Stereo valve power amplifier

plifier is
s a hig h po wer valve am at now
u that, so th
For most of kit changes
. Th is sound".
unafford ab le
jo y tha t s ublime "valve
an en
everybody c

Total solder points: 700

Difficulty level: beginner 1 2 3 4 5 ⌧ advanced

K4040

ILLUSTRATED ASSEMBLY MANUAL H4040IP-1

Features & specifications

Features:

Pure valve sound with high quality EL34 valves.

High quality black and chrome housing.
Chrome valve socket covers.
Easy bias adjustment with LED indication.
Removable bottom for easy access and service.
High quality capacitors and components.
Gold plated input and speaker terminals.
Standby function.
Soft start circuit for power transformer.

Specifications:

• 2 x 90Wrms in 4 or 8W.
• Up to 2 x 15Wrms full class A.
• Bandwidth: 8Hz to 80KHz (-3dB/1W).
• Harmonic distortion: 0.1% @ 1W/1KHz.
• Signal to noise ratio: >105dB (A weighted).
• Input sensitivity: 1Vrms.
• 115VAC or 230VAC / 500VA max.
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 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.

0 .0
00
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.

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 !

AXIAL COMPONENTS ARE TAPED IN

THE CORRECT MOUNTING SEQUENCE !

4
 Construction

Assembly of the small input PCB P4040i:

This PCB is used to connect the input signal (via two RCA sockets) via two holes at the rear of the
cabinet.

1. Ceramic Capacitor 3. Shielded wire connector

C ...

C1 : 47nF (473)

2. CINCH / RCA connector

15cm

LEFT
GND
GND
RIGHT
P4040i

L
SK1 : CINCH GND
SK2 : CINCH R
GND

5
Construction

Assembly of the main PCB P4040B:

Because of the PCB dimensions, first mount the 8 large tube sockets so that the PCB can rest on a
table, without the component leads being touched. When mounting the components, it is best to fold
back the component leads a little before turning the PCB over to solder them.

1. Valve socket mounting

Check the position of the notch in the centre of the tube socket, it must correspond to the notch in
the circle printed on the PCB. Connect the leads to the corresponding isle on the PCB using a small
piece of jumper wire.

IMPORTANT:
Make the connection exactly as shown in the figure, otherwise the small piece of wire could touch
the bottom of the cabinet.

Also mount a 15 mm spacer on the remaining

holes in the PCB (at the solder side), use a 6 mm
M3 bolt:
3
Two spacers round tube sockets V9 and V10
V... 1 A spacer next to RY3
4
5 A spacer next to T2
8 A spacer next to R1
2 7
A spacer next to SW1, together with a lock
washer at the solder side:

6mm M3 BOLT

M3 LOCK WASHER
15mm M3 BOLT
15mm M3 SPACER

VALVE SOCKET

8mm SPACER

PCB
5 6 7 8
5
8
4
15mm M3 SPACER
1
3 2 1
4

Connect the valve socket terminals 1, 3, 4, 5, and 8 to the

V1: I.O. V5: I.O. corresponding points at the solder side of the PCB. Use a
V2: I.O. V6: I.O. piece of jumpwire but take care that the connection does not
V3: I.O. V7: I.O. come above the spacer, otherwise, the wire could touch the
V4: I.O. V8: I.O. housing later (see drawing above).

6
 Construction

2. Jumpers. 3. Jumpers for voltage selection

Note that from J1 to J6, two jumper leads have to MAINS VOLTAGE SELECTION:
be mounted in the same hole.
For 100V mains input, mount:
TIP : In order to get nice straight wiring, without too
much folding and measuring, follow these hints:

Mount the lead on the PCB as it is.

Solder 1 end of the lead.
Then carefully pull on the free end of the lead
until it is straight.
Now solder the other end. A A
For 120V mains input, mount:

B B
For 230V mains input, mount:

C
J1 (2 wires)
J2 (2 wires)
J3 (2 wires) C
J4 (2 wires)
J5 (2 wires) For 240V mains input, mount:
J6 (2 wires)
J7
J8 D D
J9
J10
J11
J12
J13 REMARK: Strike out the NOT used mains
J14
J15 voltage indication at the back of the
J16 housing !! e.g. cross out with a permanent
J17 black marker.
J18
J19 4. Diodes. Watch the polarity!
J20
J21
J22
J23
J24 D...
CATHODE
J25
J26

D1 : 1N4148
D2 : 1N4148
D3 : 1N4007
D4 : 1N4007
D5 : 1N4007
D6 : 1N4007

7
Construction

D7 : 1N4007 R11 : 12K (1 - 2 - 3 - B)

