AkitikA PR-102 User manual

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PR-102 STEREO
PREAMPLIFIER
ASSEMBLY MANUAL
© 2019-2021 AkitikA LLC
All rights reserved
Revision 1p17 March 3, 2021

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Table of Contents
Table of Contents ................................................................................................................ 2
Table of Figures .................................................................................................................. 4
Section 1: About This Manual ............................................................................................ 6
Who Should Attempt this Project? ................................................................................. 6
Tools you’ll need ............................................................................................................ 6
Helpful Tools .................................................................................................................. 6
Project Overview ............................................................................................................ 6
Important Safety Notes ................................................................................................... 7
About Components ......................................................................................................... 7
Recommended Solder ..................................................................................................... 7
Warranty ......................................................................................................................... 7
Section 2: About Building the Kit ...................................................................................... 8
Section 3: Building the Power Supply PCB ....................................................................... 9
Component Order............................................................................................................ 9
Install the Diodes .......................................................................................................... 10
Install the non-polarized Capacitors ............................................................................. 10
Install the Not so Tall Polarized Capacitors ................................................................. 11
Install the Fuse and Fuse Holder ................................................................................... 11
Install the Tall Polarized capacitors .............................................................................. 11
Install the Regulators and Heat Sinks ........................................................................... 12
Install the AGD-BGD jumper ....................................................................................... 13
Install the voltage select jumpers .................................................................................. 13
These Components Are Not Loaded ............................................................................. 14
Power Supply Inspection .............................................................................................. 14
Section 4: Chassis Assembly and Power Wiring .............................................................. 15
Protect your PR-102 ...................................................................................................... 15
Install the feet ................................................................................................................ 15
Install the IR Detector Window .................................................................................... 15
Install Back Panel Power Connectors and Front Panel Power Switch ......................... 17
Power Wiring ................................................................................................................ 18
Connecting the Chassis Ground ................................................................................ 22
Connect the Toroidal Transformer to the power supply ............................................... 23
Add Power Output wires to the power supply .............................................................. 24
12 Volt Ground wires................................................................................................ 24
12 Volt Power wires.................................................................................................. 25
5 Volt Power and Ground wires................................................................................ 26
Connect Power Input wires and install the Power Supply ............................................ 26
Prepare to Test the power supply .................................................................................. 28
Test the power supply ................................................................................................... 28
Section 5: Assembling the Controller ............................................................................... 29
Component Side ............................................................................................................ 29
Install the Resistors ....................................................................................................... 29
Install the non-polarized Capacitors ............................................................................. 30
Install the IC’s and Transistor ....................................................................................... 31

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Install the Resistor Networks ........................................................................................ 31
Install the Ferrite Beads ................................................................................................ 32
Install the Control Cable Connectors and Controller Socket ........................................ 33
Components to be installed later ................................................................................... 34
Locations that remain unpopulated ........................................................................... 34
You’ve Finished this Side of the Controller PCB for Now ...................................... 34
Install the Push Buttons ................................................................................................ 34
Install the Infrared Detector .......................................................................................... 35
Install the LEDs ............................................................................................................ 36
Install the Last Four Capacitors .................................................................................... 38
Fit the Controller into the Front Panel .......................................................................... 38
Install the Controller Power Wire ................................................................................. 39
Install the Controller PCB into the Front Panel ............................................................ 39
Install the Microcontroller ............................................................................................ 39
Test the Controller PCB ................................................................................................ 40
Test the Remote Control ............................................................................................... 40
Take a Break ............................................................................................................. 40
Section 6: Assembling the Input Selector Board .............................................................. 41
Install the Resistors ....................................................................................................... 41
Choosing CD Attenuation ............................................................................................. 43
Adding 12 dB of Attenuation to the CD Input .......................................................... 43
Adding no attenuation to the CD Input ..................................................................... 43
Install the Small Capacitors .......................................................................................... 44
Install the Diodes .......................................................................................................... 44
Install the Bypass Capacitors ........................................................................................ 44
Install the Integrated Circuit Sockets ............................................................................ 45
Install the Control Cable Connector ............................................................................. 45
Install the Relays ........................................................................................................... 46
Install the Transistors .................................................................................................... 46
Install the Tall Film Capacitors..................................................................................... 47
Install the electrolytic capacitor .................................................................................... 47
Install J1 and J2 ............................................................................................................. 47
Install the Input Jack Shield .......................................................................................... 48
These Connectors Are Not Populated ........................................................................... 48
Install Input Selector Signal Wiring ............................................................................. 50
Install Input Selector Power Wiring ............................................................................. 51
Install the Op-amp Integrated Circuits into the Sockets ............................................... 52
Mount the Input Selector PCB ...................................................................................... 52
Test the Input Selector PCB Power Drain .................................................................... 53
Install 16 pin ribbon cable ............................................................................................. 53
Test Input Selector Control Interface ............................................................................ 54
Note about H1 and H2 .................................................................................................. 54
Take a Break ................................................................................................................. 54
Section 7: Assembling the Tone-Volume-Balance Board ................................................ 55
Install the Resistors ....................................................................................................... 55
Install the Motor Driver IC ........................................................................................... 57

