Velleman K8040 User Manual

Total solder points: 299
Difficulty level:

beginner 1o 2o 3o 4o 5þ advanced

HIGH-END mono mosfet power

amplifier

K8040

8040

Mosfet Power Amplifier

On

Temp. error

Clip/Auto power

ILLUSTRATED ASSEMBLY MANUAL H8040IP-1

VELLEMAN COMPONENTS

Legen Heirweg 33

9890 Gavere

Belgium

http://www.velleman.be

Assembly hints

0.000

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 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 draw-

ings.

⇒ Values on the circuit diagram are subject to changes.
⇒ Values in this assembly guide are correct*

3

Assembly hints

⇒ 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 cone­shaped and shiny

3- Trim excess leads as close as possible to the
solder joint

AXIAL COMPONENTS ARE TAPED IN

THE CORRECT MOUNTING SEQUENCE !

REMOVE THEM FROM THE TAPE ONE AT A

TIME !

4

5%

4K7= ( 4 - 7 - 2 - B )

1%

4K7= ( 4 - 7 - 0 - 1 - 1 )

COLOR= 2… 5

C

O

D

KODE

KLEUR

CODIFI-

CATION

DES

CODE

COLOUR

FARB

KODE

KODE

FARGE-

KODE

FARVE-

Color code table

E

COU-

I P E SF S DK N D GB F NL

FÄRG

SCHEMA

VÄRI

KOODI

ORES

CODIGO

DE COL-

DE

CORES

CODIGO

CODICE

COLORE

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

Construction

CATHODE

ZD...

CONSTRUCTION

The unit consists of one main PCB with all the components including trans­former 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:

1. Jump wire

q J1
q J2
q J3
q J4
q J5
q J6
q J7
q J8

2. Diodes (check the polarity)

CATHODE

q D1: 1N4148
q D2: 1N4148
q D3: 1N4148
q D4: 1N4148
q D5: 1N4148
q D6: 1N4148
q D7: 1N4148
q D8: 1N4148

D...

3. Zener diode (check the polarity)

q ZD1: 20V / 1.3W (Mount 5mm

above the PCB)

4. Resistors (check the color code)

R...

q R1: 1K (1-0-2)
q R2: 1K (1-0-2)
q R3: 15K (1-5-3)
q R4: 1K (1-0-2)
q R5: 470R (4-7-1)
q R6: 100R (1-0-1)
q R7: 15K (1-5-3)
q R8: 15K (1-5-3)

6

Construction

q R9: 15K (1-5-3)
q R10: 15K (1-5-3)
q R11: 470R (4-7-1)
q R12: 15K (1-5-3)
q R13: 15K (1-5-3)
q R14: 100R (1-0-1)
q R15: 15K (1-5-3)
q R16: 2K2 0.6W (2-2-2-9)
q R17: 100R (1-0-1)
q R18: 1K (1-0-2)
q R19: 470R (4-7-1)
q R20: 2K2 0.6W (2-2-2-9)
q R21: 1M (1-0-5)
q R22: 470R (4-7-1)
q R23: 1K (1-0-2)
q R24: 470K (4-7-4)
q R25: 470K (4-7-4)
q R26: 470K (4-7-4)
q R27: 100K (1-0-4)
q R28: 2K2 0.6W (2-2-2-9)
q R29: 2K2 0.6W (2-2-2-9)
q R30: 0R (-0-)
q R31: 15K (1-5-3)
q R32: 100K (1-0-4)
q R33: 100R (1-0-1)
q R34: 0R (-0-)
q R35: 680R (6-8-1)
q R36: 15K (1-5-3)
q R37: 100K (1-0-4)
q R38: 470R (4-7-1)
q R39: 10R / 1W (1-0-0)
q JGND: 0R (-0-)

If long input signal wires are used a
low input impedance can be useful.
In this case mount for RX a 680R (6­8-1) resistor. Check if your pre­amplifier 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.

5. Multilayer capacitors

c...

q C1: 100n (104, 0.1, u1)
q C2: 100n (104, 0.1, u1)
q C3: 100n (104, 0.1, u1)
q C4: 100n (104, 0.1, u1)
q C5: 100n (104, 0.1, u1)
q C6: 100n (104, 0.1, u1)
q C7: 100n (104, 0.1, u1)
q C8: 100n (104, 0.1, u1)

6. IC sockets (check the position)

q IC1: 8P
q IC2: 8P
q IC3: 6P

7. 10W resistor

R...

