Velleman K8040 User manual

Total solder points: 299
Difficulty level:
beginner 1o2o3o4o5þadvanced
K8040
HIGH-END mono mosfet power
amplifier
ILLUSTRATED ASSEMBLY MANUAL H8040IP-1
On
Temp. error
Clip/Auto power
8040
Mosfet Power Amplifier

VELLEMAN COMPONENTS
Legen Heirweg 33
9890 Gavere
Belgium
http://www.velleman.be

3
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
successful. 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 compo-
nents 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 draw-
ings.
⇒Values on the circuit diagram are subject to changes.
⇒Values in this assembly guide are correct*
0.000

4
⇒Use the check-boxes to mark your progress.
⇒Please read the included information on safety and customer service
* 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 sur-
face 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 !

5
Color code table
IPESF SDK NDGB FNL C O D E
CODICE
COLORE CODIGO
DE
CORES
CODIGO
DE COL-
ORES
VÄRI
KOODI FÄRG
SCHEMA FARVE-
KODE FARGE-
KODE FARB
KODE COLOUR
CODE CODIFI-
CATION DES COU-
KLEUR
KODE C
O D E
0Nero Preto Negro Musta Svart Sort Sort Schwarz Black Noir Zwart 0 1Marrone Castanho Marrón Ruskea Brun Brun Brun Braun Brown Brun Bruin 1 2Rosso Encar- Rojo Punainen Röd Rød Rød Rot Red Rouge Rood 2 3Aran- Laranja Naran- Oranssi Orange Orange Orange Orange Orange Orange Oranje 3 4Giallo Amarelo Amarillo Keltainen Gul Gul Gul Gelb Yellow Jaune Geel 4 5Verde Verde Verde Vihreä Grön Grøn Grønn Grün Green Vert Groen 5 6Blu Azul Azul Sininen Blå Blå Blå Blau Blue Bleu Blauw 6 7Viola Violeta Morado Purppura Lila Violet Violet Violet Purple Violet Paars 7 8Grigio Cinzento Gris Harmaa Grå Grå Grå Grau Grey Gris Grijs 8 9Bianco Branco Blanco Valkoinen Vit Hvid Hvidt Weiss White Blanc Wit 9 AArgento Prateado Plata Hopea Silver Sølv Sølv Silber Silver Argent Zilver A BOro Dourado Oro Kulta Guld Guld Guldl Gold Gold Or Goud B
5%
4K7= ( 4 - 7 - 2 - B )
1%
4K7= ( 4 - 7 - 0 - 1 - 1 )
COLOR= 2… 5

6
The unit consists of one main PCB with all the components including trans-
former and power supply.
FTip: 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
qD1: 1N4148
qD2: 1N4148
qD3: 1N4148
qD4: 1N4148
qD5: 1N4148
qD6: 1N4148
qD7: 1N4148
qD8: 1N4148
2. Diodes (check the polarity)
CATHODE
D...
Construction
qJ1
qJ2
qJ3
qJ4
qJ5
qJ6
qJ7
qJ8
1. Jump wire
qR1: 1K (1-0-2)
qR2: 1K (1-0-2)
qR3: 15K (1-5-3)
qR4: 1K (1-0-2)
qR5: 470R (4-7-1)
qR6: 100R (1-0-1)
qR7: 15K (1-5-3)
qR8: 15K (1-5-3)
4. Resistors (check the color code)
R...
qZD1: 20V / 1.3W (Mount 5mm
above the PCB)
3. Zener diode (check the polarity)
CATHODE
ZD...

7
Construction
qR9: 15K (1-5-3)
qR10: 15K (1-5-3)
qR11: 470R (4-7-1)
qR12: 15K (1-5-3)
qR13: 15K (1-5-3)
qR14: 100R (1-0-1)
qR15: 15K (1-5-3)
qR16: 2K2 0.6W (2-2-2-9)
qR17: 100R (1-0-1)
qR18: 1K (1-0-2)
qR19: 470R (4-7-1)
qR20: 2K2 0.6W (2-2-2-9)
qR21: 1M (1-0-5)
qR22: 470R (4-7-1)
qR23: 1K (1-0-2)
qR24: 470K (4-7-4)
qR25: 470K (4-7-4)
qR26: 470K (4-7-4)
qR27: 100K (1-0-4)
qR28: 2K2 0.6W (2-2-2-9)
qR29: 2K2 0.6W (2-2-2-9)
qR30: 0R (-0-)
qR31: 15K (1-5-3)
qR32: 100K (1-0-4)
qR33: 100R (1-0-1)
qR34: 0R (-0-)
qR35: 680R (6-8-1)
qR36: 15K (1-5-3)
qR37: 100K (1-0-4)
qR38: 470R (4-7-1)
qR39: 10R / 1W (1-0-0)
qJGND: 0R (-0-)
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 im-
pedance driving.
Rx is normally left open.
qR40: 4R7 (4.7, 4R7)
7. 10W resistor
R...
5mm
qIC1: 8P
qIC2: 8P
qIC3: 6P
6. IC sockets (check the position)
qC1: 100n (104, 0.1, u1)
qC2: 100n (104, 0.1, u1)
qC3: 100n (104, 0.1, u1)
qC4: 100n (104, 0.1, u1)
qC5: 100n (104, 0.1, u1)
qC6: 100n (104, 0.1, u1)
qC7: 100n (104, 0.1, u1)
qC8: 100n (104, 0.1, u1)
5. Multilayer capacitors
c...

