Total solder points: 700 Difficulty level: beginner 1o 2o 3o 4o 5þ advanced

ILLUSTRATED PARTLIST H4040IP-ED1

K4040 STEREO VALVE POWER AMPLIFIER ⇒ 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 8Ω • 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

stereo power amplifier 4040

5%

4K7= ( 4 - 7 - 2 - B )

1%

4K7= ( 4 - 7 - 0 - 1 - 1 )

COLOR= 2… 5

I P E SF S DK N D GB F NL CODE

CODICE COLORE

CODIGO DE

CORES

CODIGO DE

COLORES

VÄRI KOODI

FÄRG SCHEMA

FARVEKODE

FARGEKODE

FARB KODE

COLOUR CODE

CODIFI-CATION DES COU-LEURS

KLEURKODE

CODE

0 Nero Preto Negro Musta Svart Sort Sort Schwarz Black Noir Zwart 0 1 Marrone Castanho Marrón Ruskea Brun Brun Brun Braun Brown Brun Bruin 1 2 Rosso Encarnado Rojo Punainen Röd Rød Rød Rot Red Rouge Rood 2 3 Aranciato Laranja Naranjado Oranssi Orange Orange Orange Orange Orange Orange Oranje 3 4 Giallo Amarelo Amarillo Keltainen Gul Gul Gul Gelb Yellow Jaune Geel 4 5 Verde Verde Verde Vihreä Grön Grøn Grønn Grün Green Vert Groen 5 6 Blu Azul Azul Sininen Blå Blå Blå Blau Blue Blue Blauw 6 7 Viola Violeta Morado Purppura Lila Violet Violet Violet Purple Violet Paars 7 8 Grigio Cinzento Gris Harmaa Grå Grå Grå Grau Grey Gris Grijs 8 9 Bianco Branco Blanco Valkoinen Vit Hvid Hvidt Weiss White Blanc Wit 9 A Argento Prateado Plata Hopea Silver Sølv Sølv Silber Silver Argent Zilver A B Oro Dourado Oro Kulta Guld Guld Guldl Gold Gold Or Goud B

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3

VELLEMAN KIT NV Legen Heirweg 33

9890 Gavere Belgium

http://www.velleman.be

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4

STEREO VALVE AMPLIFIER TECHNICAL DATA* • Output power:

2 X 0 to 15 Wrms class A 2 x 15 to 90 Wrms class AB

• Output impedance 4 or 8 Ohms • Ultra linear output transformers • Switch-on delay, to protect the output tubes: approx. 1 minute • Standby circuit • Built-in bias current indicator • Switch-on delay for the supply transformer: 0.5s • Power bandwidth: 15 - 40kHz (-3dB, ref 50W) • Frequency range: 8 Hz - 80kHz (-3dB, ref 1W) • Harmonic distortion:

0.1% (1 kHz/1W) 0.7% (1 kHz/90W)

• Signal/noise ratio: > 105dB (A weighted wrt 90W) • Channel isolation (75dB wrt 90W) • Input impedance: 34Kohm • Input sensitivity (1Vrms) for 90W • Damping factor (100Hz): > 10 *We reserve the right to make changes. ASSEMBLY STEPS Required tools to assemble the kit: Use a small soldering iron of max. 40W. Use thin (1mm) solder, do not use any flux. Use a small cutter to trim the excess wires.

1.

2.

3.

4. Mount the components against the PCB surface and carefully solder the leads in place.

Obtain cone- shaped, shiny soldered joints by heating the component leads suffi-ciently.

This solder joint re-sults in a bad con-nection.

Trim the excess wires up to the level of the solder

• Careless assembly will certainly lead to problems. • Insert the part, oriented correctly, into its correct holes on the PCB. • Mount the components in the correct order as stated in this manual. • The component values in the circuit diagram are for reference only. The values in this parts list are

correct and must be followed. • Use the boxes q to check off your progress. FBefore starting to build, read also the general guidelines

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5

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 cabi-net.

