HIGH-END MONO MOSFET

POWER AMPLIFIER
Total solder points: 299
Difficulty level: beginner 1 2 3 4 5 ⌧ advanced

K8040
ILLUSTRATED ASSEMBLY MANUAL H8040IP-2
Features & specifications

Features :
no compromise high-end design
ideal to place next to the speaker (short wires to the speaker)
auto-power on possibility when input signal is sensed
auto-standby function when no input signal is sensed
exclusive, high finish, solid aluminium enclosure
high quality D-MOS IC output stage
total of 40.000µF power supply capacitors
relay-less speaker DC protection
Real Clipping distortion indication
power output level indication with backlight
bypass output to drive bi-wired speakers using separate amplifiers
double overheating protection with LED indication
high grade speaker and input connections
overload protection

Specifications
input:
• input sensitivity for maximum output:............. 0dBm (= 0.775Vrms)
• input impedance:................................................................ 15Kohm
• minimum auto switch on voltage:....................................... 5mVrms

output:
• maximum RMS output power 4ohm:........................................ 90W
• maximum RMS output power 8ohm:........................................ 70W
• dynamic RMS output power in 4ohm: .................................... 125W
• minimum load impedance: .................................................... 4 ohm
• damping factor (ref. 8ohm 100Hz): ...................................... > 1000

audio:
• signal-to-noise ratio (A-weighted ref. max. out): ................. >105dB
• total harmonic distortion: ............................0.003% @ 1kHz ref 1W
• frequency response:......................... 9Hz to 120kHz (-3dB) in 50W

power requirements:
• AC power: ....... 115Vac (110V to 120V) or 230Vac (220V to 240V)
• consumption:................................................................. 100W max.

dimensions: ..................................290 x 165 x 68mm (11.4" x 6.5" x 2.7")

weight (net):........................................................................ 3.4kg (7.5Lbs)

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 suc-
cessful. 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
For some projects, a basic multi-meter is required, or might 00
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

4
 Assembly hints

* 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 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

AXIAL COMPONENTS ARE TAPED IN

THE CORRECT MOUNTING SEQUENCE !

REMOVE THEM FROM THE TAPE ONE AT

A TIME !

5
Construction

CONSTRUCTION
The unit consists of one main PCB with all the components including transformer
and power supply.

Tip: The pictures on the packaging can be used as a guideline.

However, due to possible modifications they are not 100% reliable.
Mount the components in the order described:

1. Jump wire 4. Resistors (check the color code)

J1
J2
J3 R...
J4
J5
J6
J7 R1 : 1K (1 - 0 - 2)
J8 R2 : 1K (1 - 0 - 2)
R3 : 15K (1 - 5 - 3)
2. Diodes (check the polarity) R4 : 1K (1 - 0 - 2)
R5 : 470R (4 - 7 - 1)
D ... R6 : 100R (1 - 0 - 1)
R7 : 15K (1 - 5 - 3)
CATHODE R8 : 15K (1 - 5 - 3)
R9 : 15K (1 - 5 - 3)
R10 : 15K (1 - 5 - 3)
R11 : 470R (4 - 7 - 1)
D1: 1N4148 D5: 1N4148 R12 : 15K (1 - 5 - 3)
D2: 1N4148 D6: 1N4148 R13 : 15K (1 - 5 - 3)
D3: 1N4148 D7: 1N4148 R14 : 100R (1 - 0 - 1)
D4: 1N4148 D8: 1N4148 R15 : 15K (1 - 5 - 3)
R16 : 2K2 0.6W (2 - 2 - 2 - 9)
3. Zener diode (check the polarity) R17 : 100R (1 - 0 - 1)
R18 : 1K (1 - 0 - 2)
ZD... R19 : 470R (4 - 7 - 1)
R20 : 2K2 0.6W (2 - 2 - 2 - 9)
R21 : 1M (1 - 0 - 5)
CATHODE R22 : 470R (4 - 7 - 1)
R23 : 1K (1 - 0 - 2)
R24 : 470K (4 - 7 - 4)
R25 : 470K (4 - 7 - 4)
R26 : 470K (4 - 7 - 4)
ZD1: 20V / 1.3W R27 : 100K (1 - 0 - 4)
(Mount 5mm above the PCB)

