ez1073pre Mic Amplifier - Assembly manual

[“Colourbook” Issue 1c]

ez1073pre “Colourbook” Contents.

Section 1 - “Colourbook” assembly guide

Section 2 - Setup and Calibration

Section 3 - Schematics diagrams and PCB Overlays

Section 4 - Parts List

ez1073pre “Colourbook” revision history

Revision 1 - initial release

Revision 1a: Parts list correction of rotary switch type

Better PCB prep instructions
Correction to heatsink fitting instructions
Clarification of sub card identification
Removal of protective coating from chassis

Revision 1b: Change to knob fitting instruction - now uses ring nut
Alteration of molex connector drawing

Revision 1c: Change to VTB2569 fitting instruction - now has different length screws
PCB Preparation
Surge Control PCB
Output Stage PCB
Carefully snap apart the 10 PCB’s into individual boards
and trim or file off any excess tabs.

Ensure that the 2 areas highlighted are filed / trimmed completely flat

Gain Stage 2 PCB Input Transformer PCB 1

Trim Pot PCB

Switch PCB

Gain Stage 1 PCB Input Transformer PCB 2

Heatsink
Insulator PCB

This side up

Main PCB
Output Termination

Place a “blob” of solder across the two pads (SW6) for 600 Ohm termination

Switch PCB
Diodes D2, D3, D4 & D5 = 1N4007 (4)
Resistors R24 = 1R0 (1)
R25 = 2R2 (1)

R21 = 5R6 (1)

R23 = 10R (1)

Resistors R19 = 82R (1)
R20 & R22 = 100R (2)

R10 = 120R (1)

R9 = 330R (1)
Resistors R39 & R52 = 390R (2)

R34, R47, R65, R69 & R71 = 470R (5)

R8 = 510R (1)
R27 = 620R (1)
Resistors R1 = 1k0 (1)

R59 = 1k2 (1)

R26, R35 & R48 = 1k5 (3)

R16, R40, & R53 = 1k8 (3)
Resistors R17 & R60 = 2k0 (2)

R38, R51 & R56 = 2k2 (3)

R13 & R14 = 2k7 (2)

R11, R12 & R18 = 3k3 (3)

Resistors R2 & R15 = 3k9 (2)
R3 = 4k3 (1)

R31, R44 & R74 = 5k1 (3)

Resistors R28, R36, R49 & R68 = 10k (4)
R7 = 12k (1)
R37 & R50 = 15k (2)

R6 & R63 = 18k (2)

Resistors R32, R45 & R61 = 33k (3)

R72 = 39k (1)

R33 & R46 = 47k (2)

R41 & R54 = 51k (2)

Resistors R55 & R66 = 56k (2)

R30, R43 & R57 = 68k (3)

R29 & R42 = 120k (2)

R4 & R5 = 6k81 / 0.1% (2)

Resistors R67 = 47R / 3Watt (1)

R62 & R64 = Omitted (leave empty) (2)

Ceramic C11 = 47pF (1)

Capacitors C17 & C28 = 100pF (2)

C1 = 180pF (1)

C12, C13 & C39 = 220pF (3)

Ceramic C46 = 330pF (1)

Capacitors C5, C8, C16, C20, C30, C32, C47 & C48 = 100nF (8)

CL1 & CL2 = 100pF 3 Terminal L/C Network (2)

F1 & F2 = Ferrite Bead (2)

Film C18 & C29 = 680pF (2)

Capacitors C24 & C36 = 1n0F (2)

C15 & C27 = 1n5F (2)

C41 = 4n7F (1)

Film C14 = 10nF (1)

Capacitors C9 = 100nF (1)

and Relay C10 = 330nF (1)

RL1 = 24 Volt DPCO relay (1)
 Not orientations of positive terminals
Electrolytic C19, C21, C23, C25, C31, C33, C35, C37, C40 & C50 = 22uF / 63v (10)
differ
Capacitors
C22, C34, C43, C44 & C45 = 100uF / 25v (5)

C26, C38 & C49 = 470uF / 16v (3) C42 = Omit (nothing fitted) (1)
Trimmers and Molex R58 & R70 = 5k0 (2) - Side adjust style

Molex KK Series - 8 way (1) Tab towards output transformer

Headers J4 = 10 Way Box Header (1)
Fit a jumper between pins 3 & 4 of header J4 as shown
PL 28 = 2 Pin header (1)

Do NOT fit a jumper to PL28

Small Signal Transistors
Q2, Q3, Q4, Q5, Q6, Q7, Q8, Q9 & Q10 = BC550C (9)
(NOTE ORIENTATIONS)
Pot and 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
SW1 = GR-03-001 (1) - 12 position, 1 pole, 3 gang allow to cool before continuing.
R73 = 2 gang 10kA (1)