5mm

q R40: 4R7 (4.7, 4R7)

7

Construction

8. Capacitors

q C9: 2n2 (222, 2200)
q C10: 220n (.22, u22, 224)
q C11: 1uF
q C12: 1uF
q C13: 2.2uF
q C14: 2.2uF
q C15: 100n / 250V (104, 0.1, u1)
q C16: 100n / 250V (104, 0.1, u1)

9. Transistors

q T1: BC547
q T2: BC547

10. RCA connectors.
Mount them straight and
against the PCB

q SK1: MJ-523AG/R
q SK2: MJ-523AG/B

Tip:
A red and a black type are delivered
with the kit, if you bought two amplifi­ers for stereo then one amplifier can
be built with red connectors (right
amp.) and one with the black connec­tors.

11. Push button
Mount them straight against
the PCB surface !

q SW1: TS-04PV

q SW2: KRS1243

8

Construction

12. Terminal blocks

q SK3: 3 pole Mains in
q SK4: 3 pole Mains transformer

q SK5+SK6: 2x 2 pole Transformer

output

F First slide these two connec-

tors in each other.

13. Terminal connectors

Check that the position corresponds
with the PCB silk printing.

q SK7: 2 pole Temp sensor
q SK8: 2 pole Power meter

q SK9: LS+
q SK10: LS-

SK...

9

C...

Construction

14. Coil

L...

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.

q L1: 8 Turns dia 8mm

15. Electrolytic capacitors.
Check the polarity !

q C17: 10µF
q C18: 10µF
q C19: 10µF
q C20: 10µF
q C21: 10µF
q C23: 1µF
q C24: 10µF
q C25: 47µF/63V
q C26: 47µF/63V
q C27: 47µF/63V
q C28: 47µF/63V
q C29: 220µF/63V
q C30: 220µF/63V

16. Voltage regulator.
The back side corresponds to
the thick line.

VR...

q VR1 UA7805

17. Triac.
The back side corresponds to
the thick line.

TR...

q TR1: TIC246 or eq.

10

Construction

C...

18. Bridge rectifier.
Check the polarity !!

q BR1: RS603

19. LEDs

COLOR= 2...5

CATHODE

LD...

q LD1: LED3RL (3mm LED)
q LD2: LED3RL (3mm LED)
q LD3: LED3RL (3mm LED)

20. Power electrolytic capacitors.
Check the polarity !

q C31: 10.000µF
q C32: 10.000µF
q C33: 10.000µF
q C34: 10.000µF

21. Insert the IC’s into their sock­ets. Watch the position of the notch !

q IC1: VK8040 (PIC12C508)
q IC2: CA258 or eq.
q IC3: MOC3041 / KP3020

11

Construction

LD...

CATHODE

22. Mounting front LED’s. Check the polarity !
Short lead = Cathode or— !

LD...

CATHODE

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.

12mm

C

7mm

q LD4: L-424YDT
q LD5: L-424YDT
q LD6: L-424YDT
q LD7: L-424YDT

Meter backlight:

LD8 is a white LED serving as backlight
for the power meter.

q LD8: L5WD (5mm white)

CAUTION:
After bending the
leads the long
appearing lead
will be the cath­ode!

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.

12

18mm

Construction

23. Mounting the Power IC

q IC4: 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 !

B

A

A

Drop of heat conductive
compound

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.

13

Construction

24. Mounting the power transformer and mains voltage selection

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!

230V 120V
ORANGE BROWN
BROWN ORANGE
BLACK BLACK

Secondary windings connection:

Connect the Red, Yellow, Blue and Grey wire to the SK5/SK6 connector, check
the colors on the PCB.

