ez1081pre Mic Amplifier - Assembly manual [ Colourbook Issue 1]

Transcription

1 ez1081pre Mic Amplifier - Assembly manual [ Colourbook Issue 1]

2 ez1081pre Colourbook Contents. Section 1 - Colourbook assembly guide Section 2 - Setup and Calibration Section 3 - Schematics diagrams and PCB Overlays Section 4 - Parts List

3 ez1081pre Colourbook revision history Revision 1 - initial release

4 PCB Preparation Carefully snap apart the 5 PCB s into individual boards and trim or file off any excess tabs. Switch PCB Input Transformer PCB 1 Input Transformer PCB 2 Heatsink Insulator PCB (Not used on PCB Rev 2) Main PCB

5 Diodes D2, D3, D7 & D8 = 1N4148 (4) D5, D9, D10 & D11 = 1N4007 (4) D4 & D6 = BAT46 (2)

6 Resistors R61 = 1R0 (1) R59 & R60 = 1R5 (2) R62 = 2R2 (1) R50 & R58 = 10R (2)

7 Resistors R33 = 47R (1) R7 = 82R (1) R6 & R24 = 100R (2) R10, R35, R53 & R65 = 150R (4)

8 Resistors R11 = 300R (1) R46, R49 & R54 = 470R (3) R12, R34, R37, R39, R41, R52 & R55 = 560R (7) R63 = 750R (1)

9 Resistors R8 = 1k1 (1) R1 = 1k2 (1) R13 = 1k3 (1) R2 & R3 = 1k5 (2)

10 Resistors R9 = 2k0 (1) R38 & R42 = 2k2 (2) R17 = 2k4 (1) R22 & R29 = 2K7 (2)

11 Resistors R44 = 3k9 (1) R16 = 4k3 (1) R26 = 5k1 (1) R15, R21 & R23 = 7k5 (3)

12 Resistors R25, R40, R47, R57 & R64 = 10k (5) R18 = 12k (1) R14 = 13k (1) R43 & R45 = 15k (2)

13 Resistors R32 = 18k (1) R19 = 22k (1) R30 = 36k (1)

14 Resistors R20, R27, R31, R36 & R56 = 47k (5) R48 = 56k (1) R4 & R5 = 6k81 / 0.1% (2)

15 Ceramic Capacitors C8 & C29 = 47pF (2) C27 = 68pF (1) C7 & C13 = 100pF (2)

16 Ceramic Capacitors C16, C30 & C31 = 220pF (3) C23 & C28 = 100nF (2) CL1 & CL2 = 100pF 3 Terminal L/C Network (2) F1 & F2 = Ferrite Bead (2)

17 Film Capacitors C15 = 470pF (1) C1 = 1n2F (1) C32 = 4n7F (1)

18 Film Capacitors C14 & C21 = 10nF (2) C25 = 100nF (1) and Relay C26 = 330nF (1) RL1 = 24 Volt DPCO relay (1)

19 Electrolytic Capacitors C2 & C9= 10uF / 50v (2) C3, C10 & C19= 22uF / 63v (3) All positive terminals towards left C11, C12 & C17= 220uF / 25v (3)

20 Trimmers, Molex and Small Signal Transistor ( flat side towards the Lower edge of the PCB) Q9 = ZTX690B (1) Molex KK Series - 8 way (1) ZTX690B Flat Side Tab towards output transformer R28 & R51 = 5k0 (2) - Top adjust style

21 Small Signal Transistors ( flat side towards the Left Hand edge of the PCB) Q2, Q3, Q6, Q7, Q10 & Q12 = BC550C (6) Q1, Q8 & Q11 = BC560C (3)

22 Power Transistors (Part 1) BD139 Q5 = BD139 (1) Front View BD139 Rear View Install the BD139 with it s rear side facing towards the top of the PCB BD140 Q4 = BD140 (1) BD140 Install the BD140 with it s rear side facing towards the bottom of the PCB Rear towards top of PCB Rear towards bottom of PCB

23 Fit pin headers to switch PCB 1 x 10-way & 1 x 8-way Long pin goes through PCB Cut off excess pin and solder 10 way 8 way

24 Switches SW2, SW3, SW4 = 2 Position DPDT (on-on) (3) Important: The toggle switches are surprisingly sensitive to heat... solder one pin on each switch and then allow to cool before continuing. SW = GR (1) - 12 position, 1 pole, 3 gang Make sure that the toggle switches are seated perfectly so that they are perpendicular to the PCB before soldering the rest of the pins.

