K8060 VELLEMAN | Alldatasheet
Document overview
- Manufacturer or author: Provided By alldatasheet.com(free datasheet download site)
- PDF pages: 20
Technical content
200W DISCRETE POWER AMPLIFIER K8060 ILLUSTRATED ASSEMBLY MANUAL H8060IP-1 Total solder points: 74 Difficulty level: beginner 1 2 3 4 5 ; advanced Ideal for active speaker system or subwoofer, guitar amp, home theatre systems, instrument amp, etc. 200W DISCRETE POWER AMPLIFIER K8060 ILLUSTRATED ASSEMBLY MANUAL H8060IP-1 Total solder points: 74 Difficulty level: beginner 1 2 3 4 5 ; advanced Ideal for active speaker system or subwoofer, guitar amp, home theatre systems, instrument amp, etc.
Specifications: ; Excellent value for money ; Full discrete design using Epitaxial Darlington transistors ; DC supply circuit on board with LED indication ; Ideal for active speaker system or sub woofer, guitar amp, home theatre systems, instruments amp…. ; Comes complete with transistor isolators, spacers and bolts ; Overload and short circuit protection Features: y 200W music power @ 4 ohm load y 100Wrms power @ 4 ohm load y 70Wrms power @ 8 ohm load y Distortion: 0.02% @ 1KHz/10W y Damping factor: >800 y Frequency response: 3Hz to 200KHz (-3dB) y Sensitivity: 0.6Vrms y Signal to noise ratio: 115dB y Power supply: 2 x 25-30Vac / 100 - 120VA y PCB dimensions: 107x62mm (aprx.) : y Recommended power transformer: 12030 y Recommended heat-sink: HSVM100 (pre-drilled) or S44/75 (not drilled) Features & Specifications Specifications: ; Excellent value for money ; Full discrete design using Epitaxial Darlington transistors ; DC supply circuit on board with LED indication ; Ideal for active speaker system or sub woofer, guitar amp, home theatre systems, instruments amp…. ; Comes complete with transistor isolators, spacers and bolts ; Overload and short circuit protection Features: y 200W music power @ 4 ohm load y 100Wrms power @ 4 ohm load y 70Wrms power @ 8 ohm load y Distortion: 0.02% @ 1KHz/10W y Damping factor: >800 y Frequency response: 3Hz to 200KHz (-3dB) y Sensitivity: 0.6Vrms y Signal to noise ratio: 115dB y Power supply: 2 x 25-30Vac / 100 - 120VA y PCB dimensions: 107x62mm (aprx.) : y Recommended power transformer: 12030 y Recommended heat-sink: HSVM100 (pre-drilled) or S44/75 (not drilled) Features & Specifications
- 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 drawings. ⇒ Values on the circuit diagram are subject to changes. ⇒ Values in this assembly guide are correct* ⇒ 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. 0.000 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.
- 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
⇒ 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 drawings. ⇒ Values on the circuit diagram are subject to changes. ⇒ Values in this assembly guide are correct* ⇒ 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. 0.000
1.3 Soldering Hints :
1- Mount the component against the PCB surface 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 ! AXIAL COMPONENTS ARE TAPED IN THE COR- RECT MOUNTING SEQUENCE ! Assembly hints 1- Mount the component against the PCB surface 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 ! AXIAL COMPONENTS ARE TAPED IN THE COR- RECT MOUNTING SEQUENCE !
