400W MONO/STEREO AMPLIFIER
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describe this
Total solder points: 264
Difficulty level: beginner 1
2
3
4⌧ 5
advanced
K4005B
ILLUSTRATED ASSEMBLY MANUAL
H4005B-IP-2
Features & specifications
Features:
Rms output power : 2 x 100W / 4ohm ; 2 x 75W / 8ohm.
Rms mono-bridged power : 200W / 8ohm.
Total music output : 400W.
Harmonic distortion : 0.003% at 1KHz.
Signal-to-noise ratio : 96dB (A-weighted).
Stereo channel separation : 76dB.
Damping factor (at 100Hz) : > 2000.
Specifications:
•
•
•
•
•
Input impedance : 22kohm .
Input sensitivity : 150mV, 300mV or 950mV switchable .
Supply voltage for 8 ohm : + 35 to 40VDC and - 35 to 40VDC / 2.5A.
Supply voltage for 4 ohm or mono: + 25 to 30VDC and - 25 to 30VDC/ 5A
Dimensions : 350 x 62 x 85mm (13.8" x 2.5" x 3.4").
modifications reserved
2
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
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
leads,
0.0
00
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.
3
Assembly hints
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 !
DO NOT BLINDLY FOLLOW THE ORDER OF THE
COMPONENTS ONTO THE TAPE. ALWAYS CHECK
THEIR VALUE ON THE PARTS LIST!
4
Construction
1. Jumpers
J : 8X
Choice between different input sensitivities :
Mount the jumpers JH for a sensitivity of 950mV.
Mount the jumpers JM for a sensitivity of 500mV.
JH
JM
JH
JM
JH
JM
JH
JM
JH
JM
JH
JM
JB
JS
Leave both jumper connections OPEN for a sensitivity of 150mV.
A bipolair THREE POSITION switch may be mounted here as well!
Choice between stereo or mono :
Mount the jumpers JS for a stereo amplifier.
Mount the jumpers JB for a mono-bridged amplifier.
JB
JS
JB
JS
JB
JS
Here a unipolar change-over switch may be mounted as well!
2. Diodes. Watch the polarity!
CATHODE
4. 1/4W Resistors
D...
R...
D1 : 1N5404
D2 : 1N5404
3. Zener diodes. Watch the polarity!
CATHODE
ZD1 : 15V0
ZD2 : 15V0
ZD...
R1
R2
R3
R4
R5
R6
R7
R8
R9
R12
R13
:
:
:
:
:
:
:
:
:
:
:
22K
22K
22K
22K
22K
22K
22K
2K2
1K8
47K
120K
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 3 - B)
(2 - 2 - 2 - B)
(1 - 8 - 2 - B)
(4 - 7 - 3 - B)
(1 - 2 - 4 - B)
5
Construction
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
68K
220K
1K5
1K5
560
560
2K7
2K7
100K
470K
10K
33
33
33
33
390
390
390
390
(6 - 8 - 3 - B)
(2 - 2 - 4 - B)
(1 - 5 - 2 - B)
(1 - 5 - 2 - B)
(5 - 6 - 1 - B)
(5 - 6 - 1 - B)
(2 - 7 - 2 - B)
(2 - 7 - 2 - B)
(1 - 0 - 4 - B)
(4 - 7 - 4 - B)
(1 - 0 - 3 - B)
(3 - 3 - 0 - B)
(3 - 3 - 0 - B)
(3 - 3 - 0 - B)
(3 - 3 - 0 - B)
(3 - 9 - 1 - B)
(3 - 9 - 1 - B)
(3 - 9 - 1 - B)
(3 - 9 - 1 - B)
5. Metal film resistors
R...
R10 : 7K5
R11 : 20K
(7 - 5 - 0 - 1 - 1)
(2 - 0 - 0 - 2 - 1)
8. IC sockets.
IC1 : 8p
IC2 : 20p
9. Ceramic Capacitors
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
: 15pF
: 15pF
: 100pF
: 100pF
: 100pF
: 100pF
: 100pF
: 100pF
: 150pF
: 150pF
: 150pF
: 150pF
: 1n2
: 1n2
: 100nF
: 100nF
: 100nF
: 100nF
(101)
(101)
(101)
(101)
(101)
(101)
(151)
(151)
(151)
(151)
(122)
(122)
(104, µ1)
(104, µ1)
(104, µ1)
(104, µ1)
6. 1W resistors.
10. PCB tabs.
R...
R33
R34
R35
R36
:
:
:
:
1K
1K
1K
1K
(1 - 0 - 2 - B)
(1 - 0 - 2 - B)
(1 - 0 - 2 - B)
(1 - 0 - 2 - B)
7. 5W resistors.
R...
