Total solder points: 500 Difficulty level: beginner 1o 2o 3o 4o 5þ advanced

K8020

HIGH-END VALVE CONTROL AMPLIFIER

ILLUSTRATED ASSEMBLY MANUAL H8020IP-1

Valve Control Amplifier8020

Monitor

+6dB Aux CD Tuner AV

VELLEMAN KIT NV 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

I

P

E

SF

S

D

K

N

D

GB

F

NL

C

O

D

E

CO

DIC

E

CO

LOR

E C

OD

IGO

D

E

CO

RE

S

CO

DIG

O

DE

C

OLO

RE

S

VÄ

RI

KO

OD

I FÄ

RG

S

CH

EM

A FA

RV

E-

KO

DE

FA

RG

E-

KO

DE

FA

RB

K

OD

E

CO

LOU

R

CO

DE

C

OD

IFI-

CA

TIO

N

DE

S

CO

U-

KLE

UR

KO

DE

C

O

D

E

0 N

ero

P

reto

N

egro

M

usta

S

vart

S

ort

Sor

t S

chw

arz

Bla

ck

Noi

r Zw

art

0

1 M

arro

ne C

asta

nho

Mar

rón

Rus

kea

Bru

n B

run

Bru

n B

raun

B

row

n B

run

Bru

in

1

2 R

osso

E

ncar

-R

ojo

Pun

aine

n R

öd

Rød

R

ød

Rot

R

ed

Rou

ge

Roo

d 2

3 A

ran

-La

ranj

a N

aran

-O

rans

si

Ora

nge

Ora

nge

Ora

nge

Ora

nge

Ora

nge

Ora

nge

Ora

nje

3

4 G

iallo

A

mar

elo

Am

arill

o K

elta

inen

Gul

G

ul

Gul

G

elb

Yel

low

Ja

une

Gee

l 4

5 V

erde

V

erde

V

erde

V

ihre

ä G

rön

Grø

n G

rønn

G

rün

Gre

en

Ver

t G

roen

5

6 B

lu

Azu

l A

zul

Sin

inen

B

lå

Blå

B

lå

Bla

u

Blu

e B

leu

B

lauw

6

7 V

iola

V

iole

ta

Mor

ado

P

urpp

ura

Lila

V

iole

t V

iole

t V

iole

t P

urpl

e V

iole

t P

aars

7

8 G

rigi

o C

inze

nto

Gri

s H

arm

aa

Grå

G

rå

Grå

G

rau

G

rey

Gri

s G

rijs

8

9 B

ianc

o

Bra

nco

B

lanc

o

Val

koin

en V

it H

vid

H

vidt

W

eiss

W

hite

B

lanc

W

it

9

A

Arg

ento

P

rate

ado

Pla

ta

Hop

ea

Silv

er

Søl

v S

ølv

Silb

er

Silv

er

Arg

ent

Zilv

er

A

B

Oro

D

oura

do

Oro

K

ult

a G

uld

Gul

d G

uldl

G

old

Gol

d O

r G

ou

d

B

5%

4K

7=

( 4

-

7

- 2

-

B )

1%

4K

7=

( 4

- 7

- 0

- 1

- 1

)

CO

LO

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...

8

P8020B Assembly

Construction

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

SK08R09

680R

C08

100n

Mains selection

MAINS

TR1

D131N4007 D121N4007

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

RA0 17RA1 18

RA2 1

RA32RB06RB17RB28 RB3 9

RB4 10RB511

RB6 12RB7 13

VSS

5

MCLR/VPP4OSC1/CLKIN16T0CKI3 OSC2/CLKOUT 15

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-424Y

DT LD2

L-424YD

T

LD5L-424YD

T

LD6L-424Y

DT

LD7L-424YD

TLD4

L-424Y

DT

LD3L-424Y

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

220pD1

1N4148

+5V

RY2

T2

BC557

SK2

R2

10K

C2

220pD2

1N4148

+5V

RY3

T3

BC557

SK3

R3

10K

C3

220pD3

1N4148

+5V

RY4

T4

BC557

SK4

R4

10K

C4

220pD4

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

+5V 1234567891011121314151617181920

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

BC557SK01

R0110K

C01

220pD01

1N4148

+5V

Input1

RY2

T02

BC557SK02

R0210K

C02

220pD02

1N4148

+5V

Input2

RY3

T03

BC557SK03

R0310K

C03

220pD03

1N4148

+5V

Input3

RY4

T04

BC557SK04

R0510K

C04

220pD04

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/0.6W

R101M

+5VRY8

D08

1N4148

+5V

+6dB

R133K6 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

R1833K 1%

R1210K

T08

BC557

R1910K

C18 68n/630V

C21

4u7/160V

+300V

R155K6

+12.5V

R28680R

R21

27K/0.6W

R201M

+5VRY7

D07

1N4148

+6dB

R233K6 1%

1

2

3

5 9 4

8

6

7V2

ECC82

C34

47µ/350VC33

47µ/350V

R26

3K6 1%

R24

100K

R2733K 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

VELLEMAN KIT NV Legen Heirweg 33

9890 Gavere Belgium Europe

Info ?: http://www.velleman.be Questions ?: support@velleman.be

Modifications and typographical errors reserved © Velleman Kit nv H8020IP - 2000 - ED1