00W SUBWOOFER KIT s to abinet thank c ll a m s a m ss fro Powerful ba ker principle e th dual spea Total solder points: 383 Difficulty level: beginner 1 2 3 4 5 ⌧ advanced K8077 ILLUSTRATED ASSEMBLY MANUAL H8077IP-1
Features & specifications Features : bass-reflex system with adjustable tube compact size due to dual-speaker principle adjustable level and filter response auto power-on/off system phase switch (0°-180°) line level and speaker level inputs for maximum compatibility 'Full-range'-option for use in active speaker system separate chamber for electronics avoids air leaks Specifications • • • • • • • • power output: 100Wrms/ 4ohm (10% THD) filter freq.
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.
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.
Construction 1. Jump wires. J1 … J8 R3 R4 R8 R11 2. Diodes (check the polarity) D ... CATHODE D1 : BAT85 D2 : 1N4148 D3 : 1N4148 D4 : 1N4148 D5 : 1N4007 D6 : 1N4007 D7 : 1N4007 D8 : 1N4007 D9 : 1N4007 D10 : 1N4007 3. 1/4W resistors. R...
Construction 4. Metallfilm resistors. 7. LEDs. Watch the polarity! R... LD1 CATHODE R5 R6 : 100 : 470 (1 - 0 - 1 - B - 9) (4 - 7 - 1 - B - 9) R9 : 100 R10 : 470 (1 - 0 - 1 - B - 9) (4 - 7 - 1 - B - 9) R31 : 820 R32 : 820 R33 : 560 (8 - 2 - 1 - B) (8 - 2 - 1 - B) (5 - 6 - 1 - B) R38 : 2K7 (2 - 7 - 2 - B - 9) 5. Zener diodes (check the polarity) ZD... ZD1 : 5V1 ZD2 : 5V1 CATHODE LD3 : RED (-35/+35VDC) 8. IC sockets. Watch the position of the notch! IC1 : 8p IC2 : 14p IC3 : 8p 9.
Construction 14. PCB tab SK12 : GND C20 C21 C22 C23 C24 : : : : : 0,047µF / 63V 0,068µF / 63V 4700pF/ 100V 0,022µF / 63V 0,022µF / 63V 15. Flat receptacles 10. Diodes (check the polarity) D11 D12 D13 D14 : : : : 1N5404 1N5404 1N5404 1N5404 LS+ LSAC BLUE AC RED AC GREY AC YELLOW SK... CATHODE 16. Male board wire connector D ... SK11 11.
construction 17. Potentiometers 18. Electrolytic capacitors. Watch the polarity ! C... COMPONENT SIDE RV1 : Stereo log. 50K RV2 : Stereo log. 50K C25 … C28 C29 C30 … C35 C36 : : : : 10µF / 35V 22µF / 50V 100µF / 50V 470µF / 16V 19. Switches Fig 1.0 SW1 : Phase SW2 : Mode Position the switches onto the PCB first. Mount a wire jumper onto each switch connector and connect these with the switch connector on the PCB. CO O MP NT NE DE SI Fig 1.
Construction 23. LEDs 20. Relais LD1 : POWER LD2: ON RY1 : VR5V242C ( 24VDC - 5A - 2C) 21. Electrolytic capacitors. Watch the polarity ! (red) (red) Mount both LEDs on the solderside at 8mm of the PCB cathode is marked with 'C'. C37 : 3300µF / 50V C38 : 3300µF / 50V C... 22. Female cinch connectors SOLDERSIDE Cathode Anode SK...
Fixing the knobs 24. Fixing the knobs Slide the knobs fully onto the potentiometer axes.
Fixing the PCB 25. Fixing the PCB onto the heatsink Fixing the PCB onto the heatsink : (1) Slide 2 x 5mm plastic spacers over the black bolts. (2) Carefully position the PCB onto the two bolts (3) fasten using two nuts.
Fixing the PCB Tighten gently, making sure that : • • • • the leds protrude the holes the cinch (RCA) connectors do not touch the heatsink the knobs do not touch the heatsink the switches do not touch the heatsink (4) fit the remaining bolts and spacers (5) fit the nuts and tighten them all, while minding the position of the knobs, switches, leds and connectors 5X 12
Fixing power transistors 26. Fixing the power transistors T8 (TIP147) & T9 (TIP142) bend both transistors as indicated. +/ m -5 m apply a drop of heat conductive compound on the heatsink. position the mica onto the heatsink so that the hole coincide with the hole in the heatsink, press gently. • apply a drop of heat conductive compound on the mica. • Mount the transistor on the heatsink, using a 16mm bolt, lock washer and nut.
Fixing Diode D15 • Solder the transistor leads Repeat for the remaining transistor T9 (TIP142) 27. Fitting diode D15 (1N4007) Bend the leads as indicated. Put a large drop of heat conductive compound on the heatsink. Solder the diode to the two outer pins of the pin header. Make sure that the diode is bend towards the heat conductive compound. ! 14 Mind the direction of the ring.
Fitting transistor T7 28. Fitting transistor T7 (BC547) Bend the leads as indicated. Put a large drop of heat conductive compound on the heatsink. Solder the transistor to the remaining pins of the pinheader. The flat side of the transistor must face the heatsink. Make sure that the transistor and diode leads do not touch each other and make sure that the diode does not touch the power transistor.
Mounting power supply section 29. Mounting the power supply section 1. Mounting the AC connector Position the AC connector at the PCB side of the heatsink and fix by means of two 10mm black screws. 10mm screw 2. Mounting the power switch Click the power switch onto the heatsink. Make sure the '0'-position of the switch faces the AC connector.
