Garage1217 project kameleon User manual

DOCKING STATION USER MANUAL – November 24th 2016
WWW.GARAGE1217.COM
(R1.0 PCB ONLY)
WARNING:
Although Project Kameleon runs at a generally safe 24-48VDC, Injury from improper assembly is quite possible. The main
danger comes from installing the polarized capacitors backwards as they can only be installed in one direction much like a
battery (more detail on capacitor installation comes later in this manual) If a capacitor is installed backwards, it may burst
resulting in burns or eye injury. If you are not experienced in electronics or electronic kit assembly, it would be wise
to have an experienced electronics person review your work before powering the unit on. Upon first power up, wear
eye protection and be wary of any burning smells or electrical noises such as loud pops or buzzes
GARAGE1217.COM IS NOT RESPONSIBLE OR LIABLE FOR INJURY, PROPERTY LOSS OR DAMAGE AS THE RESULT OF ASSEMBLY OR USE OF THIS DO IT YOURSELFKIT. KAMELEON IS
CONSIDERED A HOBBY LEVEL PRODUCT. IT CONTAINS NO ELECTRICAL CERTIFICATIONS AND IS NOT ADVERTISED AS SUCH. USE AT YOUR OWN RISK.
Project
Kameleon

Specifications
Audio input connectors: ..................................................................................................... RCA (unbalanced)
Audio output connectors: .................................................................................................... RCA (unbalanced)
Max. Output Voltage: .......................................................................................................... 20VPP = 7VRMS
Power supply voltage: ........................................................................................................15V – 50VDC
Max current DC outlet socket: ............................................................................................ 5A, 20A peak (not fused)
Current consumption # : ...................................................................................................... around 50mA
Frequency range * # (gain set to +6dB, 'flat' module): ........................................................ 1.3Hz to 250kHz (-0.5dB)
0.4Hz to 750kHz (-3dB)
Phase *: (20Hz – 20khz, 'flat' module): ............................................................................. 180° (+/-1° )
Slew rate # : ........................................................................................................................ 10V/μs #
Input impedance: ...............................................................................................................20k
Noise (ref. 2V) # : ................................................................................................................ < -103 dB
THD # : ................................................................................................................................ < 0.01%
IMD # : ............................................................................................................................... < 0.01%
Output Resistance * : ....................................................................................................... < 470 (depends on module)
Max. allowed input voltage * : ........................................................................................... 40VPP /14VRMS / +25 dBu
* Phase, Frequency response, max. input voltage, output resistance will vary depending on the used headphone module.
# depends on components used.
Kameleon Operational Guide
Project
Kameleon
Normal Operation and Notes:
- Plug in the power supply and then RCA connections. Pay attention to which power jack you plug your
power supply into. The power supply should only go to the jack towards the right side edge of the PCB
marked power input
- Once Kameleon is turned to the ON position via the right side switch, the front
red LED will illuminate red. This indicates Kameleon is on.
- With a filter module properly inserted, you can activate the filter by turning on the filter switch. Once
active, the front LED will change from red to blue (blue indicates filter is on)
- Anytime the filter switch is in the off position, signal is bypassed from all electrical components other
than the onboard gold contact relay. In short, this is as close to a direct cable as an in-line component
gets making A/B comparisons accurate and as easy as flipping a switch
- Kameleon can be turned off and it will still act as a direct pass-through circuit
- For G1217 amplifiers, Kameleon acts as a power switch when using a pass-through cable. Simply
plug your G1217 amplifiers power cable into the power input jack. Then, plug the pass-through cable
into your G1217 amplifier. When set up this way, the power switch on Kameleon will turn on/off your
amplifier (must leave your amplifiers power switch in the on position at all times)
- Filter modules may be swapped quickly and easily without turning off Kameleon. Simply turn off the
filter, switch modules and turn the filter back on.
- Clean your Project Kameleon with a microfiber cloth and plastic cleaner (dusting with a microfiber
cloth is generally all that is required). Compressed air is also great option for dust.

