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AML ez1081pre Assembly Manual

500 series class a/b
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ez1081pre Mic Amplifier - Assembly manual
["Colourbook" Issue 1]

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Summary of Contents for AML ez1081pre

  • Page 1 Mic Amplifier - Assembly manual [“Colourbook” Issue 1]...
  • Page 2 “Colourbook” Contents. Section 1 - “Colourbook” assembly guide Section 2 - Setup and Calibration Section 3 - Schematics diagrams and PCB Overlays Section 4 - Parts List...
  • Page 3 “Colourbook” revision history Revision 1 - initial release...
  • Page 4 PCB Preparation Carefully snap apart the 5 PCB’s into individual boards and trim or file off any excess tabs. Input Transformer Input Transformer PCB 2 PCB 1 Switch PCB Heatsink Insulator PCB (Not used on PCB Rev 2) Main PCB...
  • Page 5 Diodes D2, D3, D7 & D8 = 1N4148 D5, D9, D10 & D11 = 1N4007 D4 & D6 = BAT46...
  • Page 6 Resistors R61 = 1R0 R59 & R60 = 1R5 R62 = 2R2 R50 & R58 = 10R...
  • Page 7 Resistors R33 = 47R R7 = 82R R6 & R24 = 100R R10, R35, R53 & R65 = 150R...
  • Page 8 Resistors R11 = 300R R46, R49 & R54 = 470R R12, R34, R37, R39, R41, R52 & R55 = 560R R63 = 750R...
  • Page 9 Resistors R8 = 1k1 R1 = 1k2 R13 = 1k3 R2 & R3 = 1k5...
  • Page 10 Resistors R9 = 2k0 R38 & R42 = 2k2 R17 = 2k4 R22 & R29 = 2K7...
  • Page 11 Resistors R44 = 3k9 R16 = 4k3 R26 = 5k1 R15, R21 & R23 = 7k5...
  • Page 12 Resistors R25, R40, R47, R57 & R64 = 10k R18 = 12k R14 = 13k R43 & R45 = 15k...
  • Page 13 Resistors R32 = 18k R19 = 22k R30 = 36k...
  • Page 14 Resistors R20, R27, R31, R36 & R56 = 47k R48 = 56k R4 & R5 = 6k81 / 0.1%...
  • Page 15 Ceramic C8 & C29 = 47pF Capacitors C27 = 68pF C7 & C13 = 100pF...

  • Page 16: Ceramic Capacitors

    Ceramic C16, C30 & C31 = 220pF Capacitors C23 & C28 = 100nF CL1 & CL2 = 100pF 3 Terminal L/C Network F1 & F2 = Ferrite Bead...
  • Page 17 Film C15 = 470pF Capacitors C1 = 1n2F C32 = 4n7F...
  • Page 18 Film C14 & C21 = 10nF Capacitors C25 = 100nF and Relay C26 = 330nF RL1 = 24 Volt DPCO relay...
  • Page 19 Electrolytic All positive terminals towards left C2 & C9= 10uF / 50v Capacitors C3, C10 & C19= 22uF / 63v C11, C12 & C17= 220uF / 25v...
  • Page 20 ZTX690B Trimmers, Molex and Q9 = ZTX690B Flat Side Small Signal Transistor (“flat side” towards the Lower edge Molex KK Series - 8 way Tab towards output transformer of the PCB) R28 & R51 = 5k0 (2) - Top adjust style...
  • Page 21 Small Signal Transistors Q2, Q3, Q6, Q7, Q10 & Q12 = BC550C (“flat side” towards the Left Hand edge of the PCB) Q1, Q8 & Q11 = BC560C...
  • Page 22 Front Rear Power Transistors (Part 1) View View Q5 = BD139 Install the BD139 with it’s rear side facing towards the top of the PCB Q4 = 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...
  • Page 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...
  • Page 24 Switches Important: The toggle switches are SW2, SW3, SW4 = 2 Position DPDT (on-on) surprisingly sensitive to heat... solder one pin on each switch and then allow to cool before continuing. SW = GR-03-004 (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...