1. CAPACITORS

C...

q C1: 47nF (473, 0.047)

2. CINCH / RCA CONNECTOR Mount them as straight and square as possible against the PCB

q SK1: CINCH q SK2: CINCH

3. SHIELDED WIRE CONNECTION Carefully strip the screened cable supplied and make the connection as shown in the figure

15cm

LEFT

RIGHT

GNDGND

P4040i

q L q R q GND q GND

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6

15mm M3 SPACER

8mm SPACER

PCB

VALVE SOCKET

15mm M3 BOLT

Assembly of the main PCB P4040B: Foreword: Because of the PCB dimensions, first mount the 8 large tube sockets so that the PCB can rest on a ta-ble, 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.

23

41

3

57

4

6

58

1

8

q V1: I.O. q V2: I.O. q V3: I.O. q V4: I.O. q V5: I.O. q V6: I.O. q V7: I.O. q V8: I.O.

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:

6mm M3 BOLT

M3 LOCK WASHER

15mm M3 SPACER

2 7

1

8

5

4

3

V...

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 connec-tion does not come above the spacer, otherwise, the wire could touch the housing later (see drawing above).

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7

2. JUMPERS

q J1 (mount 2 wires) q J2 (mount 2 wires) q J3 (mount 2 wires) q J4 (mount 2 wires) q J5 (mount 2 wires) q J6 (mount 2 wires) q J7 q J8 q J9 q J10 q J11 q J12 q J13 q J14 q J15 q J16 q J17 q J18 q J19 q J20 q J21 q J22 q J23 q J24 q J25 q J26

3. JUMPERS FOR VOLTAGE SELECTION

MAINS VOLTAGE SELECTION: For 100V mains input, mount:

A A For 120V mains input, mount:

B B

For 230V mains input, mount:

C

C

For 240V mains input, mount:

D D

REMARK: Strike out the NOT used mains voltage indica-tion at the back of the housing !! e.g. cross out with a permanent black marker 4. DIODES (Check the polarity!)

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:

• 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.

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8

D...CATHODE

q D1: 1N4148 q D2 :1N4148 q D3: 1N4007 q D4: 1N4007 q D5: 1N4007 q D6: 1N4007 q D7: 1N4007 q D8: 1N4007 q D9: 1N4007 q D10: 1N4007 q D11: 1N5408 not on tape ! q D12: 1N5408 not on tape ! q D13: 1N5408 not on tape ! q D14: 1N5408 not on tape ! q D15: 1N4148 q D16: 1N4148 q D17: 1N4007 q D18: 1N4148 q D19: 1N4007 q D20: 1N4007 q D21: 1N4007 q D22: 1N4148 q D23: 1N4148 q D24: 1N4148 q D25: 1N4148 q D26: 1N4007

5. ZENER DIODES (Check the polarity!)

ZD...CATHODE

q ZD1: 3V9 q ZD2: 3V9

6. ¼W RESISTORS

R...

q R1: 1K (1 - 0 - 2 - B) q R2: 1K (1 - 0 - 2 - B) q R3: 470 (4 - 7 - 1 - B) q R4: 1K (1 - 0 - 2 - B) q R5: 22K (2 - 2 - 3 - B) q R6: 220K (2 - 2 - 4 - B) q R7: 2K2 (2 - 2 - 2 - B) q R8: 2K2 (2 - 2 - 2 - B) q R9: 220K (2 - 2 - 4 - B) q R10: 22K (2 - 2 - 3 - B) q R11: 12K (1 - 2 - 3 - B) q R12: 33K (3 - 3 - 3 - B) q R13: 33K (3 - 3 - 3 - B) q R16: 12K (1 - 2 - 3 - B) q R17: 820K (8 - 2 - 4 - B) q R18: 820 (8 - 2 - 1 - B) q R19: 180 (1 - 8 - 1 - B) q R20: 1M (1 - 0 - 5 - B) q R21: 22K (2 - 2 - 3 - B) q R22: 3K9 (3 - 9 - 2 - B)