8
qT1: BC547
qT2: BC547
9. Transistors
qSW1: TS-04PV
qSW2: KRS1243
11. Push button
Mount them straight against
the PCB surface !
qSK1: MJ-523AG/R
qSK2: MJ-523AG/B
Tip:
A red and a black type are delivered
with the kit, if you bought two amplifi-
ers for stereo then one amplifier can
be built with red connectors (right
amp.) and one with the black connec-
tors.
10. RCA connectors.
Mount them straight and
against the PCB
qC9: 2n2 (222, 2200)
qC10: 220n (.22, u22, 224)
qC11: 1uF
qC12: 1uF
qC13: 2.2uF
qC14: 2.2uF
qC15: 100n / 250V (104, 0.1, u1)
qC16: 100n / 250V (104, 0.1, u1)
8. Capacitors
Construction

9
qSK3: 3 pole Mains in
qSK4: 3 pole Mains transformer
qSK5+SK6: 2x 2 pole Transformer
output
FFirst slide these two connec-
tors in each other.
12. Terminal blocks
Construction
Check that the position corresponds
with the PCB silk printing.
qSK7: 2 pole Temp sensor
qSK8: 2 pole Power meter
qSK9: LS+
qSK10: LS-
13. Terminal connectors
SK...

10
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.
qL1: 8 Turns dia 8mm
14. Coil
L...
qVR1 UA7805
16. Voltage regulator.
The back side corresponds to
the thick line.
qC17: 10µF
qC18: 10µF
qC19: 10µF
qC20: 10µF
qC21: 10µF
qC23: 1µF
qC24: 10µF
qC25: 47µF/63V
qC26: 47µF/63V
qC27: 47µF/63V
qC28: 47µF/63V
qC29: 220µF/63V
qC30: 220µF/63V
15. Electrolytic capacitors.
Check the polarity !
C...
VR...
Construction
qTR1: TIC246 or eq.
17. Triac.
The back side corresponds to
the thick line.
TR...

11
qLD1: LED3RL (3mm LED)
qLD2: LED3RL (3mm LED)
qLD3: LED3RL (3mm LED)
19. LEDs
COLOR= 2...5
LD...
CATHODE
Construction
qBR1: RS603
18. Bridge rectifier.
Check the polarity !!
qC31: 10.000µF
qC32: 10.000µF
qC33: 10.000µF
qC34: 10.000µF
20. Power electrolytic capacitors.
Check the polarity !
C...
qIC1: VK8040 (PIC12C508)
qIC2: CA258 or eq.
qIC3: MOC3041 / KP3020
21. Insert the IC’s into their sock-
ets. Watch the position of the notch !

12
First: Bend the leads exactly like the
drawing.
Next: Solder one lead, and check the
position, if necessary correct by heat-
ing the soldering.
Last: Solder the second connection.
qLD4: L-424YDT
qLD5: L-424YDT
qLD6: L-424YDT
qLD7: L-424YDT
Meter backlight:
LD8 is a white LED serving as backlight
for the power meter.
qLD8: L5WD (5mm white)
22. Mounting front LED’s. Check the polarity !
Short lead = Cathode or—!
Construction
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 cath-
ode!
LD...
CATHODE
3mm
18mm

13
qIC4: TDA7293
Mount the support plate onto the IC as shown in the drawing.
Put a drop of silicone compound on both sides of the mica isolator.
Also check the position of the plastic isolator A.
ATTENTION : The bolt should be inserted on the side of the IC holder with the
countersunk opening B !
DO NOT TIGHTEN THE NUT YET
1.Position the IC onto the PCB.
2.Make sure that the support plate is touching the PCB surface.
3.Tighten the support nut.
4.Check again that the plate is touching the PCB surface.
5.Solder the IC connections.
23. Mounting the Power IC
Construction
A
Drop of heat conductive
compound
A
B