T1
T2
T3
T4
:
:
:
:
E, B & C
E, B & C
E, B & C
E, B & C
TS : if a therminal protection is to be
connected.
2mm
R37
R38
R39
R40
6
:
:
:
:
0,1
0,1
0,1
0,1
C...
Assembly
11. Fuse holders + Fuses
15. Led’s. Watch the polarity!
LD1 : 5mm red.
LD2 : 5mm red.
F...
LD...
1
F1 : 6,3A “slow”
F2 : 6,3A “slow”
20mm
CATHODE
16. Cinch connector(s)
12. Capacitors
C...
C21 : 1µF/63V
C22 : 1µF/63V
For stereo use :
Left input
Right bridge input
13. Spade connectors
For mono-bridged use :
Right bridge input
-LS
+LS
GND : 3x
+V
-V
SK...
17. IC’s. Watch the position of the
notch!
14. Electrolytic capacitors.
Check the polarity!
C19
C20
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
0,47µF
0,47µF
2µ2
4µ7
4µ7
22µF
22µF
100µF
100µF
100µF
100µF
220µF
220µF
220µF
220µF
4µ7
IC1 : TL072
IC2 : TDA7250
C...
Resistors R41 & R42 and capacitors C37 & C38
are not being used!!!
7
PCB mounting
18. Mount the PCB in the heat sink
Slide the PCB in the largest slot of the heat sink. (See fig. 1.0)
FIG. 1.0
Note : If the optional thermal protection is used, a hexagonal bolt should be slit into the mounting slot,
and into the hole in the P.C.B. Then the THERMIC may be mounted on the heat sink and its terminals
may be connected to the positions TS (see Fig. 2.0).
Position the P.C.B. in the middle of the heat sink.
FIG. 2.0
8
Power transistors
19. Power transistors
Two transistors are mounted at both ends of the heat sink (for their positions refer to Fig. 3.0).
T1 & T2 : TIP142 of motorola!
T3 & T4 : TIP147 of motorola!
FIG. 3.0
Bend the connections of each transistor as in Fig. 4.0.
FIG. 4.0
Put them in the correct position on the heat sink and against the P.C.B., mark the place of the
transistors.
Apply a drop of thermally conductive paste to the points where the transistors will be mounted
(Fig 5.0).
FIG. 5.0
thermally conductive paste
Put an insulating mica on the drop of paste.
9
Power transistors
Apply a drop of paste on each transistor and put them in the correct position on the heat sink and
against the P.C.B. Make sure the correct type of transistor is placed in the correct position
(T1...T4).
Fix the transistors well in place by means of the supplied plate and a hexagonal bolt, which is slit
into the slot in the heat sink (see Fig. 6.0). Make sure the transistor connections do NOT TOUCH
the metal plate!
FIG. 6.0
Now the transistors may be soldered to the corresponding print pins.
10
Test & Use
20. Test
Connect a symetrical power supply unit (possibly the APS200, SPS200 or K3508 module) of +
and - 30 tot 45VDC to the positions GND (0V), -V and +V. See Fig. 7.0.
FIG. 7.0
IMPORTANT: Do not switch on the supply voltage before the connections to the amplifier are made!
Switch on the supply voltage. Normally both LEDs on the amplifier P.C.B. should light up to indicate that the power supply is alright.
Carry out the following measurements:
• Across each of the 5W resistors R37 to R40 a voltage of about 0.01V should be measured.
• Between each speaker output terminal and the GND terminal a voltage of about 0V (max. 0.5V) should
be measured.
The amplifier is now ready for use.
21. Use and connection
NOTE : Carry out all connections by means of 1.5mm wire and the supplied flat connector
bushes. Solder the wire to the connector bushes and slide the insulation over them.
1. As a stereo amplifier:
• See Fig. 8.0 for the connection of the power supply and the speakers.
• Watch the polarity of the speakers!
FIG. 8.0
11
Use & connections
2. As a mono-bridged amplifier:
• See Fig. 9.0 for the connection of the power supply and the speaker.
• Make sure that the impedance of the connected speaker is not less than 8 ohms.
FIG. 9.0
IMPORTANT: Always connect the outputs first, before the power supply is switched on.
If the amplifier is to be used as a free-standing unit, it may be attached by means of M4 hexagonal
bolts and the corresponding slots in the heat sink.
Always mount a 10 ohm (1/4W) resistor in series with the piezo tweeter, both for
stereo and for mono amplification
12
Diagram
22. Diagram power supply
13
PCB
23. PCB
14
VELLEMAN NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com
VELLEMAN KIT NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
Info ?: http://www.velleman.be
Modifications and typographical errors reserved
© Velleman Kit nv
H4005B_IP - 2004 - ED2 (rev2)
5 410329 291891
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