D8 : 1N4007 R12 : 33K (3 - 3 - 3 - B)
D9 : 1N4007 R13 : 33K (3 - 3 - 3 - B)
D10 : 1N4007 R16 : 12K (1 - 2 - 3 - B)
R17 : 820K (8 - 2 - 4 - B)
D11 : 1N5408 not on tape ! R18 : 820 (8 - 2 - 1 - B)
D12 : 1N5408 not on tape ! R19 : 180 (1 - 8 - 1 - B)
D13 : 1N5408 not on tape ! R20 : 1M (1 - 0 - 5 - B)
D14 : 1N5408 not on tape ! R21 : 22K (2 - 2 - 3 - B)
R22 : 3K9 (3 - 9 - 2 - B)
D15 : 1N4148 R23 : 820K (8 - 2 - 4 - B)
D16 : 1N4148 R24 : 820 (8 - 2 - 1 - B)
D17 : 1N4007 R25 : 180 (1 - 8 - 1 - B)
D18 : 1N4148 R26 : 1M (1 - 0 - 5 - B)
D19 : 1N4007 R27 : 22K (2 - 2 - 3 - B)
D20 : 1N4007 R28 : 3K9 (3 - 9 - 2 - B)
D21 : 1N4007 R29 : 10K (1 - 0 - 3 - B)
D22 : 1N4148 R30 : 10K (1 - 0 - 3 - B)
D23 : 1N4148 R31 : 10K (1 - 0 - 3 - B)
D24 : 1N4148 R32 : 10K (1 - 0 - 3 - B)
D25 : 1N4148 R33 : 10K (1 - 0 - 3 - B)
D26 : 1N4007 R34 : 10K (1 - 0 - 3 - B)
R35 : 1K5 (1 - 5 - 2 - B)
R36 : 1K5 (1 - 5 - 2 - B)
5. Zener diodes. Watch the polarity! R37 : 560 (5 - 6 - 1 - B)
R38 : 10K (1 - 0 - 3 - B)
R39 : 220K (2 - 2 - 4 - B)
R40 : 100K (1 - 0 - 4 - B)
ZD... R41 : 220K (2 - 2 - 4 - B)
CATHODE R42 : 100K (1 - 0 - 4 - B)
R43 : 220K (2 - 2 - 4 - B)
R44 : 100K (1 - 0 - 4 - B)
R45 : 220K (2 - 2 - 4 - B)
R46 : 100K (1 - 0 - 4 - B)
ZD1 : 3V9 R47 : 1K5 (1 - 5 - 2 - B)
ZD2 : 3V9 R48 : 33K (3 - 3 - 3 - B)
R49 : 12K (1 - 2 - 3 - B)
R50 : 220K (2 - 2 - 4 - B)
6. 1/4W Resistors R51 : 10K (1 - 0 - 3 - B)
R52 : 100K (1 - 0 - 4 - B)
R53 : 220K (2 - 2 - 4 - B)
R54 : 100K (1 - 0 - 4 - B)
R55 : 220K (2 - 2 - 4 - B)
R... R56 : 100K (1 - 0 - 4 - B)
R57 : 220K (2 - 2 - 4 - B)
R58 : 100K (1 - 0 - 4 - B)

7. Metal film resistors (1/2W)

R1 : 1K (1 - 0 - 2 - B)
R2 : 1K (1 - 0 - 2 - B)
R3 : 470 (4 - 7 - 1 - B)
R4 : 1K (1 - 0 - 2 - B) R...
R5 : 22K (2 - 2 - 3 - B)
R6 : 220K (2 - 2 - 4 - B)
R7 : 2K2 (2 - 2 - 2 - B)
R8 : 2K2 (2 - 2 - 2 - B)
R9 : 220K (2 - 2 - 4 - B) R59 : 100K (1 - 0 - 4 - B - 9)
R10 : 22K (2 - 2 - 3 - B) R60 : 100K (1 - 0 - 4 - B - 9)
R61 : 47K (4 - 7 - 3 - B - 9)

8
 Construction

R62 : 47K (4 - 7 - 3 - B - 9) 9. LEDs. Watch the polarity!

R63 : 220 (2 - 2 - 1 - B - 9)
R64 : 220 (2 - 2 - 1 - B - 9)
R65 : 820 (8 - 2 - 1 - B - 9)
R66 : 220 (2 - 2 - 1 - B - 9) LD...

R67 : 220 (2 - 2 - 1 - B - 9)
R68 : 820 (8 - 2 - 1 - B - 9)
R69 : 330K (3 - 3 - 4 - B - 9)
R70 : 330K (3 - 3 - 4 - B - 9)
R71 : 330K (3 - 3 - 4 - B - 9)
CATHODE
R72 : 330K (3 - 3 - 4 - B - 9)
R73 : 330K (3 - 3 - 4 - B - 9)
R74 : 330K (3 - 3 - 4 - B - 9)
R75 : 330K (3 - 3 - 4 - B - 9)
LD1 : 5mm Red blinking
R76 : 330K (3 - 3 - 4 - B - 9)
LD2 : 3mm Bicolour
8. 1W resistors
Carefully check the assembly of this LED :

R...

3
1 2 1 3
2mm

2 LD...

R77 : 270 (2 - 7 - 1 - B)
R78 : 10K (1 - 0 - 3 - B)
R79 : 10K (1 - 0 - 3 - B)
R80 : 15K (1 - 5 - 3 - B) 5mm
R81 : 680K (6 - 8 - 4 - B)
R82 : 15K (1 - 5 - 3 - B)
R83 : 47K (4 - 7 - 3 - B)
R84 : 47K (4 - 7 - 3 - B) 5mm
R85 : 390K (3 - 9 - 4 - B)
R86 : 47K (4 - 7 - 3 - B) LD3 : 3mm RED
R87 : 47K (4 - 7 - 3 - B) LD4 : 3mm RED
R88 : 390K (3 - 9 - 4 - B) LD5 : 3mm RED
R89 : 180 (1 - 8 - 1 - B) LD6 : 3mm RED
R90 : 180 (1 - 8 - 1 - B) LD7 : 3mm GREEN
R91 : 180 (1 - 8 - 1 - B) LD8 : 3mm GREEN
R92 : 180 (1 - 8 - 1 - B) LD9 : 3mm RED
R93 : 180 (1 - 8 - 1 - B) LD10 : 3mm RED
R94 : 180 (1 - 8 - 1 - B) LD11 : 3mm RED
R95 : 180 (1 - 8 - 1 - B) LD12 : 3mm RED
R96 : 180 (1 - 8 - 1 - B)
R97 : 10 (1 - 0 - 0 - B) 10. IC socket. Watch the position of the
R98 : 10 (1 - 0 - 0 - B) notch!
R99 : 10 (1 - 0 - 0 - B)
R100 : 10 (1 - 0 - 0 - B)
R101 : 10 (1 - 0 - 0 - B)
R102 : 10 (1 - 0 - 0 - B)
R103 : 10 (1 - 0 - 0 - B)
R104 : 10 (1 - 0 - 0 - B)