Required Assembly Tools:
- Soldering iron, 25W minimum – Variable temp soldering station preferred with 1.5 – 2mm wide chisel tip
- .032 diameter 60/40 or 63/37 Tin/Lead solder is recommended. Lead free is difficult to work with and not recommended
- We specifically recommend Kester 331 water soluble flux solder, available on our website for purchase under (Parts – Buy)
- Magnifying glass (recommended but not required)
- Rubber Gloves (recommended but not required)
- 3M Green or Red Scotch Brite (recommended but not required)
- 3/32th Allen Key
- Flush cuts
- 90%+ Isopropyl alcohol (recommended but not required)
- Paper Towels (recommended but not required)
- Digital Multi Meter (DMM or DVOM)
Thank you for purchasing the Project Kameleon Headphone EQ / Docking station. This kit requires minimal
electronics and soldering knowledge. The layout is easy to follow and setup is a snap! Please make sure to follow
the instructions outlined in this guide and you will be enjoying your Kameleon in no time. First, lets go over the
tools and items required for your build which are as follows:
Before You Start Soldering:
Prep work needs to be done. Wash your hands thoroughly and dry. Put on the recommended rubber gloves and scrub down
the PCB (circuit board) on both the front and back side with 90%+ isopropyl alcohol to clean any residuals off of the board
from manufacturing. Once the board has been cleaned, set it on a dry paper towel out of the way. Try to use the rubber
gloves during the entire assembly process to keep oils off of the board and solder joints.
Proper soldering is key to a quality final product. If you are new to soldering, here are some basic guidelines to
follow. It would be wise to buy a copper project board and a few cheap resistors or other components to practice
with before starting this project.
Soldering and Solder Joints:
- For best results and maximum conductivity of any component, Wipe each wire lead down using Scotch Bright. Only one
or two passes are required, making sure all of the surface has been cleaned. This removes oxidation or any other build up
on the metal that has accumulated over time. Once cleaned, it is a good idea the further clean the wire leads with 90%+
isopropyl alcohol. Make sure all alcohol has evaporated prior to soldering as alcohol is VERY FLAMMABLE.
- Do not use to much or to little solder on each joint. See images below to get an idea of what you should be looking for
- The idea is to heat the pad and the component wire lead quickly and efficiently so that solder flows to each equally.
Wetting the tip of your iron with a very small amount of solder will aid in quickly heating up the pad and wire lead.
- Having to heat a component for long periods of time, especially capacitors or LEDs is NOT a good thing. When soldering
capacitors or LEDs, heat them only long enough to ensure a quality joint and let the unit cool down before soldering the
second lead.
- The solder joint should look bright and metallic. A dull or dark gray looking joint is referred to as a
cold solder jointCold solder joints may not pose a problem initially, but can show up later in the amps life.
- After every solder joint, make sure to clean the flux off your soldering iron tip with a wet sponge that should be
provided with your soldering iron kit.
SOLDER
PAD
PCB
CUTAWAY WIRE
LEAD
PROPER SOLDER JOINT:
- Solder is bright and shiny. It is curved
smoothly starting at the edge of the solder
pad until it reaches the lead from the
component
- Solder should fill the via and flow through
the board slightly. It is ok to add solder to
the top side of the board, however it is not
required
CUTAWAY OF A VIA AND SOLDER PAD
PRIOR TO SOLDERING:
IMPROPER SOLDER JOINT:
- A large blob of solder, often dull in color is
not desired. The solder may not flow into
the via hole and cause a poor connection
or failure later in the amplifiers life.
VIA / HOLE TOP OF PCB TOP OF PCB
Project
Kameleon

Assembly Guide
FILTER MODULE SOCKET
BI-COLOR LED
RED = POWER ON
BLUE = FILTER ON
POWER
SWITCH
RCA LINE-IN POWER
INPUT
RCA LINE-OUT
Project
Kameleon
1.0
FILTER
SWITCH
POWER
OUT LOOP