6
 construction

R28 : 2K2 0.6W (2 - 2 - 2 - 9) 6. IC sockets. Watch the position

R29 : 2K2 0.6W (2 - 2 - 2 - 9) of the notch!
R30 : 0R
R31 : 15K (1 - 5 - 3) IC1 : 8p
R32 : 100K (1 - 0 - 4) IC2 : 8p
R33 : 100R (1 - 0 - 1) IC3 : 6p
R34 : 0R
R35 : 680R (6 - 8 - 1)
R36 : 15K (1 - 5 - 3) 7. 10W resistor
R37 : 100K (1 - 0 - 4)
R38 : 470R (4 - 7 - 1) R...
R39 : 10R / 1W (1 - 0 - 0)
JGND: 0R
5mm

If long input signal wires are used a low

input impedance can be useful.
In this case mount for RX a 680R (6-8-1)
resistor. R40 : 4R7 (4.7, 4R7)

Check if your pre-amplifier can drive low 8. Capacitors

impedance!
Our K8021 is OK for low impedance.
C9 : 2n2 (222)
Our K8020 is not suited for low
impedance driving. C10 : 220n (224)
C11 : 1uF
Rx is normally left open. C12 : 1uF
C13 : 2.2uF
C14 : 2.2uF
5. Capacitors C15 : 100n / 250V (104)
C16 : 100n / 250V (104)
C1 : 100nF (104) c...
C2 : 100nF (104)
C3 : 100nF (104) 9. Transistors
C4 : 100nF (104)
C5 : 100nF (104)
C6 : 100nF (104) T1: BC547
C7 : 100nF (104) T2: BC547
C8 : 100nF (104)

7
Construction

10. RCA connectors. Mount them 12. Terminal blocks

straight and against the PCB

SK3: 3p "Mains in"

SK4: 3p "Mains transformer"
SK1: MJ-523AG/R
SK2: MJ-523AG/B

Tip:
A red and a black type are delivered
with the kit, if you bought 2 amplifiers
for stereo then one amplifier can be
built with red connectors
(right amp.) and one with the black
connectors. SK5+SK6: 2x 2 pole Transformer
output
11. Push button. Mount them
First slide these two
straight against the PCB surface !
connectors in each other.

13. Terminal connectors

Check that the position

corresponds with the PCB
silk printing.
SW1: TS-04PV

SK7: 2 pole Temp sensor

SK8: 2 pole Power meter

SK9: LS+
SW2: KRS1243 SK10: LS-

8
 construction

14. Coil 16. Voltage regulator. The back

side corresponds to the thick line.

L... VR1 UA7805

VR...

This coil will have to be made by

yourself. Use the supplied copper
wire (1.5mm) with the kit.
Wind this wire round a 8mm drill or 17. Triac. The back side
other round object and make 8 turns. corresponds to the thick line.
You can snip off the remaining copper
Then remove (scratch) the isolation TR1: TIC246 or eq.
from the connections using a knife. TR...
Mount the coil and make sure to have
a perfect soldering.

L1: 8 Turns dia 8mm

18. Bridge rectifier.
Check the polarity !!
15. Electrolytic capacitors.
Check the polarity !

BR1: RS603
C17: 10µF
C18: 10µF C...
C19: 10µF
C20: 10µF
C21: 10µF
C23: 1µF
C24: 10µF 19. LEDs
C25: 47µF/63V
C26: 47µF/63V COLOR= 2...5

C27: 47µF/63V
C28: 47µF/63V
LD...
C29: 220µF/63V
C30: 220µF/63V CATHODE

LD1: LED3RL (3mm LED)

LD2: LED3RL (3mm LED)
LD3: LED3RL (3mm LED)

9
Construction

20. Power electrolytic capacitors. 21. IC’s. Watch the position of the
Check the polarity ! notch !

C31: 10.000µF
C32: 10.000µF
C33: 10.000µF
C34: 10.000µF C...