IC1 : 18p

9
Construction

11. REED relays. Check the position of 15. DIP switches

the notch!

RY...
SW...
1
1
PIN 1

Check that switch 1 corresponds to pin 1.

RY1 : VR05R121 SW2 : DS-4P

RY2 : VR05R121 SW3 : DS-4P

12. Resistors trimmers (vertical type) 16. Capacitors

RV1 : 100K
RV2 : 100K C...
RV3 : 100K
RV4 : 100K RV...
RV5 : 100K
RV6 : 100K
RV7 : 100K
RV8 : 100K Check the minimum voltage !

C3 : 100p/400V
C4 : 100p/400V
13. Transistors C5 : 22n/630V (0.022)
C6 : 22n/630V (0.022)
C7 : 470n (0.47, 474)
T1 : BC547C
C8 : 2n2 (222, 2200)
T2 : BC547C
C9 : 22n/630V (0.022)
T3 : BC547C
C10 : 100p/400V
T4 : BC516
C11 : 22n/630V (0.022)
C12 : 22n/630V (0.022)
C13 : 22n/630V (0.022)
C14 : 22n/630V (0.022)
C15 : 22n/630V (0.022)
C16 : 2n2 (222, 2200)
C17 : 470n (0.47, 474)
C18 : 100p/400V (101)
14. 5W resistors C19 : 22n/630V (0.022)
C20 : 22n/630V (0.022)
C21 : 22n/630V (0.022)
R... C22 : 22n/630V (0.022)

17. Electrolytic capacitors (check the

polarity)
2mm
C23 : 4µ7
C24 : 100µF / 25V
C25 : 470µF / 25V
REMARK: You will have two 8.2 Ohm 5W resis- C26 : 470µF / 25V
tors left over for later use. C27 : 470µF / 25V
C28 : 470µF / 25V C...
R105 : 15 C29 : 47µF / 100V
R106 : 15 C30 : 100µF / 100V
R107 : 15 C31 : 47µF / 100V
R108 : 15 C32 : 47µF / 25V
C33 : 47µF / 25V
C34 : 100µF / 25V

10
 Construction

18. PCB connectors 20. Power relays

With the holes facing the PCB edge ! The various relays have leads that correspond to
the printing on the PCB:

RY3 : VR5V122C

RY...
SK3 : 2p
SK4 : 2p

SK9 : 2p
SK10 : 2p RY4 : VR10V121C
SK11 : 2p RY5 : VR10V121C
SK12 : 2p
SK13 : 2p
SK14 : 2p
SK15 : 2p
SK16 : 2p

RY...

21. Fuse holder + fuse

SK5 : 3p
SK6 : 3p F1
SK7 : 3p
SK8 : 3p
F...
19. Valve sockets

6 1
V...
2
Insert a 5A fuse for 115V
7
Insert a 2.5A fuse for 230V
8 3
Fit the protective cap to the fuse holder.
5 9 4

22. Transformer

Mount them square against the PCB!

TRAFO...
V9 : B9A
V10 : B9A
V11 : B9A
TR1 : 12VAC

11
Construction

23. Electrolytic capacitors (check the

polarity)

Generally these capacitors are from the snap-in

type and cannot be mounted incorrectly.

C35 : 22µF/350V
C36 : 22µF/350V
C37 : 100µF/400V
C38 : 100µF/400V
C39 : 220µF/450V C...
C40 : 220µF/450V
C41 : 220µF/450V
C42 : 220µF/450V

24. Switch

IMPORTANT:
Don't leave a gap between
the SWITCH and the PCB!

SW...
SIDE VIEW

Mount him as square as possible against the PCB,

also solder the metal support.

SW1 : 3P ON-ON-ON

25. IC. Watch the position of the notch!

IC1 : LM3914

12
 Valve wiring

26. 6,3V Valve wiring

Wiring for the 8 tube sockets V1 to V8. Use twisted brown wire for each one. For safety, it is advis-
able to check with an ohmmeter that the two 6.3V terminals are not short circuited.

f1 f2 f1

6.3VAC 6.3VAC
f2 f2 f1 f2 f1

V7 V6 3 V3 V2 3

5 6 7 2 5 6 7 2
8 1 3 4 8 1 3 4
5 5
8 1 4 8 1 4
4 1 8 4 1 8
4 5 4 5
3 2 1 8 5 3 1 8 7 5
7 6 2 6

3 3

VIEWED FROM SOLDERSIDE

V8 V5 3 V4 V1 3

5 6 7 5 6 7 2
8 1 2 3 4 8 1 3 4
5 5
8 1 4 8 1 4
4 1 8 4 1 8
4 5 4 5
3 1 8 5 3 1 8 5
2 7 6 2 7 6

3 3

Again thoroughly check all the components for miss

mounting (polarity!) , including soldering errors !!