25 Voltage Regulator U1 = 7808 voltage regulator (1) M3 Nyloc nut Insulating bush Insulating washer/sheet PCB M3 Nylon Washer M3x12 screw

26 Large Electrolytic Capacitors C6, C22 & C24= 470uF / 35v (3) C4, C5, C18 & C20= 1000uF / 35v (4) All positive terminals towards left

27 Power Transistors (Part 2) HS1 = Heatsink + 2 x M3 plain washers BD139 Q13 = BD139 Transistor (1) + TO220 insulator (bush not required) BD140 Q14 = BD140 Transistor (1) + TO220 insulator (bush not required) Insert heatsink through M3 washers and then into main PCB 1 M3 plain washers Tack in place first then check they are vertical before soldering completely. Tack in place. Check Vertical Solder fully 5 Front View Rear View Install the BD139 on the left side of the heatsink in position Q13, and the BD140 on the right side of the heatsink in position Q14, (with their rear sides towards the heatsink) and a TO220 insulator behind each device. Secure in place with an M3 x 12mm screw and Nyloc nut. Trim transistor legs and then solder in place. 4 M3 Nyloc. BD139 TO220 Insulators BD140 M3 x 12mm BD139 6

28 Solder the right angle pin headers to the circuit boards - the longer pin goes through the PCB - trim off the excess pin (PL8 is 8-way, PL6 is 10-way) Transformer silk screen print on this side AML Spanner logo on this side Fit the transformer ensuring that Pins 2 to 6 are at the bottom Pins 7 to 11 are at the top ie Pin 2 is nearest to the PL6 on the PCB Remove the 2 original brass screws from the end of the transformer which has the pins. (do not discard) On the end of the transformer which has pins, fit an M3 nylon washer between the PCB and the transformer (this is to stop the PCB bending when screwed down). Fit loosely using the longer (6BA x 1/4 in) steel screws On the end of the transformer without pins fit shakeproof washers onto the original brass screws Fit the screws loosely Fit the assembly into the main PCB and then tighten up the screws - but not too tightly!! Tighten up all the screws Remove the assembly again and then solder the transformer to its PCB Solder the assembly to the main PCB Input Transformer Assembly and Fitting Original brass screws Longer steel screws Input Transformer PCB 1 Input Transformer PCB 2 Fit the transformer (VTB9045) to the 2 PCB s as shown in the daigram.

29 Switch PCB Fitting Insert switch PCB into main PCB ensuring that it is perpendicular and solder in place. 90

30 Rotary Switch Adjustment Pin Fit pin in position shown then apply the self adhesive silver washer over the pin holes to stop the pin coming out. [Keep the nut, discard the shakeproof washer]. **** Make sure the spindle is in the position shown before fitting pins **** [0 clicks up from factory setting] Flat is at this angle Fit pin at 12 O clock position

31 48v LED installation Fit the 48v indicator LED to the solder side of the PCB such that the base of the LED aligns with the front edge of the PCB. Flat of LED BACK OF PCB Long Leg n front edge of LED base......with edge of PCB Solder Side.

32 Chassis Assembly Secure faceplate to chassis with 2 x M3 Nyloc Nuts 2 x M3 Nyloc nut 1 2 Secure PCB to chassis with 5 x M3x8 Sems screws Install PCB onto chassis 3 4

33 Rotary switch / knob Install the nut for the rotary switch. [The shakeproof washer is not required]. Install the knob in the 15dB" position. (Tighten using a 1/16 inch hex key) AM ez1081-pre AM ez1081-pre Rotate the switch shaft fully counter-clockwise v 48v AML - UK AML-UK AML - UK AML-UK

