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  5. Illustrated Assembly Manual

Velleman K8077 Illustrated Assembly Manual

Manual is about: Velleman K8077 100W Subwoofer Kit

Summary of K8077

  • Page 1

    Total solder points: 383 difficulty level: beginner 1 2 3 4 5 ⌧ advanced 100w subwoofer kit illustrated assembly manual h8077ip-1 powerful bas s from a sma ll cabinet tha nks to the dual spea ker principle k8077 k8077.

  • Page 2

    2 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 ...

  • Page 3

    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 ...

  • Page 4

    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 aga...

  • Page 5

    5 construction r1 : 22k (2 - 2 - 3 - b) r2 : 22k (2 - 2 - 3 - b) r7 : 47k (4 - 7 - 3 - b) r12 : 22k (2 - 2 - 3 - b) r13 : 22k (2 - 2 - 3 - b) r14 : 33k (3 - 3 - 3 - b) r15 : 22k (2 - 2 - 3 - b) r16 : 10k (1 - 0 - 3 - b) r17 : 22k (2 - 2 - 3 - b) r18 : 1k (1 - 0 - 2 - b) r19 : 10k (1 - 0 - 3 - b) r20...

  • Page 6

    6 r5 : 100 (1 - 0 - 1 - b - 9) r6 : 470 (4 - 7 - 1 - b - 9) r9 : 100 (1 - 0 - 1 - b - 9) r10 : 470 (4 - 7 - 1 - b - 9) r31 : 820 (8 - 2 - 1 - b) r32 : 820 (8 - 2 - 1 - b) r33 : 560 (5 - 6 - 1 - b) r38 : 2k7 (2 - 7 - 2 - b - 9) construction zd1 : 5v1 zd2 : 5v1 zd3 : 15v0 zd4 : 15v0 zd5 : 9v1 5. Zener...

  • Page 7

    7 construction d11 : 1n5404 d12 : 1n5404 d13 : 1n5404 d14 : 1n5404 10. Diodes (check the polarity) c a t h o d e c20 : 0,047µf / 63v c21 : 0,068µf / 63v c22 : 4700pf/ 100v c23 : 0,022µf / 63v c24 : 0,022µf / 63v rv3 : 1k turn rv3 fully counter- clockwise 11. Trim potentiometer r4 t1 : bc547b t2 : bc...

  • Page 8

    8 c25 … c28 : 10µf / 35v c29 : 22µf / 50v c30 … c35 : 100µf / 50v c36 : 470µf / 16v construction rv1 : stereo log. 50k rv2 : stereo log. 50k 17. Potentiometers 18. Electrolytic capacitors. Watch the polarity ! C... Sw1 : phase sw2 : mode position the switches onto the pcb first. Mount a wire jumper ...

  • Page 9

    9 ry1 : vr5v242c ( 24vdc - 5a - 2c) 20. Relais construction c37 : 3300µf / 50v c38 : 3300µf / 50v 21. Electrolytic capacitors. Watch the polarity ! C... Mount them on the solderside ! Mount first : sk1 : low level in 'right' sk3 : high level in 'right' mount now : sk2 : low level in 'left' sk4 : hig...

  • Page 10

    10 fixing the knobs slide the knobs fully onto the potentiometer axes. Turn potentiometers fully counterclockwise 24. Fixing the knobs ! Watch the position of the dot !.

  • Page 11

    11 25. Fixing the pcb onto the heatsink m3 nut spacer m3 bolt 16mm fixing the pcb 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..

  • Page 12

    12 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 p...

  • Page 13

    13 26. Fixing the power transistors t8 (tip147) & t9 (tip142) fixing power transistors bend both transistors as indicated. • 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 ...

  • Page 14

    14 • solder the transistor leads repeat for the remaining transistor t9 (tip142) fixing diode d15 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 to- wards the heat c...

  • Page 15

    15 fitting transistor t7 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 ot...

  • Page 16

    16 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 29. Mounting the power supply section 10mm screw 1. Mounting the ac connector position the ac connector at the pcb side of the heat...

  • Page 17

    17 2a t 3. Mounting the fuse holder place the fuse holder and fix with the included nut. Place a 2a t fuse. Mounting power supply section if necessary , enlarge mounting hole.

  • Page 18

    18 4. Fixing the transformer rotate the transformer in such a way that the red/yellow/blue/grey wires point towards the pcb. Tighten the nut mounting power supply section bolt washer transformer washer disk nut.

  • Page 19

    19 5. Wiring the ground connection connect one end of the cable to the red ring terminal. Connect the ring terminal to the chassis by means of a black bolt, spring washer and nut. Solder the other end to the pcb tab (sk12) mounting power supply section 1 2 m3 nut spring washer 16mm m3 bolt scratch o...

  • Page 20

    20 6. Transformer wiring (red/yellow/blue/grey wires) slide an insulation sleeve over each wire. Solder a connector to each wire slide the sleeve over the connector • connect the wires to the pcb. Mind the colours! • group the wires by means of two cable ties • cut the largest of the two heatshrink ...

  • Page 21

    21 120vac : orange 235vac : brown 120vac : brown 235vac : orange black black black • trim the black transformer wire to a length of 14cm. Slide a piece of heatshrink tube (3cm) over the black transformer wire. • solder the wire to the ac connector • use the remaining black wire to connect the second...

  • Page 22

    22 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 l...

  • Page 23

    23 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-ou...

  • Page 24

    24 (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)...

  • Page 25

    25 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 op...

  • Page 26

    26 adj. Line out l r line in speaker in l r 33. Connection just below the power switch you will notice two ac voltage indications (120vac- 235vac). 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 ...

  • Page 27

    27 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 sig- nal ('auto-on'), depending on the position of the 'mode'-sw...

  • Page 28

    28 pcb 35. Pcb.

  • Page 29

    29 36. Schematic diagram schematic diagram sk 8 ye ll o w sk 10 re d sk 7 bl u e sk 9 gre y gnd d5 1n 40 07 d6 1n 40 07 c3 4 10 0µ f/ 50 v gn d zd 1 5v 1 gnd c2 7 10µ f gnd r3 3 56 0 d2 1n 4 148 t1 bc 54 7 gnd r3 9 10 k c8 10 0n gnd gn d d9 4x 1n 40 0 7 d8 d1 0 d7 zd 3 15 v zd 4 15v r3 1 82 0/ 0. 6w...

  • Page 30

    30 sk6 ls - c3 8 4700µf /5 0v c3 7 4700 µf /50v -40v c9 10 0nf c1 0 10 0n f c1 3 47n f c1 4 47p c1 6 47 p c1 1 68 0p c1 5 47 p c1 2 68 0p c2 8 10 µf r4 1 33k r4 3 47 k r5 2 3k 3 r4 9 3k 3 r4 7 3k 3 r5 1 10 ld 3 le d 3r l t9 t ip 142 t8 t ip 147 r6 0 0. 47 / 5w r5 9 +4 0v gn d d1 4 1n 5404 d1 1 1n 54...

  • Page 31

    31 filter section : rv 1a rv 2b 50k lo g rv 2a 50 k l og (g ai n: = x2) s_ g n d r6 2 470 sk 1 2 (* ) s el ec t ope ra tio n m ode : su bw oo fe r: r 6 1: no t m ount ed r 2 3: 1k f ull r an ge : r 6 1: 1k 8 r 2 3: no t m ount ed f ul l r ange w ith 6db ba ss bo os t: r 6 1: 1k 8 r 2 3: 1k am p r6 1...

  • Page 32

    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 3.0) 5 4 1 0 3 2 9 3 5 9 6 7 6.