STEP 1: POPULATE ALL SMALL COMPONENTS ON THE BOARD SUCH AS RESISTORS, DIODES AND SMALL
CAPACITORS. THROUGHOUT YOUR BUILD, ALWAYS INSTALL THE SMALLER PARTS FIRST, WORKING YOUR
WAY UP TO THE LARGER COMPONENTS
PAY CLOSE ATTENTION TO
THE BLACK BAND ON ALL
DIODES OR ZENERS AS THEY
ARE DIRECTIONAL
- RESISTORS ARE NONPOLAR AND CAN BE FITTED IN EITHER DIRECTION. WHEN INSTALLING COMPONENTS,
MAKE SURE THE COMPONENT VALUES ALWAYS FACE UP SO THEY ARE VISIBLE (CAN AID IN TROUBLESHOOTING IF A
COMPONENT IS PLACED IMPROPERLY)
- DIODES, TRANSISTORS, IC S AND ELECTROLYTIC CAPACITORS ARE POLAR AND PROPER ORIENTATION IS REQUIRED
Project
Kameleon
CERAMIC CAPACITORS
ARE NONPOLAR
MEANING THEY HAVE NO
STRIPE AND CAN BE
INSTALLED IN EITHER
DIRECTION

STEP 2: POPULATE ALL MID & LARGE SIZE COMPONENTS SUCH AS
RCAS, POWER COMPONENTS, SMALL CAPACITORS, RELAY, AND
SO FORTH
POLARIZED CAPACITORS MUST BE INSTALLED IN THE
CORRECT DIRECTION (WILL HAVE A STRIPE DOWN THE SIDE
DESIGNATING POLARITY) INSTALL THIS STRIPE FACING THE
FLAT SPOT ON THE CAPACITOR OUTLINE ON THE BOARD
CORRECT INCORRECT
PLEASE NOTE: CENTER
PIN OF DC SOCKETS ARE
POSITIVE 24-48V
Project
Kameleon
BOLT DOWN BOTH TO-220
DEVICES USING SUPPLIED
4-40 ALLEN BOLT AND NUT
PCB
WHEN INSTALLING TO-220
DEVICES, INSERT INTO PCB
UNTIL THEY STOP. THEN
BEND OVER EACH DEVICE
AND THEY WILL LINE UP
PERFECTLY WITH THE PCB
OUTLINE AND HOLE

COMPLETED KAMELEON LAYOUT
Project
Kameleon

Chassis Assembly:
ASSEMBLE EACH OF THE 4 RUBBER FEET AS
SHOWN, ATTACHING EACHFOOT TO THE GRAY
SMOKEDACRYLIC BOTTOM CHASSIS
THUMB SCREW
HEX STANDOFF
PCB
CHASSIS BOTTOM
CHASSIS TOP
- ONCE THE PCB HAS BEEN ASSEMBLED,
SET IT ONTO THE FOURTHREADS
STICKING OUT OF THE BOTTOMGRAY
ACRYLICCHASSIS THAT YOU
PREVIOUSLY ASSEMBLED.
- THREAD ON EACHOF THE FOUR HEX
STANDOFFS ONTO THE THREADS THAT
ARE NOW PROTRUDING THROUGHTHE
PCB, SECURING THE PCB TO THE
CHASSIS BOTTOM. PROCEED
TO POWER ON THE UNIT (AS DESCRIBED
ON PAGE 2, WEARING EYE PROTECTION
ANDATA SAFE DISTANCE IN CASE OFA
MISTAKE INASSEMBLY)
- ONCE THE DOCKING STATIONS
FUNCTIONALITY HAS BEEN TESTED,
PLACE THE TOP COVER ON ANDSECURE
THREADED SPACER
RUBBERFOOT
NYLON WASHER
4-40 BUTTON CAP SCREW
GRAY ACRYLICBOTTOM
THREADED SPACER
Project
Kameleon
Chassis Prep:
- The laser cut acrylic chassis plates come with a protective coating to prevent damage. The brown
coatings will peel off clean without any glue residue. The blue covering may leave some glue residue
where you peel up the edge. Once you peel up the blue coating, use its sticky side to dab the glue
residue and it will come off. If any residue is left that you cannot remove, use a microfiber towel with a
small amount of isopropyl alcohol and wipe away any leftover glue
- Never wipe down the acrylic chassis with anything other than clean microfiber or scratches may occur
- Never scrub acrylic by pressing hard onto the surface
- Clean the acrylic using a microfiber towel and LCD or similar plastic safe cleaner
- CNC chassis can be cleaned or wiped down with a soft washcloth. Compressed air works equally well