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Install the Diodes and the Low-Profile Capacitors ....................................................... 57
Install C1 and C2. ..................................................................................................... 57
Install the sockets for IC1 through IC5. ........................................................................ 57
Install the Bypass Caps ................................................................................................. 58
Install the Relays ........................................................................................................... 58
Install the 14-pin cable connector. ................................................................................ 59
Install the remaining non-polar capacitors .................................................................... 59
Install the polarized electrolytic bypass capacitor ........................................................ 59
Install the bipolar transistors. ........................................................................................ 60
Install the tone control pots. .......................................................................................... 60
Volume and Balance Motor Pot Installation ................................................................. 60
Final Inspection ............................................................................................................. 61
Install the Op-amps into the sockets ............................................................................. 62
Section 8: Preliminary Final Assembly ............................................................................ 63
Wire and install the front panel input connector ........................................................... 63
Install the headphone jack ............................................................................................. 63
Connect Power to the Tone Volume PCB .................................................................... 64
Tone Volume Signal Wiring ......................................................................................... 64
Install the Tone Volume PCB: ...................................................................................... 65
Test the Tone Volume PCB Step 1 ............................................................................... 65
Test the Tone Volume PCB Step 2 ............................................................................... 65
Section 9: Final Mechanical Assembly............................................................................. 66
Final Mechanical Assembly .......................................................................................... 66
Section 10: About the Preamp Architecture ..................................................................... 67
Features ......................................................................................................................... 67
Gain Customization ...................................................................................................... 68
Specifications ................................................................................................................ 68
Appendix 1 – Shielded Cable Preparation ........................................................................ 69
Block Diagram .............................................................................................................. 71
Schematics .................................................................................................................... 72
Table of Figures
Figure 1-Empty the power supply components into a soup bowl ....................................... 9
Figure 2-Component side of power supply PCB before loading ........................................ 9
Figure 3-Fuse holder body solders into board, installing fuse into lid of fuse holder ...... 11
Figure 4-Assembling Heatsink to a Regulator .................................................................. 12
Figure 5-Solder heat sink mounting rods to retain the heat sink ...................................... 13
Figure 6-Preparing power supply jumper wires................................................................ 13
Figure 7-Install AGND to BGND jumper ........................................................................ 13
Figure 8-Jumper installation for 120 Volt Operation (left side) and 240 Volt (right side)
........................................................................................................................................... 14
Figure 9-Power Supply before transformer is installed, wired for 120 Volts ................... 14
Figure 10-Install 4 feet with 6-32x1/2" silver colored screws .......................................... 15
Figure 11-IR Window with release paper, die cut mounting tape .................................... 16
Figure 12-Installing power outlets and IEC connector...watch orientation! Installing the
power switch…watch orientation! .................................................................................... 18

