NOT touch the metal cabinet anywhere.
Mount the mains voltage connector to the housing using two black Allen bolts. Solder a 12 cm length of blue wire to the N terminal of the mains connector. Solder a 12 cm length of brown wire to the L terminal of the mains connector. Solder a 20 cm length of yellow/green earth wire and a 12 cm 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 connector. 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
Also stick a piece of insulating foil on the inside edge of the cabinet above each place where a used to prevent the connector piercing through the transformer.
transformer has to be put (see fig. 6).
ADHESIVE PROTECTION FOIL
Fig. 4.0
15
Assembly into the unit Mount the ring core transformers: Stick a adhesive foot to the base of the cabinet, in the middle where each transformer has to be put. METAL CASE RUBBER WASHER
Cut 4 x 4 cm TRANSFORMER
RUBBER WASHER
Fig. 5.0
PLATE
BOLT
Mount an output transformer on the left-hand side of the housing, see figure 6.0. WIRES
ADHESIVE PROTECTION FOIL
OUTPUT TRANSFORMER ZD043
ADHESIVE FOOT
ADHESIVE FOOT
Fig. 6.0
ADHESIVE PROTECTION FOIL
POWER TRANSFORMER 8D002
OUTPUT TRANSFORMER ZD043
WIRES
WIRES
ADHESIVE PROTECTION FOIL
ADHESIVE FOOT
WIRES
WIRES
Check the position of the leads.
Turn over the housing and solder the transformer leads to the output terminals, see figure 7.0.
8 0 4 HEAT-SHRINK SLEEVE
Fig. 7.0
BLUE RED YELLOW
Do not forget to insert 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 up until the solder melts easily. Then slide the insulating heat shrink sleeve over the leads.
16
Assembly into the unit Twist the previously soldered red and yellow wires together and fit them as shown in the figure, the cable ties supplied can also be used. 8 0 4
OUTPUT TRANSFORMER ZD043
8 0 4
OUTPUT TRANSFORMER ZD043
YELLOW
BLUE
RED
RED
BLUE
YELLOW
Fig. 8.0
Mount the supply transformer in the middle of the cabinet. Ensure that the leads are positioned as shown in the figure 6. The thick grey and green wires must be at the highest point. Mount an output transformer along the right-hand side of the housing, see figure 6. Check the position of the wires. Solder the transformer leads 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 over the leads.
!
IMPORTANT: Ensure that the transformers do not touch any metal parts such as the loudspeaker terminals or the input connector.
17
Assembly and wiring
28. Assembly and wiring Fit the main PCB into the housing and screw it down with the black Allen bolts along the underside. Connect the mains lead to the screw connector, MAINS, with the blue wire to the N terminal and the brown wire to the L terminal. The short earth wire is connected to the EARTH connector. Connection of the transformers:
!
IMPORTANT: The connector leads of the transformer may not be shortened. If there is more than one wire in an insulating sleeve, then they MUST be soldered together, and only then connected to the screw connector.
Connect the left-hand output transformer to the left-hand connector, SK7, and the right-hand output transformer to the right-hand connector, SK8.
The twisted yellow and red wires must also be connected to the proper connector. See fig. 9 8 0 4
OUTPUT TRANSFORMER ZD043
8 0 4
OUTPUT TRANSFORMER ZD043
YELLOW
BLUE RED
RED
YELLOW
BLUE
YELLOW LS+
RED LS-
RED LS-
YELLOW LS+
ORANGE
VIOLET
BROWN
GREEN
BLACK
BLACK
BLACK
BLACK
GREEN
Fig. 9.0
VIOLET
BROWN ORANGE
Connect the leads of the supply transformer to the screw connector, SK6. 8 0 4
8 0 4
L
MAINS
OUTPUT TRANSFORMER ZD043
POWER TRANSFORMER 8D002
OUTPUT TRANSFORMER ZD043
L GND GND R
PINK BROWN BLACK YELLOW YELLOW BLUE ORANGE RED
EARTH N BLUE L BROWN
6.3VAC GRAY
R
Fig. 10
6.3VAC GREEN
The thick grey wires may be twisted and connected the 6.3V connection (SK3) of the left-hand amplifier. The thick green wires should be connected in the same way to the 6.3V connection of the righthand 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.
18
Final inspection
29. Final inspection
!
ATTENTION: THERE ARE VOLTAGES OF MORE THAN 400V AT MANY POINTS ON THE PCB. Ensure that suitable insulated measuring leads are used. Ensure that no children are in the vicinity.