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9

q R23: 820K (8 - 2 - 4 - B) q R24: 820 (8 - 2 - 1 - B) q R25: 180 (1 - 8 - 1 - B) q R26: 1M (1 - 0 - 5 - B) q R27: 22K (2 - 2 - 3 - B) q R28: 3K9 (3 - 9 - 2 - B) q R29: 10K (1 - 0 - 3 - B) q R30: 10K (1 - 0 - 3 - B) q R31: 10K (1 - 0 - 3 - B) q R32: 10K (1 - 0 - 3 - B) q R33: 10K (1 - 0 - 3 - B) q R34: 10K (1 - 0 - 3 - B) q R35: 1K5 (1 - 5 - 2 - B) q R36: 1K5 (1 - 5 - 2 - B) q R37: 560 (5 - 6 - 1 - B) q R38: 10K (1 - 0 - 3 - B) q R39: 220K (2 - 2 - 4 - B) q R40: 100K (1 - 0 - 4 - B) q R41: 220K (2 - 2 - 4 - B) q R42: 100K (1 - 0 - 4 - B) q R43: 220K (2 - 2 - 4 - B) q R44: 100K (1 - 0 - 4 - B) q R45: 220K (2 - 2 - 4 - B) q R46: 100K (1 - 0 - 4 - B) q R47: 1K5 (1 - 5 - 2 - B) q R48: 33K (3 - 3 - 3 - B) q R49: 12K (1 - 2 - 3 - B) q R50: 220K (2 - 2 - 4 - B) q R51: 10K (1 - 0 - 3 - B) q R52: 100K (1 - 0 - 4 - B) q R53: 220K (2 - 2 - 4 - B) q R54: 100K (1 - 0 - 4 - B) q R55: 220K (2 - 2 - 4 - B) q R56: 100K (1 - 0 - 4 - B) q R57: 220K (2 - 2 - 4 - B) q R58: 100K (1 - 0 - 4 - B)

7. 1/2W RESISTORS

R...

q R59: 100K (1 - 0 - 4 - B - 9) q R60: 100K (1 - 0 - 4 - B - 9) q R61: 47K (4 - 7 - 3 - B - 9) q R62: 47K (4 - 7 - 3 - B - 9) q R63: 220 (2 - 2 - 1 - B - 9) q R64: 220 (2 - 2 - 1 - B - 9) q R65: 820 (8 - 2 - 1 - B - 9) q R66: 220 (2 - 2 - 1 - B - 9) q R67: 220 (2 - 2 - 1 - B - 9) q R68: 820 (8 - 2 - 1 - B - 9) q R69: 330K (3 - 3 - 4 - B - 9) q R70: 330K (3 - 3 - 4 - B - 9) q R71: 330K (3 - 3 - 4 - B - 9) q R72: 330K (3 - 3 - 4 - B - 9) q R73: 330K (3 - 3 - 4 - B - 9) q R74: 330K (3 - 3 - 4 - B - 9) q R75: 330K (3 - 3 - 4 - B - 9) q R76: 330K (3 - 3 - 4 - B - 9)

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8. 1W RESISTORS

R...

2mm

q R77: 270 (2 - 7 - 1 - B) q R78: 10K (1 - 0 - 3 - B) q R79: 10K (1 - 0 - 3 - B) q R80: 15K (1 - 5 - 3 - B) q R81: 680K (6 - 8 - 4 - B) q R82: 15K (1 - 5 - 3 - B) q R83: 47K (4 - 7 - 3 - B) q R84: 47K (4 - 7 - 3 - B) q R85: 390K (3 - 9 - 4 - B) q R86: 47K (4 - 7 - 3 - B) q R87: 47K (4 - 7 - 3 - B) q R88: 390K (3 - 9 - 4 - B) q R89: 180 (1 - 8 - 1 - B) q R90: 180 (1 - 8 - 1 - B) q R91: 180 (1 - 8 - 1 - B) q R92: 180 (1 - 8 - 1 - B) q R93: 180 (1 - 8 - 1 - B) q R94: 180 (1 - 8 - 1 - B) q R95: 180 (1 - 8 - 1 - B) q R96: 180 (1 - 8 - 1 - B) q R97: 10 (1 - 0 - 0 - B) q R98: 10 (1 - 0 - 0 - B) q R99: 10 (1 - 0 - 0 - B) q R100: 10 (1 - 0 - 0 - B) q R101: 10 (1 - 0 - 0 - B) q R102: 10 (1 - 0 - 0 - B) q R103: 10 (1 - 0 - 0 - B) q R104: 10 (1 - 0 - 0 - B)

9. LEDs (Check the polarity!)

LD...

