Audio Note EL34 User Manual

Manual Version 1.1 - August 2009

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Page 1

Table of Contents

Section1: Introduction ............................................................................................................................................................. 3

Component Placement Breakdown..................................................................................................................................... 4

Electrical Safety Warning .................................................................................................................................................... 5

Section 2: First Steps .............................................................................................................................................................. 6

Installing the feet ................................................................................................................................................................. 6

IEC Section Installation ....................................................................................................................................................... 7

Mains Transformer Installation ............................................................................................................................................ 7

IEC Section.......................................................................................................................................................................... 8

Preparing the Secondary leads ......................................................................................................................................... 11

Section 3: Power Supply Board Construction ....................................................................................................................... 12

Installing the Components ................................................................................................................................................. 12

Section 4: Choke Installation and HT Wiring ........................................................................................................................ 14

Section 5: ECF80 Driver Board Construction ....................................................................................................................... 16

Parts List............................................................................................................................................................................ 17

Installing the Spacers and Valve Base .............................................................................................................................. 18

Installing the Resistors ...................................................................................................................................................... 19

Installing the Capacitors .................................................................................................................................................... 20

Section 6: EL34 Hardwired Section ...................................................................................................................................... 22

Parts List............................................................................................................................................................................ 23

Assembly ........................................................................................................................................................................... 23

Section 7: Layout Recap ....................................................................................................................................................... 30

Section 8: EL34 Board Filament Hook-Up ............................................................................................................................ 31

Section 9: EL34 Board To Output Transformer Wiring ......................................................................................................... 33

Section 10: HT and GND Connections to EL34 Board ......................................................................................................... 35

Section 11: Speaker Post Connections ................................................................................................................................ 37

Section 12: Driver Board Filament Hook-up ......................................................................................................................... 41

Section 13: ECF80 to EL34 Board Interconnections ............................................................................................................ 43

Section 14: RCA Connections and Final Earth ..................................................................................................................... 46

Section 15: Powering On and Testing .................................................................................................................................. 49

Power On Procedure ......................................................................................................................................................... 49

Appendix ............................................................................................................................................................................... 50

Resistor Color Code Reference......................................................................................................................................... 51

Mains Transformer Windings Diagram .............................................................................................................................. 52

Power Supply Board Schematic ........................................................................................................................................ 53

Driver Board Schematic..................................................................................................................................................... 54

Output Board Schematic ................................................................................................................................................... 55

Output Section Hardwiring Diagram .................................................................................................................................. 56

General Wiring Diagram .................................................................................................................................................... 57

Full Schematic ................................................................................................................................................................... 58

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Page 2

Section1: Introduction

Thanks for purchasing the AudioNote L4 Series EL34 Push-Pull Power Amplifier. Our goal is to provide you with the highest quality Kit that you will build from scratch with these instructions. If you have any questions or comments during the build feel free to contact us and we would be happy to help out.

You will need a soldering iron or soldering station with a sponge along with wire strippers and a Phillips screwdriver. A nut driver or a pair of pliers would be useful as well. We have divided the manual up into a series of step-by-step instructions for the successful build and debug of the kit. There are several places during the build that you will perform tests and/or checks to make sure that you are on track. This way when you complete the kit you will know that all the major sections are working.

You will find a number of component bags supplied with your kit. These bags will be referred to throughout this manual.

Here are some tips from working with many kit builders over the last few years:

 Perform your work in small manageable chunks. Do not be in a hurry to listen to your finished kit.

 Savor the build experience. Here’s a chance to really get to know your audio kit that will give you many hours of

enjoyment.

 Better to work on a section and then spend the time to check over the section rather than just carrying on.

 The kit building experience should be a pleasant one so find a place that you can build the kit with relative peace

so you can concentrate on the instructions.

 If you plan for a long build stretch on a Saturday afternoon for example then take plenty of breaks with constant

re-checks of your work.

Whilst working through this manual, please feel free to give us your feedback and any other information that may allow us to improve the build experience.

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Page 3

Component Placement Breakdown

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Page 4

Electrical Safety Warning

There are sufficient voltages in this kit to give you a very nasty and harmful shock so be careful when powering on, debugging, and probing around.

