high-end valve control amplifier
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Total solder points: 500 Difficulty level: beginner 1o 2o 3o 4o 5þ advanced
K8020
HIGH-END VALVE CONTROL AMPLIFIER
ILLUSTRATED ASSEMBLY MANUAL H8020IP-1
Val ve Cont r o l Ampl if ier8 0 2 0
Monitor
+ 6dB Aux CD Tuner AV
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
Co
lor c
od
e ta
ble
I P E SF S DK N D GB F NL
C O D E
CODICE
COLORE
CODIGO
DE
CORES
CODIGO
DE
COLORE
S
VÄRI
KOODI
FÄRG
SCHEMA
FARVE-
KODE
FARGE-
KODE
FARB
KODE
COLOUR
CODE
CODIFI-
CATION
DES
COU-
KLEUR
KODE
C O D E
0 Nero Preto Negro Musta Svart Sort Sort Schwarz Black Noir Zwart 0
1 Marrone Castanho Marrón Ruskea Brun Brun Brun Braun Brown Brun Bruin 1
2 Rosso Encar- Rojo Punainen Röd Rød Rød Rot Red Rouge Rood 2
3 Aran- Laranja Naran- Oranssi Orange Orange Orange Orange Orange Orange Oranje 3
4 Giallo Amarelo Amarillo Keltainen Gul Gul Gul Gelb Yellow Jaune Geel 4
5 Verde Verde Verde Vihreä Grön Grøn Grønn Grün Green Vert Groen 5
6 Blu Azul Azul Sininen Blå Blå Blå Blau Blue Bleu Blauw 6
7 Viola Violeta Morado Purppura Lila Violet Violet Violet Purple Violet Paars 7
8 Grigio Cinzento Gris Harmaa Grå Grå Grå Grau Grey Gris Grijs 8
9 Bianco Branco Blanco Valkoinen Vit Hvid Hvidt Weiss White Blanc Wit 9
A Argento Prateado Plata Hopea Silver Sølv Sølv Silber Silver Argent Zilver A
B Oro Dourado Oro Kulta Guld Guld Guldl Gold Gold Or Goud B
5%
4K7= ( 4 - 7 - 2 - B )
1%
4K7= ( 4 - 7 - 0 - 1 - 1 )
C O L O R = 2 … 5
6
The unit consists out of two PCB’s, one is the main PCB, P8020B and the other is the left channel input section P8021L. First we will start with the small P8021L, then we assemble the P8021B.
FTip: The pictures on the packaging can be
used as a guideline. However, due to possible changes it is not 100% reliable.
CONSTRUCTION
q D1: 1N4148 q D2: 1N4148 q D3: 1N4148 q D4: 1N4148 q D5: 1N4148 q D6: 1N4148
1. Diodes (check the polarity)
CATHODE
D...
q R1: 10K (1-0-3) q R2: 10K (1-0-3) q R3: 10K (1-0-3) q R4: 10K (1-0-3) q R5: 10K 1-0-3) q R6: 10K (1-0-3) q R7: 1K (1-0-2) q R8: 1K (1-0-2)
2. Resistors (check the color code)
R...
Construction
P8021L
7
q T1: BC557 q T2: BC557 q T3: BC557 q T4: BC557 q T5: BC557 q T6: BC557
5. transistors
q C1: 220p (221) q C2: 220p (221) q C3: 220p (221) q C4: 220p (221) q C5: 220p (221) q C6: 220p (221)
3. Capacitors
C...
Construction
q RY1: VR05051AS or eq. q RY2: VR05051AS or eq q RY3: VR05051AS or eq q RY4: VR05051AS or eq q RY5: VR05051AS or eq q RY6: VR05051AS or eq.
4- Reed relays (check the position
of the notch)
q SK1: MJ-523AG/B BLACK q SK2: MJ-523AG/B BLACK q SK3: MJ-523AG/B BLACK q SK4: MJ-523AG/B BLACK q SK5: MJ-523AG/B BLACK q SK6: MJ-523AG/B BLACK
6. RCA connectors. Mount them straight and against the PCB
q SK7: HDR20/26
7. Pin connector. Mount it exactly as indicated
RY...