COLOR = 2...5

CATHODE

q LD1: 5mm red blinking q LD2: 3mm bicolor: Carefully check the assembly of this LED:

1 2

LD...2

3

1 3

5mm

5mm

LD2 ONLY !

q LD3: 3mm RED q LD4: 3mm RED q LD5: 3mm RED q LD6: 3mm RED q LD7: 3mm GREEN q LD8: 3mm GREEN q LD9: 3mm RED q LD10: 3mm RED q LD11: 3mm RED q LD12: 3mm RED

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11

10. IC SOCKETS (Check the position of the notch!)

IC...

1

q IC1: 18P

11. REED RELAYS (Check the position of the notch!)

PIN 1

1

RY...

q RY1: VR05R121 q RV2: VR05R121

12. RESISTOR TRIMMERS, vertical type

RV...

q RV1: 100K q RV2: 100K q RV3: 100K q RV4: 100K q RV5: 100K q RV6: 100K q RV7: 100K q RV8: 100K

13. TRANSISTORS

T...

T...

T...

T...

q T1: BC547C q T2: BC547C q T3: BC547C q T4: BC516

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12

14. 5W RESISTORS

R...

2mm

REMARK: You will have two 8.2 Ohm 5W resis-tors left over for later use. q R105: 15 q R106: 15 q R107: 15 q R108: 15

15. DIP SWITCHES

1

SW...

Check that switch 1 corresponds to pin 1. q SW2: DS-4P q SW3: DS-4P

16. CAPACITORS

C...

Check the minimum voltage ! q C3: 100p/400V q C4: 100p/400V q C5: 22n/630V (0.022) q C6: 22n/630V (0.022) q C7: 470n (0.47, 474) q C8: 2n2 (222, 2200) q C9: 22n/630V (0.022) q C10: 100p/400V q C11: 22n/630V (0.022) q C12: 22n/630V (0.022) q C13: 22n/630V (0.022) q C14: 22n/630V (0.022) q C15: 22n/630V (0.022) q C16: 2n2 (222, 2200) q C17: 470n (0.47, 474) q C18: 100p/400V (101) q C19: 22n/630V (0.022) q C20: 22n/630V (0.022) q C21: 22n/630V (0.022) q C22: 22n/630V (0.022)

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13

17. ELECTROLYTIC CAPACITOR (Check the polarity!)

C...

q C23: 4u7 q C24: 100u q C25: 470u q C26: 470u q C27: 470u q C28: 470u q C29: 47u/100V q C30: 100u/100V q C31: 47u/100V q C32: 47u q C33: 47u q C34: 100u

18. PCB CONNECTOR

With the holes facing the PCB edge ! q SK3: 2 POLE q SK4: 2 POLE q SK5: 3 POLE q SK6: 8 POLE q SK7: 8 POLE q SK8: 8 POLE

19. VALVE SOCKET

5 9

8

7

4

3

2

V...6 1

Mount them square against the PCB q V9: B9A q V10: B9A q V11: B9A

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14

20. POWER RELAYS The various relays have leads that correspond to the printing on the PCB: q RY3: VR5V122C

RY...

q RY4: VR10V121C q RY5: VR10V121C

RY...

21. FUSE HOLDER

F...

q F1 Insert a 5A fuse for 115V Insert a 2.5A fuse for 230V Fit the protective cap to the fuse holder.

22. TRANSFORMER

TRAFO...

q TR1: 12VAC

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15

23. ELECTROLYTIC CAPACITOR (Check the polarity!) Generally these capacitors are from the snap-in type and cannot be mounted incorrectly.

C...

q C35: 22u/350V q C36: 22u/350V q C37: 100u/400V q C38: 100u/400V q C39: 220u/450V q C40: 220u/450V q C41: 220u/450V q C42: 220u/450V

24. SWITCH

SW...

SIDE VIEW

IMPORTANT:Don't leave a gap betweenthe SWITCH and the PCB!

Mount him as square as possible against the PCB, also solder the metal support. q SW1: 3P ON-ON-ON

25. INSERT THE IC (Check the position of the notch!)

IC...PIN 1

1

q IC1: LM3914

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16

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.

