Audio Note DAC Kit 3.1 Instruction Manual

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Manual Version 2.2 – March 2011

DAC3.1, DAC3.1 Signature, DAC4.1 Limited Edition

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www.AudioNoteKits.com

audionotekits@rogers.com

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Summary of Contents for Audio Note DAC Kit 3.1

Page 1 Manual Version 2.2 – March 2011 DAC3.1, DAC3.1 Signature, DAC4.1 Limited Edition Build instructions for Copyright © 2006-2011 AudioNote Kits Page 1 www.AudioNoteKits.com audionotekits@rogers.com...
Page 2: Table Of Contents
Table of Contents Section1: Introduction ................................4 Overview .................................... 5 Component Placement Breakdown ............................ 6 Electrical Safety Warning ..............................8 Section 2: Mechanical Assembly ............................9 Installing the feet ................................9 Mains Transformer, Choke, and Mains Installation ......................9 Configuring the Primary Winding for your World Region ....................11 Installing the IEC Socket (AC Socket) and Rocker Switch ...................
Page 3 Digital Board Installation ..............................56 Section 8: Digital Board Power Supply Connections ......................57 Section 9: Line Board Construction ............................. 58 Installing the Valve Bases ..............................58 Parts List ..................................58 Installing the Resistors ..............................59 Installing the Electrolytic Capacitors..........................61 Installing the Film (non-polarized) Capacitors ........................
Page 4: Section1: Introduction
C-core output transformers comes in RCA/Balanced. Thanks for purchasing the AudioNote DAC Kit 3.1 or 4.1. Our goal is to provide you with the highest quality Kit that you will build from scratch with these instructions. If you have any questions or comments during the build feel free to contact us and we would be happy to help out.
Page 5: Overview
Overview Here is a rough guide to the steps you will be following. You may want to use this page as a general checklist, crossing out each item as it is done. 1. Install Feet on Chassis 2. Install M2 Mains Transformer and Choke into chassis 3.
Page 8: Electrical Safety Warning
Electrical Safety Warning There are sufficient voltages in this kit to give you a very nasty and harmful shock so be careful when powering on, debugging, and probing around. Please be aware of proper electrical safety. Please contact AudioNote kits via phone or email to discuss any precautions necessary when building the kit if you feel unsure about what you are doing at any stage of the build.
Page 9: Section 2: Mechanical Assembly
Section 2: Mechanical Assembly In this beginning section we will start by installing the 4 feet from the Fittings Bag then we will install the Mains transformer and Choke as shown in the pictures below. Installing the feet Insert 4 feet in the bottom of the chassis. Fix them each in place using an M4 nut and washer.
Page 10 Trim the wire to about __ inches. Strip about ¼” of insulation off the end of the green wire. Tin the bare wire by adding solder to the end. Copyright © 2006-2011 AudioNote Kits Page 10 www.AudioNoteKits.com audionotekits@rogers.com...
Page 11: Configuring The Primary Winding For Your World Region
Add solder to secure the GND Lug to the end of the wire. Configuring the Primary Winding for your World Region Next step is to decide what world voltage you require – for example we have some of the most popular regions listed below: United States 120v...
Page 13 Now we must configure our Mains transformer for the World Voltage that we reside in. For this example we will show 120V Operation. Start by cutting two short pieces of wire approx 2” in length each, stripping the insulation off the ends and tinning the wire.
Page 14: Installing The Iec Socket (Ac Socket) And Rocker Switch
Here, the wires are soldered onto the top-most 0v and the bottom-most 120v for North American/Canadian 120v. Remember, we are wiring here for 120v - if your region is different then you will need to consult the regional wiring chart to determine how you inter-wire for your region. Installing the IEC Socket (AC Socket) and Rocker Switch The rocker switch simply snaps into pace in the chassis slot.
Page 15: Installing The Choke
Installing the Choke Since the Choke fits into a tight location we suggest you put the screws and washers into position through the holes in the choke covers – then lower the choke into position making sure that you align with the non painted hole - see opposite.