IC1: VK8040 (PIC12C508)

IC2: CA258 or eq.
IC3: MOC3041 / KP3020

22. Mounting front LED’s. Check the polarity !

Short lead = Cathode or - !

CAUTION:
LD ... After bending the
leads the long
appearing lead will
C ATH O DE
be the cathode!

IMPORTANT
First: Bend the leads exactly like the
Mount these LED’s exactly like in the
drawing. drawing, otherwise some LED’s will
Next: Solder one lead, and check the not fit correctly in the front panel.
position, if necessary correct by Please also use the front panel as a
heating the soldering. positioning reference.
Last: Solder the second connection.

LD4: L-424YDT
LD5: L-424YDT 12m m
LD6: L-424YDT
LD7: L-424YDT
C
7mm

LD...
Meter backlight:
LD8 is a white LED serving as backlight
for the power meter.

LD8: L5WD (5mm white) CATHODE

18mm

3mm

10
 construction

23. Mounting the Power IC

IC4: TDA7293

Mount the support plate onto the IC as shown in the drawing.

Put a drop of silicone compound on both sides of the mica isolator.
Also check the position of the plastic isolator A.

ATTENTION : The bolt should be inserted on the side of the IC holder with the
countersunk opening B ! B
A

Drop of heat conductive

compound

DO NOT TIGHTEN THE NUT YET

1. Position the IC onto the PCB.

2. Make sure that the support plate is touching the PCB surface.
3. Tighten the support nut.
4. Check again that the plate is touching the PCB surface.
5. Solder the IC connections.

11
Construction

24. Mounting the power transformer and mains voltage selection

Mount the transformer as in the drawing (see also the picture on the packaging)
Use the supplied straps (4 pcs) to fix the transformer.

Primary windings (MAINS) connection:

Check the table on the PCB for the correct voltage selection and connect
the wires :
For 230V (220V to 240V), edge orange, then brown and black.
For 115V (110V to 120V), edge brown, then orange and black.

Using a black marker, erase the not used voltage on the rear panel of the
unit!

230V 120V

ORANGE BROWN

BROWN ORANGE

BLACK BLACK

Secondary windings connection:

Connect the Red, Yellow, Blue and Grey wire to the SK5/SK6 connector, check
the colors on the PCB.

12
 Enclosure preparation

25. Enclosure preparation

Cut the thread in the

holes for the enclosure
feet in one of the alu-
minum profiles, using
the supplied special
M4 screw as a tap.
FIG. 1

Mount the feet on the

aluminum profile, using
two M4 hexagonal Allen
screws. Use the supplied
Allen wrench. It is advis-
able to stick the protection
adhesive onto the feet.

FIG. 2

Cut the thread in the front

and back of the aluminum
profiles, using the supplied
special M4 screw (4 holes
per piece)

FIG. 3

13
Enclosure preparation

Position the main PCB in the aluminum profile that is prepared with the feet.

Mark the center position of

the three fixation holes on
the aluminum. A reference
indication is also on the
PCB edge.

FIG. 4

Remove the pcb and use a knife or a screwdriver to scratch the paint from
the aluminum fixation, from the hole closest to the back end. This fixation will
be used later to connect the ground and earth.

FIG. 5

Mount the three 5mm (0.14”) spacers as shown in the drawing. Use three
hexagonal screws and 3 washer. Do not tighten the spacers yet.

FIG. 6

M3 hex. nut
5mm M3 spacer
Washer

Position the PCB in the enclosure and check if the position of the spacers is
correct, if so, remove the PCB and tighten the spacers.

14
 Enclosure preparation

Using an ohmmeter, measure between the edge of the aluminum profile and
the back spacer, if there is a good electric contact (less then 10 ohm).
If not, repeat the above step to remove the paint under the spacer.

