Caledonian Audio Phono Classique Assembly Manual
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Caledonian Audio Phono Classique Assembly Manual

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Assembly Manual
Phono Classique
Version 1.0
Caledonian Audio

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Summary of Contents for Caledonian Audio Phono Classique

  • Page 1 Assembly Manual Phono Classique Version 1.0 Caledonian Audio...
  • Page 2 Version History Version Date Changes 1.0_draft 3 August 2020 Initial creation 18 October 2020 Reviewed and corrected.
  • Page 3 400V. So, please treat any 6.3V or 12V terminals with extreme care. Caledonian Audio will not be held responsible to any incident caused directly or indirectly by any work or product mentioned in this manual.

  • Page 4: Table Of Contents

    Table of contents Introduction ....................7 Scope of this document ..............7 Assumptions ..................7 Tools / parts needed: ................. 7 Assembly Instructions ............... 8 Disclaimer ..................8 PCBs Preparation ..................9 Integrated Power Supply PCB ............10 2.1.1 Resistors .................. 11 2.1.2 Capacitors ................
  • Page 5 Caledonian Audio Phono Classique Assembly Manual Integrated Power Supply PCB Components ........43 Wiring Diagram – UK / Europe (230VAC) ........45 Wiring Diagram – US (115VAC) ............46 VII. Schematics - Phono Amp Circuit ............. 47 VIII. Schematics – Power Supply Circuit ..........48 Figure 1 Integrated power supply PCB ............
  • Page 6 Figure 32 - Audio level cables and star earth ..........36...

  • Page 7: Introduction

    1.2 Assumptions 1. Only parts and devices, which are part of this kit, are used in the build. Caledonian Audio will not support usage of any other parts or components other than supplied and mentioned by us in this document 2.

  • Page 8: Assembly Instructions

    1.4 Assembly Instructions The general assembly plan is as follows: 1. Prepare all PCBs (Power supply and phono amplifier board) 2. Mount 2 power transformers onto mounting board 3. Mount all connectors (power and audio) 4. Install power cables 5. Install hookup cables Components and devices shown in this manual might be slightly different compared to ones included in the kit.

  • Page 9: Pcbs Preparation

    Caledonian Audio Phono Classique Assembly Manual 2 PCBs Preparation It would be advisable that you line up all supplied components in front of you to make sure that you know what they are. Refer to the supplied part list. All your electronic components should have a label either on the packaging or on the part itself.

  • Page 10: Integrated Power Supply Pcb

    Familiarize yourself with the schematics and the wiring diagram. Understanding the circuit will help you to build this phono amplifier with confidence and minimize risks of getting it wrong. Study the wiring diagram and maybe try to visualize how your build before actually doing it.

  • Page 11: Resistors

    Caledonian Audio Phono Classique Assembly Manual Figure 1 - Integrated power supply PCB 2.1.1 Resistors Start with placing and soldering all resistors on the board. Figure 2 Resistors on the power supply PCB displays all resistors and their purposes. Resistor Purpose Note R1, R2, Dropper Place and solder them standing up (vertically).

  • Page 12: Capacitors

    R7 is there to enable you to lower the voltage (if necessary) before it gets into the voltage regulator. If you find that the later stage that the voltage going into the regulator is too high (perhaps due to local fluctuation of AC voltage coming into your property) and the regulator is doing too much of work ramping it down to 12VDC, then you can ease the work of the regulator a little bit...

  • Page 13: 12Vdc Voltage Regulator And Heatsink

    Caledonian Audio Phono Classique Assembly Manual Figure 3 Power supply PCB with resistors, capacitors and diodes installed. 2.1.4 12VDC Voltage Regulator and Heatsink Please take extra precaution on this section as a mistake at this stage can be expensive as it might not be reversible. We have three important parts: 1.

  • Page 14: Common Mode Choke - Emi Filter

    Double check and make sure that the regulator feet are still placed correctly. Once you are happy with everything, you can then solder the legs of the voltage regulator. Additionally, you can also solder the two pins of the heatsink onto the PCB.
  • Page 15 Caledonian Audio Phono Classique Assembly Manual Figure 6 - Power supply PCB with heatsink attached to the voltage regulator Figure 7 - Another view of the completed power supply PCB...

  • Page 16: Phono Preamp Pcb

    You have now successfully completed the power supply PCB. 2.2 Phono preamp PCB The phono PCB is the main part of the audio amplification system. It handles both left and right audio channel. The PCB has been designed in such a way that that all components (apart from the valve holders) can be mounted in either side of the board.

  • Page 17: Soldering Resistors

    Caledonian Audio Phono Classique Assembly Manual Figure 8 - Phono amp PCB with valve sockets installed. Note that valve sockets might differ to the ones supplied in your kit 2.2.2 Soldering Resistors Now turn the PCB to side A. All components will be mounted from this side. Place and solder all resistors.