Page 16: Wiring Up The Mains
When installing the Mains transformer be sure to line it up with the unpainted hole in order to ensure a ground connection. Secure the transformer at all four corners. Wiring up the Mains Once the transformer is installed you can connect up the Blue and Brown Crimped wires from the Mains transformer directly to the Rocker Switch.
Page 17: Shield Positioning
Add the twisted wire (Cable #3) and the ground wire (Cable #4) as shown in the graphic opposite. Let‟s add one final GROUND wire connection from the M4 screw in the chassis. Take a piece of bare wire and solder it between the V300 and 0 terminals as shown opposite.
Page 18 Here correct installation of the shield – You will need to remove it later on when we wire up to the Mains transformer but for now you can leave it in and show off your wonderful work to your wife! This concludes the IEC Wiring section for the Mains Transformer.
Page 19: Section 3: M2 Power Supply
Section 3: M2 Power Supply In this section we will be assembling the M2 Power Supply Board PCB. Here is a view of the parts that you will find in the M2 Power Supply Kit Bag Most of the parts for this section can be found in the M2 Power Supply bag (although the filament wires may be located elsewhere).
Page 20: M2 Power Supply Board Parts List
M2 Power Supply Board Parts List The Complete Parts list for the M2 board is shown below. For resistor color code chart refer to the APPENDIX. You can also find an 'Interactive Resistor Color Code Calculator' on our website (available from the Links page). Category Quantity Part...
Page 21: M2 Power Supply Board Construction Steps
M2 Power Supply Board Construction Steps Installing the Valve Bases Lets start by installing the 8-pin valve base with correct orientation. The 8-pin (octal) valve base is shown opposite. It‟s a fairly tight fit into the board so take you will need to take your time and make sure all the legs are individually positioned over the holes in the board.
Page 22 The next job is to solder the valve base into position – Once you have fitted the octal into position I suggest you use a cap or something to support the board so that it is nice and horizontal. The reason for this is so that the valve base will be soldered into the board nice and level –...
Page 23: Installing The Resistors
Installing the Resistors Resistors 100R R5, R6 100K R1 ,R10 150K 220K 470K If you have a voltmeter you can check the value of each resistor prior to soldering in OR you can refer to the color code chart in the above parts list. Identity the correct resistor and then install in the specified designator (R1 for example).
Page 24 Above shows the installation of the 100R resistor into the R8 position – Bend the legs slightly on the underside to keep the resistor in place. We suggest you install the spacers on the board at this point. Once you are feeling confident of your resistor installation it is time to solder on the underside of the board.
Page 25: Installing Resistors In The Ht Adjust Position
Once the joints have been made, give them a quick inspection and touch up any that look suspicious in any way. Next step is to clip the leads - you want to do this but be careful not to clip off too close to the board where you endanger the pad –...
Page 26: Zener Diode Installation
Bend one of the legs over and through the hole in the board as shown - solder into position from the top of the board. Take the leg of the other resistor and twist it around the leg of the other one as shown opposite. Here you can see the resistors in position –...
Page 27: Electrolytic Capacitor Installation
Here you can see the Zener diode installed in the correct orientation. Electrolytic Capacitor Installation Capacitors (Electrolytic) 2200uF 35V 22uF 450V C6 ,C7 Do not install C2 and C4 at this stage 68uF 450V C3, C5 We are now going to install the Electrolytic Capacitors into the power supply Board.
Page 28 Here we can see both 68uF capacitors (C3 and C5) correctly installed. Install the remaining electrolytic capacitors that are required at this stage (i.e. C9, C6, and C7). You can see these installed in the picture opposite. Copyright © 2006-2011 AudioNote Kits Page 28 www.AudioNoteKits.com audionotekits@rogers.com...
Page 29: Installing The Bridge Rectifier
Installing the Bridge Rectifier Semiconductor Devices KBU6J6A Install the Bridge Rectifier into position in U1. Note the notch is located facing into the middle of the board - you will also see a corresponding notch stenciled on the PCB. Installing the Non-Polarized Capacitors Capacitors (Non-polarized) Disc 4700uF 3000v .22uf 600V...