Make sure that the toggle switches are

seated perfectly so that they are
perpendicular to the PCB before soldering
the rest of the pins.
Fit pin headers to PCBs 1 x 8-way & 1 x 10-way (Switch PCB) Assembly Tip:
1 x 4-way & 1 x 2-way (Trim Pot PCB) Use a jumper (like that fitted
to J4) to hold the header in
1 x 4-way (Surge Control PCB) place... solder a couple of
pins... remove the jumper..
2 x 4-way (Gain stage 3 PCB) trim the pins... then solder
the rest.
1 x 4-way & 1 x 3-way (Gain stage 1 & 2 PCBs)

Long pin goes through PCB Cut off excess pin and solder

10 way 8 way

2 way 4 way 10 way 8 way

4 way 3 way 4 way 3 way 4 way 4 way 4 way

 Transistor and Regulator HS1 = Heatsink TIP3055
Q1 = TIP3055 Transistor (1) MC8708
U1 = MC7808 Regulator (1)
+ TO247 insulator + TO220 insulator
+ heathink insulator PCB
(bush not required) (with bush)

Check Vertical
Solder fully
Insert heatsink through Tack in place first then check
insulator PCB Heatsink Insulator they are vertical before
then into main PCB PCB soldering completely. Tack in place.

2 3 4
1

5
Front Install the TIP3055 on the left side of the
View heatsink in position Q1, and the 7808
on the right side of the heatsink in position U1,
(with their rear sides towards the heatsink)
with a TO247 insulator behind the TIP3055 TIP3055
M3
device and a TO220 insulator behind and a
Nyloc.
bush in front of the 7808. Secure in place with M3 x 12mm
an M3 x 12mm screw and Nyloc nut. 4 6
Trim legs and then solder in place.
TIP3055
The TO220 insulator may be trimmed to fit MC7808
TO247
better.
Insulator
TO220
Insulator
+ Bush
 AML “Spanner” logo
Transformer silk screen on this side
Solder the right angle pin headers
print on this side
to the circuit boards - the longer pin
goes through the PCB - trim off the
Input Transformer Input Transformer
excess pin (PL8 is 8-way, PL6 is PCB 1 PCB 2

10-way)

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)

Fit the transformer (VTB9045) to the 2

PCB’s as shown in the daigram.

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

Longer steel screws
Original brass screws

Fit the assembly into the main PCB

and then tighten up the screws - Tighten up all the screws
but not too tightly !!
Input Transformer Assembly and Fitting (VTB9045)

Remove the assembly again and then

solder the transformer to its PCB

Solder the assembly

to the main PCB
Switch PCB Fitting Assembly Tip:

Solder only a couple of pins

Insert switch PCB until you have fitted the trim
into main PCB pot PCB (next page)... just in
90 case it needs a little nudge
ensuring that it is
to get them alligned.
perpendicular and
solder in place.
Trim Pot PCB Fitting Assembly Tip:

The bush of the pot slots

Insert Trim Pot PCB into the top of the switch
into main PCB PCB
90
ensuring that it is
perpendicular and
solder in place.

After Soldering the trim pot PCB to

the main PCB, fit the pot nut
until it JUST TOUCHES the front of
the switch pcb, the apply solder
to each side of the switch PCB
where it meets the trim pot PCB

Solder here

Nut
Amplifiers and surge Assembly Tip:
Gain stage 1 & 2 are identical
control PCB Fitting however they have different
Insert the amplifiers component idents.
and surge control PCBs
90 PL18 & PL19 are on Gain Stage 1
into main PCB
PL20 & PL21 are on Gain Stage 2
ensuring that it is
perpendicular and
solder in place.
Large C2, C3, C4, C6 & C7= 1000uF / 35v (5) All positive terminals towards left

Electrolytic
Capacitors
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.

[Discard the nut and shakeproof washer].

**** Make sure the spindle is in the position shown before fitting pins ****

[0 clicks up from factory setting]

Flat
is at
this
angl
e

Fit pin at
“12 O’clock”
position
 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

Solder Side.
gn front edge of LED base...

.....with edge of PCB

Chassis Assembly

1] Remove the protective plastic coating from the chassis.

2] Secure faceplate to chassis with 2 x M3 Nyloc Nuts

2 x M3 Nyloc nut

Secure PCB to chassis with 5 x M3x8 Sems screws

s sis
ha
on to c
PCB
Install

3
4
Rotary switch / knob

Install the knob

Install the ring nut for the rotary switch. in the “10dB" position.

[The shakeproof washer is not required]. (Tighten the 2 screws using a small screwdriver - do not over-tighten)

ez1073-pre ez1073-pre

20 25 30 20 25 30
15 35 15 35
10 40 10 40
65 45 65 45
60 55 50 Rotate the switch shaft 60 55 50
fully counter-clockwise...