  • Page 18: Soldering Capacitors

    Figure 9 - Phono amp PCB with all resistors installed 2.2.3 Soldering Capacitors Place and solder all capacitors. It is a good practice to start off with the smallest of the components and move on to the larger ones. As usual, please observe the polarities of the electrolytic capacitors: •...

  • Page 19: Mounting Parts On The Mounting Plate

    Caledonian Audio Phono Classique Assembly Manual Figure 10 - Phono amp with capacitors installed You should now have a complete phono amp PCB. 3 Mounting Parts on The Mounting Plate Now that we have prepared the PCBs, we can start mounting all other parts onto the mounting plate.
  • Page 20 We will be mounting all the parts from the bottom side of the mounting plate. So, place the plate with the bottom part on the top as shown in Figure 11 - mounting plate - bottom view and Figure 12 - Placement of all parts and PCBs on the mounting plate –...

  • Page 21: Iec Power Socket

    Caledonian Audio Phono Classique Assembly Manual Figure 12 - Placement of all parts and PCBs on the mounting plate 3.1 IEC Power Socket By using a pair of countersunk M3 screw [Fix-8] and M3 Hex nut [Fix-9] secure the IEC power socket [IEC-1] onto the plate as shown in Figure 13 - IEC socket mounted and Figure 14 - IEC socket mounted - front view - note the orientation.
  • Page 22 Figure 13 - IEC socket mounted Figure 14 - IEC socket mounted - front view - note the orientation...

  • Page 23: Rca Connectors

    Caledonian Audio Phono Classique Assembly Manual 3.2 RCA Connectors Mount the four RCA connectors. The orientations of the connectors do not matter too much. Just bear in mind that there will be two connectors for audio input (from turntable), and two for audio output (going to line level amplifier). See Figure 15 as an example.

  • Page 24: Pcbs

    Figure 16 - Main power switch secured to the mounting plate 3.4 PCBs There are only two PCBs that we will be mounting onto the plate. The PCBs will be mounted using M3 steel hex standoff [FIX-4] and two sets of screws [FIX-2] and [FIX-6].

  • Page 25: Transformers

    Caledonian Audio Phono Classique Assembly Manual Figure 18 - The orientations of the PCBs 3.5 Transformers There are two power transformers included in the kit. One for supplying power to the valve heaters (marked as Transformer 1 in Figure 12) and the other one for powering the amplifier board (marked as Transformer 2 in Figure 12).
  • Page 26 Figure 19 - Transformers mounted onto the plate Figure 20 - Heater transformer...

  • Page 27: Ground Lift (Isolator) Circuit (Not Included)

    Caledonian Audio Phono Classique Assembly Manual Figure 21 - Main transformer 3.6 Ground Lift (Isolator) Circuit (Not Included) Some extra space (see the dotted area in Figure 12) and a drill hole have been prepared to accommodate a simple ground lift circuit. The space is large enough to secure a 35A bridge rectifier, a capacitor and a 5W resistor.

  • Page 28: Wiring / Connecting Cables

    4 Wiring / Connecting Cables Before we start the wiring, it would be a good idea to study the wiring diagram and the schematics. See Appendix V (UK wiring) or Appendix VI (US wiring) and the schematics on Appendix VII and VIII. The wiring can generally be divided into two sections: power (high voltages) and audio level.

  • Page 29: Main Switch To Transformers

    Caledonian Audio Phono Classique Assembly Manual Figure 23 - Power cables connecting the live and neutral terminals on the IEC socket to the main power switch 4.1.3 Main Switch to Transformers We will now connect the output from the power switch to the primary winding terminals on both of the transformers.
  • Page 30 Figure 24 - Two pairs of cables connecting the output from the power switch, to the two transformers...
  • Page 31 Caledonian Audio Phono Classique Assembly Manual Figure 25 - Primary windings of Transformer 2 connected to the mains AC voltage from the switch. Please note the wiring for 230VAC system. Figure 26 - Primary windings of Transformer 1 connected to the mains AC voltage from the switch...

  • Page 32: Transformer 1 To Heater Power Supply

    4.1.4 Transformer 1 To Heater Power Supply We will now connect the secondary winding of Transformer 1 to the heater supply section of the integrated power supply board. Please pay attention on the terminals of the secondary winding on the transformer.

  • Page 33: Power Supply Board Gnd Connection

    Caledonian Audio Phono Classique Assembly Manual 4.1.7 Power Supply Board GND Connection Connect a cable from J11 (on the power supply board) to the star earth. Please use the crimp ring terminal [FIX-10] for the connection at the star earth. 4.1.8 Heater Tap Jumper Connection Place a jumper cable to connect J3 and J10 on the integrated power supply PCB.

  • Page 34: Audio Cables

    Figure 29 - Powering the valve heaters from the integrated power supply PCB Figure 30 - Valve heaters connected in parallel to the power supply PCB We have now completed the wiring for the power cables. 4.2 Audio Cables There is very little audio cable wiring involved in this stage. However please follow the exact wiring suggested in this document to avoid hum/noise.

  • Page 35: Left Audio In

    Caledonian Audio Phono Classique Assembly Manual screened cables if possible and remember to only connect the screen wire only on one end and not both. It would be a good idea to study the wiring diagram and Figure 31. Please pay a proper attention at the audio in and out section especially the ground level cables as they might not be as you would have expected.

  • Page 36: Right Audio Out

    So, connect a single cable (can be a screened cable as well) from the RCA connector (positive terminal) to J7 on the preamp PCB. The negative terminals on the RCA connectors (left out and right out) can be connected together at the connectors and run a single cable from here to start earth point.

  • Page 37: Powering Up For The First Time

    Caledonian Audio Phono Classique Assembly Manual 1. To chassis safety earth ground point 2. To the Integrated PSU PCB 0V point 3. To phono preamp PCB 0V point (labelled T/T GND) 4. To left and right audio RCA connector negative terminals You should now have something like Figure 32. 5 Powering Up for The First Time There are a number of items that you have to prepare/gather before powering up the amplifier for the first time.
  • Page 38 Perform a complete voltage reading verification by comparing the voltages stated in the schematic diagram. Please allow margin of 10% on the reading, due to the fluctuations of the main AC supply and the electronic components. Pay particular attention to the B+ and heater voltages.

  • Page 39: Questions / Support

    Caledonian Audio Phono Classique Assembly Manual Questions / Support If you have any question, please get in touch with us at: sales@caledonianaudio.co.uk...

  • Page 40: Appendix

    7 Appendix I. Screws / Nuts / Bolts Sizes The exact fittings/screws/bolts will depend on the kit which you have purchased. Table below summarizes the sizes of the fixings used for all parts (use it as a reference). Part Fixings •...
  • Page 41 Caledonian Audio Phono Classique Assembly Manual • Speaker binding post [T-1] Star ground point • RS PRO Uninsulated Tin-Plated Crimp Ring Terminal, M4 Stud Size, 0.5mm² to 1.5mm², 22AWG to 16AWG [FIX-10] • No extra parts needed. Audio input terminals (RCA/Phono) [T-...

  • Page 42: Index Of All Fixings Used In A Kit

    II. Index of All Fixings Used In A Kit Label Specification FIX-1 Slot Pan Head Machine Screw Brass Nickel Plated, M4, 12mm FIX-2 Slot Pan Head Machine Screw Brass Nickel Plated, M3, 6mm FIX-3 RS PRO, M4, Bright Zinc Plated Steel Nylon Insert Lock Nut FIX-4 RS PRO Steel Hex Standoff Female/Female, 20mm, M3 x M3 FIX-5...
  • Page 43 Caledonian Audio Phono Classique Assembly Manual R7, R8 RS PRO 0932 Wire Lead Metal Film Fixed Resistor 2kΩ ±0.5% 1W ±25% R9, R13 RS PRO 0932 Wire Lead Metal Film Fixed Resistor 1MΩ ±0.5% 1W ±25% R10, R11 RS PRO 200kΩ 1W Metal Film Resistor ±0.5% ±25% TE Connectivity HOLCO Series Axial Metal Film Fixed Resistor 36.5kΩ...
  • Page 44 RS PRO 100kΩ 1W Metal Film Resistor ±0.5% ±25% RS PRO 220kΩ 1W Metal Film Resistor ±0.5% ±25% Heater Supply Components: 2 x 5 mH Wurth Elektronik WE-CMB Common Mode Choke 95 mΩ C7, C8, C9 Nichicon 6800μF 25V dc Aluminium Electrolytic Capacitor, Through Hole 16 (Dia.) x 35.5mm +105°C 16mm 7.5mm Vishay 100nF Multilayer Ceramic Capacitor MLCC 50V dc ±10% Through Hole K104K10X7RF53L2 C11, C12...
  • Page 45 Caledonian Audio Phono Classique Assembly Manual V. Wiring Diagram – UK / Europe (230VAC)
  • Page 46 VI. Wiring Diagram – US (115VAC)
  • Page 47 Caledonian Audio Phono Classique Assembly Manual VII. Schematics - Phono Amp Circuit...
  • Page 48 VIII. Schematics – Power Supply Circuit...

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