13
Assembly into the unit

27. Assembly into the unit

Mount the cage nuts into the square holes concerned,

from the inside to the outside, (with the nut along the
inside). These nuts are used to fasten the covers down, CLICK INTO HOLE
and there are 7 of them in the cabinet base.
Fig. 1.0

M3 NUT

M3 LOCK WASHER

Mount the input PCB on the right-hand side of the housing as

shown in the figure. It is possible that a masking sticker from
the cabinet will have to be removed, so that one of the sup-
porting bushes can make contact with the cabinet.
5mm SPACER

16mm M3 BUTTON HEAD BOLT

Fig. 2.0

Mount the chrome feet at the four corners of the cabinet using an M4 bolt. A piece of felt can be sticked
under each foot.

Mount the loudspeaker terminals (repeat twice):

Mount the three loudspeaker terminals on the triangular PCB plate (see figure), the connecting eyes
should not be used.

16mm M3 BUTTON HEAD BOLT

Fig. 3.0
HOUSING (REAR)

LS TERMINAL

PCB SUPPORT
M3 LOCK WASHER
M3 NUT

NUT LS TERMINAL
NUT LS TERMINAL

14
 Assembly into the unit

Check that the solder side of the PCB, is along the side of the nuts.

Solder a 35 cm length of yellow wire to the 4 Ohm connection (YEL).

Solder a 35 cm length of red wire to the 0 connection (RED).

HINT: In order to tighten the nuts well, immobilise the loudspeaker terminal by inserting a
screwdriver through the hole for the loudspeaker lead.

Fit the unit onto the housing with three black Allen bolts, fix with a shakeproof washer and nut.

IMPORTANT: The loudspeaker terminals must NOT touch the metal cabinet anywhere.

Mount the mains voltage connector to the housing using two black Allen bolts.
Solder a 12 cm length of blue wire to the N terminal of the mains connector.
Solder a 12 cm length of brown wire to the L terminal of the mains connector.
Solder a 20 cm length of yellow/green earth wire and a 12 cm length to the middle terminal of the
mains connector.

Slide a 1.5 cm length of insulating heat shrink sleeve over each terminal all the way up the con-
nector. This can be shrunken by hot air (e.g. with a hair dryer).

IMPORTANT: Stick a piece of insulating foil on the connector, see figure 4.0. This will later be
used to prevent the connector piercing through the transformer.

Also stick a piece of insulating foil on the inside edge of the cabinet above each place where a
transformer has to be put (see fig. 6).

ADHESIVE PROTECTION FOIL

Fig. 4.0

15
Assembly into the unit

Mount the ring core transformers:

Stick a adhesive foot to the base of the cabinet, in the middle where each transformer has to be put.

METAL CASE

RUBBER WASHER

Cut
4 x 4 cm
TRANSFORMER

RUBBER WASHER
PLATE
Fig. 5.0 BOLT

Mount an output transformer on the left-hand side of the housing, see figure 6.0.
WIRES ADHESIVE
WIRES
ADHESIVE ADHESIVE
PROTECTION PROTECTION
PROTECTION
FOIL FOIL
FOIL

OUTPUT POWER OUTPUT

TRANSFORMER TRANSFORMER TRANSFORMER
ZD043 8D002 ZD043

ADHESIVE ADHESIVE ADHESIVE

FOOT FOOT FOOT
WIRES WIRES WIRES

Fig. 6.0

Check the position of the leads.

Turn over the housing and solder the trans-

former leads to the output terminals, see 8
figure 7.0.
0

4
BLUE
HEAT-SHRINK
SLEEVE
RED

Fig. 7.0 YELLOW

Do not forget to insert a 3 cm length of insulating heat shrink sleeve over the wires:

Solder the double yellow wire to the 4 Ohm loudspeaker terminal.

Solder the red wire to the 0 loudspeaker terminal.
Solder the blue wire to the 8 Ohm loudspeaker terminal.

IMPORTANT: Heat the terminals up until the solder melts easily. Then slide the insulating heat
shrink sleeve over the leads.

16
 Assembly into the unit

Twist the previously soldered red and yellow wires together and fit them as shown in the figure,
the cable ties supplied can also be used.

8 0 4 8 0 4

OUTPUT TRANSFORMER OUTPUT TRANSFORMER

ZD043 ZD043
YELLOW BLUE
RED RED
BLUE YELLOW

Fig. 8.0

Mount the supply transformer in the middle of the cabinet. Ensure that the leads are positioned as
shown in the figure 6. The thick grey and green wires must be at the highest point.

Mount an output transformer along the right-hand side of the housing, see figure 6. Check the
position of the wires.

Solder the transformer leads to the output terminals, see figure 7. Do not forget to slide a 3 cm
length of insulating heat shrink sleeve over the wires:

Solder the double yellow wire to the 4 Ohm loudspeaker terminal.

Solder the red wire to the 0 loudspeaker terminal.
Solder the blue wire to the 8 Ohm loudspeaker terminal.

IMPORTANT: Heat the terminals until the solder melts easily.

Then slide the insulating heat shrink sleeve over the leads.

IMPORTANT: Ensure that the transformers do not touch any metal parts
! such as the loudspeaker terminals or the input connector.

