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AML Colourbook ez1073pre-mk2 Assembly Manual

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ez10
73pre-mk2 Mic/Line/DI
Amplifier - Assembly manual
["Colourbook" Issue 1a]

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Summary of Contents for AML Colourbook ez1073pre-mk2

  • Page 1 ez10 73pre-mk2 Mic/Line/DI Amplifier - Assembly manual [“Colourbook” Issue 1a]...
  • Page 2 ez10 73pre-mk2 “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 ez10 73pre-mk2 “Colourbook” revision history Revision 1 - nitial release Revision 1a - Correction of text on page 37...
  • Page 4 PCB Preparation Main PCB Carefully snap apart the PCB’s into individual boards and trim or file off any excess tabs. Upper PCB Combi PCB Pot Spacer Transformer Spacer Heatsink Spacer...

  • Page 5: Output Termination

    Output Termination Place a “blob” of solder across the two pads (SW ) for 600 Ohm termination...
  • Page 6 Diodes ZD1 & ZD2 Zener Diode - 9v1 - D15 = 1N4007 [Note Orientations Differ !!!!]...
  • Page 7 Resistors 74 & R100 45 & R71 R46 & R54...
  • Page 8 Resistors 70 & R84 R2 = 34, R35, R68 & R73 = 1 0R...
  • Page 9 Resistors 19 & R39 17, R37, R49 & R56...
  • Page 10 Resistors R58 & R93 620R 31, R60, R61 & R85 1k2 1 R16 R38 & R...
  • Page 11 Resistors 6, R20 & R42 1k8 33 & R97 18, R40, R59 & R95 27 & R28...
  • Page 12 Resistors 7, R25, R26 & R87 & R 91 & R94 24, R64 & R67...
  • Page 13 Resistors 12, R41, R47, R48, R50, R51, R53, R55, R69, R77, R78, R79, R80, R83, R96 & R106 4 & R11 29 & R101...
  • Page 14 Resistors & R & R 8, R63, R90 & R92...
  • Page 15 Resistors 44 & R102 R15, R36 & R R86, R88 & R = 1 0k 3 & R9 120k...
  • Page 16 Resistors 65 & R66 6k81 0.1% Omitted...
  • Page 17 Ceramic 36, C45 & C47 = 47pF Capacitors & C = C = 1...
  • Page 18 Ceramic 37, C38, C44, C46, C49, C50 & C57 220p Capacitors 21, C22, C23, C24, C34, C39, C40, C54, C64 & C65 100n (1 ) Omitted...
  • Page 19 , F2, F3, F4, F5 & F = Ferrite Bead omponent CL1 & CL2 = 100pF 3 Terminal L/C Network...
  • Page 20 Film 5 & C11 Capacitors 3 & C20 4 & C10...
  • Page 21 Film Capacitors 100n...
  • Page 22 Film 220n Capacitors 330n Omitted...
  • Page 23 Relays (Top side of PCB) Relays mounted on top side L , RL2, RL3, RL5, RL6, RL7, RL10, RL11 & RL12 = 24 Volt DPCO relay (NOTE ORIENTATIONS DIFFER)
  • Page 24 Electrolytic & C uF / Capacitors C , C , C 14, C15, C17, C32, C41 & C = 22uF / 63v 56, C58, C62 & C = 100uF / 25v 6, C18 & C31 0uF / Positive terminals to the left...
  • Page 25 Trimmers and Molex & R = 5k0 ( ) - Side adjust style Molex KK Series - 8 way Tab towards output transformer...
  • Page 26 Small Signal Transistors 13, Q18 & Q BC557B (NOTE ORIENTATIONS) 1, Q2, Q3, Q4, Q5, Q6, Q7, Q9, Q10, Q11, Q12, Q14, Q15, Q16, Q20 & Q BC550C...
  • Page 27 48v LED installation Bend the legs down at 7mm away from the base 3mm LED Fit the 48V indicator LED to the solder side of the PCB. (1 - Mounted on underside NOTE THE ORIENTATION ut off any excess legs sticking through the component side..
  • Page 28 Headers J = 10 Way Box Header Fit a jumper between pins 3 & 4 of header J as shown J = 20 Way Box Header (1) ** Note orientation **...
  • Page 29 Toggle Switches 7, SW8 & SW9 = 2 Position PDT (on-on) [Horizontal - sub-min CK-03-00 ] [Mounted on underside of PCB] SW , SW 5 & SW = 2 Position PDT (on-on) [Horizontal - sub-min CK-03-00 ] Important: The toggle switches are Make sure that the switches are surprisingly sensitive to heat...
  • Page 30 Relays (Underside of PCB) L4, RL8 & RL9 = 24 Volt DPCO relay Relays mounted on underside (NOTE ORIENTATIONS DIFFER)

  • Page 31: Rotary Switches

    Rotary Switches SW = GR-03-001 (1) - 12 position, 1 pole, 3 gang Make sure that the switch is seated perfectly so that it is perpendicular to the PCB before soldering the rest of the pins.
  • Page 32 Rotary Switch Adjustment Pins 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 correct position shown before fitting pins **** SW3 (gain) is 1...
  • Page 33 Potentiometer 1 Gang 5kA - 249 series Pot Spacer PCB 1 + 10mm Pot Nut (1) After soldering the Pot in place, fit the spacer PCB and 10mm nut onto the pot. Ensure that when it is fitted, the flat of the nut is parallel to the PCB below so that the points of the nut do not dig into the PCB below.
  • Page 34 Large Capacitors and Resistor uF / C27, C28, C29 & C 1000 uF / 47R/5W...
  • Page 35 Transistor and Regulator Q = TIP3055 Transistor U1 = MC7808 Regulator HS1 = Heatsink TIP3055 MC8708 + 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...
  • Page 36 Combi Connector PCB 1x10 way R/A header [Mounted from rear side of PCB] COMBI1 Neutrik NCJ10FI-V-0 Long pin goes through PCB Cut off excess pin and solder 10 way...
  • Page 37 Input Transformer T1 = AML-18-002 (1) - Mic transformer - Maroon series + Relay Pin Insulator PCB Lay the Relay Pin Insulator PCB on top of the main PCB over the relay pins, then install the input transformer over the insulator PCB...

  • Page 38: Ribbon Cable

    Pin 1 Marker Ribbon Cable J1 = 20-way ribbon (1) 40 mm Cable length required =...
  • Page 39 Combi PCB Fitting Insert Combi into main PCB ensuring that it is perpendicular and solder in place.
  • Page 40 Standoffs to support upper PCB mm -F standoff mm -F standoff Component side Component side Solder side M3 x 8mm SEMS screw Solder side...

  • Page 41: Output Transformer

    Output Transformer T2 = VTB2569 (1) 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]. Make certain that the molex connector is pushed all the way down.
  • Page 42 Fit upper PCB Plug the ribbon cable into J4 Fold the ribbon cable and align the holes of the upper PCB with the standoffs below Push the ribbon cable inwards so that it looks like the diagram below Screw the upper PCB in place using 2 x M3x8mm SEMS screws..do not tighten the yet.. leave them loose. Screw the upper PCB in place using 2 x M3x8mm SEMS screws..

  • Page 43: Chassis Assembly

    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 main PCB to chassis with M3x8mm SEMS Screws DO NOT TIGHTEN YET... LEAVE THEM LOOSE Solder side Brown Violet...
  • Page 44 Ring Nuts and Kn Ring Nut 2 - EL-06-001 Marconi Winged Knob - Maroon 1 - GC-04-001 12mm Knob - Grey 1 - GC-04-007 Combi Connector Screw Black 2 - NE-06-002 Install the ring nut for the rotary switch and pot Then install the 2 x Combi Screws Install the knobs as shown [The shakeproof washer s are...

  • Page 45: Final Assembly

    Final Assembly VERY IMPORTANT: Do NOT tighten the screws very tight... use a thread locking adhesive applied to Brown the end of the screw. Violet Green Blue Orange Overtightening will alter the air gap... that would Black Yellow not be good ! M3 x 30mm screw M3 x 28mm screw at front 2 holes...

  • Page 46: Calibration Setup

    ez10 pre-mk2 Calibration / Setup 1 ] Before powering up the module, set all the rotary controls and toggle switches as follows: Input gain switch - 5 clicks up from fully counter-clockwise (ie 40dB mic / 0dB line position) Level trim - Fully Clockwise Mic/Line switch - Down (Line) 48v switch - Up (off) Pad switch - Up (No Pad)
  • Page 47 Gain Stage Sub Assembly V Ref Neg Agnd - Upper Card Output Stage Sub Assembly Audio Maintenance Limited E-Mail: service@audiomaintenance.com Title ez1073pre-mk2 Number AML-07-156 Date 17th Oct. 2024 Drawn by C Adshead File AML-07-156 - rev3 Sheet 1 of 2...
  • Page 48 Front-Rear Ctrl - Upper Card E-Mail: service@audiomaintenance.com DI to Line Ctrl - Upper Card Title ez1073pre-mk2 (DI Circuit) Number AML-07-156 B- Relays Upper Card Date 17th Oct. 2024 Drawn by C Adshead File AML-07-156 - rev3 Sheet 2 of 2...