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Figure 13-Insert cable ties, then lay twisted pair into the chassis corner ......................... 19
Figure 14-Form switch wires to avoid the ground stud .................................................... 21
Figure 15-Adding Lug to Ground Harness ....................................................................... 22
Figure 16-AC Power and Ground Wiring ......................................................................... 22
Figure 17-Transformer and power supply assembly ready for installation ...................... 23
Figure 18-Fasten the transformer to the preamp right side wall ....................................... 27
Figure 19-Power Supply assembled and installed ............................................................ 27
Figure 20-Silk screen of the “component side” of the controller PCB ............................. 29
Figure 21-Insert all the IC’s so that the U-shaped indent matches the silk-screen ........... 31
Figure 22-14 and 16 pin cable connector installation ....................................................... 33
Figure 23-showing socket orientation ............................................................................... 33
Figure 24-Switch and LED side of Controller Board ....................................................... 34
Figure 25-Bending the IR Detector Leads and setting the mounting height .................... 35
Figure 26-LED with white spacer added .......................................................................... 36
Figure 27-Observe D8 installed and orientation of the lead frame of the LED ................ 37
Figure 28-Completed controller, push-button and LED side and component side........... 38
Figure 29-Silkscreen side of the Input Selector Board shows component locations ........ 41
Figure 30-Align socket feature with silk screen ............................................................... 45
Figure 31-Correct orientation for P1 on the selector board .............................................. 46
Figure 32-Mounting the input connector shield................................................................ 48
Figure 33-Assembled Input Selector board ...................................................................... 49
Figure 34-Insert opamp so semi-circular indentation in IC package matches silk-screen
feature ............................................................................................................................... 52
Figure 35-16 pin ribbon cable orientation and installation ............................................... 53
Figure 36-Silkscreen side of the tone volume board shown component locations ........... 55
Figure 37-orientation of IC6 ............................................................................................. 57
Figure 38-Carefully note the connector orientation .......................................................... 59
Figure 39-Motor POT wire preparation ............................................................................ 60
Figure 40-Motor POT wiring detail .................................................................................. 60
Figure 41-Assembled Tone Volume board (oblique view) .............................................. 62
Figure 42-Tone volume board viewed from directly above ............................................. 62
Figure 43-Connecting wires to front panel (FP) 1/8" phono jack ..................................... 63
Figure 44-Inserting 1/8" jacks in the front panel .............................................................. 63
Figure 45-Showing 14 pin Ribbon Cable Installation and Orientation ............................ 65
Figure 46-Install plastite screws (6) in the holes between the left and right channel input
jacks .................................................................................................................................. 66
Figure 47-Two of the three cover plates have been installed ........................................... 67
Figure 48-Tone Volume schematic ................................................................................... 72
Figure 49-Controller Schematic page 1 ............................................................................ 73
Figure 50-Controller Schematic Page 2 ............................................................................ 74
Figure 51-Input selector page 1 ........................................................................................ 75
Figure 52-Input selector page 2 ........................................................................................ 76
Figure 53-input selector page 3......................................................................................... 77
Figure 54-power supply schematic ................................................................................... 78

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Section 1: About This Manual
This manual gives the information needed to build and use Akitika LLC’s PR-102 Stereo
Preamplifier. It’s very similar to its predecessor, the PR-101, but it has the following new
features:
 The F3 button is now named MONO. When the LED is ON, both left and right
channel inputs are combined into a monophonic signal.
 The F4 button is now named HUSH. When the LED is ON, the output level drops
by 20 dB.
Who Should Attempt this Project?
You can build this kit if you can:
1. Solder (using normal rosin core solder and a soldering iron).
2. Use simple hand tools like screwdrivers, wire cutters, and pliers.
3. Read and follow directions.
It helps if you:
1. know a bit about electronics, or
2. have a friend who knows a bit about electronics
3. can get to YouTube to watch a few helpful videos about the assembly process
(none are posted as of this version of the manual).
Tools you’ll need
You’ll need the following tools:
1. Phillips screwdriver (#1 and #2)
2. Pliers or nut drivers suitable for #4 and #6 hardware
3. needle nose pliers (helpful, but not strictly necessary)
4. pencil type soldering iron of 25 to 50 Watts (no huge honking soldering guns or
blowtorches)
5. wire cutters and strippers
6. multi-meter to measure power supply voltages and confirm resistor values
(strongly recommended)!
Helpful Tools
These tools aren’t strictly necessary, but make building the kit easier.
1. magnifying glass, if you’re over 42!
2. lead bending jig to form axial component leads to the correct span for insertion in
the PCB.
Project Overview
The project consists of the following steps:
1. Building these circuit boards:
a. Power Supply
b. Controller
c. Input Selector
d. Volume/Tone Control