17
Assembly and wiring

28. Assembly and wiring

Fit the main PCB into the housing and screw it down with the black Allen bolts along the underside.
Connect the mains lead to the screw connector, MAINS, with the blue wire to the N terminal and the
brown wire to the L terminal. The short earth wire is connected to the EARTH connector.
Connection of the transformers:

IMPORTANT: The connector leads of the transformer may not be shortened.

! If there is more than one wire in an insulating sleeve, then they MUST be
soldered together, and only then connected to the screw connector.

Connect the left-hand output transformer to the left-hand connector, SK7, and the right-hand
output transformer to the right-hand connector, SK8.

The twisted yellow and red wires must also be connected to the proper connector. See fig. 9
8 0 4 8 0 4

OUTPUT TRANSFORMER OUTPUT TRANSFORMER

ZD043 ZD043
YELLOW BLUE
RED RED
BLUE YELLOW

YELLOW LS+ RED LS-

RED LS- YELLOW LS+
ORANGE VIOLET
BROWN GREEN
BLACK BLACK
BLACK BLACK
GREEN
VIOLET
Fig. 9.0 BROWN
ORANGE

Connect the leads of the supply transformer to the screw connector, SK6.
8 0 4 8 0 4
L R
MAINS

OUTPUT TRANSFORMER POWER TRANSFORMER OUTPUT TRANSFORMER

ZD043 8D002 ZD043

EARTH L
N BLUE GND
L BROWN GND
R
BROWN

ORANGE
RED
BLACK
PINK

BLUE
YELLOW
YELLOW

6.3VAC
GRAY
Fig. 10 6.3VAC
GREEN

The thick grey wires may be twisted and connected the 6.3V connection (SK3) of the left-hand
amplifier.
The thick green wires should be connected in the same way to the 6.3V connection of the right-
hand amplifier PCB.
Connect the screened cable from the input PCB to the L connection (left channel) and the screen
to the GND connection. Do the same for the right channel, R.

18
 Final inspection

29. Final inspection

ATTENTION: THERE ARE VOLTAGES OF MORE THAN 400V AT MANY POINTS

! ON THE PCB. Ensure that suitable insulated measuring leads are used. Ensure
that no children are in the vicinity.

Switch the mains voltage switch to OFF, ie. fully down.

Connect the mains connector via a lead to a mains outlet. The plug may have to be changed for your
country. In that case, cut off the plug from the lead, and connect an appropriate plug for your country.
Connect the blue wire to the N connector of the mains, the brown wire to the L connector and the
yellow/green wire to the earth.
When connected to the mains, the red LED at the front should light up.
Switch the mains switch to ON ie. fully up. The LED at the front should flicker green/red while the
amplifier is warming up. After approx. one minute, the green LED will be continuously lit, you will also
hear a relay energise.

Check the following voltages with a volt meter:

Approx. 6.3 VAC on the terminals marked 6.3 VAC (SK3 and SK4) on each amplifier half. 6.3V should
also be found at connectors 2 and 7 of the tube sockets, V1 to V8.

2 7
1

7 2
Fig. 11

FIRST SWITCH OFF THE MAINS VOLTAGE AND REMOVE THE MAINS CORD
! FROM THE SOCKET. WAIT FOR A COUPLE OF MINUTES UNTIL THE HIGH
VOLTAGES ON THE SUPPLY ELCOS HAVE DISSAPEARED.

Fit the small tubes:

V9 and V10, type ECC83 or 12AX7, CV492.

V11, type ECC82 or 12AU7, CV491.

Again connect the amplifier to the mains and set the mains switch to ON (fully up).
Wait until the green LED is lit continuously.

Now check the voltages on the PCB, measure the voltages with respect to earth. Earth can be taken
from lead J26 (next to the mains switch). Measure the voltages at the points indicated on the PCB.

NOTE: The measured voltages may differ depending on the tolerances of the mains connected.
Voltages of 0.4V cannot yet be checked.

19
Setting - up

30. Setting up

Switch off the mains voltage.

Turn all trimmer potentiometers, RV1 to RV8, fully anticlockwise.
Mount the 8 tubes, V1 to V8, type EL34 (or C6A7, CV1741) into their sockets (check the position of the
notch).

IMPORTANT: Connect an 8.2 Ohm 5W resistor between the output terminals

(0 and 8 Ohm) of both channels. The output of a tube amplifier must always be
! loaded. Make sure that there is a good contact with the loudspeaker terminals,
the connections of the resistors may have to be thickened a little with solder.

Standby current adjustment

No measuring equipment is needed for the following adjustment, the standby or bias current of each tube
can be seen from the LED scale on the front. The individual tube to be checked can be selected using
the small DIP switches. RV1 corresponds to V1, RV2 to V2, etc.

ATTENTION: The following adjustment is a reference for the bias current of

the power tubes. Be very careful in setting them. Also respect the order of
! adjustment. No signal may be connected to the input.

Set all 8 DIP switches to the OFF position (up). Each switch has an associated tube, never set more than
one switch ON (down) otherwise you will get an incorrect reading of the LED scale.
Switch the mains voltage on and wait until the green LED is lit continuously.

Adjustment of the left-hand channel:

Switch the first switch of SW2 (left-hand DIP switch) ON (down).

Carefully adjust RV1 until the second or third LED lights up (LD4 or LD5).
Switch OFF the first switch (up).
Switch ON the second switch (down).
Carefully adjust RV2 until the second or third LED lights up.

Complete the adjustment for all tubes of the left-hand channel.