48v 48v

300 300
1200 1200

AML-UK AML-UK
 Output Transformer Assembly and Fitting

VERY IMPORTANT:
T2 = VTB2569 (1)
Assembly Tip:
Do NOT tighten the screws very tight... It is usually easier to plug in
use a thread locking adhesive applied to the molex connector before
screwing the transformer in
the end of the screw. place

Overtightening will alter the air gap... that would

not be good !

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].
Gently screw the output transformer to the chassis using 2 x M3 x 28mm screws
and 2 x M3 x 30mm screws and 4 x M3 shakeproof washers. Do not overtighten the screws.
Ideally, apply some LocTite thread adhesive to the screws (if available).

M3 x 30mm screw M3 x 28mm screw

at front 2 holes at rear 2 holes

M3 shakeproof washer
Brown Brown

Violet Violet

Red

Red Green
AML-07-128 (rev 2)

Green Blue

Orange
Blue Black

Orange Yellow

Black
Yellow

M3 x 30mm screw M3 x 28mm screw

at front 2 holes at rear 2 holes
ez1073pre Calibration / Setup

1 ] Before powering up the module, turn the “Bias Adjust” trimmer R58 fully counter-clockwise (about 10 turns)

2 ] Power up module, measure the DC voltage between bias test points TP1 & TP2
[It should typically measure about 40-50 mV (after relay clicks)]

3 ] Slowly turn the “Bias Adjust” trimmer R58 clockwise until the DC voltage now measures 90mV

4 ] Apply a signal of -40dBu to the input and then turn front panel gain control up to +60dB

5 ] Ensure that the front panel brass coloured “Trim” control pot is turned fully clockwise

6 ] Measure the output signal, and adjust the “Gain Adjust” trimmer R70 until output measures +20dBu
 48v

AGnd +16v pin 12

Switch PCB Main PCB
API References
Sub +48v +48v pin 15
+48v switched Chassis Ground; Pin 1
Sub +48v switched
+48v LED switched Output HI; Pin 2
SUB +48v LED switched
SUB +16v pin 12 +16v pin 12 Output LO; Pin 4
LoZ SUB +16v pin 12 +16v pin 12 Analogue Ground; Pin 5
Sub - Post Pad Hot Post Pad Hot
Sub - Post Pad Cold Post Pad Cold
Sub - Agnd
Input Tx paralleled cold Input Tx paralleled cold Input LO; Pin 8
Sub - Input Tx paralleled hot Input Tx paralleled hot
Input HI; Pin 10

Sub - Agnd Agnd +16v DC; Pin 12

+48v DC; Pin 15 PSU Common; Pin 13
Sub - Post Phase Hot Post Phase Hot
Sub - Post Phase Cold -16v DC; Pin 14
Post Phase Cold +48v DC; Pin 15
Sub - Agnd Agnd
Sub - Agnd Agnd
Sub - Blue Blue TP1 TP2
Sub - Violet Violet V Ref Pos
0
Sub - Agnd Agnd
0 Switch PCB Main PCB
Input Hi - Pin 10

+16v DC
Pin 12

Input Lo - Pin 8
0 V Stage 3 + V Stage 2 + V Stage 1 +
0
Analogue Ground
Increasing Gain Pin 5

PSU Common AGnd AGnd

Pin 13
Chassis
Analogue
Ground
Ground
Gain Stage 1 Input Chassis Ground
Pin 1
Gain Stage 1 Output

-16v DC
Pin 14

V Ref Neg

Input Transformer Sub Assembly VTB9045

with mechanical support PCB

Phase

VTB2569 Output Hi - Pin 2

Yellow Blue

Orange Green

Red Black
Output Lo - Pin 4

Gain Stage 2 Boost

Gain Stage 2 Input

Increasing Gain Increasing Gain

Gain Stage 1 Input

Brown Violet
V Ref Neg
Gain Stage 1 Output
V Stage 1 +

V Stage 3 +
V Stage 2 +
Agnd

Chassis
Ground
Agnd
Agnd

Gain Stage 1 Boost Gain Stage 2 Output

V Ref Neg
Surge Control Sub Assembly
V Ref Pos

Gain Stage Sub Assembly Gain Stage Sub Assembly

Agnd V Ref Neg

Output Stage Sub Assembly

Agnd
V Ref Neg

Audio Maintenance Limited

E-Mail: service@audiomaintenance.com
Title
ez1073-pre
Number Rev
AML-07-120 3
Date 9th Nov. 2017 Drawn by C Adshead
File AML-07-120 - rev3 Sheet 1 of 1
 Bias Test (ez1073-pre)
AML-07-120 (Rev 3)
Output Stage Sub Assembly
Surge Control Sub Assembly