9
q J1... J26
1. Jump wires
q R01: 10K (1-0-3) q R02: 10K (1-0-3) q R03: 10K (1-0-3) q R04: 1K (1-0-2) q R05: 10K (1-0-3) q R06: 10K (1-0-3) q R07: 1K (1-0-2) q R08: 10K (1-0-3) q R09: 680R (6-8-1) q R10: 1M (1-0-5) q R11: 27K/0.6W (2-7-3-9) q R12: 10K (1-0-3) q R13: 3K6 1% (3-6-0-1) q R14: 100K (1-0-4) q R15: 5K6 (5-6-2) q R16: 680R (6-8-1) q R17: 3K6/1% (3-6-0-1) q R18: 33K/1% (3-3-0-2) q R19: 10K (1-0-3) q R20: 1M (1-0-5) q R21: 27K/0.6W (2-7-3-9) q R22: 10K (1-0-3) q R23: 3K6/1% (3-6-0-1) q R24: 100K (1-0-4) q R25: 10K (1-0-3) q R26: 3K6/1% (3-6-0-1) q R27: 33K/1% (3-3-0-2) q R28: 680R (6-8-1) q R29: 5K6 (5-6-2) q R30: 1K (1-0-2) q R31: 1K (1-0-2) q R32: 27K/0.6W (2-7-3-9) q R33: 27K/0.6W (2-7-3-9) q R34: 27K/0.6W (2-7-3-9) q R35: 1R (1-0) q R36: 10K (1-0-3)
3. Resistors (check the color code)
q D1: 1N4148 q D2: 1N4148 q D3: 1N4148 q D4: 1N4148 q D5: 1N4148 q D6: 1N4148 q D7: 1N4148 q D8: 1N4148 q D9: 1N4148 q D10: 1N4007 q D11: 1N4007 q D12: 1N4007 q D13: 1N4007 q D14: 1N4007 q D15: 1N4007 q D16: 1N4007 q D17: 1N4007 q D18: 1N4007 q D19: 1N4007 q D20: 1N4007
2. Diodes (check the polarity)
CATHODE
D...
R...
Construction
10
q R37: 4K7 (4-7-2) q R38: 10K (1-0-3) q R39: 4K7 (4-7-2) q R40: 10K (1-0-3) q R41: 1K (1-0-2) q R42: 10K (1-0-3) q R43: 10K (1-0-3) q R44: 10K (1-0-3) q R45: 1K (1-0-2) q R46: 1K (1-0-2) q R47: 10K (1-0-3) q R48: 1K (1-0-2)
q Mount 9 pins in
each hole for the valve supports V1 and V2.
q Mount 3 pins in
the holes for VR1.
4. PCB pins
q IC1: 18P
5. IC sockets
q C01: 220p (221) q C02: 220p (221) q C03: 220p (221) q C04: 220p (221) q C05: 220p (221) q C06: 220p (221) q C07: 220p (221) q C08: 100n (104, 0.1, u1) q C09: 100n (104, 0.1, u1) q C10: 100n (104, 0.1, u1) q C11: 100n (104, 0.1, u1) q C12: 100n (104, 0.1, u1) q C13: 100n (104, 0.1, u1) q C14: 100n (104, 0.1, u1) q C15: 100n (104, 0.1, u1)
6. Capacitors
C...
Construction
11
1
V1
V2
VR1
11
q RY9: VR5C122C
9. Power relay
q T01: BC557 q T02: BC557 q T03: BC557 q T04: BC557 q T05: BC557 q T06: BC557 q T07: BC557 q T08: BC557 q T09: BC557
q T10: BC547
8. transistors
RY...
q SK1: MJ-523AG/R RED q SK2: MJ-523AG/R RED q SK3: MJ-523AG/R RED q SK4: MJ-523AG/R RED q SK5: MJ-523AG/R RED q SK6: MJ-523AG/R RED
11. RCA connectors. Mount them straight and against the PCB
q SK7: 20P (type 96120205)
7. Female header
q RY1: VR05051AS or eq. q RY2: VR05051AS or eq q RY3: VR05051AS or eq q RY4: VR05051AS or eq q RY5: VR05051AS or eq q RY6: VR05051AS or eq. q RY7: VR05051AS or eq. q RY8: VR05051AS or eq.
10. Reed relays (check the position
of the notch)
RY...
J...SK..
Construction
12
q SW1: TS-04PV q SW2: TS-04PV q SW3: TS-04PV q SW4: TS-04PV q SW5: TS-04PV
Remark: The metal part of these but-tons are used as jump wire. Be sure not to test or use the unit without soldering these push buttons.