34 Output Transformer Assembly and Fitting T2 = VTB2568 (1) Screw the output transformer to the chassis using 4 x M3 x 28mm screws and 4 x M3 shakeproof washers. Do not overtighten the screws. Ideally, apply some LocTite thread adhesive to the screws (if available). Plug the output transformer molex connector into molex on the PCB MAKE SURE THAT THE CONNECTOR IS FITTED SO THAT THE WIRE COLOURS ARE AS SHOWN BELOW. [This may require the cable to be rotated round]. M3 x 28mm screw M3 shakeproof washer Brown Violet Red Green Blue Orange Black Yellow

35 ez1081pre Calibration / Setup 1 ] Before powering up the module, turn the bias trimmer R51 fully clockwise (about 10 turns) 2 ] Power up module, measure DC voltage between bias test points TP6 & TP7 [It should typically measure about mv] 3 ] Apply a signal of -40dBu to the input and then turn gain control up to +60dB 4 ] Measure the output signal, and adjust gain trimmer R28 until output measures +20dBu 5 ] Measure DC voltage between bias test points TP6 & TP7 and adjust bias trimmer R51 until it measures 90mV

36 Sub +48v Sub +48v switched SUB +48v LED switched SUB +16v pin 12 Sub - Post Pad Hot Sub - Post Pad Cold Sub - Agnd Input Tx paralleled cold Sub - Input Tx paralleled hot Switch PCB Main PCB +48v pin v switched +48v LED switched +16v pin 12 SUB +16v pin v pin 12 Post Pad Hot Post Pad Cold Input Tx paralleled cold Input Tx paralleled hot Chassis Ground; Output HI; Output LO; Analogue Ground; Pin 1 Pin 2 Pin 4 Pin 5 Input LO; Pin 8 API References AGnd 48v +16v pin 12 Sub - Agnd Sub - Post Phase Hot Sub - Post Phase Cold Sub - Agnd Sub - Agnd Sub - Blue Sub - Violet Sub - Agnd Switch PCB Agnd Post Phase Hot Post Phase Cold Agnd Agnd Blue Violet Agnd Main PCB Input HI; Pin v DC; Pin 12 PSU Common; Pin 13-16v DC; Pin v DC; Pin 15 LoZ BA338 Pin 6 - B+ +48v DC; Pin 15 TP1 TP2 TP3 Mic Gain Signal In Mic Gain Signal Out Phase TP4 BA340 Pin 6 - B+ Input Hi - Pin Gain Control TP5 VTB2568 Yellow Blue Output Hi - Pin 2 Orange Green Input Lo - Pin 8 0 Mic Gain FB Return Red Black Output Lo - Pin 4 0 Brown Violet Mic Gain FB Send Chassis Ground Analogue Ground Chassis Ground Input Transformer Sub Assembly with mechanical support PCB VTB9045 Chassis Ground Audio Maintenance Limited service@audiomaintenance.com Title ez (Main) Number AML Date 8th Aug Drawn by File AML rev 2Sheet Rev C Adshead 1 of 4 2

37 VFloatNeg VFloatNeg BA338 High Gain Amp BA340 Output Amp Audio Maintenance Limited Title ez (Amplifiers) Number AML Date 8th Aug Drawn by File AML rev 2Sheet 2 of 4 Rev 2 C Adshead

38 GR (stopped at 12 positions) AGnd Mic Gain Signal In +70dB +65dB +60dB +55dB +50dB +45dB +40dB +35dB +30dB +25dB +20dB +15dB +70dB +65dB +60dB +55dB +50dB +45dB +40dB +35dB +30dB +25dB +20dB +15dB Mic Gain Signal Out +70dB +65dB +60dB +55dB +50dB +45dB +40dB +35dB +30dB +25dB +20dB +15dB Mic Gain FB Return AGnd Mic Gain FB Send Audio Maintenance Limited Title ez (Gain Control) Number AML Date 8th Aug Drawn by File AML rev 2Sheet 3 of 4 Rev 2 C Adshead

39 TP6 TP7 Surge Control Sub Assembly +16v DC Pin 12 BA338 Pin 6 BA340 Pin 6 Analogue Ground Pin 5 PSU Common Pin 13 AGnd AGnd Chassis Ground Pin 1-16v DC Pin 14 VFloatNeg *R65 = 10R if surge control omitted R65 = 150R if surge control fitted Audio Maintenance Limited service@audiomaintenance.com Title ez (Power) Number AML Rev 2 Date 8th Aug Drawn by C Adshead File AML rev 2Sheet 4 of 4