VTB9045

This side up
Molex 1
Yellow 1
Black
Orange
CUTOUT
VTB2569

Blue
Green
Red
Violet
Brown 8
Gain Stage 2 Sub Assembly
Gain Stage 1 Sub Assembly
Serial No:
48v

Gain Adjust
11 10 9 8 7
LoZ
Transformer fitted
on this side
2 3 4 5 6
Bias Adjust
O/P Phase
Regulator Resistor 0.25W 3k3 R11-12, R18
7808 U1 Resistor 0.25W 2k7 R13-14
Resistor 0.25W 1k8 R16, R40, R53
Capacitors Resistor 0.25W 2k0 R17, R60
Resistor 0.25W 82R R19
Cap Plate 0.1 Pitch 180pF C1 Resistor 0.25W 100R R20, R22
Cap Pol 0.2 (12.5mm Daimeter) 1000uF/35v C2-4, C6-7 Resistor 0.25W 5R6 R21
Cap Plate 0.1 Pitch 100nF C5, C8, C16, C20, C30, C32, C47-48 Resistor 0.25W 10R R23
Cap Wima 0.2 Pitch (0.3 x 0.1) 100n C9 Resistor 0.25W 1R0 R24
Cap Wima 0.2 Pitch(0.3 x 0.15) 0u33 C10 Resistor 0.25W 2R2 R25
Cap Plate 0.1 Pitch 47pF C11 Resistor 0.25W 1k5 R26, R35, R48
Cap Plate 0.1 Pitch 220pF C12-13, C39 Resistor 0.25W 620R R27
Cap Wima 0.2 Pitch (0.3 x 0.1) 10nF C14 Resistor 0.25W 10k R28, R36, R49, R68
Cap Wima 0.2 Pitch (0.3 x 0.1) 1n5 C15, C27 Resistor 0.25W 120k R29, R42
Cap Plate 0.1 Pitch 100pF C17, C28 Resistor 0.25W 68k R30, R43, R57
Cap Wima 0.2 Pitch (0.3 x 0.2) 680pF C18, C29 Resistor 0.25W 5k1 R31, R44, R74
Cap Pol 0.1 (6.3mm Daimeter) 22uF/63v C19, C21, C23, C25, C31, C33, C35, Resistor 0.25W 33k R32, R45, R61
C37, C40, C50 Resistor 0.25W 47k R33, R46
Cap Pol 0.1 (6.3mm Daimeter) 100uF/25v C22, C34, C43-45 Resistor 0.25W 470R R34, R47, R65, R69, R71
Cap Wima 0.2 Pitch (0.3 x 0.1) 1n0 C24, C36 Resistor 0.25W 15k R37, R50
Cap Pol 0.2 (10mm Daimeter) 470uF/16v C26, C38, C49 Resistor 0.25W 2k2 R38, R51, R56
Cap Wima 0.2 Pitch (0.3 x 0.1) 4n7 C41 Resistor 0.25W 390R R39, R52
Cap Pol 0.1 (6.3mm Daimeter) omit C42 Resistor 0.25W 51k R41, R54
Cap Plate 0.1 Pitch 330pF C46 Resistor 0.25W 56k R55, R66
Trimmer - Vert - dual layout 4k7 R58, R70
Diodes Resistor 0.25W 1k2 R59
LED - L144 D1 Resistor 0.25W omit R62
1N4001 D2-5 Resistor 1W 47R/1Watt - Omit R64
Resistor 1W 47R/3Watt R67
Connectors Resistor 0.25W 39k R72
Header - 10 Way J4 POT Sfernice P9A 2 Gang 10k Lin R73
Jumper - 2 Pin SIL PL1, PL25
Jumper - 10 Pin SIL PL2, PL6, PL13, PL17 Transistors
Jumper - 8 Pin SIL PL3, PL7, PL15-16 TIP3055 Q1
Jumper - 4 Pin SIL PL4-5, PL9, PL11-12, PL14, PL18, PL20, PL22-24, PL27 BC550C Q2-10
Jumper - 3 Pin SIL PL8, PL10, PL19, PL21
Jumper - 2 Pin PL28 Others
EMI Filter - Murata 1K CL1-2
Resistors Ferrite Bead F1-2
Resistor 0.25W 1k0 R1 Heatsink - TO247 HS1
Resistor 0.25W 3k9 R2, R15 Relay 2 Pole Changeover RL1
Resistor 0.25W 4k3 R3 Switch - Grayhill 71 12W1P3G SW1
Resistor 0.25W 6k8 0.1% R4-5 Switch - C&K SubMin DPDT on-on SW2-4
Resistor 0.25W 18k R6, R63 Solder Switch SW6
Resistor 0.25W 12k R7 Transformer - VTB9045 T1
Resistor 0.25W 510R R8 Transformer - VTB2569 T2
Resistor 0.25W 330R R9
Resistor 0.25W 120R R10