13. Push button Mount them straight against the PCB surface !
Construction
q C16: 2,2uF( 2u2, 225 ) q C17: 2,2uF( 2u2, 225 ) q C18: 68nF/630V (0.068, 683) q C19: 68nF/630V (0.068, 683) q C20: 22nF/630V (0.022, 223) q C21: 4,7uF/160-250V( 4u7) q C22: 4,7uF/160-250V( 4u7)
14. Capacitors
C...
q V1: B9A q V2: B9A The valve socket is mounted on top of the allready mounted PCB pins.
• First position the socket over the pins and solder one lead.
• Check the hight of opprox. 23mm (0.9”)
12. Valve socket mounting
5 9
8
7
4
3
2
V...6 1
13
q C23: 100µ q C24: 470µ q C25: 1000µ q C26: 1000µ q C27: 1000µ q C28: 47µ/350V q C29: 47µ/350V q C30: 47µ/350V q C31: 47µ/350V q C32: 47µ/350V q C33: 47µ/350V q C34: 47µ/350V
16. Electrolytic capacitors. Check the polarity !
q VR2: UA7805 VR1 will be mounted later
15. Voltage regulator. The back side corresponds to the thick line.
C...
VR...
q TR1: TR8020, 2x18V, 12V, 220V/
16VA First fix the transformer using four 6mm M3 screws and nuts (nuts at solder side), then solder his connec-tions.
Tip: It is advisable to secure the nuts using a drop of glue.
17. Transformer.
TRAFO...
Construction
14
q RV1: STRK27103 (2x50K ALPS)
CAUTION: This is a high quality potentiometer, handle it with care. Follow the mounting instructions exactly and in order! 1.Mount the support bracket onto the
potentiometer. Tighten the nut carefully.
2.Mount the potentiometer onto the
PCB, using two 6mm (0.23”) screws and M3 nut.
Only slightly tighten the nuts ! Do not solder the potentiometer connections yet !
18. Volume potentiometer.
Use a piece of isolated brown wire to select the mains (outlet) voltage, as indicated on the PC board.
q For 115Vac (100 to 120Vac) A jumper between A-B, and a jumper between C-D.
q For 230Vac (220 to 240Vac) A jumper between B-C.
Using a black marker, erase the not used voltage at the back of the unit.
19. Mains voltage selection
q Connect a 10cm blue wire to the
point N of SK8. q Connect a 10cm brown wire to the
point L of SK8. q Connect a 10cm yellow/green
wire to the earth point of SK8. Later these connection will be soldered to the mains connector.
20. Mains voltage connection preparation
RV...
Construction
A B C D
B C
15
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. q LD7 L-424YDT q LD1 L-424YDT q LD2 L-424YDT q LD3 L-424YDT q LD4 L-424YDT q LD5 L-424YDT q LD6 L-424YDT q LD8 L-424YDT
21. Mounting the 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 po-sitioning reference.
3mm
3mm C
CATHODE
LD...
FIG. 1
FIG. 2
FIG. 3
CAUTION: After bending the leads the long appearing lead will be the cath-ode!
16
q Mount four 2cm (0.8”)
M3 spacers at the indi-cated positions using four 6mm (0.23”) M3 screws.
22. Mounting the sub PCB support
Construction
17
q Cut the thread in the holes for the en-closure feet in one of the aluminum profiles, using the supplied special M4 screw as a tap.
q Cut the thread in the front and
back of the aluminum profiles, using the supplied special M4 screw (4 holes per piece)
q Mount the feet on the aluminum pro-
file, using four M4 hexagonal Allen screws. Use the supplied Allen wrench. It is advisable to stick the pro-tection adhesive onto the feet.
q Mount the valve pro-
tection covers on one of the aluminum pro-files. Use four M4 hex-agonal Allen screws.
23. Enclosure preparation
Enclosure preparation
FIG. 2
FIG. 3
FIG. 4
FIG. 1
18
q Position the main PCB in the
aluminum profile that is pre-pared with the feet.
q Mark the center position of the three fixation holes on the aluminum.
Align pcb with profile !
Enclosure preparation
FIG. 5
19
q Remove the pcb and use a
knife or a screwdriver to scratch the paint from the alu-minum fixation, from the hole closest to the back end. This fixation will be used later to connect the ground and earth.
q Mount the 3, 5mm
(0.14”) spacers like in the drawing. Using three hexagonal screws and a washer. Do not tighten the spacers yet.
q Position the PCB in the enclosure and check if the position of the spacers is
correct, if so, remove the PCB and tighten the spacers. q Using an ohmmeter, measure between the edge of the aluminum profile and
the back spacer, if there is a good electric contact (0 ohm). If not, repeat the above step to remove the paint under the spacer.