0.0
FIG. 7 00

Slide two M3 nuts and two

hexagonal bolts into the profile,
the nuts will be used for the
temperature sensor, the bolts will
be used for the IC support plate:

FIG. 8

Mount the temperature sensor,

check the exact position. Make sure
there is silicone compound between
the sensor and the enclosure! 11
cm
Solder the wires of the supplied two
pole connector onto the sensor.
There is no polarity.

FIG. 9

15
Final assembly

26. final PCB mount

RE-CHECK CAREFULLY THE PCB FOR MOUNTING AND

SOLDERING ERRORS!

Mount the pcb into the enclosure, check the position of the power IC.
The IC support must fit onto the previously inserted hexagonal bolts.
Make sure there is silicone compound between the IC support and the
enclosure!

Glue the included insert C between the transformer and housing.

Make sure the PCB is aligned with the back of the enclosure
IMPORTANT: FIRST fix the IC support
THEN fix the pcb using three 5mm spacers + washer.

DO NOT TIGHTEN THESE FIXATIONS YET.

Note: Not all components are visible on the drawing.

16
 Final assembly

27. Speaker and mains connector assembly

Prepare the wiring of the mains connector like in the drawing.

First mount the switch into the mains connector assembly.
Do not forget to isolate the soldering connections using a piece of shrink tube.

Use the supplied 0.5mm wire:

Blue for Neutral
Brown for Live
Yellow/green for earth

Use 3 pieces of about 10cm for later connection to the PCB mains connector.

Brown
Blue

Yellow/green

Mount the speaker connectors onto the rear panel. (black = negative)
Take care of the isolation washers, there are two different types!
See picture.
Make sure the connectors are very tight fit, and do not make electrical
contact with the panel (check using ohm meter!).

Isolation washer !

17
Final assembly

28. Final assembly and connection

Solder a 15cm (2.5mm) wire to the LS connectors. Black = negative, Red=

positive, use a shrink tube to isolate the connection.
Solder a spade terminal to the other end, do not forget the terminal isolation.

15cm

Mount (insert) the mains connector onto the rear panel. Insert a 2A fuse into
the connector (there is also room for a spare fuse).

18
 Final assembly

Mount the rear panel onto the enclosure, using two M4 Allen screws.

Connect the speaker wires to the speaker output tabs. Check the polatity!
Black= LS-, Red= LS+.

DO NOT CONNECT THE MAINS WIRING WITH THE PCB YET!

!
29. Preparing the front panel

Connect the two wired connector to the meter, RED =

+, BROWN = - to the meter.
Mount the power meter onto the front panel.
Fix the meter using a piece of transparent adhesive
tape (four sides).
Make sure the meter is positioned straight.

Connect the meter to the PCB (SK8)

Mount the front panel onto the front, using two M4
Allen screws.

Check the position of the LED’s and check if the button is working correctly.
It could be that paint covering the holes, is preventing the buttons from
smooth operation.

Now the three PCB fixations can be tightened.

Check the push button.

19
Test

30. Test

21. Mains voltage connection

! Check again all connections of transformer and mains
preparation

Connect the mains wires to the mains connector SK3, Blue= Neutral, green/
yellow= Earth.
Connect a 60W light bulb in series with the Live (Brown wire) and the Live
connection on the PCB. Connect a 10cm blue wire to the
Mount both the fuse and the spare fuse inpoint of SK12.
theNfuse holder.

Connect a 10cm brown wire to the

point L of SK12.

Connect a 10cm yellow/green

wire to the earth point of SK12.

Later these connection will be sol-

dered to the mains connector.

! CAUTION: Some points on the PCB are connected to the

dangerous mains voltage.

Connect the mains AC voltage to the mains. See also the user manual about
the power cord.
Normally after switching ON the amplifier, the light bulb should briefly light up.
If the bulb glows constantly, disconnect the power immediately and
recheck all connections.

• Normally the standby LED on the front panel should light as should both 35V
power indication LED’s LD2 and LD3.

20
 Test

Test continued:

• Now push the DC protection test button SW2,

the bulb should light if the
button is pressed. Be careful not to touch any
exposed live parts.

• Disconnect the mains plug.

