K8040 Illustrated Assembly Manual (English)
Contents
1. Slide two M3 nuts and two hexagonal bolts into the pro file 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 Final assembly vellemen 26 final PCB mount RE CHECK CAREFULLY THE PCB FOR MOUNTING AND SOLDERING ERRORS Mount the pcb into the enclosure check the position of the power IC The IC support must fit onto the previously inserted hexagonal bolts Make sure there is silicone compound between the IC support and the enclosure Glue the included insert 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 lt Note Not all components are visible on the drawing velleman Final assembly 27 Speaker and mains connector assembly Prepare the wiring of the mains connector like in the drawing First mount the switch into the mains connector assembly Do not forget to isolate the soldering connections using a piece of shrink tube Use the supplied 0 5mm wire Blue for Neutral Brown for Live Yellow green for earth Use 3 pieces of about 10cm for later con2. 100n 47 gt Ne a 4 R11 R28 470R 2K2 0 6W LD3 INTEGRATED MONO MOSFET AMPLIFIER 77 R29 a 2K2 0 6W K8040 1 0 Power supply indication LED3RL 5mV input signal detector N Values are for reference only ay oee Zop Of ze Jo T 8AS zea of fo 019 or of suas ol a 268 suss dus 57 i IE Q 9 5 voo mp BE 43147 TaWV 0145 mat fo LER lt O wv ja O0 Pele T Ov08d 1109415 119313 er anna 5 7 UENAOASNYAL 9 JYN9IS LNANI Q 1 13 TD d m EP AP MEEST ofa p 975 IYW olea Tua 391334403 143 as 2 011931044 OEI 8484 jO Sog 21 39 L70N HOIH NEN PEEP Jo LINIJAII TOHLNOI 61 G NO 812 DE 7 9 692 ran 49150 Foto Bn 28 23 ASALSILNN 3145 ced ONY ISN AISHI 351354 LNOHLIM LINIAII NOILIALOAd 2 SNION OL jo 193NNOI AININ Fe dk exs Pp NOILNYI NMOAS J9NYHO NOEZ 0115313 3991100 SNIYW VELLEMAN Components Legen
3. Heirweg 33 9890 Gavere Belgium Europe Info http www velleman be Modifications and typographical errors reserved Velleman H8040IP 2001 ED1
4. 5 Check the user manual to test all functions and operation of the unit Finally the cover can be mounted Y Please note that the user manual is also used for the assembled version some remarks may not apply to the kit version vellemen DIAGRAMS 25 Mains in from 2A fuse switch BRIDGE RS603 VR1 R40 TIC246M 40 000uF 50V 10 000UF 50V ZD1 UA7805 5V Transfo Prim SK5 D7 Power meter 4 7 10W ERE a SK3 SK4 20V 1 3W C17 100K R17 c2 1N4148 R22 vor AN 10u 100n 023 4708 O A 35V 3 2K2 0 6W 100NF 250VAC En SW KRS1243 DC prot test 470R 25VAC 2A SKG 10 000UF 50V 10 0000 50 Den S Ben u 2K2 0 6W D3 10 6 1N4148 SK1 ei C29 12 DJ IC3 1uF 15K MOC3041 D4 220u 63V 1N4148 100NF 250VAC C30 8T 1 5mm dia 8mm 1N4148 1 22 V DC Protection fuse blow 06 15 SK9 BYPASS 1N4148 LS SK10 5V A R33 Je LD4 El 1008 Ei L 424YDT 9 15 OFF Stby 2n2 Ri R39 1K 2 R13 Re 12 10R 1W 2 10 DE ay lg 15K A 5 47p 63V Ci0 ol Cig 5V 4 A a 10 i R35 H A A 10u 680R Temp sens L 424YDT 2 LD5 R7 5 ENTI 15 U BC547 15K ont C14 C28 R3 R4 D8 R9 15K fik otd 2u2 47u 63V 15K LD6 3 a R2 D1 L 424YDT R6 1K 1N4148 R24 Temp error 5V 100R 470K 5V CLIP R34 STBY ON SW1 NZ 7 C25 5
5. 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 operation 0 Now the three fixations be tightened Check the push button vellemen Test 30 Test Check again all connections of transformer and mains Connect the mains wires to the mains connector Blue Neutral green yellow Earth 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 CHECK FUSE AND R AFTER DC ERROR INPUT SIGNAL DETECTION CIRCL Ar CAUTION Some points on the 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 the bulb glows constantly disconnect the power immediately and re check all connections e Normally the standby LED on the front panel should light as should both 35V power indication LED s LD2 and LD3 Test vellemen Test continued Now push the DC protection test button SW2 the bulb should light if the but ton is pressed Be careful not to touch any exposed live parts Disconnect the mains plug Now the brown Live wire can be connected directly to the connector