Inserting EQ Filter Module
Project
Kameleon
NOTICE THE FILTER
MODULE SOCKET IS OFFSET
TO THE LEFT. THIS IS TO
HELP PREVENT ACCIDENTAL
IMPROPER INSTALLATION
IF THE MODULE IS INSERTED
BACKWARDS, IT WILL BE
OFFSET. TAKE NOTE OF THE
TWO WHITE ARROWS ON THE
FILTER MODULE, THEY
SHOULD POINT TO THE FRONT
OF THE DOCKING STATION
CORRECTION POSITION OF
THE FILTER MODULE WITH
WHITE ARROWS FACING
FORWARD
MAKE SURE ALL 8 PINS ARE SEATED INTO THE SOCKET. IF MODULE IS SET TO FAR BACK OR OUT OF
ALIGNMENT, IT IS POSSIBLE ONLY 4 OR 6 PINS MAY BE INSERTED. INSERTING THE MODULE IMPROPERLY
WILL RESULT IN NO SOUND
MODULE CAN BE LOCKED
INTO PLACE BY INSERTING
TWO 4-40 X ¼SCREWS
INTO THE BOTTOM ACCESS
HOLES OF THE CHASSIS.
UNDER NORMAL USE, THIS
IS NOT NECISSARY

Switch Functions
Project
Kameleon
LED NOT ILLUMINATED WHEN
POWER SWITCH IS OFF. IF THE
LED LIGHT IS ON WITH THE
POWER SWITCH IN THE OFF
POSITION, THE POWER
SUPPLY IS PLUGGED INTO THE
OUTPUT JACK
WITH THE POWER SWITCH
ON, THE BI-COLOR LED WILL
ILLUMINATE RED
WITH WHEN THE FILTER SWITCH
IS TURNED ON, THE BI-COLOR
LED WILL CHANGE FROM RED
TO BLUE INDICATING THE FILTER
IS TURNED ON
MAKE SURE ALL 8 PINS ARE SEATED INTO THE SOCKET. IF MODULE IS SET TO FAR BACK OR OUT OF
ALIGNMENT, IT IS POSSIBLE ONLY 4 OR 6 PINS MAY BE INSERTED. INSERTING THE MODULE IMPROPERLY
WILL RESULT IN NO SOUND

Project Kameleon 1.0
Resistors
R1 = 470R X 2
R2 = 10K X 6
R3 = 33K X 2
R4 = 2.2K X 1
R5 = 22K X 1
R6 = 100K X 2
R7 = 18K X 1
R8 = 390R X 1
R9 = 1K X 2
OPT-2 1K X 1
Diodes
Z1 = BZX79-C10 X 1
D1 = 3MM BI-COLOR LED X 1
D2 = 1N4148 X 2
D3 = TO-260 DIODE X 1
D4 = 1N4007 X 1
Regulators / IC
IC1 = LM4562 X 2
IC2 = LM317HV X 1
MF1 = IRF5210 X 1
Jacks
J1 / J2 = HEADPHONE JACK X 2
J3 = BLACK RCA JACK X 2
J4 = RED RCA JACK X 2
Capacitors
C1 = 1pF 100V X 2
C2 = 100nF 100V X 4
C3 = 22uF 63V X 2
C4 = 100uF 25V X 4
C5 = 100uF 16V X 4
C6 = 100uF 50V X 1
C7 = 470uF 10V X 1
Transistors
Q1 = BC547 X 2
Q2 = BC557 X 1
Switches
SW1 / SW2 = SWITCHES X 2
Relay
U1 = 24V RELAY X 1
Other
DC-DC X 1
SOC1 = DIP-8 SPRING SOCKET X 1