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Kilpatrick Audio Format Technical Specifications

Kilpatrick Format
Technical Specications
Kilpatrick Format
Technical Specifications
A Specification and Guide for Module Designers
Copyright 2014: Kilpatrick Audio / Andrew Kilpatrick
Written by: Andrew Kilpatrick
07/02/2014 Page 1 of 29
Kilpatrick Format
Technical Specications
Table of Contents
Introduction................................................................................................................................................4
A Few Words of Welcome.....................................................................................................................5
Use of the Kilpatrick Format Specification...............................................................................................6
Naming Requirements...........................................................................................................................6
Keep Kilpatrick Audio Informed...........................................................................................................6
Errors, Omissions and Suggestions.......................................................................................................6
Physical Specifications..............................................................................................................................7
Module Stack-up Overview...................................................................................................................7
Panel Material........................................................................................................................................8
Panel Retaining Screw...........................................................................................................................9
Module Power Plugs...........................................................................................................................10
Module Stack-up Details.....................................................................................................................11
Panel Dimensions and Thickness........................................................................................................12
PCB Dimensions and Thickness.........................................................................................................12
Panel to Top PCB Spacing..................................................................................................................12
Top PCB to Bottom PCB Spacing.......................................................................................................13
Enclosures................................................................................................................................................14
Module Mounting Plate.......................................................................................................................15
Power Supply......................................................................................................................................16
Active / Passive Enclosure Interconnect.............................................................................................17
Connecting Multiple Active Enclosures..............................................................................................17
Power Wiring and Power Supplies...........................................................................................................18
Analog and Digital Grounds................................................................................................................18
System Power Grounding....................................................................................................................19
Power Supplies on Modules................................................................................................................19
Audio and Control Signals.......................................................................................................................20
Signal Impedance................................................................................................................................20
Input and Output Voltage Range.........................................................................................................20
Gates and Pulses..................................................................................................................................21
Audio and CV Signals.........................................................................................................................21
Indicator LEDs.........................................................................................................................................21
Module Design Techniques......................................................................................................................22
Module Power Supply Example..........................................................................................................22
Pulse Input Circuit...............................................................................................................................23
+3.3V to +5V Pulse Amplifier.............................................................................................................24
Bi-colour LED Driver.........................................................................................................................25
07/02/2014 Page 2 of 29
Kilpatrick Format
Technical Specications
Split Supply Using an Opamp.............................................................................................................26
Going Between AGND and DGND....................................................................................................27
Appendix A – Part Reference...................................................................................................................28
Appendix B – Module Reference Drawings............................................................................................29
Appendix C – Enclosure and Power Supply Drawings...........................................................................29
07/02/2014 Page 3 of 29
Kilpatrick Format
Technical Specications
Introduction
The Kilpatrick Format is a unique and flexible modular synthesizer format with many useful features. The format can be applied to modular synthesizers, audio equipment, lighting and video system, and any system where low-power modules, straight-forward module design, high quality construction and easy module installation and removal is desirable.
Main Features:
• 4U (7”) panel height - makes designing attractive and functional modules enjoyable
• Easy Plug-in System - makes installing and removing modules easy – no panel screws used
• Simple module construction – improves design work flow and removes guess-work – all
modules fit all enclosures
• Improved Electrical Properties – 15V rails plus separate analog and digital grounds provide a better electrical environment for circuit designers
• Banana Cables for Patching – the use of standard banana connectors offer a high quality, stackable, colour-coded connector which is low-cost and easy to assemble on PCBs
• Off-the-Shelf Components – no custom connectors or tooling means parts are available from most distributors
07/02/2014 Page 4 of 29
Kilpatrick Format
Technical Specications
A Few Words of Welcome
On behalf of Kilpatrick Audio I thank you for taking the time to get to know more about the Kilpatrick Format. After many years searching for the “ultimate” format for my own designs I developed the Kilpatrick Format to solve a number of problems I saw when designing for other modular systems.
After experimenting with 5U Modcan style and 3U Eurorack formats and being frustrated by both, I realized that 4U is the “right” size for modular synths. Buchla and Serge definitely had it right, and although I could have copied their proprietary formats, there were aspects that bothered me.
I finally came up with what I feel lends itself to easy module design. Products can be built in small quantities. (important if you want to offer a lot of modules on a built-to-order basis) It has good electrical characteristics, feels good physically, and uses all off-the-shelf parts which should make boutique designs somewhat future-proof. The enclosure and power supply design are low-cost and reliable.
I hope that you are inspired to make your own modules in the Kilpatrick Format and I look forward to seeing and hearing what you come up with!