D1 : 1N4148 D2 : 1N4148 1. Diodes. Watch the polarity ! D...CATHODE ZD1 : 9V1 2. Zenerdiode. Watch the polarity ! 3. Resistors R... CATHODE ZD... À Cut a piece of 3 pins (fig) of the pin header and mount it for T6 À Cut a piece of 6 pins and mount it for T7 À Cut a piece of 6 pins and mount it for T8 4. Transistor connections Construction D1 : 1N4148 D2 : 1N4148 1. Diodes. Watch the polarity ! D...CATHODE ZD1 : 9V1 2. Zenerdiode. Watch the polarity ! 3. Resistors R... CATHODE ZD... À Cut a piece of 3 pins (fig) of the pin header and mount it for T6 À Cut a piece of 6 pins and mount it for T7 À Cut a piece of 6 pins and mount it for T8 4. Transistor connections
Construction & connection C1 : 47pF (47) C2 : 47pF (47) C3 : 47pF (47) C4 : 680pF (681) C5 : 680pF (681) C6 : 47nF (473) C7 : 100nF (104) C8 : 100nF (104) 6. Capacitors. C... LD1 : Red 9. LED. Watch the polarity! LD... CATHODE T1 : BC640 T2 : BC640 T3 : BC639 T4 : BC547B T5 : BC557B 8. Transistors. RV1 : 1K 7. Trim potentiometer RV1 IN GND 10. PCB tabs. LS+ LS- AC (2x) AC-0 (2x) 12. PCB terminals C9 : 10µF C10 : 100µF C11 : 470µF 11. Electrolytic Capacitors. Watch the polarity ! C... D3 : 1N5404 D4 : 1N5404 D5 : 1N5404 D6 : 1N5404 5. Power diodes. Watch the polarity ! D... CATHODE +/-5mm Construction & connection C1 : 47pF (47) C2 : 47pF (47) C3 : 47pF (47) C4 : 680pF (681) C5 : 680pF (681) C6 : 47nF (473) C7 : 100nF (104) C8 : 100nF (104) 6. Capacitors. C... LD1 : Red 9. LED. Watch the polarity! LD... CATHODE T1 : BC640 T2 : BC640 T3 : BC639 T4 : BC547B T5 : BC557B 8. Transistors. RV1 : 1K 7. Trim potentiometer RV1 IN GND 10. PCB tabs. LS+ LS- AC (2x) AC-0 (2x) 12. PCB terminals C9 : 10µF C10 : 100µF C11 : 470µF 11. Electrolytic Capacitors. Watch the polarity ! C... D3 : 1N5404 D4 : 1N5404 D5 : 1N5404 D6 : 1N5404 5. Power diodes. Watch the polarity ! D... CATHODE +/-5mm
R19 : 0,47 R20 : 0,47 13. 5W resistors R... 2mm C12 : 3300µF C13 : 3300µF )Hint for tweakers : Replace the original caps with 4700µF/50V types for even better performance. 14. Electrolytic Capacitors. Watch the polarity ! C... IMPORTANT * Check the complete assembly carefully before mounting the heat sink. * Once the heat sink is mounted, the solder-side is no longer accessible. Construction R19 : 0,47 R20 : 0,47 13. 5W resistors R... 2mm C12 : 3300µF C13 : 3300µF )Hint for tweakers : Replace the original caps with 4700µF/50V types for even better performance. 14. Electrolytic Capacitors. Watch the polarity ! C... IMPORTANT * Check the complete assembly carefully before mounting the heat sink. * Once the heat sink is mounted, the solder-side is no longer accessible.
A custom pre-drilled heat sink is available from your distributor (order code HSVM100). Any other heat sink must be able to dissipate at least 30W (1.25°C/W) (see fig.1.0). ) Use the template as a drill guide. 15. Final assembly Fig. 1.0 Final Assembly A custom pre-drilled heat sink is available from your distributor (order code HSVM100). Any other heat sink must be able to dissipate at least 30W (1.25°C/W) (see fig.1.0). ) Use the template as a drill guide. 15. Final assembly Fig. 1.0
- Mount 4 bolts + 8 nuts (PCB support). (fig.2.0) Final assembly 2 x M3 nut M3 15mm bolt
- Slide the PCB over the 4 bolts, and fix using 4 nuts (Fig 3.0). Fig. 2.0 Fig. 3.0
- Mount 4 bolts + 8 nuts (PCB support). (fig.2.0) Final assembly 2 x M3 nut M3 15mm bolt
- Slide the PCB over the 4 bolts, and fix using 4 nuts (Fig 3.0). Fig. 2.0 Fig. 3.0
- Mounting the transistor T6 on the heat sink:
- Apply a drop of heat conductive compound in the heat sink hole (fig. 4.0). Fig. 4.0 Transistor T6 16. Mounting the transistor T6 on the heat sink:
- Apply a drop of heat conductive compound in the heat sink hole (fig. 4.0). Fig. 4.0
- Apply a drop of heat conductive compound on the heat sink (see fig 8.0.)