Enclosure preparation
FIG. 6
M3 hex. nut 5mm M3 spacer
Washer
FIG. 7
0.000FIG. 8
20
Final assembly
q Mount the PCB into the enclosure like before. q Fix the pcb using a
5mm spacers next to C9.
q Mount the knob onto the potentiome-
ter. (check the notch position)
FUse the supplied Allen wrench
Tip: Check if the pcb does not have to much play at the potentiometer posi-tion. If there is too much play, put a piece of tape round the edge of the pcb to remove the slack.
Play?
24. Potentiometer assembly and final PCB mount
FIG. 1
FIG. 2
MAX MIN
FIG. 3
21
q Now carefully mount the front panel, us-
ing two M4 Allen screws. Check the posi-tion of the LED’s.
q Check if the potentiometer turns smoothly without touching the front panel, other-wise correct his position or the position of the front panel.
F Use the supplied Allen wrench
q Remove the front panel and fix the nuts of the potentiometer bracket. q Remove the PCB from the enclosure and solder the potentiometer connec-
tions.
IMPORTANT: q Slide an M3 hexagonal screw into the profile
side. Position the screw about in the center of the profile.
q Again mount the pcb into the enclosure. q Fix the pcb using a 2cm (0.8”)
spacer at the position next to SK07 and use 5mm spacers to fix the other two positions. Measure, using an ohm meter (or continuity beeper) if the 2cm spacer is electrically con-nected to the ground wire (yellow green wire). If not, re-check if the paint of the alumi-num is correctly removed.
q Mount the left channel PCB onto
the spacers, check that the con-nector is correctly inserted. Fix the PCB using five 6mm M3 screws.
Final assembly
FIG. 4
SPACER
FIG. 6
FIG. 5
FIG. 7
22
Mounting the voltage regulator: q VR1: 7812 (isolated plastic type)
First bend his leads like in the drawing
Then mount him onto the previously in-serted hexagonal screw, at the appropri-ate position according to the PCB. Use a 5mm spacer screw.
Last solder his connections. q Mount (insert) the
mains connector onto the rear panel. Insert a 250mA fuse into the connector (there is also room for a spare fuse).
q Mount the rear panel onto the enclosure, us-ing two M4 Allen screws.
25. Final assembly and connection
Final assembly
FIG. 1
FIG. 2
FIG. 3
23
q Connect the mains wires to the
mains connector, Blue= Neutral, Brown= Live, and green/yellow= Earth. Use a piece of 1.5cm (0.6”) shrink tube to isolate each connec-tion.
q Mount the front panel onto the
front, using two M4 Allen screws.
FCheck the position of the
LED’s and check if all buttons are working correctly. It could be that paint rest over in the holes, is preventing the buttons from smooth opera-tion.
Test
FIG. 4
FIG. 5
24
Insert the IC into his socket. Watch the position of the notch! q IC1 VK8020 / PIC16C54RC Insert the valves into their socket (watch the position) q V1: ECC82, 12AU7, CV491, 6189, 8136 q V2: ECC82, 12AU7, CV491, 6189, 8136
Connect the power cord to the mains connector. Connect the power cord to the mains output
CAUTION: Some points on the PCB are connected to the danger-ous mains voltage or high DC voltage.
Push the power button (or one of the input selection buttons) Check if the power supply LED LD08 is lit. This means that the high voltage is correct. Normally the valves filaments (or heaters) must also work. Disconnect the mains plug. Check the user manual to test all functions and operation of the unit, then the aluminum cover can be mounted. Please note that the user manual is also used for the ready assembled version. Some remarks may not be related to the kit version.
26. IC and Valve mounting
!