Andrew Kilpatrick - 2014
07/02/2014 Page 5 of 29
Kilpatrick Format
Technical Specications
Use of the Kilpatrick Format Specification
The goal of this specification is to encourage the use the Kilpatrick Format by both commercial manufacturers and DIY builders. Please follow the specification as closely as possible, or contact Kilpatrick Audio if your needs are not accounted for here. With so many low-quality products available for other formats, strict compatibility is necessary to maintain the quality of the system. If your goal is to make the cheapest possible products then please choose a different format. However, if you want to make excellent modules that are cost-effective and very high quality then you are probably in the right place!
Naming Requirements
Somewhere within your advertised specifications, you must indicate that your product is a “Kilpatrick Format” module or accessory. Use of the name means that the module or accessory meets the requirements set out within this specification, or whichever version of the spec is current at the time you undertake your design. This help customers who purchase modules to know that they are getting a quality product that will work well with existing and future module designs from other manufacturers.
Keep Kilpatrick Audio Informed
Use of the Kilpatrick Format is free of charge, but you must tell us if you release a module so that we can keep track of products available in the format. We will also offer a module swap service so that builders can put together nice systems at low cost. When you have a module ready let us know and we'll arrange to swap a module of similar value with yours. We hope you will extend this opportunity to other builders as well.
If you don't want to trade modules, sending some info that we can post on our website would be great also. We are interested in linking to both commercial and DIY sites if you want to become part of the family. Prospective buyers often ask what other modules are available.
Errors, Omissions and Suggestions
Please help to improve this specification by reporting any errors, information that is missing or difficult to understand, and any other ideas that would help to improve it.
07/02/2014 Page 6 of 29
Kilpatrick Format
Technical Specications
Physical Specifications
The Kilpatrick Format is built around panels which are one or more spaces wide. A space is set as 1/4 of a rack width, and 4U (7”) tall. Four spaces occupy one rack-mountable enclosure. Wider enclosures are possible, with 5 or 6 spaces being the most useful. Spaces are 4.250" x 7.000", but panels are manufactured as 4.240" x 6.990" to compensate for slight manufacturing tolerances and also alignment when the modules are plugged into the system. The dimensions should be reduced by 0.005” on each edge so that all holes, etc. are centered within the panel.
One and two space panels are the most useful sizes, although three and four spaces can be made as well. You must not make modules wider than four spaces because all modules should fit into a rack-mounted enclosure. The corners of modules are always rounded with a 0.125” radius to make them less sharp and also hide small alignment problems when the modules are sitting next to each other. If you have an idea for a huge module it might make more sense to break it up into several smaller designs.
Module Stack-up Overview
Before we go into detail on the each part of a module, have a look at the following diagram which shows the components of a module as a section view. All modules are built with the same stack-up and spacing between layers.
Fig 1 - Module Stack-up – Side View
07/02/2014 Page 7 of 29
Kilpatrick Format
Technical Specications
The spacings are chosen to allow the use of common components such as banana jacks, toggle switches, board to board stacking headers, etc. Some components like pushbuttons and some kinds of jacks may require additional PCBs or different spacings, but for most modules the suggested spacing should offer the most flexibility.
Panel Material
Panels are generally made from 14GA (0.062" or 1/16” thick) anodized aluminum. Kilpatrick panels are vertically brushed and anodized and screened with black epoxy ink. Other finishes are acceptable such as powder coating. Panels must be made from metal. The panel thickness must be 0.062” to ensure that all module faces are aligned when installed in a system.
Note: The use of PCB material or acrylic as a panel material is not acceptable. If these materials are required for specific reasons, they should be installed within an area of a metal panel and not used to support the banana jacks or mounting bolts.
Fig 2 - Raw Panels
07/02/2014 Page 8 of 29
Kilpatrick Format
Technical Specications
Panel Retaining Screw
Below each module space in an enclosure is a blind M3x0.5 standoff used to secure a module to the enclosure. Each module must contain a captive M3x0.5 x 25mm hex head cap bolt that uses a 2.5mm hex key. The bolt is installed between the two PCB layers with a spacer between PCBs. The retaining feature is accomplished by a nylon insert lock nut underneath the PCB. A hole in the top panel gives access to the bolt. The module can be secured by gently tightening the bolt. When banana cables are pulled out many at a time, the bolt keeps the module from pulling out of the enclosure. In production the nut should be tightened part way to allow some play in the bolt. The spacer prevents over-tightening and damage to the PCBs.
Fig 3 - Retaining Screw – Side View
07/02/2014 Page 9 of 29
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