- Mount the isolation mica onto the heat sink, check the position of the hole. Apply a drop of heat conductive compound on the mica.
- Carefully bend the leads, see fig. 9.0
- Mount the transistor on the heat sink, using a bolt, washer, lock washer and nut. * IMPORTANT: If metal body transistors are used, a plastic isolation washer must be applied (see 9.0.) 17. Mounting of the power transistors T7 (TIP147) and T8 (TIP142). M3 nut Lock washer washer plastic isolation washer Heat conductive compound Heat conductive compound M3 bolt M3 bolt Fig. 8.0 Fig. 9.0 +/- 4mm Power transistors
- Apply a drop of heat conductive compound on the heat sink (see fig 8.0.)
- Mount the isolation mica onto the heat sink, check the position of the hole. Apply a drop of heat conductive compound on the mica.
- Carefully bend the leads, see fig. 9.0
- Mount the transistor on the heat sink, using a bolt, washer, lock washer and nut. * IMPORTANT: If metal body transistors are used, a plastic isolation washer must be applied (see 9.0.) 17. Mounting of the power transistors T7 (TIP147) and T8 (TIP142). M3 nut Lock washer washer plastic isolation washer Heat conductive compound Heat conductive compound M3 bolt M3 bolt Fig. 8.0 Fig. 9.0 +/- 4mm
- Solder the connections of the power transistors with the pin headers, see fig. 10. Fig. 10 Power transistors
- Solder the connections of the power transistors with the pin headers, see fig. 10. Fig. 10 Power transistors
- Use a 2 x 25 to 30Vac / 100 - 120VA transformer.
- Connect the transformer to the AC power connections of the PCB.
- The Velleman transformer colour scheme is specified on the pcb. * Careful : Other brands may feature a different scheme ! Y: yellow, R: red, B: blue, G: grey.
- Make sure to put a 1A T (slow-blow) fuse in series with the primary winding of the transformer (see diagram). 18. Test and adjustments Test & adjustments Y R G B SOLDER
- Use a 2 x 25 to 30Vac / 100 - 120VA transformer.
- Connect the transformer to the AC power connections of the PCB.
- The Velleman transformer colour scheme is specified on the pcb. * Careful : Other brands may feature a different scheme ! Y: yellow, R: red, B: blue, G: grey.
- Make sure to put a 1A T (slow-blow) fuse in series with the primary winding of the transformer (see diagram). 18. Test and adjustments Test & adjustments Y R G B SOLDER
Test & adjustments Test & adjustments
Test & adjustments
- Turn the RV1 bias adjust trimmer fully counter clockwise (turn left) before applying power for the first time. * ADVICE: For safe first-time testing insert a 60W light bulb in series with the AC power and the trans- former. If the light bulb lights up continuously, disconnect the transformer and check all your wiring and assembly. Reconnect the power supply. If the lamp remains off, everything is OK, replace the light bulb with a fuse. If the TR8040 transformer is used there is a selection of primary AC voltage : 120Vac: black / brown. 230Vac: black/orange. * IMPORTANT: Insulate the wire that is not being used. * NOTE: Two amplifiers and two transformers are required for stereo. Never attempt to run two amplifi- ers from a single transformer! Setting the bias:
- Connect a multimeter (lowest DC voltage range 1V or lower) over the leads of R19 (polarity is indicated on the PCB).
- Turn on the power, the power LED should light.
- Check the multimeter, it should read 0V, adjust RV1 carefully to about 10mV (0.01V) Wait a few minutes until the meter reading remains stable.
- Turn off the AC power. The amplifier is now ready for use. Test & adjustments
- Turn the RV1 bias adjust trimmer fully counter clockwise (turn left) before applying power for the first time. * ADVICE: For safe first-time testing insert a 60W light bulb in series with the AC power and the trans- former. If the light bulb lights up continuously, disconnect the transformer and check all your wiring and assembly. Reconnect the power supply. If the lamp remains off, everything is OK, replace the light bulb with a fuse. If the TR8040 transformer is used there is a selection of primary AC voltage : 120Vac: black / brown. 230Vac: black/orange. * IMPORTANT: Insulate the wire that is not being used. * NOTE: Two amplifiers and two transformers are required for stereo. Never attempt to run two amplifi- ers from a single transformer! Setting the bias:
- Connect a multimeter (lowest DC voltage range 1V or lower) over the leads of R19 (polarity is indicated on the PCB).