14

25. Enclosure preparation

q Cut the thread in

the holes for the
enclosure feet in
one of the alumi­num profiles, us­ing the supplied
special M4 screw
as a tap.

q Mount the feet on the

aluminum profile, using
two M4 hexagonal Al­len screws. Use the
supplied Allen wrench.
It is advisable to stick
the protection adhe­sive onto the feet.

q Cut the thread in the

front and back of the
aluminum profiles, us­ing the supplied spe­cial M4 screw (4 holes
per piece)

Enclosure preparation

FIG. 1

FIG. 2

FIG. 3

15

Enclosure preparation

q Position the main PCB in the aluminum profile that is prepared with the feet.
q Mark the center position

of the three fixation holes
on the aluminum. A refer­ence indication is also on
the PCB edge.

q Remove 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.

q Mount the three 5mm (0.14”) spacers as shown in the drawing. Use three

hexagonal screws and 3 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.

FIG. 5

5mm M3 spacer

FIG. 4

FIG. 6

M3 hex. nut
Washer

16

Enclosure preparation

0.000

q Using 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.

q Slide two M3 nuts and two

hexagonal bolts into the pro­file, the nuts will be used for
the temperature sensor, the
bolts will be used for the IC
support plate:

q Mount the temperature sensor, check

the exact position. Make sure there is
silicone compound between the sensor
and the enclosure!

q Solder the wires of the supplied two

pole connector onto the sensor.
There is no polarity.

FIG. 7

FIG. 8

11cm

FIG. 9

17

Final assembly

26. final PCB mount

RE-CHECK CAREFULLY THE PCB FOR MOUNTING AND

SOLDERING ERRORS!

q Mount 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!

q Glue the included insert C between the transformer and housing.

C

q Make sure the PCB is aligned with the back of the enclosure
q IMPORTANT: FIRST fix the IC support
q THEN fix the pcb using three 5mm spacers + washer.

DO NOT TIGHTEN THESE FIXATIONS YET.

F Note: Not all components are visible on the drawing.

18

Final assembly

27. Speaker and mains connector 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.

q Mount the speaker connectors onto the rear panel. (black = negative)

Brown

Blue

Yellow/green

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!).

Isolation washer !

19

Final assembly

28. Final assembly and connection

q Solder a 15cm (2.5mm) wire to the LS connectors. Black = negative, Red=

positive, use a shrink tube to isolate the connection..

q Solder a spade terminal to the other end, do not forget the terminal isolation.

q Mount (insert) the mains connector onto the rear panel. Insert a 2A fuse into

the connector (there is also room for a spare fuse).

15cm

20

Final assembly

q Mount the rear panel onto the enclosure, using two M4 Allen screws.

q Connect the speaker wires to the speaker output tabs. Check the polatity!

Black= LS-, Red= LS+.

!

DO NOT CONNECT THE MAINS WIRING WITH THE PCB YET!

21

Final assembly

29. Preparing the front panel

q Connect the two wired connector to the meter, RED = +, BROWN = - to the

meter.

q Mount the power meter onto the front panel.
q Fix the meter using a piece of transparent ad-

hesive tape (four sides).

FMake sure the meter is positioned straight.

q Connect the meter to the PCB (SK8)
q Mount the front panel onto the front, using two M4 Allen screws.

FCheck the position of the LED’s and check if the button is working correctly.

It could be that paint covering the holes, is preventing the buttons from
smooth operation.

q Now the three PCB fixations can be tightened. Check the push button.

22

Test

30. Test

Check again all connections of transformer and mains

!

q Connect the mains wires to the mains connector SK3, Blue= Neutral, green/

yellow= Earth.

q Connect a 60W light bulb in series with the Live (Brown wire) and the Live

connection on the PCB.

q Mount both the fuse and the spare fuse in the fuse holder.

!

Connect the mains AC voltage to the mains. See also the user manual about
the power cord.

CAUTION: Some points on the PCB are connected to the

dangerous mains voltage.

21. Mains voltage connection
preparation

q Connect a 10cm blue wire to the

point N of SK12.

q Connect a 10cm brown wire to the

point L of SK12.

q Connect a 10cm yellow/green

wire to the earth point of SK12.

Later these connection will be sol-
dered to the mains connector.

FNormally after switching ON the amplifier, the light bulb should briefly light

up.

FIf the bulb glows constantly, disconnect the power immediately and re-

check all connections.

• Normally the standby LED on the front panel should light as should both 35V
power indication LED’s LD2 and LD3.

23

Test

Test continued:

• Now push the DC protection test button SW2, the bulb should light if the but­ton is pressed. Be careful not to touch any exposed live parts.