Please be aware of proper electrical safety.

Please contact AudioNote Kits via phone or email to discuss any precautions necessary when building the kit if you feel unsure about what you are doing at any stage of the build.

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Page 5

Section 2: First Steps

In this beginning section we will start by installing the 4 feet then we will install the Mains transformer and wire up the IEC section.

Installing the feet

Our first task is to install the 4 rubber feet into the holes in the 4 corners of the chassis using the provided hardware in the “Feet” Bag (found in the big Hardware bag). Use the M4 screw along with the big washer on the outside of the foot and then a M4 nut and M4 black serrated washer against the chassis on the inside of the chassis!

Might be handy to use an M4 nut driver or something similar to tighten the nuts for the feet on the inside of the chassis as shown below.

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Page 6

IEC Section Installation

Let’s install the input AC receptacle and rocker switch known as the IEC socket & Rocker in the rear of the chassis.

Shown opposite is the rocker switch slot above the fitted IEC socket.

Mains Transformer Installation

Here you can see the correct installation of the IEC plug in the rear of the chassis along with the Rocker switch.

2 rubber strips are used to isolate the mains transformer from the chassis.

Lay down the two rubber strips so that they are over the correct holes in the chassis (these holes are about 100mm apart).

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Page 7

Place the Mains transformer carefully over top. Note that the primary of the Mains transformers (2 black + 2 white + 1 green wire) is placed towards the back of the chassis while the Secondaries are placed towards the front.

The provided Hardware in the bag marked “Mains transformer” will be used to secure down the Mains transformer – Prior to securing the transformer in place we suggest you hook up the IEC section with the provided cables found in the “IEC” Bag.

IEC Section

The supplied Mains Transformer is capable of being configured for different mains supply voltages. The examples here are showing configuration for 120v operation. If you are in a region of the world that requires a different voltage then

please refer to the regional wiring chart shown below and derive the correct wiring from that instead.

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Mains wiring - Regional variations

Page 8

Remember, the following example shows how to wire for 120v operation only.

The next step is trim the wires lengths once they have been twisted such that the length would reach to the top of the chassis (approx 7 or 8 inches).

* Applies to 120v operation only.

Take both black twisted wires and strip about ½ inch of insulation – then twist the ends together – then TIN this end by applying solder to it to make sure that it is nicely formed.

Then place a blue CRIMP on the end of the wire. Here’s the tricky part – add solder so that the TINNed end of wire adheres to the crimp – you will probably need to add a surprising amount of solder to make sure there is a very good connection along with quite a bit of heat.

Once the crimp has been added then you can place the heat shrink over the exposed metal end of the crimp and apply your heat gun.

REPEAT for the White twisted wires.

* Applies to 120v operation only.

If you live in a 120V AC world voltage then we will twist the black wires together as shown as well as twisting the white wires.

We will also be working with the green screen wire.

* Applies to 120v operation only.

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Page 9

Now let’s deal with the green wire coming out of the Mains Primary. This is the ground lead that we will be attaching to chassis ground.

Strip the wire and tin it and then solder the ground lug to it.

This is where you will attach the earth wire to. You will secure it using an M4 16mm pan screw from under the chassis and use a nut to secure the ground lug from the Mains transformer.

Note that the mains input earth will also be joining it shortly.

In order to complete the IEC wiring, you will be using 2 pre-terminated cables.

The first one is the earth cable shown here. This connects to the IEC mains socket’s earth lug, which is in turn connected to the chassis earth lug (discussed previously).

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Now use the twisted pair cable (shown opposite) to complete the wiring between the mains input socket and the mains switch - refer to the wiring diagram shown previously.

You will have to apply some pressure to position the crimps correctly onto the lugs.

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Preparing the Secondary leads

The IEC section is now complete.

The picture opposite shows the completed wiring for 120v operation.

* Applies to 120v operation only.

Pull out your insert sheet showing the Mains transformer windings for the secondary.

The first step is to twist the wires according to the windings:

• Blue & Yellow

• Red & Blue/White

• Brown & Black/Green

• Orange & Violet & Orange/White (Braid these wires

– you may have to ask your wife!)