Switch the mains voltage switch to OFF, ie. fully down.
Connect the mains connector via a lead to a mains outlet. The plug may have to be changed for your country. In that case, cut off the plug from the lead, and connect an appropriate plug for your country. Connect the blue wire to the N connector of the mains, the brown wire to the L connector and the yellow/green wire to the earth. When connected to the mains, the red LED at the front should light up.
Switch the mains switch to ON ie. fully up. The LED at the front should flicker green/red while the amplifier is warming up. After approx. one minute, the green LED will be continuously lit, you will also hear a relay energise. Check the following voltages with a volt meter: Approx. 6.3 VAC on the terminals marked 6.3 VAC (SK3 and SK4) on each amplifier half. 6.3V should also be found at connectors 2 and 7 of the tube sockets, V1 to V8.
7
2 1
1
2
7 Fig. 11
!
FIRST SWITCH OFF THE MAINS VOLTAGE AND REMOVE THE MAINS CORD FROM THE SOCKET. WAIT FOR A COUPLE OF MINUTES UNTIL THE HIGH VOLTAGES ON THE SUPPLY ELCOS HAVE DISSAPEARED.
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 (next to the mains switch). Measure the voltages at the points indicated on the PCB.
NOTE: The measured voltages
may differ depending on the tolerances of the mains connected. Voltages of 0.4V cannot yet be checked.
19
Setting - up
30. Setting up Switch off the mains voltage. Turn all trimmer potentiometers, RV1 to RV8, fully anticlockwise. Mount the 8 tubes, V1 to V8, type EL34 (or C6A7, CV1741) into their sockets (check the position of the notch).
!
IMPORTANT: Connect an 8.2 Ohm 5W resistor between the output terminals (0 and 8 Ohm) of both channels. The output of a tube amplifier must always be loaded. Make sure that there is a good contact with the loudspeaker terminals, the connections of the resistors may have to be thickened a little with solder.
Standby current adjustment No measuring equipment is needed for the following adjustment, the standby or bias current of each tube can be seen from the LED scale on the front. The individual tube to be checked can be selected using the small DIP switches. RV1 corresponds to V1, RV2 to V2, etc.
!
ATTENTION: The following adjustment is a reference for the bias current of the power tubes. Be very careful in setting them. Also respect the order of adjustment. No signal may be connected to the input.
Set all 8 DIP switches to the OFF position (up). Each switch has an associated tube, never set more than one switch ON (down) otherwise you will get an incorrect reading of the LED scale. Switch the mains voltage on and wait until the green LED is lit continuously. Adjustment of the left-hand channel: Switch the first switch of SW2 (left-hand DIP switch) ON (down). Carefully adjust RV1 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 RV2 until the second 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 until the second or third LED lights up. Complete the adjustment for all tubes of the right-hand channel. Now wait for around 10 minutes. Repeat the complete adjustment but adjust until one of the two green LEDs lights up. After adjusting all tubes, the voltages of around 0.4V can be checked.
20
Test & final assembly of the cabinet
31. Test The amplifier can now be connected to loudspeakers of 8 or 4 Ohms, the common connection is in the middle. IMPORTANT If 8 Ohm loudspeakers have been connected, then first check that not too much hum can be heard in the loudspeakers, which is why a preamplifier should not yet be connected. Should too much hum be audible, then the output transformer of the channel concerned should be turned a little clockwise or anti-clockwise until the hum weakens. This operation has no effect on the 4 Ohm connection.
!
Note that the amplifier is under voltage. Be careful when turning the transformer because if any of the leads come away the transformer will be damaged. It is best to place a small loudspeaker close to the amplifier such that you can turn and listen for the best result.
Now a preamplifier can be connected and the unit can be tested with music.
32. Final assembly of the cabinet 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 loose earthing wire, the last lead goes to the rear mirror.
Fig. 12
Mount the cage nuts in the rear mirror (be careful of scratches), the groove for the earth lead goes upwards, then the nuts of the cage nuts should be below. Attach the cover plate for the tubes to the rear mirror (do not yet tighten the bolts). When using a black cover, a masking sticker may have to be removed from around one of the holes, such that plates can make an electrical contact. Mount the cover plate and rear mirror on the cabinet and fasten them temporarily with Allen bolts.
21
Final assembly of the cabinet The cabinet can now be completed 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).
HOUSING
6mm M3 BUTTON HEAD BOLT LOCK WASHER SUPPORT BRACKET FRONT PANEL 6mm M4 BUTTON HEAD BOLT
Fig. 13
If it all fits together well, then all bolts can be fully tightened.
22
Usage
33. Usage
!
WARNINGS.
THIS UNIT GETS HOT, KEEP OUT OF REACH AND AWAY FROM CHILDREN. CHECK THAT THE MAINS VOLTAGE CORRESPONDS TO THAT OF THE UNIT. BEfORE OPENING THE UNIT, THE MAINS CORD MUST BE REMOVED IN ORDER TO AVOID ELECTRIC SHOCKS.
It is normal for the tubes and cabinet to get very hot, so place the amplifier in a well ventilated area, certainly not in a closed cabinet or rack. We advise to check the standby current adjustment once a year, certainly if the end tubes are new. This can easily be done by removing the front panel. If the amplifier is not used for a short period of time, then set it to standby by putting the mains switch in the middle position.
34. Troubleshooting No high voltage. Check the transformer wiring. Check the fuses. Irregular crackling in the loudspeaker. Replace R88 or R85 of the channel concerned. A continuous buzzing in the loudspeaker (continuous oscillation of the amplifier) or crackling in bass peaks. When using a piezo 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). THE ABOVE ADJUSTMENTS SHOULD NOT BE DONE IN ANTICIPATION, ONLY IN THE EVENT OF PROBLEMS AND AFTER HAVING THOROUGHLY CHECKED ALL COMPONENTS, CABLING AND SOLDERING. 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 associated anode resistance of 10 Ohm will almost certainly be defective, also check the 220 Ohm resistors, R63, R64, R66 and R67.
!
ATTENTION: Should the amplifier not work, just send it to us so that we can check it. Please only send the MAIN PCB !. If you decide to send the complete unit, you MUST order a special protective shipping box (order code DM4040) from you distributor. If not then the unit will surely be damaged during transport and it will suffer damage beyond repair. Velleman Kit can never be hold responsible for damage during transport! Happy listening.
23
230
9
1N4007
C
1N4007
1N4007
B 120 MAINS
100 A 7
D4
D6
D3
D5 R3
1N4007
470u
1N4007
+V
OFF
C24 100u
L-56BHD
C28
R9 220K
R37
1K5
560
270/1W BC547C
T3
R35 1K5
D24
D15
1N4148
R6
R7
220K
2K2
SI
D16
C26
1N4148
470u
RY5 VR10V121C
GREEN
RED
1N4148
BC516
D18 1N4148
1N4007
R77
C25 C23 470u ZD2 T4
LD1
R36
D17
1N4007 4u7
D19 1N4148
470
0
D26
D21 D25
1N4007
12VAC/2.5VA
1N4007
D20 ON SW1
12VDC
+V1L
415VDC
LD2 R8
L-93WEGW
BC547C
T2
R80
2K2
+V3L
D2
1K
1N4148
15K/1W
1N4148
R4 D1
TRANSFO2
RY4 ZD1 7V5
C27
R78
RED
VR10V121C
C40
C37
220u/450V
220u/450V
100u/400V
R79 1N5408
10K/1W10K/1W D13 1N5408
BC547C
T1
C39
+V1R
D14
R82
300V/1.3A
VR5V122C
RED
R105 R107 R108 R106 15/5W
15/5W
15/5W
15/5W
VIOLET 245 ORANGE
D12 1N5408