Diagram
27. Test
25
Diagram
POWER SUPPLY SECTION
CONTROLLER SECTION © Velleman Kit
D101N4007
D111N4007
D16
1N4007 D19 1N4007
D18
1N4007
D17
1N4007
C10
100n
C11
100nA
D
C
B
230V
N
B+C
115V
L
A+BC+D
IO
GN
D
VR2uA7805+5V
C15
100n
C14
100n
C13
100n
C12
100n
C23
100µ
C27
1000µ
C26
1000µ
C24
470µ
+12.5V
R351R
SK10
SK09
SK08
R09
680R
C08
100n
Mains selection
MAINS
TR1
D131N4007 D12
1N4007
D15
1N4007
D14
1N4007
D09
1N4148
RY9
PWR
+12V
+12V
C25
1000µ
C29
47µ/350V
C28
47µ/350V
C30
47µ/350V
+300V
R34
27K/0.6W
R30
1K
R31
1K
C2022n/630V
IO
GN
D
VR1 uA7812P
R33
27K/0.6W
R32
27K/0.6W
LD8
L-424YDT
18V
18V
12V
220V
0
21V@230Vac in
265V@230Vac in
RA017
RA118
RA21
RA32
RB06
RB17
RB28
RB39
RB410
RB511
RB612
RB713
VSS
5
MCLR/VPP4
OSC1/CLKIN16
T0CKI3
OSC2/CLKOUT15
VD
D14
IC1
PIC16C54RC
R39
4K7C07
220p
Input1
Input2
Input3
Input4
Monitor
+6dB
Mute
R47
10K
R44
10K
R43
10K
R42
10K
R40
10K
+5V SW4
SW3
SW2
SW1
SW5
R451K
R481K
+5V
R461K
R41
1K
LD1
L-4
24Y
DT LD2
L-4
24Y
DT
LD5
L-4
24Y
DT
LD6
L-4
24Y
DT
LD7
L-4
24Y
DT
LD4
L-4
24Y
DT
LD3L-4
24Y
DT
C09
100n
REC
TUNER
CD
PU/LINE
STBY / MUTE
T09
BC557
R38
10K
T10
BC547
R37
4K7
R36
10K
+5V
PWR
D201N4007
+12V
+5V
26
Diagram
RY1
T1
BC557
SK1
R1
10K
C1
220p
D1
1N4148
+5V
RY2
T2
BC557
SK2
R2
10K
C2
220p
D2
1N4148
+5V
RY3
T3
BC557
SK3
R3
10K
C3
220p
D3
1N4148
+5V
RY4
T4
BC557
SK4
R4
10K
C4
220p
D4
1N4148
+5V
RY5
T5
BC557
SK5
R5
10K
C5
220pD5
1N4148
+5V
RY6
T6
BC557
SK6
R6
10K
C6
220p
D6
1N4148
+5V
R8
330R
R7
1K
+5V1234567891011121314151617181920
SK7
CD
PU/LINE
TUNER
REC
MONITOR
LINE OUT L
LEFT INPUT / OUTPUT SECTION © Velleman Kit
27
RIGHT INPUT / OUTPUT SECTION AND AMPLIFIER SECTION
© Velleman Kit
RY1
T01
BC557
SK01
R0110K
C01
220p
D01
1N4148
+5V
Input1
RY2
T02
BC557
SK02
R0210K
C02
220p
D02
1N4148
+5V
Input2
RY3
T03
BC557
SK03
R0310K
C03
220p
D03
1N4148
+5V
Input3
RY4
T04
BC557
SK04
R0510K
C04
220p
D04
1N4148
+5V
Input4
RY5
T05
BC557
SK05
R0610K
C05
220pD05
1N4148
+5V
Monitor
RY6
T06
BC557
SK06
R08
10K
C06
220p
D06
1N4148
+5V
Mute
R07
1K
R04
1KC16
2.2uF
+12.5V
R16680R
R11
27K
/0.6
W
R101M
+5V
RY8D08
1N4148
+5V
+6dB
R13
3K6 1%
RV1B
50K
RV1A
50K
C17
2.2uF
123456789
1011121314151617181920
SK07
Input1Input2
Input3Input4
MuteMonitor
Line out L
Line out L
CD
PU/LINE
TUNER
REC
MONITOR
LINE OUT R
1
2
3
5 9 4
8
6
7V1
ECC82
C32
47µ/350VC31
47µ/350V
R17
3K6 1%
R14
100K
R18
33K
1%
R1210K
T08
BC557
R1910K
C18 68n/630V
C21
4u7/160V
+300V
R155K6
+12.5V
R28680R
R21
27K
/0.6
W
R201M
+5V
RY7D07
1N4148
+6dB
R233K6 1%
1
2
3
5 9 4
8
6
7V2
ECC82
C34
47µ/350VC33
47µ/350V
R26
3K6 1%
R24
100K
R27
33K
1%
R2210K
T07
BC557
R2510K
C19 68n/630V
C22
4u7/160V
R295K6
+300V
Line out R
Line out R
170v
7V -4V 115V
130V - 100V
220V
Diagram
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