6. 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 R28 2K2 0 6W 2 2 2 9 R29 2K2 0 6W 2 2 2 9 R30 OR 0 R31 15K 1 5 3 R32 100K 1 0 4 R33 100R 1 0 1 R34 OR 0 R35 680R 6 8 1 R36 15K 1 5 3 R37 100K 1 0 4 R38 470R 4 7 1 R39 10R 1W 1 0 0 JGND OR 0 E E E E E E E E E E E E E If long input signal wires used a low input impedance can be useful In this case mount for RX a 680R 6 8 1 resistor Check if your pre amplifier can drive low impedance Our K8021 is OK for low impedance Our K8020 is not suited for low im pedance driving Rx is normally left open Construction 5 Multilayer capacitors 100n 100n 100n 100n 100n 100n 100n 100n 104 0 1 1 104 0 1 1 104 0 1 1 104 0 1 1 104 0 1 1 104 0 1 1 104 0 1 1 104 0 1 1 D U IC1 8P 2 8 IC3 6P 7 10W resistor Q R40 4R7 4 7 4R7 Construction 8 Capacitors 9 2 2 222 2200 10 220n 22 u22 224 C11 1uF C12 1uF C13 2 2uF C14 2 2uF C15 100n 250V 104 0 1 ul C16 100n 250V 104 0 1 ul D U 9 Transistors T1 BC547 T2 BC547 vellemen 10
7. RCA connectors Mount them straight and against the PCB SK1 MJ 523AG R Q SK2 MJ 523AG B Tip A red and a black type are delivered with the kit if you bought two amplifi ers for stereo then one amplifier can be built with red connectors right amp and one with the black connec tors 11 Push button Mount them straight against the PCB surface SW1 TS 04PV SW2 KRS1243 vellemen 12 Terminal blocks SK3 3 pole Mains in SK4 pole Mains transformer SK5 SK6 2x 2 pole Transformer output 5 First slide these two connec tors in each other Construction 13 Terminal connectors Check that the position corresponds with the PCB silk printing 7 2 pole Temp sensor SK8 2 pole Power meter SK9 LS LY SK10 LS Construction This coil will have to be made by yourself Use the supplied copper wire 1 5mm with the kit Wind this wire round a 8mm drill or other round object and make 8 turns You can snip off the remaining copper Then remove scratch the isolation from the connections using a knife Mount the coil and make sure to have a perfect soldering L1 8 Turns dia 8mm 15 Electrolytic capacitors Check the polarity 10 10uF 10uF 10uF 10uF 1 10uF 47uF 63V 47uF 63V 47uF 63V 47uF 63V 220uF 63V 220uF 63V vellemen 16 Voltage regulator The back side c
8. Total solder points 299 HIGH Q NEZ Difficulty level 20 40 SM advanced velemen kil HIGH END mono mostet power amplifier K8040 M A mpl if 0 osfet Power Amplifier DANGER Observe all safety requirements ILLUSTRATED ASSEMBLY MANUAL H8040IP 1 VELLEMAN COMPONENTS Legen Heirweg 33 9890 Gavere Belgium http www velleman be vellemen 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 e good quality soldering iron 25 40W with a small tip Na e Wipe it often on a wet sponge or cloth to keep it clean then apply solder 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 e Thin raisin core solder Do not use any flux or grease e A diagonal cutter to trim excess wires To avoid injury when cutting excess leads hold the lead so they cannot fly towards the eyes e Needle nose pliers for bending leads or to hold compo nents in place e Small blade and phillips screwdrivers A basic range is fine A For some projects a basic multi meter is required or might be handy 1 2 Assembly Hints Make sure the skill leve
9. ion 23 Mounting the Power IC IC4 TDA7293 Mount the support plate onto the IC as shown in the drawing Put a drop of silicone compound on both sides of the mica isolator Also check the position of the plastic isolator A ATTENTION The bolt should be inserted on the side of the IC holder with the countersunk opening Drop of heat conductive compound 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 Construction vellemen 24 Mounting the power transformer and mains voltage selection Mount the transformer as in the drawing see also the picture on the packaging Use the supplied straps 4 pcs to fix the transformer Primary windings MAINS connection Check the table on the PCB for the correct voltage selection and connect the 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 velleman Enclosure preparation 25 Enclosure preparation Cut the thread in the holes for the enclosure feet in one of the alumi num profiles us i
10. l 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 draw ings Values on the circuit diagram are subject to changes Values in this assembly guide are correct Assembly hints vellemen 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 sur face and carefully solder the leads 2 Make sure the solder joints are cone shaped and shiny un 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 Color code table vellemen 8 pnoo 10 PICO ping pins ping ein opeinog Ua y AdBATIS INS INS eadoH ejeld TCT OT CT TE SIE neig EEWIEH 2 9 ong neig inzy 147477 9 EEE m an no neo en on geni opion op opion 5 b 1999 ou