  • Page 25: Voltage Regulator

    Voltage Regulator U1 = 7808 voltage regulator M3 Nyloc nut Insulating bush Insulating washer/sheet M3 Nylon Washer M3x12 screw...
  • Page 26 Large All positive terminals towards left C6, C22 & C24= 470uF / 35v Electrolytic Capacitors C4, C5, C18 & C20= 1000uF / 35v...
  • Page 27 Power Transistors (Part 2) Q13 = BD139 Transistor Q14 = BD140 Transistor HS1 = Heatsink + TO220 insulator + TO220 insulator + 2 x M3 plain washers (bush not required) (bush not required) Check Vertical Solder fully Insert heatsink through Tack in place first then check M3 washers and M3 plain washers...
  • Page 28 Input Transformer Assembly and Fitting Original brass screws Longer steel screws...
  • Page 29 Switch PCB Fitting Insert switch PCB into main PCB ensuring that it is perpendicular and solder in place.
  • Page 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] Fit pin at “12 O’clock”...
  • Page 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 gn front edge of LED base..with edge of PCB...

  • Page 32: Chassis Assembly

    Chassis Assembly 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...
  • Page 33 Install the nut for the rotary switch. (Tighten using a 1/16 inch hex key) [The shakeproof washer is not required]. ez1081-pre ez1081-pre AM16-500 AM16-500 25 30 35 25 30 35 Rotate the switch shaft fully counter-clockwise... 1200 1200 AML-UK AML-UK AML - UK AML - UK...
  • Page 34 Output Transformer Assembly and Fitting T2 = VTB2568 (1) Screw the output transformer to the chassis using 4 x M3 x 28mm screws Plug the output transformer molex connector into molex on the PCB and 4 x M3 shakeproof washers. Do not overtighten the screws. Ideally, apply some LocTite thread adhesive to the screws (if available).
  • Page 35 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 50-60 mV]...
  • Page 36 Ground Ground VTB9045 Input Transformer Sub Assembly with mechanical support PCB Audio Maintenance Limited E-Mail: service@audiomaintenance.com Title ez1081-500 (Main) Number AML-07-119 Chassis 8th Aug. 2017 Date Drawn by C Adshead Ground File AML-07-119 - rev 2 Sheet 1 of 4...
  • Page 37 VFloatNeg VFloatNeg BA340 Output Amp Audio Maintenance Limited E-Mail: service@audiomaintenance.com BA338 High Gain Amp Title ez1081-500 (Amplifiers) Number AML-07-119 8th Aug. 2017 Date Drawn by C Adshead File AML-07-119 - rev 2 Sheet 2 of 4...
  • Page 38 Mic Gain Signal Out Mic Gain FB Return AGnd Mic Gain FB Send Audio Maintenance Limited E-Mail: service@audiomaintenance.com Title ez1081-500 (Gain Control) Number AML-07-119 8th Aug. 2017 Date Drawn by C Adshead File AML-07-119 - rev 2 Sheet 3 of 4...
  • Page 39 *R65 = 10R if surge control omitted R65 = 150R if surge control fitted Audio Maintenance Limited E-Mail: service@audiomaintenance.com Title ez1081-500 (Power) Number AML-07-119 8th Aug. 2017 Date Drawn by C Adshead File AML-07-119 - rev 2 Sheet 4 of 4...
  • Page 40 Bias Test Brown Violet Green Blue Orange Black Yellow This side up VTB2568 Bias Trim AML-07-119 (Rev 2) (ez1081-500 preamp)
  • Page 43 IC Component; Resistor 0.25W 7808 U1 Resistor 0.25W R20, R27, R31, R36, R56 Resistor 0.25W R22, R29 Capacitors; Resistor 0.25W R25, R40, R47, R57, R64 Cap Wima 0.2 Pitch (0.3 x 0.1) Resistor 0.25W Cap Pol 0.08 (5mm Daimeter) 10uF/50v C2, C9 Trimmer - Vert - dual layout 5K R28, R51...