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2. Install and wire the circuit boards, switches, connectors, and power transformer
into the chassis.
Important Safety Notes
By purchasing, using, or assembling this kit, you have agreed to hold Akitika LLC
harmless for any injuries you may receive in its assembly and/or use. To prevent injuries:
 Wear safety glasses when soldering or clipping wires to prevent eye injuries.
 Always unplug the power before working on the amplifier.
 Large capacitors hold lots of energy for a long time. Before you put your hands
into the amplifier:
o Pull the AC plug!
o Wait 2 full minutes for the capacitors to discharge!
 Remove jewelry and rings from your hands and wrists, or anything that might
dangle into the amplifier.
 If working one the equipment with the power on, keep one hand in your pocket,
especially if you’re near the power supply or power supply wires. This can
prevent serious shocks.
 Build with a buddy nearby. If you’ve ignored all the previous advice, they can
dial 911 or get you to the hospital.
 Read and understand the safety manuals of all the tools you use.
About Components
We reserve the right to make design/or component changes at any time without prior
notification.
Recommended Solder
The kit must be assembled with 60/40 Rosin Core solder. The recommended diameter is
0.032 inches. Among many such sources of solder, I have used Radio Shack part number
64-009. It contains 8 oz. of solder, which is much more than you’ll need to assemble the
PR-102 kit.
Warranty
With the exception of fuses, Akitika will replace for free any parts of a correctly
assembled PR-102 that fail within one year of the date of purchase when the amplifier
has been used in home stereo applications. It is the responsibility of the kit builder to
install the replacement part(s). This warranty applies to the original purchaser only. It
does not apply to units that have been physically or electrically abused, modified without
prior factory authorization, or assembled with other than 60/40 Rosin Core solder.
Akitika LLC’s liability shall in no event exceed the cost paid to Akitika LLC for the kit.

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Section 2: About Building the Kit
Yes, I know you want to ignore this section, and jump right into building the kit.
However, please take a minute and read the advice of this section. I’ve condensed it into
bullets so that even you guys who are in a hurry can benefit.
 There are 4 PCB’s to build:
o Power supply
o Tone/Volume
o Input Selector
o Controller
 Stop any time you’re feeling confused, tired, or anxious. Taking breaks at those
strategic times will keep the build enjoyable and greatly enhance your chances of
first-time success.
 Finish one PCB before you build the next.
 A soup bowl is your friend. Before you build a board, carefully empty the parts
for only that board into a broad, flat, light colored soup bowl. That makes it easy
to find the parts, and keeps them from getting lost.
 A digital ohm-meter is an easy way to make sure that you’ve picked the right
resistor. It’s a great cross-check on the resistor color code. Measure twice and
solder once!
 A lead-bending jig can make for quicker, neater assembly. It’s certainly not
necessary.
 Is something in this manual confusing? Does something look wrong? Send your
questions by email to [email protected]. You’ll help yourself and everyone who
builds the kit.

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Section 3: Building the Power Supply PCB
This section details the process of building the power supply circuit board. Begin by
carefully emptying the contents of the envelope marked “PR-101 Power Supply” into a
broad soup bowl, as shown below. The envelope might also be marked “PR-102 power
supply”. FYI, the power supply did not change between the PR-101 and PR-102. In
general, you’ll start with the components that lay closest to the board, working your way
towards the taller components.
Figure 1-Empty the power supply components into a soup bowl
Component Order
Figure 2-Component side of power supply PCB before loading

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You’ll notice that the component designations in the directions don’t go exactly in order.
We have grouped them so that all components with the same value appear together. This
makes assembly easier. You’ll find in the parts kit that similar parts, e.g. 3 1K resistors,
are typically (though not always) taped together.
Install the Diodes
In general, you install axial leaded components (like the 1N4004 diodes) by placing the
body on the silk screen side of the board, and the leads through the indicated holes. Bend
the leads over on the back of the board to keep the resistors from falling out until your
solder them in place. Try to bend the leads in a direction that won’t lead to solder bridges
between traces that should remain disconnected.
We recommend the following procedure:
1. Insert all components of the same value or type
2. Bend the leads as described above.
3. Solder the leads on the back of the board.
4. Clip the leads.
Track your progress by placing a check-mark in the done column as you install each
component.
Diodes – Polarity is important!
Make sure that the banded ended of the diode
matches the banded end of the silk screen
Use 0.45” spacing for lead
-
bending jig (optional) for 1N4004 diodes
Designation
Type
Rating,
Marking
Done? (

)
D3
1N4004
400 PIV 1 Amp, 4004
D4
1N4004
400 PIV 1 Amp, 4004
D5
1N4004
400 PIV 1 Amp, 4004
D6
1N4004
400 PIV 1 Amp, 4004
D7
1N4004
400 PIV 1 Amp, 4004
D8
1N4004
400 PIV 1 Amp, 4004
D9
1N4004
400 PIV 1 Amp, 4004
D10
1N4004
400 PIV 1 Amp, 4004
D11
1N4004
400 PIV 1 Amp, 4004
Use 0.5” spacing for lead
-
bending jig (optional) for 2A04
diodes
D1
2A04
400 PIV 2 Amp
, 2A04
D2
2A04
400 PIV 2 Amp
, 2A04
D
12
2A04
400 PIV 2
Amp
, 2A04
D
13
2A04
400 PIV 2
Amp
, 2A04
Install the non-polarized Capacitors
The capacitors we install in this section can be installed in either orientation.
Non Polarized Capacitors
Designation
Value
Rating, Marking
Done? (

)
C1 0.1 µF 100 V Ceramic, 104 (stands for 10104=105 pF
=0.1 µF
C2
0.1 µF
100 V Ceramic, 104

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C3
0.1 µF
100 V Ceramic, 104
C4
0.1 µF
100 V Ceramic, 104
C7
0.1 µF
100 V Ceramic, 104
C8
0.1 µF
100 V Ceramic, 104
C5
0.01 µF
400 V Mylar,
10n (stands for 10 nano
-
Farads)
C6
0.01 µF
400 V Mylar,
10n (stands for 10 nano
-
Farads)
C18
0.033 µF
300 V AC, box shaped cap
Install the Not so Tall Polarized Capacitors
It’s important to install these caps with the proper polarity. The negative end of the cap is
marked with a minus sign. The silk screen on the board marks where the positive end of
the cap goes. Make sure that the negative end of the cap is away from the plus sign on the
circuit board.
Polarized Capacitors
–
polarity matters!
Designation
Value
Rating
Done? (

)
C9
22
µF
35 V electrolytic
C10
22
µF
35 V
electrolytic
C11
22
µF
35 V electrolytic
C12
22
µF
35 V electrolytic
C13
22
µF
35 V electrolytic
C14
22
µF
35 V electrolytic
Install the Fuse and Fuse Holder
Action
Done? (

)
Solder the body of the fuse holder shown on the left side of Figure 3 into
the silk
-
screen marked F1 on the PCB.
Insert the 0.25 Amp (for 120-Volt operation) or the 0.125 Amp (for 240-
Volt operation) fuse into the fuse holder lid.
Fit the combination of the fuse plus the fuse-holder lid into the body to
complete fuse installation.
Figure 3-Fuse holder body solders into board, installing fuse into lid of fuse holder
Install the Tall Polarized capacitors
Polarized Capacitors
–
polarity matters!
D
ouble check the rated voltage
!
C15
4700
µF
35
V electrolytic
C16
4700
µF
3
5 V electrolytic
C17
4700
µF
16
V electrolytic