11. nection to the PCB mains connector Yellow green Mount the speaker connectors onto the rear panel black negative Take care of the isolation washers there are two different types See pic ture 5 Make sure the connectors very tight fit and do not make electrical con tact with the panel check using ohm meter Isolation washer Final assembly velleman 28 Final assembly and connection Solder a 15cm 2 5mm wire to the LS connectors Black negative Red positive use a shrink 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 2A fuse into the connector there is also room for a spare fuse velleman Final assembly Mount the rear panel onto the enclosure using two M4 Allen screws Connect the speaker wires to the speaker output tabs Check the polatity Black LS Red LS DO CONNECT THE MAINS WIRING WITH THE PCB YET 29 Preparing the front panel Connect the two wired connector to the meter RED BROWN to the meter Mount the power meter onto the front panel LI Fix the meter using a piece of transparent ad O hesive tape four sides 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 5
12. ner Moje OTEL INS ope poy 1euZ OSSOH und und wid ws und uud und one suuer 1 0 Memz HON yoelg Ziemyas MOS MOS HEAS esni 4 01944 0 5340 nn NOILVO AGOM AGOM VNAHOS IGOOmM 340109 An IAIGODENOTOD FAdVA 59474 IHYA O9IGOI 321 02 sq Zep AP amp AR G 2 40109 Construction vellemen CONSTRUCTION The unit consists of one main PCB with all the components including trans former and power supply The pictures on the packaging can be used as a guideline However due to possible modifications they are not 100 reliable Mount the components in the order described 1 Jump wire 3 Zener diode check the polarity CATHODE 201 20V 1 3W Mount 5mm above the PCB E E E 4 Resistors check the color code CATHODE 1N4148 1N4148 1N4148 1N4148 1N4148 1N4148 1N4148 1N4148 1K 1 0 2 1K 1 0 2 15K 1 5 3 1K 1 0 2 470R 4 7 1 1008 1 0 1 15K 1 5 3 15K 1 5 3 0009000986 D U vellemen 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 100 1 0 1 R18 1K 1 0 2
13. ng the supplied special M4 screw as a tap Mount the feet on the aluminum profile using two M4 hexagonal Al len screws Use the supplied Allen wrench It is advisable to stick the protection adhe sive onto the feet Cut the thread in the front and back of the aluminum profiles us ing the supplied spe cial M4 screw 4 holes N per piece Cam UG vellemen Enclosure preparation Position the main PCB in the aluminum profile that is preparen with the feet Mark the center position of the three fixation holes on the aluminum A refer ence indication is also on the PCB edge 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 Q lt 9 FIG 5 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 hex nut mmm VASNET WII 5mm spacer Li 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 velleman Enclosure preparation Using an ohmmeter measure between the edge of the aluminum profile and the back spacer if there is a good electric contact less then 10 ohm If not repeat the above step to remove the paint under the spacer
14. orresponds to the thick line LY VR1 UA7805 17 Triac The back side corresponds to the thick line TR1 TIC246 or eq vellemen 18 Bridge rectifier Check the polarity BR1 RS603 19 LEDs COLOR 2 5 5 101 LED3RL 3mm LED LD2 LED3RL 3mm LED LD3 LED3RL 3mm LED Construction 20 Power electrolytic capacitors Check the polarity C31 10 000uF C32 10 000uF C33 10 000u F C34 10 000uF 21 Insert the IC s into their sock ets Watch the position of the notch IC1 VK8040 PIC12C508 IC2 CA258 or eq IC3 MOC3041 KP3020 Construction vellemen 22 Mounting front LED s Check the polarity Short lead Cathode CATHODE I First Bend the leads exactly like the drawing Next Solder one lead and check the position if necessary correct by heat ing the soldering Last Solder the second connection 104 L 424YDT 105 L 424YDT 106 L 424YDT 107 L 424YDT Meter backlight LD8 is a white LED serving as backlight for the power meter 108 L5WD 5mm white CAUTION After bending the leads the long appearing lead will be the cath ode si 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 the front panel as a positioning reference 18mm CATHODE vellemen Construct
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