Adjustment of the right-hand channel:

Ensure that all switches of the left-hand channel are OFF (up).
Switch the first switch of SW3 (right DIP switch) ON (down).
Carefully adjust RV5 until the second or third LED lights up (LD4 or LD5). Switch OFF the first
switch (up).
Switch ON the second switch (down).
Carefully adjust RV6 until the second or third LED lights up.

Complete the adjustment for all tubes of the right-hand channel.

Now wait for around 10 minutes.

Repeat the complete adjustment but adjust until one of the two green LEDs lights up. After adjusting all
tubes, the voltages of around 0.4V can be checked.

20
 Test & final assembly of the cabinet

31. Test

The amplifier can now be connected to loudspeakers of 8 or 4 Ohms, the common connection is in the
middle.
IMPORTANT
If 8 Ohm loudspeakers have been connected, then first check that not too much hum can be heard
in the loudspeakers, which is why a preamplifier should not yet be connected. Should too much
hum be audible, then the output transformer of the channel concerned should be turned a little
clockwise or anti-clockwise until the hum weakens. This operation has no effect on the 4 Ohm
connection.

Note that the amplifier is under voltage. Be careful when turning the transformer because
! if any of the leads come away the transformer will be damaged. It is best to place a small
loudspeaker close to the amplifier such that you can turn and listen for the best result.

Now a preamplifier can be connected and the unit can be tested with music.

32. Final assembly of the cabinet

Before fitting the covers, check the supply and amplifier PCBs to see that no components have been
mounted too high.

Mount the cover on the base (set the cabinet on its side) using black Allen bolts.
Make a loop of the three earth connections in the cabinet, via the spade plugs and the length of loose
earthing wire, the last lead goes to the rear mirror.

Fig. 12

Mount the cage nuts in the rear mirror (be careful of scratches), the groove for the earth lead
goes upwards, then the nuts of the cage nuts should be below.

Attach the cover plate for the tubes to the rear mirror (do not yet tighten the bolts). When using a
black cover, a masking sticker may have to be removed from around one of the holes, such that
plates can make an electrical contact.

Mount the cover plate and rear mirror on the cabinet and fasten them temporarily with Allen bolts.

21
Final assembly of the cabinet

The cabinet can now be completed by first fitting the covers for the supply transformers.

Mount the front panel to the cabinet, use the support brackets supplied, together with M3 and M4
Allen bolts. Check the position of the switch and the LED (see figure 13).

HOUSING

6mm M3 BUTTON HEAD BOLT

LOCK WASHER

SUPPORT BRACKET

FRONT PANEL

6mm M4 BUTTON HEAD BOLT

Fig. 13

If it all fits together well, then all bolts can be fully tightened.

22
 Usage

33. Usage

! WARNINGS.

THIS UNIT GETS HOT, KEEP OUT OF REACH AND AWAY FROM CHILDREN.
CHECK THAT THE MAINS VOLTAGE CORRESPONDS TO THAT OF THE UNIT.
BEfORE OPENING THE UNIT, THE MAINS CORD MUST BE REMOVED IN ORDER TO
AVOID ELECTRIC SHOCKS.

It is normal for the tubes and cabinet to get very hot, so place the amplifier in a well ventilated area,
certainly not in a closed cabinet or rack.

We advise to check the standby current adjustment once a year, certainly if the end tubes are new. This
can easily be done by removing the front panel.

If the amplifier is not used for a short period of time, then set it to standby by putting the mains switch in
the middle position.

34. Troubleshooting

No high voltage.
Check the transformer wiring.
Check the fuses.
Irregular crackling in the loudspeaker.
Replace R88 or R85 of the channel concerned.
A continuous buzzing in the loudspeaker (continuous oscillation of the amplifier) or crackling in bass peaks.
When using a piezo tweeter, a 10 Ohm resistor must be placed in series with the tweeter.
Increase R65 and R68 in value e.g. 1k or 1K5 (the input sensitivity will then be somewhat higher).

THE ABOVE ADJUSTMENTS SHOULD NOT BE DONE IN ANTICIPATION, ONLY IN THE

EVENT OF PROBLEMS AND AFTER HAVING THOROUGHLY CHECKED ALL
COMPONENTS, CABLING AND SOLDERING.

NOTES: As tubes are very sensitive to shocks, do NOT move the unit when the tubes are hot.
Should a tube nevertheless fail, then this can be seen by the sudden bright red glow of the lamp. In
the event of the lamp discharging, then the associated anode resistance of 10 Ohm will almost
certainly be defective, also check the 220 Ohm resistors, R63, R64, R66 and R67.

ATTENTION: Should the amplifier not work, just send it to us so that we can
! check it. Please only send the MAIN PCB !.

If you decide to send the complete unit, you MUST order a special protective
shipping box (order code DM4040) from you distributor. If not then the unit will surely
be damaged during transport and it will suffer damage beyond repair.

Velleman Kit can never be hold responsible for damage during transport!

Happy listening.