• Disconnect the mains plug.

• Now the brown Live wire can be connected directly to the connector AK3.

F Check the user manual to test all functions and operation of the unit.

Finally the cover can be mounted.

F Please note that the user manual is also used for the assembled version,

some remarks may not apply to the kit version.

24

DIAGRAMS

25

C24

10µ

5mV input signal detector

R23

1K

1M

R21

100K

R27

LM258

Auto on

100R

C21

10µ

R15

15K

R10

15K

CLIP LED

R5

470R

R11

470R

Power supply indication

R28

2K2 / 0.6W

R29

2K2 / 0.6W

LD3

LED3RL

INTEGRATED MONO MOSFET AMPLIFIER

K8040 1.0

Values are for reference only

470K

1N4148

D2

IC2A

LM258

5

1N4148

R14

BC547

L-424YDT

LED3RL

LED3RL

R26

2

1

6

7

D8

Stby / ON

T2

LD7

LD1

LD2

100n

C7

47µ/63V

C25

0R

1uF

C11

Clip detect

470K

1N4148

3

84

470K

IC2B

SW1STBY / ON

+5V

CLIP

+5V

+35V

R34

R25

D1

100n

C5

R24

LD6

Temp error

L-424YDT

+5V

L53MWC

100R

R2

1KR6

1

STBY-GND

8

-VS

15

-PWVs

-35V

15K

1K

2u2

47µ/63V

TDA7293V

15K

8

Vss
GP5/OSC1/CLKIN

+5V

2

CLIP LED

R3

R4

R7

15K

T1

BC547

R8

15K

LD8

backlight

ON

C14

C28

+5V

R9

GP4/OSC2

Auto on

Temp sens.

LD5

L-424YDT

GP3/MCLR/Vpp

3

4

Stby / ON

+5V

SK7

1

2

10µ

+5V+5V

10µ

R35

680R

SHUTDOWN PROTECTION

THERMAL S/C

220nF

PIC12C508A

GP2/T0CKl

5

Clip detect

C20

15K

C19

CLIP DET

5

47µ/63V

C10

C8

100n

1

Vdd

IC1

100n

+5V

C1

GP07GP1

6

R1

1K

LD4

L-424YDT

OFF / Stby

R13

15K

R12

2u2

100R

C9

2n2

R31

15K

STBY9MUTE10SGND4IN+3IN-

MUTE

STBY

BOOT LOADER

BOOTSTRAP

OUT

12

6

C27

10R/1W

14

R39

R32

100K

SK2

BYPASS

RX

Rload

+5V

C13

R33

1N4148

2

BUFFER DRIVER

SK10LS-

SK1

INPUT

100NF/250VAC

C16

DC Protection (fuse blow)

64

12

IC3

MOC3041

D5

D6

D4

1N4148

1N4148

220µ/63V

220µ/63V

+VS

C29

C30

100n

C6

7

47µ/63V

11

13

+PWVs

C12

1uF

15K

IC4

8T 1.5mm dia 8mm

L1

SK9LS+

R18

1K

R19

470R

D3

1N4148

C26

R30

0R

+35V

R36

SW2

2K2 / 0.6W

R20

100NF/250VAC

C15

SK625VAC / 2A

C4100n

10.000uF/50V

C32

10.000uF/50V

C31

-35V

2K2 / 0.6W

R16

SW KRS1243

DC prot. test

R38

470R

+35V

470R

0R

SK3

Mains in from 2A fuse + switch

R40

4.7R / 10W

R22

R17

100R

TIC246M

TR1

Transfo Prim

SK4

25VAC / 2A

SK5

100n

C3

BR1

BRIDGE RS603

AC1AC2

+-

10.000uF/50V

C34

10.000uF/50V

C33

+35V

JGND

20V 1.3W

ZD1

10µ

C18

VR1

UA7805

I O

GND

10µ

C17

+5V

C2

100n

D7

1N4148

R37

100K

C23

1µ

Power meter

SK8

1

2

© Velleman Kit

VELLEMAN Components

Legen Heirweg 33

9890 Gavere

Belgium Europe

Info ?: http://www.velleman.be

Modifications and typographical errors reserved
© Velleman
H8040IP - 2001 - ED1