Page 30: Wiring The M2 Power Supply Board
Wiring the M2 Power Supply Board Get your Bag #2 from the Wire Bag as we will be installing the “filament” wires onto the board. We are going to connect several wires to the M2 power supply board – this is easier to do at this stage. FILAMENT LESSON: In order for a tube to function it must be supplied with a Filament Voltage –...
Page 31 Now take the short wire from BAG #2 - we will be using this to hardwire from the 8-pin valve base to the 9-pin valve base. The graphic to the left shows the connections for the twisted wires. EXPLANATION: On the M2 Power Supply Board will...
Page 32 Here is the completed connection of the “parallel filament”. We are now going to install the 6X5 filament wire - this is the THICK black & white twisted wire that is located in Bag #1 of your WIRE BAG. This is the wire that will connect from the Mains transformer secondary to the 6X5 filament.
Page 33: Filament Component Section Of The M2 Power Supply Board
Now get out your BAG#3 from the wire bag and we will install the red and black wires that will be used as the B+ (High Voltage) and corresponding Ground wire. These pictures show the red and black wires installed in the B+ and GND holes on the M2 power supply board.
Page 34: Regulator Installation
The 1N4007 Diodes are polarized and therefore need to be installed correctly. In the picture above you will note the D3 & D6 designators which shows a bar – this bar lines up with the gray strip on the zener diode – Note how they are correctly installed.
Page 35: Installing The Led Harness
The pictures above and opposite show a successfully configured regulator. Once these components are in place you can then install the remaining two electrolytic capacitors (C2 and C4). Installing the LED Harness Take the LED Harness from your M2 PS bag and you can solder it onto the board as shown opposite.
Page 36: Installing The Heatsink
Then take the twisted thick RED wires and connect these to the 300V 300V on the PCB. The picture opposite is what your M2 Power supply board should now look like! Installing the Heatsink Feel free now to “place” (do not screw in) your newly assembled board into position in the chassis.
Page 37: Installing The Choke Wire
Installing the Choke Wire The Black CHOKE that is located at the rear of the chassis and has a red and black wire. you will want to twist these wires by hand and feed them along the shield towards the M2 PCB.
Page 38: Inter-Wiring To The Mains Transformer
Inter-wiring to the Mains Transformer I would suggest at this stage to REMOVE the black shield so that we can work on this side of the chassis. The following graphic shows the wiring between the M2 PCB and Mains Transformer. Note that the „second‟ transformer is simply another view of the same mains transformer.
Page 39 We are now going to take the 3 pairs of twisted wires that are already connected to the M2 Power Supply Board and connect these directly to the SECONDARY of the Mains transformer. Start by taking the RED / RED twisted pair and trim to a good length and then solder to the „300‟...
Page 40 The third pair of wires is the Red/Black twisted pair that is connected to the 13V6 on the M2 power supply board. Note that the 0 tap is not used here. The last wire for hookup in this section will be the long green wire with the GND lug on one end found in your IEC Kit Bag- Secure the GND lug end on the M4 screw in the chassis and trim and solder from the top of the board the green wire into the GND hole located near the 13V6 pads on the M2 power supply Board.
Page 41: Securing The Regulators To The Heatsink
Securing the Regulators to the Heatsink We are now going to secure the regulators to the Heat Sink that is installed in the chassis. The picture opposite shows the parts that are necessary to do this. EXPLANATION: It is ideal to electrically isolate the regulator from the ground on the chassis (i.e.
Page 42 That completes our assembly of the M2 Power Supply Board. Feel free to re install the shield back into position or you can wait until nearer the end of the kit build if you prefer. Copyright © 2006-2011 AudioNote Kits Page 42 www.AudioNoteKits.com audionotekits@rogers.com...
Page 43: Section 4: M2 Power Supply Testing
Section 4: M2 Power Supply Testing Preparations Fitting the Mains Fuse In this section we are going to electrically test the power supply. Start by installing a 1A Slo Blo fuse (IEC BAG) into position as shown. Use a screwdriver or flat edge or your fingers pull the Fuse holder out - you will need to squeeze to completely remove it.