23
24
2.5A SLOW @ 230-245VAC
TRANSFORMER Diagram
5A SLOW @ 100-120VAC D 245
L
F1 230 9 1N4007
C D20 1N4007
1N4007 1N4007 12VDC
ON D21 D26
D4 D6 SW1 1N4007
B 120 +V 1N4007 D17
MAINS 100 D25 4u7 1N4007
1N4007 D19 R77
A D3 D5 C25 C23
1N4007 OFF 1N4148 C24 270/1W BC547C
7 R3 470u 100u 470u ZD2 T3
C28 L-56BHD 1N4148
12VAC/2.5VA T4
470 LD1 D24 D15
N R9 BC516 SI
0 D18
R36 R37 220K 1N4148 1N4148 D16
1K5 560 R35 R6 R7 C26
1K5 220K 2K2 1N4148 470u
35. Diagram power supply

RY5
GREEN VR10V121C
RED
LD2 415VDC +V1L
R8 BC547C T2 R80 365VDC
L-93WEGW 2K2 +V3L
D2 15K/1W
C39 C40 C37
1N4148 TRANSFO2 220u/450V 220u/450V 100u/400V
R4 RY4
1K RED R78 R79
D1 ZD1 VR10V121C
1N5408 +V1R
BC547C 10K/1W10K/1W D13
1N4148 7V5 1N5408 D14 365VDC
T1 R82
C27 300V/1.3A +V3R
470u 15K/1W
VR5V122C D11 D12 R81 C38
RY3 RED 1N5408 1N5408 C41 C42
680K/1W 220u/450V 220u/450V 100u/400V
R105 R107 R108 R106 VIOLET
15/5W 15/5W 15/5W 15/5W 245 YELLOW +V
ORANGE D7 R70 SW2 1N4148
D10 -50VDC 1
230 1N4007 1N4007 BIAS1
R5 V+
330K/0.5W D22
50V/0.1A -VL C34 3 0.5
R69 2 100u
LD12
22K 10
BLUE D9 D8 BIAS2 RED
YELLOW 1N4007 C29 330K/0.5W
1N4007 47u/100V 0.475 LD11
120 MODE 11
R71 3 RED
BROWN NC 9
GREEN BIAS3 0.45 LD10
100 f1 330K/0.5W 12
RED
LEFT -50VDC R72 4 SIG
0.425 LD9
6.3V/7A BIAS4 5
CHANNEL R10 13
BLACK 330K/0.5W RED
GREEN -VR R74 SW3 0.4 LD8
0 f2 100u/100V 22K 1
14
BIAS5 REF LM3914 GREEN
GRAY C30 C31 330K/0.5W
f1 47u/100V 7 0.375 LD7
R73 15
2 R48 GREEN
LEFT BIAS6 33K
6.3V/7A 0.35 LD6
CHANNEL 330K/0.5W RHI 16
6 RED
GRAY R75 3
f2 0.325 LD5
BIAS7 17
330K/0.5W RED
R76 RLO 0.3 LD4
4
4 18
BIAS8 RED
330K/0.5W 0.275
D23 LD3
8 2 1
1N4148 1K5 12K RED
R47 R49 ADJ V-
 -VR -50VDC

100K 100K
RV6 RV5
180/1W EL34 180/1W
3 3 EL34
+V3R 365VDC R54 R52 R50 R93 R94
100K 100K 220K
V5 V6
1
C18 4 4
R62 100p/400V 260VDC 22n/630V
36. Diagram (right channel)

335VDC 47K/.5W R51 0.4VDC 0.4VDC

TRANSFO4
R28 R88 R86
3K9 10K 5 5 ZD043
390K/1W 47K/1W C20
110VDC 8 8 ORANGE BLUE
C36 R60 BIAS5 BIAS6 8 Ohm
100K/.5W
22u/350V 7 7
2 2
6 1
22n
22n/630V ECC83 R53 R103 R101
1/2 V11 1
C5 V10 220K 10/1W 10/1W
ECC82 C15 22n/630V
R2 R27 2 f1 f2 f1 f2 BROWN YELLOW
2 7 C19 4 Ohm
IN R33
415VDC
1K 22K BLACK
R13 R26 R23 10K
RIGHT INPUT C4 820K +V1R
C2 33K 1M 22n/630V
100p 3 R32
8 3
GND BLACK
100p 9 4 5 5 4 10K
R16 9 C21 f1 f2 f1 f2
SI GREEN
1 14 12K R55
6 R104 R102
470n 220K 10/1W 10/1W
RY2 f1 f2 R24 f1 f2
VR05R121A 2 13 820 2 7 2 7
7 8 47u C33 C17 EL34 EL34 VIOLET RED
100VDC GND
22n/630V V8 BIAS7 V7 BIAS8
2n2 R87 C22 8 8
R25 R68 R34 LS GND
47K/1W 5 5
180
820/.5W C16 0.4VDC 0.4VDC
10K
-VR -VR
4 1 4 1
R57
100K 220K
R96 R95
GREEN f1 100K 180/1W
RV7 180/1W 3 3
R66 RV8
220/.5W
R56 R58
6.3VAC 100K 100K
R67
220/.5W
GREEN f2

25
Diagram
26
Diagram

-VL -50VDC

100K 100K
RV2 RV1
180/1W EL34 180/1W
3 3 EL34
+V3L 365VDC R42 R40 R39 R89 R90
100K 100K 220K
V1 V2
1
C10 4 4
R61
37. Diagram (left channel)