40 CUTOUT This side up VTB Transformer fitted on this side Brown Violet Red Green Blue Orange Black Yellow Bias Trim 48v LoZ Bias Test VTB9045 Gain Trim AML (Rev 2) (ez preamp) O/P Phase

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43 IC Component; 7808 U1 Capacitors; Cap Wima 0.2 Pitch (0.3 x 0.1) 1n2 C1 Cap Pol 0.08 (5mm Daimeter) 10uF/50v C2, C9 Cap Pol 0.1 (6.3mm Daimeter) 22uF/63v C3, C10, C19 Cap Pol 0.2 (12.5mm Daimeter) 1000uF/25v C4-5, C18, C20 Cap Pol 0.2 (10mm Daimeter) 470uF/35v C6, C22, C24 Cap Plate 0.1 Pitch 100pF C7, C13 Cap Plate 0.1 Pitch 47pF C8, C29 Cap Pol 0.15 (8mm Daimeter) 220uF/25V C11-12, C17 Cap Wima 0.2 Pitch (0.3 x 0.1) 10nF C14, C21 Cap Wima 0.2 Pitch (0.3 x 0.2) 470pF C15 Cap Plate 0.1 Pitch 220pF C16, C30-31 Cap Plate 0.1 Pitch 100nF C23, C28 Cap Wima 0.2 Pitch (0.3 x 0.1) 100n C25 Cap Wima 0.2 Pitch(0.3 x 0.15) 0u33 C26 Cap Plate 0.1 Pitch 68pF C27 Cap Wima 0.2 Pitch (0.3 x 0.1) 4n7 C32 Diodes; LED - L144 D1 1N4148 D2-4, D6-8 1N4001 D5, D9-11 Connectors; Jumper - 10 Pin SIL PL1, PL4-6 Jumper - 8 Pin SIL PL2-3, PL7-8 Resistors; Resistor 0.25W 1k2 R1 Resistor 0.25W 1K5 R2-3 Resistor 0.25W 6k8 0.1% R4-5 Resistor 0.25W 100R R6, R24 Resistor 0.25W 82R R7 Resistor 0.25W 1K1 R8 Resistor 0.25W 2k0 R9 Resistor 0.25W 150R R10, R35, R53 Resistor 0.25W 300R R11 Resistor 0.25W 560R R12, R34, R37, R39, R41, R52, R55 Resistor 0.25W 1k3 R13 Resistor 0.25W 13k R14 Resistor 0.25W 7K5 R15, R21, R23 Resistor 0.25W 4k3 R16 Resistor 0.25W 2k4 R17 Resistor 0.25W 12K R18 Resistor 0.25W 22K R19 Resistor 0.25W 47K R20, R27, R31, R36, R56 Resistor 0.25W 2K7 R22, R29 Resistor 0.25W 10k R25, R40, R47, R57, R64 Resistor 0.25W 5K1 R26 Trimmer - Vert - dual layout 5K R28, R51 Resistor 0.25W 36K R30 Resistor 0.25W 18K R32 Resistor 0.25W 47R R33 Resistor 0.25W 2k2 R38, R42 Resistor 0.25W 15K R43, R45 Resistor 0.25W 3K9 R44 Resistor 0.25W 470R R46, R49, R54 Resistor 0.25W 56k R48 Resistor 0.25W 10R R50, R58 Resistor 0.25W 1R5 R59-60 Resistor 0.25W 1R0 R61 Resistor 0.25W 2R2 R62 Resistor 0.25W 750R R63 Resistor 0.25W 150R R65 Transistors; BC560C BC550C BD140 BD139 ZTX690 Q1, Q8, Q11 Q2-3, Q6-7, Q10, Q12 Q4, Q14 Q5, Q13 Q9 Others; EMI Filter - Murata 1K CL1-2 Ferrite Bead F1-2 Heatsink - TO220 HS1 Relay 2 Pole Changeover RL1 Switch - Grayhill 71 12W1P3G SW1 Switch - C&K DPDT on-on SW2-4 Transformer - VTB9045 T1 Transformer - VTB2568 T2