- Turn on the power, the power LED should light.
- Check the multimeter, it should read 0V, adjust RV1 carefully to about 10mV (0.01V) Wait a few minutes until the meter reading remains stable.
- Turn off the AC power. The amplifier is now ready for use.
Final connection:
- The input (GND and in) can be connected directly to an audio source (pre-amp or mixing panel) or a vol- ume control (potentiometer) can be used (see diagram).
- Connect the speaker (4 ohm or higher) to the connections LS+ and GND. * CAUTION: VOLTAGES OF ABOUT 80V ARE PRESENT. MAKE SURE TO USE A SUITABLE ENCLO- SURE AND ISOLATE ALL AC CONNECTIONS Test & adjustments Final connection:
- The input (GND and in) can be connected directly to an audio source (pre-amp or mixing panel) or a vol- ume control (potentiometer) can be used (see diagram).
- Connect the speaker (4 ohm or higher) to the connections LS+ and GND. * CAUTION: VOLTAGES OF ABOUT 80V ARE PRESENT. MAKE SURE TO USE A SUITABLE ENCLO- SURE AND ISOLATE ALL AC CONNECTIONS Test & adjustments
- Diagram Diagram Title GND +40V K8060 100W amplifier GND 1N5404 1N5404 1N5404 1N5404 AC-0 SK6 AC-0 SK5 AC SK3 LS+ SK8 LS- SK7 47 00 µ/50V C13 4700µ/50V C12 AC SK4 -40V 100nF 100nF 47nF 47 p 47 p 680p 47p 68 0p 10 µF 33 K R18 47 K 3K 3 R11 3K 3 3K 3 R10 LED3RL LD1 TIP1 42 TIP1 47 GND SK1 In SK2 0. 47 / 5W R19 0. 47 / 5W R20 BC547 BC547 BC557 BC639 330R 10 0R 1K 8 R14 680R 3K 3 50 0RRV1 ZB9V1 ZD1 +40V +40V+40V GN D GND GN D GND -40V -40V -40V 470µ/16V C11 3K 3 R13 1K 5 R12 47R 220R R17 47R R16 1N4148 1N4148 22 0R 100µ/50V C10 Bias current (cold) 10-15mV over R19 Bias adj. BC640 T1 BC640 R15 19. Diagram Diagram Title GND +40V K8060 100W amplifier GND 1N5404 1N5404 1N5404 1N5404 AC-0 SK6 AC-0 SK5 AC SK3 LS+ SK8 LS- SK7 47 00 µ/50V C13 4700µ/50V C12 AC SK4 -40V 100nF 100nF 47nF 47 p 47 p 680p 47p 68 0p 10 µF 33 K R18 47 K 3K 3 R11 3K 3 3K 3 R10 LED3RL LD1 TIP1 42 TIP1 47 GND SK1 In SK2 0. 47 / 5W R19 0. 47 / 5W R20 BC547 BC547 BC557 BC639 330R 10 0R 1K 8 R14 680R 3K 3 50 0RRV1 ZB9V1 ZD1 +40V +40V+40V GN D GND GN D GND -40V -40V -40V 470µ/16V C11 3K 3 R13 1K 5 R12 47R 220R R17 47R R16 1N4148 1N4148 22 0R 100µ/50V C10 Bias current (cold) 10-15mV over R19 Bias adj. BC640 T1 BC640 R15
Modifications and typographical errors reserved © Velleman Components nv. H8060IP - 2005 - ED1 (rev.1) VELLEMAN Components NV Legen Heirweg 33
9890 Gavere
www.velleman.be www.velleman-kit.com 5 410329 335076 Modifications and typographical errors reserved © Velleman Components nv. H8060IP - 2005 - ED1 (rev.1) VELLEMAN Components NV Legen Heirweg 33 www.velleman.be www.velleman-kit.com 5 410329 335076