D10 1N4007
D7
100 BLACK 0
R81 680K/1W
-50VDC
1N4007
R5
C42
C38
220u/450V
100u/400V
C41 220u/450V
D9 YELLOW GREEN 6.3V/7A
GREEN GRAY 6.3V/7A
GRAY
R70 BIAS1
1N4007
D8
22K
C29
1N4007
f1 LEFT CHANNEL f2
SW2
+V 1N4148 V+
D22
C34
2
3
100u
0.5 10
330K/0.5W
R71 BIAS3
3
NC
-50VDC
R10
R72
11 0.45
BIAS4
C30
22K
C31
5
R74 BIAS5
1
13
SW3 14
47u/100V
R73 BIAS6
7
2
R75
15
33K
330K/0.5W
BIAS7
0.375
R48
16 0.325 17
330K/0.5W
R76 BIAS8
RLO
4
330K/0.5W
1N4148
18
1K5
8
12K
R47 R49
ADJ
2
1 V-
LD4 RED
0.275
D23
LD5 RED
0.3 4
LD6 RED
6
3
LD7 GREEN
0.35 RHI
LD8 GREEN
LM3914
REF
LD9 RED
0.4
330K/0.5W
LD10 RED
0.425
330K/0.5W
-VR 100u/100V
SIG
LD11 RED
9 12
4
LD12 RED
0.475 MODE
330K/0.5W
LEFT CHANNEL f2
R69 BIAS2
47u/100V
f1
1
330K/0.5W
-VL
50V/0.1A
120 BROWN
15K/1W
D11 1N5408
YELLOW
230 BLUE
365VDC
+V3R
470u
RY3
365VDC
LD3 RED
Diagram
TRANSFORMER D 245
F1
N
35. Diagram power supply
24 2.5A SLOW @ 230-245VAC 5A SLOW @ 100-120VAC
L
+V3R
365VDC
36. Diagram (right channel)
-VR
-50VDC
100K
100K
RV6
RV5 180/1W
R54
R52
100K
R50
100K
220K
180/1W
EL34
3
R93
3
R94
V5
EL34
V6
1
C18
R62
335VDC
260VDC
100p/400V
47K/.5W
R60
C36
4
R28
R88
3K9 110VDC
390K/1W
47K/1W
1/2 V11
1
ECC82
R2
C2
33K
100p
100p
R16
SI
1 14
C5
6
V10
0.4VDC
0.4VDC
5
TRANSFO4
5 8
ZD043 8
BIAS5
C15
BIAS6
ORANGE
BLUE
820K
1M 9
220K
C19
BROWN
YELLOW
8 4 9
12K
10/1W
415VDC
22n/630V
R32
C21
10K
f1 f2
470n
R24 820
R25 180
47u
C33 R68 820/.5W
C17
BLACK f1 f2
f1 f2
2n2
C16
22n/630V
R87
C22
47K/1W
-VR
-VR
R102
10/1W EL34
100VDC
GREEN
R104
220K
f1 f2
7
2
V8 R34
4 Ohm
BLACK
+V1R
R55
7 8
10/1W
f1 f2
10K
3 5
4 5
R101
f1 f2
R33
8 Ohm
7
2
R103
22n/630V
R23
R26 3
7
R53
2
7
22K
RY2 2 13
22n
ECC83
R27
R13
GND
VR05R121A
22n/630V
2
IN RIGHT INPUT
10K
2
1
6
C4
R51
C20
100K/.5W
22u/350V
1K
22n/630V
R86
4
10/1W EL34
8
7
2
BIAS7 V7
5
BIAS8 LS
5 0.4VDC
10K 4
1
RED
VIOLET 8
GND
GND
0.4VDC 4
1
R57 220K
100K
GREEN
f1 R66
RV7
100K
RV8
R95
R96 180/1W
3
180/1W
3
220/.5W
R56
6.3VAC
100K
R58 100K
R67 220/.5W
GREEN
f2
Diagram
25
365VDC
-50VDC
100K
100K
RV2
RV1 180/1W
R42
R40
100K
R39
100K
220K
180/1W
EL34
3
R89
3
R90
V1
EL34
V2 1
C10
R61
R59
C35
260VDC
100p/400V
47K/.5W
335VDC
R22
R85
3K9 110VDC
390K/1W
1/2 V11
6
ECC82
LEFT INPUT
47K/1W
C3
C1
ECC83
C9
V9 R21
100p
R12
6
1 14
TRANSFO3 ZD043
8
BIAS1
820K 8
BIAS2
ORANGE
BLUE
BROWN
YELLOW
4
R99
9
470n
R18 820
R19 180
47u
C32 R65 820/.5W
C7
415VDC
R29
C14
10K
BLACK f1 f2
f1 f2
2n2
C8
C13
47K/1W
-VL
-VL
f1 R63
RV3
RV4
220/.5W
6.3VAC R64 220/.5W
f2
R44
R46
100K
100K
10/1W EL34
8
7
2
BIAS3 V3
5 0.4VDC 4
1
BIAS4 LS
R92
0.4VDC 4
1
R91
180/1W
180/1W 3