We will be using these twisted wires later – lets move on to the Power Supply Board.

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Page 11

Section 3: Power Supply Board Construction

Here are the parts for the Power Supply Board along with the spacer hardware.

Quantity Description

4 1,000v 3A fast Diodes

2 220uF 450v Electrolytic Capacitors

1 330K 1W resistor

2 1M5 1W resistor

Installing the Components

IMPORTANT: The Diodes that we are using have a stripe on one side that you need to match with the PCB. They must not be inserted the wrong way around.

Bend the leads so that they can be inserted into the PCB.

Next, install the 3 resistors.

Note that the board shown in the picture was a Beta board with wrong stencil markings but as you can see the 330K resistor is at the bottom of the board and the 2 x 1.5M are above it.

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Page 12

The next job is to install the Electrolytic Capacitors.

Quick Lesson on Electrolytic Capacitors These capacitors have a Positive and Negative side to them and need to be installed correctly or they will BLOW up!

The Stripe on the side of the capacitor can designates the NEGATIVE side.

You will also see the + sign marked on the PCB denoting the positive side

Here you can see the capacitor being correctly installed in the board.

Here you can see the Power Supply Board correctly populated.

Check over the board for correct positioning and polarities before finally soldering the components in place.

Finally, you can install the spacers on each corner of the board and position the board into its correct location in the chassis.

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Page 13

Section 4: Choke Installation and HT Wiring

Here is how the choke and the Power supply board will be positioned in the chassis.

You will want to bring the Mains transformer secondary leads through on this side of the chassis and position the twisted filament wires from the secondary windings going the other way into the amplifier.

Use the supplied hardware (M3 screws and nuts) to secure the choke into position.

Trim and tin the Choke wires (yellow and black) so that you can connect them to the power supply board.

Insert them underneath the board if you like and apply solder from the top of the board – plenty of solder will be used and then you can trim the extra tinned wire poking through the board.

Connect the yellow and black wires from the Choke into holes CH-1 and CH-2 – it does not matter which wire goes to which hole.

Now lets take the High Voltage wires (Yellow and Blue) and trim to length.

Strip the end of the wires and tin.

Connect to HAC1 (High Voltage AC 1) and HAC2 (High Voltage AC 2).

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Page 14

Finally, bring the triple braided wire down the length of the chassis for later use.

Now we can move onto the next stage of the build.

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Page 15

Section 5: ECF80 Driver Board Construction

In this section we will be building the first of the 2 Driver Boards, which contain the ECF80 tube. See the Appendix for the schematic for this board.

The build of this board is quite straightforward and shouldn’t pose any problems. Just make sure that the three electrolytic capacitors are inserted the correct way around - observing correct polarity.

SPECIAL NOTE: R12 and R13 have been moved from this board to the Output Board. Therefore, you should replace these resistors with wire links!

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Page 16

Parts List

Resistors

Quantity Value Designator Description

1 100R R6 1W

1 470R R5 1W

1 1K R2 1W

1 2K2 R15 1W

2 10K

R12, R13 1W

Wire links

1 22K R9 1W

3 33K R7, R8, R14 1W

1 100K R1 1W

1 330K R3 1W

2 470K R10, R11 1W

1 1.8K R16

2 51K R4a, R4b

The resistors that used to be here have been moved to the Output Board for performance reasons. W ire links should now be used here in their place.

Capacitors

1 470uF 16v C2 ECF80 cathode 1 10uF 450v C1 ECF80 1 100uF 450v C3 HT / GND 2 .22uF 630v Input to EL34 1 100pF 630v C6 ECF80 input 1 820pF C7

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Page 17

Installing the Spacers and Valve Base

Here is a reference picture of the unpopulated board.

To begin construction you will need the following hardware parts:

Install the 5 spacers and secure them into position.

Using the M3 16mm screws, spacers and M3 nuts, you can secure the valve base into position on the board.

Then solder the pins of the valve base on the underside of the board so that they are connected to the PCB.

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Page 18

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Audio Note EL34 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual