AML ezPDI-500 User manual

ezPDI-500 Passive DI - Assembly manual
[“Colourbook” Issue 1]

ezPDI-500 “Colourbook” Contents.
Section 1 - “Colourbook” assembly guide
Section 2 - Schematics diagrams and PCB Overlays
Section 3 - Parts List

Revision 1 - initial release
ezPDI-500 “Colourbook” revision history

The kit is intended to be used in a lunchbox / 500 series rack.
However, as it is entirely passive (needing no power), it can be used as a “standalone” unit.
An additional PCB is provided which can be used to easily provide XLR termination. The parts for that option are not provided.
ezPDI-500 - Lunchbox or Standalone ?
Unfortunately, there is no standard for Chassis Ground/Analogue Ground linking in 500 series racks / lunchboxes.
It varies depending upon which product you use.
Some manufacturers fit a switch on the rear to allow the chassis/analogue grounds to be separated or connected.
Some units have in internal link which can be easily removed.
Some units have in internal link which must be cut or de-soldered.
If the ezPDI-500 is used in a unit where the Chassis Ground and Analogue Ground are connected,
the Ground Lift switch on the ezPDI-500 will be ineffective.
Lunchbox/500 series Racks and Earth Lift.

Carefully snap apart the 3 PCB’s into individual boards
and trim or file off any excess tabs.
Ensure that the 3 areas highlighted are filed / trimmed completely flat
PCB Preparation
Main PCB
Trim Pot PCBXLR Option PCB

Place a “blob” of solder across the two pads (SW7) for Zobel network termination
Zobel Network Termination

For 500 series “lunchbox/rack” use:
Ground lift filtering selection
(on rear of trim pot PCB)
Turn Trim Pot PCB over
Place a “blob” of solder across the two pads of SW8
Do not put a “blob” on SW9
For “standalone” use:
Place a “blob” of solder across the two pads of SW9
Do not put a “blob” on SW8
OR
STANDALONELUNCHBOX
SW9 = OFF
SW8 = ON
SW9 = ON
SW8 = OFF

R2 & R3 = 100R (2)
R4 & R10 = 1k0 (2)
R13 = 1k8 (1)
Resistors

Resistors R5, R6, R7, R8 & R9 = 7k5 (5)
R11 & R12 = 1M0 (2)
F1, F2, F3, F4, F5 & F6 = Ferrite Bead (6)
RSIL1 = 4M7 (6)

C7, C8, C9, C10 & C13 = 47pF (5)
Ceramic
Capacitors C14 & C15 = 220pF (2)
C1, C2 & C11 = 100nF (3)

C4, C6 & C16 = 15nF (3)
C3 & C5 = 100nF (2)
Film
Capacitors
CL1 & CL2 = 100pF 3 Terminal L/C Network (2)

Connectors,
M3 Screw points
and Electrolytic
Capacitor
PL3 & PL4 = 8 Way Female Header (2)
M3 = M3 screw fitting (4)
C12 = 10uF / 63v NON-Polarised Electrolytic Capacitor (1) - Can be fitted either way round (not polarised)

SW1, SW2, SW5 & SW6 = Toggle Switch 2-way (DPDT on-on) - (4)
[Horizontal - sub-min CK-03-006]
Switches
SW3 & SW4 = Toggle Switch 3-way (DP3T on-on-on) - (2)
[Horizontal - sub-min CK-03-009]
Important: The toggle switches are
surprisingly sensitive to heat... solder
one pin on each switch and then
allow to cool before continuing.

Jack Sockets
and Transformer
T1 = AML-18-001 (1) - DI Stepdown transformer - Maroon series
J1, J2, J3 & J4 = Stereo Jack Socket (NRJ6HH-AU) (4)
IMPORTANT - The transformer must be fitted the correct way round
CHECK THE PIN NUMBERS ON THE BOTTOM COINCIDE WITH
THE NUMBERS PRINTED ON THE PCB

Potentiometer
and Standoffs
= 24mm Standoff (Female-Female) - (3) fitted using 8mm SEMS screws (3)
R1 = Potentiometer - 10k Linear with bracket [OM-01-095] (1)
IMPORTANT - Cut the legs very short before soldering
Standoff
SEMS
Main PCB Solder side
Component side

Inter-PCB Connectors
PL1 & PL2 = 8 Way Male Pin Header (2)
Solder side
Component side

Assemble PCBs
Turn over the Pot PCB and place over the main PCB,
aligning the pins of PL1 & 2 over the holes of PL3 & 4
and push down to engage the pins.
Secure with 3 M3x6mm button head screws
Secure with 3 M3x6mm
button head screws
(using 2mm allen key)

Chassis Assembly
2 x M3 Nyloc nut
In
st
al
l
PC
B
o
n
to
c
h
a
s
si
s
Secure PCB to chassis with 4 x M3x8 Sems screws
1] Remove the protective plastic coating from the chassis if fitted.
2] Secure faceplate to chassis with 2 x M3 Nyloc Nuts
1
2
3
4

ezPDI-500
INPUT
THRU
HI Level
LIFT
GND
PRI.
6:1
12:1
TRIM
IN
INPUT
THRU
LO Level
RATIO
6:1
12:1
RATIO
SEC.
1
f
f2
OFF
1
f
f2
OFF
0
0
0
TRIM
ezPDI-500
INPUT
THRU
HI Level
LIFT
GND
PRI.
6:1
12:1
TRIM
IN
INPUT
THRU
LO Level
RATIO
6:1
12:1
RATIO
SEC.
1
f
f2
OFF
1
f
f2
OFF
0
0
0
TRIM
Rotary switch / knob
Rotate the potentiometer
shaft fully counter-clockwise...
Install the ring nut for the Trim Potentiometer.
[The shakeproof washer is not required].
Turn the pot shaft fully counter-clockwise.
Install the knob in the “- infinity" position.
(Tighten the 2 screws using a small screwdriver - do not over-tighten)

Lid* 1] Remove the protective plastic coating from the lid if fitted.
2] Place the 0.4mm insulator over the trim pot PCB
3] Place the lid over and secure with 4 x M3x6mm button head screws (using 2mm allen key)
0.4mm insulator
2
3
* Not fitted for Standalone option
See next page