100p/400V 260VDC 22n/630V

335VDC 47K/.5W R38 0.4VDC 0.4VDC
TRANSFO3
R22 R85 R83
3K9 10K 5 5 ZD043
390K/1W 47K/1W C12
110VDC 8 8 ORANGE BLUE
C35 R59 BIAS1 BIAS2 8 Ohm
100K/.5W
22u/350V 7 7
2 2
6 1
22n
6 22n/630V ECC83 R41 R99 R97
1/2 V11
C9 V9 220K 10/1W 10/1W
ECC82 C6 22n/630V
R1 R21 2 f1 f2 f1 f2 BROWN YELLOW
7 7 C11 4 Ohm
IN R30
415VDC
1K 22K BLACK
R12 R17 10K
LEFT INPUT C3 33K R20
C1 820K 22n/630V +V1L
100p 8 1M R29
8 3
GND BLACK
47n 9 4 5 5 4 10K
R11 9 C14 f1 f2 f1 f2
SI GREEN
1 14 12K R43
6 R100 R98
470n 220K 10/1W 10/1W
RY1 f1 f2 R18 f1 f2
VR05R121A 2 13 820 2 7 2 7
7 8 47u C32 C7 EL34
100VDC EL34 VIOLET RED
22n/630V V4 BIAS3 V3 BIAS4 GND
2n2 R84 C13 8 8
R19 R65 R31 LS GND
47K/1W 5 5
180
820/.5W C8 0.4VDC 0.4VDC
10K
-VL -VL
4 1 4 1
R45
100K 220K R92 R91
100K 180/1W 180/1W
GRAY f1 RV3 3 3
R63 RV4
220/.5W
R44 R46
6.3VAC 100K 100K
R64
220/.5W
GRAY f2
 A: 100VAC C: 230VAC
B: 120VAC D: 245VAC C23 T4
R3 R77 J13

VIOLET
ORANGE
BLUE
YELLOW
RED
RED

BROWN
BLACK
YELLOW
VOLTAGE SELECTION

D15
C D17 C25 C24
D R6
EARTH RY5 T3 C26
T2

D16
DA B
C SK6 SK7 SK8 RY1 RY2
AB

38. PCB
SK6...8 L

ZD2
D18

R7
R8
R9
N

SK5
R78 R79 R1
MAINS R105 R106 R12 GND

0
RY3 RY4 C41 C3

1
1
L D11 D13 -50VDC C4 R2

245V
230V
120V
100V
J18 5 J19 GND

D9

D7
D8
D10
C30 R59 6 4
SK5 TRANSFORMER R81 R10 R
D12 D14
C31
7
J7 R82 3 C36
D1 D2
12VAC R80 J2 C35
2 R16
8

R4
C27 R13

ZD1
T1 9
-50VDC 1 R60
C28 V11

R5
R107 R108 C38

R11
C39 C40 C42
C37 J20

D4

D3
C29
365VDC
R62
J1 J3 R61 335VDC
F1
335VDC
365VDC
J15

D5
D6
415VDC
J10 415VDC

5A SLOW AT 100/120VAC
J16 J17 J21

2.5A SLOW AT 230/245VAC

C5

GRAY
GRAY
12VDC

GREEN
GREEN
6.3VAC 6.3VAC
YELLOW LS+
f1 f2 f1

SK12
RED LS- J8 R63 R64 J9

R83
R66 R67
SK3 SK4
J4 f1 f2 f1 RED LS-
ORANGE SK3 C32 f2 f2 C33
1 9 J14 1 SK4 9

SK11
SK16

BROWN C8 C16 YELLOW LS+

R84
R19
R20
R65
R86
R87
R25
R26
R68
260VDC
BLACK R18 R24 VIOLET
J11

SK10
C6 C9
SK15

C7 C17

C15
BLACK 100VDC 260VDC GREEN

R17
R23
J12
GREEN R21 R27 BLACK
100VDC

SK9
V9 V10
SK14

VIOLET BLACK
J22 J23
SK9...12 BROWN
R85 R88
110VDC DANGER 110VDC
SK13

R22 R28 ORANGE

C10 HIGH VOLTAGE R93 C18 SK13...16
J5 J6
R94

R89
R90
C11
C12
C13
C14
C21

C19
C20
C22

3 V2 V3 3 V6 V7
R29 R32
5 5
4 1 8 4 1 8

R91
R95

4 4
8 1 8 1
5 5

R98 R102
R97 3 R101 3

R92
R96

0.4VDC R31 0.4VDC 0.4VDC R34 0.4VDC

R30 R33

D26

J24 J25

D19 VELLEMAN P4040B'2

0.4VDC 0.4VDC
D24 3 V1 0.4VDC 3 0.4VDC
R99 V4 V5 R103 V8
R100 R104
5 5

D21
D20
4 1 8 4 1 8

R35

4 4

D25
8 1 8 1
5 R69 5 R73
LD1 R70 R74

R36
2 R47
R49
R38 3 C34 R48 3
D23

R71
1

R72

R37
1
3
R75
R76

R51

D22

LD3 LD4 LD5 LD6 LD7 LD8 LD9 LD10 LD11 LD12
SW2

SW1
SW3

R41

R39
R43
R45
R50
R53
R55
R57

LD2

RV2
RV3
RV4
RV6
RV7
RV8

RV1
J26 IC1 RV5

R40
R42
R44
R46
R52
R54
R56
R58

PCB CONNECTED TO MAINS

1 3
0.5V

RED
RED
RED
RED
RED
RED
RED
RED

1 1 HIGH VOLTAGE

0.275V
GREEN
GREEN

1 2 3 4 1 2 3 4

27
PCB
 VELLEMAN KIT NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
Info ?: http://www.velleman.be

Modifications and typographical errors reserved

© Velleman Kit nv
H4040IP - 2004 - ED1 (rev. 1.0)
5 410329 319182