Mounting power supply section 3. Mounting the fuse holder 2A T If necessary , enlarge mounting hole Place the fuse holder and fix with the included nut. Place a 2A T fuse.
Mounting power supply section 4. Fixing the transformer Rotate the transformer in such a way that the red/yellow/blue/grey wires point towards the PCB.
Mounting power supply section 5. Wiring the ground connection Connect one end of the cable to the red ring terminal. 1 2 Connect the ring terminal to the chassis by means of a black bolt, spring washer and nut.
Mounting power supply section 6. Transformer wiring (red/yellow/blue/grey wires) Slide an insulation sleeve over each wire. Solder a connector to each wire SOLDER Slide the sleeve over the connector REMARK : In case you trim the wires, always remove the insulating lacquer (+/- 1cm) • Connect the wires to the PCB.
Mounting power supply section • Trim the black transformer wire to a length of 14cm. Slide a piece of heatshrink tube (3cm) over the black transformer wire. 120VAC : ORANGE Unused lead 235VAC : BROWN 120VAC : BROWN 235VAC : ORANGE BLACK BLACK BLACK HEATSHRINK TUBE • Solder the wire to the AC connector • Use the remaining black wire to connect the second AC connector lug with the center connector of the fuse holder. Don't forget to slide a piece of heatshrink tube (4cm) over the wire.
Testing the unit 30. Testing the unit 60W (120 / 235VAC) From K8077 Power supply 120 / 235VAC Make sure that the IC’s are removed from their sockets. We recommend to construct a small test-jig, and connect the unit as shown below. 1. Put the power switch in the ‘I’ position 2. Put the ‘MODE’-switch in the ‘AUTO-ON’-position. 3. When power is applied, the ‘POWER’ led should light. If the light bulb remains lit, turn off the power immediately and check your circuit.
Enclosure assembly 31. Assembly of the enclosure Refer to the included mounting instructions. (A) Mark all holes according to the diagram. Use a 2mm drill to pre-drill the holes (B) Mark the two holes for the speakers, as indicated. Mark the hole for the reflex tube, as indicated Carefully cut-out the holes using an electric jigsaw If necessary, smooth the edges with sanding paper (C) Mark the position of the wooden supports for the heatsink.
Enclosure assembly (I) - Fix the speaker wires with some glue and trim them to a length of 20cm - Slide an insulating sleeve over both wires. Solder a connector to both wires and slide the insulating sleeves over the connector. - Fix the 4 plastic feet by means of a 23mm screw and put the enclosure on its feet. (J) - put the heatsink in place and mark the 10 holes. - remove the heatsink - pre-drill the holes with a 1.
Placement 32. Placement For best results, experiment with different positions. We recommend to put the unit between the main speakers. The closer to a wall or corner, the higher the efficiency (volume) will be, at the cost of a reduced sound quality. Remark: The unit is not magnetically shielded. Do not operate the unit in the close vicinity of CRT television sets or magnetic media.
Connection 33. Connection Just below the power switch you will notice two AC voltage indications (120VAC235VAC). Strike out the one that does not apply with a black permanent marker. Use the supplied cord to connect the unit to the AC power grid. If necessary, cut the plug and replace it with a plug (not incl.) that fits your outlets. The audio inputs accept either a line level signal or a speaker level signal. LINE LEVEL SIGNAL SUBWOOFER AMPLIFIER - PREAMP - RECEIVER - ...
Use 34. Use Turn the volume control (OUTPUT LEVEL) fully counter clockwise before first power-on. • Turn-on the 'POWER'-switch. The 'POWER'-led will light. • The unit will either immediately turn on ('ON'), or wait for an incoming audio signal ('AUTO-ON'), depending on the position of the 'MODE'-switch. If 'AUTO-ON' has been selected, the unit will automatically turn-on when an audio signal is present. If the audio signal is absent for a while (e.g.
PCB 35.
RED GREY YELLOW BLUE SK10 SK9 SK8 SK7 GND D10 D9 GND 4x1N4007 D7 D8 C33 100µF/50V ZD3 15V 820/0.6W R32 15V C32 100µF/50v 2K7 0.6W R38 560 ZD4 820/0.
C14 47p S_GND amp blue yellow GND R43 47K 10µF C28 R42 100R R47 3K3 BC640 C36 680R R48 R49 3K3 R52 3K3 +40V GND C37 -40V T4 BC640 4700µF/50V C38 4700µF/50V 470µF/16V T3 ZD5 ZB9V1 GND 1N5404 D11 1N5404 D12 1N5404 D13 1N5404 D14 3K3 R50 C15 47p C35 100µF/50V -40V C10 100nF C9 100nF +40V 47p C16 -40V BC639 T6 R56 1K 1K R55 680 R54 3K3 R53 1K5 +40V RV3 Bias adj.
SK12 S_GND S_GND Connect to chassis ground High in (R) SK4 High in (L) SK3 Low in (R) SK1 SK2 Low in (L) 4K7 R3 470 R8 1K 1K 1K S_GND R5 1K R9 R4 S_GND S_GND 4K7 4K7 R62 R6 4K7 R11 R10 C2 390p C1 390p R1 filter 22K R13 22K R12 22K R2 22K 22n C24 S_GND 9 10 IC2C TL074 8 S_GND High pass (30Hz) 390K R25 C4 100n -15V 1 C3 100n +15V R7 47K (gain:=x2) -15V 4 IC1A TL072 8 S_GND 2 R24 100K 22n C23 4n7 C22 S_GND 3 +15V C6 100n 33K R22 -15V 10
VELLEMAN KIT NV Legen Heirweg 33 9890 Gavere Belgium Europe Info ?: http://www.velleman.be Modifications and typographical errors reserved © Velleman Kit nv H8077IP - 2006 - ED1 (rev 3.