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Velleman-Kit HIGH-Q K8040 User manual

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Total solder points: 299
Difficulty level: beginner 1 2 3 4 5 ⌧advanced
HIGH-END MONO MOSFET
POWER AMPLIFIER
ILLUSTRATED ASSEMBLY MANUAL H8040IP-2
K8040
K8040
3
Features & specifications
Features :
 no compromise high-end design
 ideal to place next to the speaker (short wires to the speaker)
 auto-power on possibility when input signal is sensed
 auto-standby function when no input signal is sensed
 exclusive, high finish, solid aluminium enclosure
 high quality D-MOS IC output stage
 total of 40.000µF power supply capacitors
 relay-less speaker DC protection
 Real Clipping distortion indication
 power output level indication with backlight
 bypass output to drive bi-wired speakers using separate amplifiers
 double overheating protection with LED indication
 high grade speaker and input connections
 overload protection
Specifications
 input:
• input sensitivity for maximum output:............. 0dBm (= 0.775Vrms)
• input impedance:................................................................ 15Kohm
• minimum auto switch on voltage:....................................... 5mVrms
 output:
• maximum RMS output power 4ohm:........................................ 90W
• maximum RMS output power 8ohm:........................................ 70W
• dynamic RMS output power in 4ohm: .................................... 125W
• minimum load impedance: .................................................... 4 ohm
• damping factor (ref. 8ohm 100Hz): ...................................... > 1000
 audio:
• signal-to-noise ratio (A-weighted ref. max. out): ................. >105dB
• total harmonic distortion:............................0.003% @ 1kHz ref 1W
• frequency response:......................... 9Hz to 120kHz (-3dB) in 50W
 power requirements:
• AC power: ....... 115Vac (110V to 120V) or 230Vac (220V to 240V)
• consumption:................................................................. 100W max.
 dimensions: ..................................290 x 165 x 68mm (11.4" x 6.5" x 2.7")
 weight (net):........................................................................ 3.4kg (7.5Lbs)
4
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 suc-
cessful. Read them carefully.
1.1 Make sure you have the right tools:
• A good quality soldering iron (25-40W) with a
small tip.
• Wipe it often on a wet sponge or cloth, to keep it clean; then apply
solder to 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.
• Thin raisin-core solder. Do not use any flux or grease.
• A diagonal cutter to trim excess wires. To avoid injury when
cutting excess leads, hold the lead so they cannot fly towards the
eyes.
• Needle nose pliers, for bending leads, or to hold components in
place.
• Small blade and Phillips screwdrivers. A basic range is fine.
For some projects, a basic multi-meter is required, or might
be handy
1.2 Assembly Hints :
⇒Make sure the skill level 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
drawings.
⇒Values on the circuit diagram are subject to changes.
⇒Values in this assembly guide are correct*
⇒Use the check-boxes to mark your progress.
⇒Please read the included information on safety and customer service
0.000
5
* 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 surface
and carefully solder the leads
2- Make sure the solder joints are cone-shaped
and shiny
3- Trim excess leads as close as possible to the
solder joint
REMOVE THEM FROM THE TAPE ONE AT
A TIME !
Assembly hints
AXIAL COMPONENTS ARE TAPED IN
THE CORRECT MOUNTING SEQUENCE !
6
Construction
The unit consists of one main PCB with all the components including transformer
and power supply.
 Tip: 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:
CONSTRUCTION
 J1
 J2
 J3
 J4
 J5
 J6
 J7
 J8
1. Jump wire
 R1 : 1K (1 - 0 - 2)
 R2 : 1K (1 - 0 - 2)
 R3 : 15K (1 - 5 - 3)
 R4 : 1K (1 - 0 - 2)
 R5 : 470R (4 - 7 - 1)
 R6 : 100R (1 - 0 - 1)
 R7 : 15K (1 - 5 - 3)
 R8 : 15K (1 - 5 - 3)
 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 : 100R (1 - 0 - 1)
 R18 : 1K (1 - 0 - 2)
 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)
4. Resistors (check the color code)
R...
 ZD1: 20V / 1.3W
(Mount 5mm above the PCB)
3. Zener diode (check the polarity)
CATHODE
ZD...
2. Diodes (check the polarity)
CATHODE
D...