• Now the brown Live wire can be connected

directly to the connector SK3.

Check the user manual to test all functions

and operation of the unit. Finally the cover can
be mounted.

Please note that the user manual is also used for

the assembled version, some remarks may not apply to the kit version.

21
22

Schematic diagram
31. Schematic diagram
Mains in from 2A fuse + switch BRIDGE RS603 VR1
TIC246M 10.000uF/50V 10.000uF/50V ZD1 UA7805 +5V
R40
Transfo Prim SK5 Power meter

AC1
I O D7
R37
4.7R / 10W 25VAC / 2A BR1
+35V

GND
SK3 SK4 C3 20V 1.3W C17
TR1 100K SK8
100n C34 C33 C18 C2 1N4148
R17
R22 100R
- + JGND 2
10µ 10µ 100n C23 1
470R 0R 1µ
+35V
C15 -35V

AC2
100n C4 C32 C31 R38
2K2 / 0.6W
100NF/250VAC SW KRS1243 DC prot. test2K2 / 0.6W 470R
R16
25VAC / 2A SK6 10.000uF/50V 10.000uF/50V
SW2 R20

R18 R19 D3
1K 470R 1N4148 +35V R36 15K
C29 C26 R30
SK1

1
C16 IC3 C6 47µ/63V 0R C12
INPUT D4 220µ/63V 100n 1uF
K3020P
1N4148
100NF/250VAC

11

13
8T 1.5mm dia 8mm

2
C30

+VS
D5

+PWVs
1N4148 L1
220µ/63V BUFFER DRIVER
DC Protection (fuse blow) IC4
D6 LS+ SK9
R32 BYPASS 1N4148
100K LS- SK10
SK2 RX
Rload +5V C13 2 IN-
+5V R33
LD4 3 IN+
C8
2u2 100R OUT 14
100n R31
C1 L-424YDT C9 15K
100n OFF / Stby 2n2 4
R1
SGND R39
1K
12
1 Vdd

10R/1W
7 R13 10 BOOT LOADER
GP0 MUTE MUTE
IC1 C27
15K R12
GP1 6 9 STBY STBY BOOTSTRAP 6
PIC12C508A 47µ/63V C10
15K
5 Clip detect
C20
C19 CLIP DET 5
GP2/T0CKl +5V SK7 220nF
4 10µ +5V R35 THERMAL S/C
GP3/MCLR/Vpp Stby / ON 2 10µ
680R SHUTDOWN PROTECTION
3 1 +5V
GP4/OSC2 Auto on backlight
L-424YDT
Temp sens.
LD5
Vss

GP5/OSC1/CLKIN 2 CLIP LED R7

+5V
T1 R8
BC547 15K ON C14 C28

STBY-GND
15K
8

+5V R3 R4 LD8 R9
15K 1K 15K

-PWVs
2u2 47µ/63V
TDA7293V

-VS
HFWA05
C5 LD6
R2
R25 100n L-424YDT R6 1K -35V

15
D1

8
1N4148 R24 Temp error +5V 100R
470K +5V CLIP +5V +35V R34
8
470K

3 IC2B STBY / ON SW1

LD7 LD1 LD2 0R C11
1 6 D8 C7 C25
Stby / ON Clip detect

LED3RL
L-424YDT

T2 1uF
LED3RL

R26 2 7 100n 47µ/63V

D2 IC2A 5
1N4148 R14 BC547
1N4148 LM258
470K

LM258 100R R5 R11 R28

R23 R27 R10 470R 470R 2K2 / 0.6W INTEGRATED MONO MOSFET AMPLIFIER
R21 LD3
1K 100K R15 15K
Auto on R29
10µ 1M C21 15K
C24 10µ 2K2 / 0.6W
K8040 1.0
LED3RL
CLIP LED
Power supply indication

5mV input signal detector for AUTO ON

 PCB

32. PCB

23
 VELLEMAN KIT NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
Info ?: http://www.velleman.be

Modifications and typographical errors reserved

© Velleman Kit nv
H8040IP - 2009 - ED2
5 410329 416775