VIEWED FROM SOLDERSIDE

3

4

5

4

3

5 6

V8

8

1

2

7

1 8

8 1

V5

8

1

7

2

65

4

5

3

3

4

4

3

3

4

5

56

V7

1

8

2 1 8

78 1

8

1

75

6

4

5

V6

23

3

4

f26.3VAC

f2 f1

f1

5

3

44

5

3

1

2

8

V4

6 7

1

8 2

8

8

1

1

675

4

V1

3

3

5

4

6.3VAC

5

3

44

5

3 2

1

8

1

6

V3

78

f2

f2

8

8

1

675

4

1

V2

23

3

5

4

f1

f1

Again thoroughly check all the components for miss mounting (polarity!) , includ-ing soldering errors !! Assembly into the cabinet: • 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

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17

• 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.

• 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.

M3 NUTM3 LOCK WASHER

LS TERMINAL

NUT LS TERMINAL

PCB SUPPORT

NUT LS TERMINAL

HOUSING (REAR)

16mm M3 BUTTON HEAD BOLT

FIG 3

Check that the solder side of the PCB, is along the side of the nuts. 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.

16mm M3 BUTTON HEAD BOLT

5mm SPACER

M3 NUT

M3 LOCK WASHER

FIG 2

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18

• 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. This will later be used to

prevent the connector piercing through the transformer. Also stick a piece of insulating foil on the inside edge of the cabinet above each place where a

transformer has to be put (see fig. 6).

ADHESIVE PROTECTION FOIL AND WIRING

FIG 4 • Mount the ring core transformers:

PLATE

RUBBER WASHER

TRANSFORMER

RUBBER WASHER

METAL CASE

BOLTFIG 5

◊ Stick a adhesive foot to the base of the cabinet, in the middle where each transformer has to be put.

◊ Mount an output transformer on the left-hand side of the housing, see figure. Check the position of the leads.

cut4 X 4 cm

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19

OUTPUTTRANSFORMER

ZD043TRANSFORMER

8D002

POWERTRANSFORMER

ZD043

OUTPUT

WIRES WIRESWIRES

WIRES

ADHESIVEFOOT FOOT

ADHESIVEFOOT

ADHESIVE

WIRESADHESIVEPROTECTION

FOILPROTECTION

FOIL

ADHESIVEPROTECTION

FOIL

ADHESIVE

FIG 6 ◊ Turn over the housing and solder the transformer leads to the output terminals, see figure.

4

0

8

BLUE

YELLOW

REDHEAT-SHRINK

SLEEVEFIG 7

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.

◊ 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.

OUTPUT TRANSFORMERZD043

YELLOW

RED

BLUE

8 40

ZD043OUTPUT TRANSFORMER

BLUE

RED

YELLOW

8 0 4

FIG 8

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20

◊ 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 po-

sition 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 to 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.

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

GREEN

VIOLET

YELLOW LS+

BROWN

BLACK

BLACK

RED LS-

ORANGE

OUTPUT TRANSFORMERZD043

YELLOW

RED

BLUE

8 40

BROWNORANGE

RED LS-

BLACKBLACK

GREENVIOLET

YELLOW LS+

ZD043OUTPUT TRANSFORMER

BLUERED

YELLOW

8 0 4

FIG 9

Connect the leads of the supply transformer to the screw connector, SK6.

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21

POWER TRANSFORMER

N BLUEL BROWN

6.3VACGRAY

RE

DR

ED

YE

LLO

WY

ELL

OW

BLA

CK

BR

OW

NB

LUE

OR

AN

GE

ZD043OUTPUT TRANSFORMER

08 4

6.3VACGREEN

GNDR

GNDL

OUTPUT TRANSFORMER8D002

8 0 4

ZD043

L RMAINS

EARTH

VIO

LET

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 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. 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.

2

1

71

7

2

FIG 11

_______________________________________________________________________________________________________________________________________________________

22

! 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. 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.

__________________________________________________________________________________________________________________________________________________________

23

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. 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.

_______________________________________________________________________________________________________________________________________________________

24

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. ◊ 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).

6mm M3 BUTTON HEAD BOLTLOCK WASHER

6mm M4 BUTTON HEAD BOLT

FRONT PANEL

SUPPORT BRACKET

HOUSING

FIG 13

◊ If it all fits together well, then all bolts can be fully tightened.

__________________________________________________________________________________________________________________________________________________________

25

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. TROUBLE SHOOTING 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.

_______________________________________________________________________________________________________________________________________________________

26

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__________________________________________________________________________________________________________________________________________________________

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_______________________________________________________________________________________________________________________________________________________

28

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__________________________________________________________________________________________________________________________________________________________

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