3
RED
VIOLET 8
5
10K
220K 100K
7
2
V4 R31
R45 100K
GRAY
R98
10/1W
22n/630V
R84
GREEN
R100 EL34
100VDC
4 Ohm
BLACK
+V1L
220K
f1 f2
10/1W
f1 f2
R43 f1 f2
R97
10/1W
10K 22n/630V
8 Ohm
7
2
f1 f2
R30
3 5
7
220K
C11
12K
7 8
GRAY
0.4VDC 5
8
22n/630V
R17
4 5
9
RY1 2 13
0.4VDC 5
R41
C6 2
7
1M
8
R11
SI
22n
R20
33K
47n
10K
2
1
22K
GND
VR05R121A
22n/630V
7
1K
R38
C12
R83
6
IN
22n/630V
100K/.5W
22u/350V
R1
4
4
GND
GND
Diagram
+V3L
37. Diagram (left channel)
26 -VL
D15
C25
D16
C26 RY1
D14
R59 C31
R80
J2
C40
C38
C42
365VDC J3
R61
GREEN
BLACK
GREEN
SK13...16
J6 C21
3
V3
ORANGE
C22
V7
V6
R29
R32 5
5
8
8
5 1
5
8
8
4
1
R31
3
0.4VDC
4
1 R102
R92
R98 R97
4
R95
1
R91
4
R101
0.4VDC
R30
3
0.4VDC
R34
R96
C13
C14
C11
C12
C18
R93 R94
V2
110VDC
R28
C20
J5
SK14
BLACK
BROWN
R88
C19
C10
DANGER HIGH VOLTAGE
110VDC
R22
SK15
VIOLET C17
J23
R85
0.4VDC
YELLOW LS+
V10
J22
SK16
R68
R25
RED LSC16
R27
100VDC
SK9...12
R90
f2 C33
SK13
260VDC
J12
V9
R89
f2
9
R23
C9
C7
SK4 SK4
R24
J11
R21
3
J21
C5
R67 f1 1
R87
J14
C8
R86
R65
C32
R20
R84 C6
J17
R66
R18
SK9
VIOLET
f2
9
R19
SK3
1
260VDC 100VDC
GREEN
SK3
f1
J4
J16
f1 J9
R64
C15
BLACK
R63
335VDC
6.3VAC
f2
R17
BLACK
R83
SK12
J8
SK10
BROWN
415VDC
6.3VAC
SK11
ORANGE
J10
GRAY
GRAY
415VDC
R62
335VDC
J15 GREEN
D6
D5
365VDC
R26
D4
D3
J1
f1
R16 R13
R60
J20
C37
RED LS-
1
V11
GND
C36
2 9
C29
12VDC
GND C3
R2
R
C35
C39
F1
YELLOW LS+
C4
3
8 C28
R108
R11
R107
5 J19 4
J18 6
7
C27 -50VDC
L
R1
-50VDC R10
R81
1
D13
D12
12VAC
RY2
R12
C41
1
D7 D8 D9 D10
C24
R79
D11
R5
T1
T4
R6
R82
D2
ZD1 R4
D1
C23
J13
T3
C30
TRANSFORMER J7
RED
RED
YELLOW
BLUE
BLACK
ORANGE
BROWN
VIOLET
YELLOW
SK8
T2
0
230V
RY4
100V
245V
R106
SK5
5A SLOW AT 100/120VAC 2.5A SLOW AT 230/245VAC
SK7 SK6...8
R78
RY3
L
SK6
120V
R105
MAINS
RY5
R7 R8 ZD2 R9 D18
SK5
N
R77 D17
C D DA B C AB
EARTH
38. PCB
A: 100VAC C: 230VAC B: 120VAC D: 245VAC VOLTAGE SELECTION
R3
R33
D26 J24
J25
VELLEMAN P4040B'2
D19 0.4VDC D24
0.4VDC
V1
3
0.4VDC
R99
3
V4
V5
0.4VDC
R103
D21
D20
R100
V8
R104 5
4
1
5
8
5
8
4
1
5
8
8
4
1 R73 R74
R49
1
R75 R76
3
2
3
4
SW3 R58
RV5
R56 RV8 R57
IC1
R54 RV7 R55
R51 R50
D22 D23
C34
R52 RV6 R53
RED 0.5V
RED
RED
RED
GREEN
RED
GREEN
1
RED
4
RED
3
RED
2
3 LD3 LD4 LD5 LD6 LD7 LD8 LD9 LD10 LD11 LD12 0.275V
R46 RV4 R45
27
1
R44 RV3 R43
J26
R42 RV2 R41
3
SW2
R47 R48
1
!
PCB CONNECTED TO MAINS HIGH VOLTAGE
PCB
1
R71 R72
R38 3 R40 RV1 R39
SW1
1
LD2
4
1 R69 R70
2
R37
R36
LD1
1
D25
R35
VELLEMAN NV Legen Heirweg 33, B-9890 GAVERE Belgium (Europe)
Modifications and typographical errors reserved © Velleman Kit nv H4040IP’1 - 2014 (rev. 3.0)
5 410329 319182