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Figure 4-Assembling Heatsink to a Regulator
Install the Regulators and Heat Sinks
For each of the three regulators (U1, U2, and U3), the installation process is the same,
with the result as shown in Figure 4. Note: U2 uses the tall heat sink!
 Smear a thin film of thermal compound on back of the regulator. Be careful not to
get thermal compound on the leads of the regulator.
 Fasten the regulator to a heat-sink using a 4-40x5/16” Phillips pan-head screw and
a 4-40 keps nut (keps nuts have built-in lock-washers). Each heat sink has 3
mounting holes. Use the center of the three holes to mount the regulator.
 Tighten the hardware pretty well while keeping everything at right angles. A ¼”
nut driver is very handy tool for this step.
 Follow the silk screen outlines and install each heatsink/regulator assembly into
its correct place on the board, as indicated in the table below.
 The silver colored mounting rods on the bottom of the heat sink fit into pads on
the PCB.
 Hold the heat sink flush against the PCB and solder the mounting rods to the
mounting tabs.
 Solder the regulator leads into the PCB.
Regulators – orientation matters! Double check the part numbers. They are not
interchangeable!
Designation
Value
Rating
Done? (

)
U1
7912
12 V negative
regulator
(use a short heat sink)
U2
7805
5 V positive regulator
(
use the tall heat sink
)
U3
78
12
12 V positive regulator
(use a short heat sink)

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Figure 5-Solder heat sink mounting rods to retain the heat sink
Install the AGD-BGD jumper
Prepare three 22 AWG red wires as shown in Figure 6. One will be used to connect AGD
to BGD. The other two will be used for voltage select as described in the next section.
Figure 6-Preparing power supply jumper wires
Connect AGD and BGD. Insert one of the red wires into the AGD and BGD eyelets of
the power supply PCB. Insert it from the component side and solder it on the solder side.
Figure 7-Install AGND to BGND jumper
Install the voltage select jumpers
The PR-102 may be wired for either 120-Volt or 240-Volt operation. This is done by
adding jumpers to the power supply board in the marked places.
Jumper locations are shown in Figure 8.
 For 120 Volts, use the left half of Figure 8.
 For 240 Volts, use the right half of Figure 8.

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Figure 8-Jumper installation for 120 Volt Operation (left side) and 240 Volt (right side)
Figure 9-Power Supply before transformer is installed, wired for 120 Volts
These Components Are Not Loaded
Three-pin headers TB1-TB6 and two-pin headers TB7-TB10 are not loaded in the
standard kit assembly. You will solder to some of these locations in later assembly steps,
but for now, the assembly of the power supply is complete.
Power Supply Inspection
Recheck your work to verify:

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1. Correct diode polarity.
2. Correct polarity of polarized capacitors
3. Correct location of power supply voltage selection jumpers for the intended
power source (either 120V or 240 V)
4. Verify that all installed components have been soldered.
Section 4: Chassis Assembly and Power Wiring
We’ll take a detour from PCB assembly to do some of the chassis assembly. This will
give you a safe way to power up and test the power supply.
Protect your PR-102
Spread a towel over your work surface before you begin the steps outlined in this section.
That towel will prevent you from scratching the finish of your PR-102 during these
assembly steps.
Install the feet
Install the four feet into the corners of the bottom of the chassis using 6-32 x 3/8” Phillips
head screws (these are zinc-plated, so will look silver). Snug the screws, but don’t over-
tighten. Installing the feet will protect the bottom of the chassis from damage.
Figure 10-Install 4 feet with 6-32x1/2" silver colored screws
Install the IR Detector Window
A black plastic window sits just behind the front panel. It allows light to reach the remote
control’s IR detector. You’ll find it shipped in its own pink-poly bag with a die-cut
mounting tape. Here’s how to install it:
1. Remove the chassis from the packing material. Use a small Phillips head screw
driver to remove the 11 screws that hold the cover in place (8 on the top, 3 along

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the back edge). Make sure to save the screws someplace safe, like your soup
bowl.
2. The next steps describe installation of the IR window into the chassis. It installs
from the inside, into the indicated rectangular hole:
3. Locate the black plastic window. Peel the release paper from both sides of the
window if it is present.
Figure 11-IR Window with release paper, die cut mounting tape
4. Locate the die-cut piece of double-sided sticky tape found in the same pink poly
bag.
5. Remove the non-printed release paper from the die-cut double-sided sticky tape.
6. Press the exposed sticky against the inside of the chassis, centered behind the IR
detector rectangular window. The hole in the tape is about 1/16” wider all the way
around than the hole in the chassis.