 D1: 1N4148
 D2: 1N4148
 D3: 1N4148
 D4: 1N4148
 D5: 1N4148
 D6: 1N4148
 D7: 1N4148
 D8: 1N4148
7
 R28 : 2K2 0.6W (2 - 2 - 2 - 9)
 R29 : 2K2 0.6W (2 - 2 - 2 - 9)
 R30 : 0R
 R31 : 15K (1 - 5 - 3)
 R32 : 100K (1 - 0 - 4)
 R33 : 100R (1 - 0 - 1)
 R34 : 0R
 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: 0R
If long input signal wires are 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
impedance driving.
Rx is normally left open.
 C1 : 100nF (104)
 C2 : 100nF (104)
 C3 : 100nF (104)
 C4 : 100nF (104)
 C5 : 100nF (104)
 C6 : 100nF (104)
 C7 : 100nF (104)
 C8 : 100nF (104)
5. Capacitors
c...
 IC1 : 8p
 IC2 : 8p
 IC3 : 6p
6. IC sockets. Watch the position
of the notch!
7. 10W resistor
R...
5mm
 R40 : 4R7 (4.7, 4R7)
 C9 : 2n2 (222)
 C10 : 220n (224)
 C11 : 1uF
 C12 : 1uF
 C13 : 2.2uF
 C14 : 2.2uF
 C15 : 100n / 250V (104)
 C16 : 100n / 250V (104)
8. Capacitors
 T1: BC547
 T2: BC547
9. Transistors
construction
8
Construction
 SW1: TS-04PV
 SW2: KRS1243
11. Push button. Mount them
straight against the PCB surface !
 SK1: MJ-523AG/R
 SK2: MJ-523AG/B
Tip:
A red and a black type are delivered
with the kit, if you bought 2 amplifiers
for stereo then one amplifier can be
built with red connectors
(right amp.) and one with the black
connectors.
10. RCA connectors. Mount them
straight and against the PCB
 SK3: 3p "Mains in"
 SK4: 3p "Mains transformer"
 SK5+SK6: 2x 2 pole Transformer
output
 First slide these two
connectors in each other.
12. Terminal blocks
Check that the position
corresponds with the PCB
silk printing.
 SK7: 2 pole Temp sensor
 SK8: 2 pole Power meter
 SK9: LS+
 SK10: LS-
13. Terminal connectors
9
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
14. Coil
L...
 VR1 UA7805
16. Voltage regulator. The back
side corresponds to the thick line.
 C17: 10µF
 C18: 10µF
 C19: 10µF
 C20: 10µF
 C21: 10µF
 C23: 1µF
 C24: 10µF
 C25: 47µF/63V
 C26: 47µF/63V
 C27: 47µF/63V
 C28: 47µF/63V
 C29: 220µF/63V
 C30: 220µF/63V
15. Electrolytic capacitors.
Check the polarity !
C...
VR...
 TR1: TIC246 or eq.
17. Triac. The back side
corresponds to the thick line.
TR...
construction
 LD1: LED3RL (3mm LED)
 LD2: LED3RL (3mm LED)
 LD3: LED3RL (3mm LED)
19. LEDs
COLOR= 2...5
LD...
CATHODE
 BR1: RS603
18. Bridge rectifier.
Check the polarity !!
10
Construction
 C31: 10.000µF
 C32: 10.000µF
 C33: 10.000µF
 C34: 10.000µF
20. Power electrolytic capacitors.
Check the polarity !
C...
 IC1: VK8040 (PIC12C508)
 IC2: CA258 or eq.
 IC3: MOC3041 / KP3020
21. IC’s. Watch the position of the
notch !
First: Bend the leads exactly like the
drawing.
Next: Solder one lead, and check the
position, if necessary correct by
heating the soldering.
Last: Solder the second connection.
 LD4: L-424YDT
 LD5: L-424YDT
 LD6: L-424YDT
 LD7: L-424YDT
Meter backlight:
LD8 is a white LED serving as backlight
for the power meter.
 LD8: L5WD (5mm white)
22. Mounting front LED’s. Check the polarity !
Short lead = Cathode or - !
7mm
C
12mm
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.
CATHODE
LD...
CAUTION:
After bending the
leads the long
appearing lead will
be the cathode!
LD...
CATHODE
3mm
18mm