14
Mount the transformer as in the drawing (see also the picture on the packaging)
Use the supplied straps (4 pcs) to fix the transformer.
Primary windings (MAINS) connection:
Check the table on the PCB for the correct voltage selection and connect
the wires :
For 230V (220V to 240V), edge orange, then brown and black.
For 115V (110V to 120V), edge brown, then orange and black.
Using a black marker, erase the not used voltage on the rear panel of the
unit!
Secondary windings connection:
Connect the Red, Yellow, Blue and Grey wire to the SK5/SK6 connector, check
the colors on the PCB.
24. Mounting the power transformer and mains voltage selection
Construction
230V 120V
ORANGE BROWN
BROWN ORANGE
BLACK BLACK

15
qCut the thread in
the holes for the
enclosure feet in
one of the alumi-
num profiles, us-
ing the supplied
special M4 screw
as a tap.
qMount the feet on the
aluminum profile, using
two M4 hexagonal Al-
len screws. Use the
supplied Allen wrench.
It is advisable to stick
the protection adhe-
sive onto the feet.
qCut the thread in the
front and back of the
aluminum profiles, us-
ing the supplied spe-
cial M4 screw (4 holes
per piece)
25. Enclosure preparation
Enclosure preparation
FIG. 1
FIG. 2
FIG. 3

16
qPosition the main PCB in the aluminum profile that is prepared with the feet.
qMark the center position
of the three fixation holes
on the aluminum. A refer-
ence indication is also on
the PCB edge.
qRemove the pcb and use a knife or a screwdriver to scratch the paint from
the aluminum fixation, from the hole closest to the back end. This fixation will
be used later to connect the ground and earth.
qMount the three 5mm (0.14”) spacers as shown in the drawing. Use three
hexagonal screws and 3 washer. Do not tighten the spacers yet.
qPosition the PCB in the enclosure and check if the position of the spacers is
correct, if so, remove the PCB and tighten the spacers.
Enclosure preparation
FIG. 4
FIG. 5
M3 hex. nut
5mm M3 spacer Washer
FIG. 6

17
qUsing an ohmmeter, measure between the edge of the aluminum profile and
the back spacer, if there is a good electric contact (less then 10 ohm). If not,
repeat the above step to remove the paint under the spacer.
qSlide two M3 nuts and two
hexagonal bolts into the pro-
file, the nuts will be used for
the temperature sensor, the
bolts will be used for the IC
support plate:
qMount the temperature sensor, check
the exact position. Make sure there is
silicone compound between the sensor
and the enclosure!
qSolder the wires of the supplied two
pole connector onto the sensor.
There is no polarity.
Enclosure preparation
0.000
FIG. 7
FIG. 8
11cm
FIG. 9

18
Final assembly
RE-CHECK CAREFULLY THE PCB FOR MOUNTING AND
SOLDERING ERRORS!
qMount the pcb into the enclosure, check the position of the power IC. The IC
support must fit onto the previously inserted hexagonal bolts.
Make sure there is silicone compound between the IC support and the
enclosure!
qGlue the included insert Cbetween the transformer and housing.
qMake sure the PCB is aligned with the back of the enclosure
qIMPORTANT: FIRST fix the IC support
qTHEN fix the pcb using three 5mm spacers + washer.
DO NOT TIGHTEN THESE FIXATIONS YET.
FNote: Not all components are visible on the drawing.
26. final PCB mount
C

19
Final assembly
Prepare the wiring of the mains connector like in the drawing.
First mount the switch into the mains connector assembly.
Do not forget to isolate the soldering connections using a piece of shrink tube.
Use the supplied 0.5mm wire:
Blue for Neutral
Brown for Live
Yellow/green for earth
Use 3 pieces of about 10cm for later connection to the PCB mains connector.
qMount the speaker connectors onto the rear panel. (black = negative)
FTake care of the isolation washers, there are two different types! See pic-
ture.
FMake sure the connectors are very tight fit, and do not make electrical con-
tact with the panel (check using ohm meter!).
27. Speaker and mains connector assembly
Yellow/green
Brown
Blue
Isolation washer !

20
qSolder a 15cm (2.5mm) wire to the LS connectors. Black = negative, Red=
positive, use a shrink tube to isolate the connection..
qSolder a spade terminal to the other end, do not forget the terminal isolation.
qMount (insert) the mains connector onto the rear panel. Insert a 2A fuse into
the connector (there is also room for a spare fuse).
28. Final assembly and connection
Final assembly
15cm