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7. When you look at the front of the chassis, the tape should not be visible.
8. Remove the “3M” paper backing from the double-sided tape.
9. Press the black plastic window against the newly exposed sticky side of the tape,
being careful to center the window on the tape. Please note that the hole is rather
smaller than the window, so there is reasonable room for error.
10. If you’re satisfied with the window position, press it firmly against the chassis to
seat it well in place.
Install Back Panel Power Connectors and Front Panel Power
Switch
The switched outlet, non-switched outlet, and IEC power input connector push into the
chassis from the outside and are retained by an amazingly effective built-in spring clip
mechanism. Install these three items in the orientation shown in Figure 12. Make sure

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you get the orientation of the IEC power connector correct…it’s pretty well impossible to
remove once installed!
Figure 12-Installing power outlets and IEC connector...watch orientation! Installing the power
switch…watch orientation!
Push the front panel power switch into the front panel from the outside. Make sure you
have the orientation correct with the O on the switch toward the chassis bottom before
you push it in. It is very difficult to remove once installed.
Power Wiring
The kit includes five pre-built wiring harnesses with fully insulated FASTON connectors
to make the power wiring easy and safe. The FASTONs take a little force to push on, and
a lot more force to remove. You can save your fingers if you use needle nose pliers to
push the FASTON connectors in place.
Read the instructions carefully to make sure you have them in the right place before you
push them on the terminals.
Locate the black unswitched power harness. It has black wire with 3 FASTONs.
1. Connect the blue 0.25” wide FASTON to the IEC power contact closest to the
chassis wall.
2. Connect the red 0.187” wide FASTON to the unswitched outlet contact closest to
the chassis wall.

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3. For now, leave the remaining long end with the FASTON connector loose.
Locate the white unswitched power harness. It has white wire with 3 FASTONs.
4. Connect the blue 0.25” wide FASTON to the IEC power contact farthest from the
chassis wall.
5. Connect the red 0.187” wide FASTON to the unswitched outlet contact farthest
from the chassis wall.
6. For now, leave the remaining long end with the FASTON connector loose.
7. Twist the white and black wires from steps 3 and 6 together to form an insulated,
twisted pair. About 1 twist per inch will take up enough length so that there’s only
a little bit left to tuck into the corners.
8. Insert a pair of small cable ties into the tie down points as indicated in Figure
13and lay the twisted pair over the cable tie, forming the twisted pair into the
corner of the chassis. Don’t close the cable ties yet.
Figure 13-Insert cable ties, then lay twisted pair into the chassis corner

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9. Connect Black wire of the twisted pair to the bottom row switch contact closest to
the chassis wall.
10. Connect White wire of the twisted pair to the remaining bottom row switch
contact.
Locate the black switched power harness. It has black wire with 2 FASTONs.
1. Connect the blue 0.187” wide FASTON to the switched outlet contact closest to
the chassis wall.
2. The black 22 AWG wire will connect to the power supply PCB in a later step.
3. Route the long 18 AWG black wire with the red 0.25” wide FASTON towards the
front of the chassis, but don’t connect it yet.
Locate the white switched power harness. It has white wire with 2 FASTONs.
4. Connect the blue 0.187” wide FASTON to the switched outlet contact farthest
from the chassis wall.
5. The white 22 AWG wire will connect to the power supply PCB in a later step.
6. For now, leave the remaining long end with the FASTON connector loose.
7. Twist the white and black wires from steps 3 and 6 together to form an insulated,
twisted pair. About 1 twist per inch will take up enough length so that there’s only
a little bit left to tuck into the corners.
8. Lay the twisted pair over the cable tie and the existing twisted pair. Form the
wires into the corner of the chassis.