Page 44: Installing The Led Indicator
Installing the LED Indicator The LED on the M2 Power Supply Board will be the first indicator that we have power – I would suggest just taping the LED – make sure the metal leads of the LED are not touching any other circuitry or chassis –...
Page 45: Ohm Check
Ohm Check EXPLANATION: There are a number of terms that we will be using in this section that we should be familiar with – the HT or High Voltage or B+ is all the same thing – this is the HIGHEST DC voltage in the circuit typically and is the voltage that we will be supplying to the Tubes in our audio signal path.
Page 46 First measure from B+ to GND on the M2 PCB (use the ground point closest to the LED section). You should read approximately 260v DC. Now measure the filament voltages - these are the connections labeled +6V2- on top of the PCB. These should be approximately 12v DC.
Page 47: Voltage Check Summary
While in AC mode measure the 13V6 pads on the M2 PCB – We have 8 0 8 taps which should give us roughly 16V Voltage Check Summary DC Voltage Checks Location Approx Reading B+ to GND 260v DC +6V2- 12v DC +6V2- 12v DC...
Page 48: Section 5: Digital Power Supply Pcb
Section 5: Digital Power Supply PCB In this section we will be building, installing and testing the Digital Power Supply PCB that is used in the DAC2.1 and 3.1 kits. EXPLANATION: This small board receives an 18V AC signal from the 9-0-9 taps on the Mains transformers and converts it to several DC voltages that are required by the DAC board.
Page 49: Installing The Led"S
Installing the LED’s Install the LED‟s into the LED1 and LED2 positions. You will notice a square end on the stencil and a rounded end – Insert the LONG lead of the led on the SQUARE end. Installing the Capacitors Capacitors (Electrolytic) 4700uf 16V C1, C2...
Page 50: Installing The Diodes
Note that each capacitor only has the POSITIVE side noted – You will have to locate the Stripe on the capacitor as shown above and insert correctly – Don‟t be confused by the two caps close together. The picture opposite shows the capacitors correctly installed.
Page 51: Installing The Resistors
Standard Diode Installation Opposite is a picture of the standard diode inserted – you will want to line up the gray stripe on the diode that denotes the positive side and position it where the White Dot is. Installing the Resistors Resistors R3, R4 R1, R2...
Page 52: Board Installation And Wiring
Board Installation and Wiring Position the Digital Power Supply board into the chassis as shown with the DC voltage side (AGND DGND etc.) positioned away from the Power Supply. BE SURE THAT THE KIT IS NOT PLUGGED INTO THE WALL at this point. Take the prepared twisted blue wire and locate the 9-0-9 taps on the Mains transformer secondary.
Page 53 You should now have 3 wires connected between the Digital Power Supply Board and the mains transformer. If you are feeling good about your connections install your AC plug into the back of the chassis and switch the unit ON (1 pressed flush to the chassis) –...
Page 54: Section 6: Install The Screen
Section 6: Install the Screen The next step is to install the metal screen. It is important that a good electrical contact is maintained between the chassis and the screen itself. This picture shows the hole that will make that contact from the chassis –...
Page 55: Section 7: Installing The Digital Pcb
Section 7: Installing the Digital PCB Digital Board Overview The Digital Board is supplied with the kit built and tested. The board was originally designed for use in the DAC1.1 Kit, which had the analog filter and IV circuitry. This circuitry is removed now and you will notice tantalum resistors located in R34 and R35.
Page 56: Digital Board Installation
Digital Board Installation Install the 5 aluminum spacers on the board and position in the chassis. Once the board has been positioned in the chassis you will want to connect up the input RCA‟s. You will need to install three RCA‟s – 2 are for the analog output and one is for the digital input. The RCA‟s on top of each other are the analog output RCA‟s, install these into position along with the single input RCA.
Page 57: Section 8: Digital Board Power Supply Connections
Section 8: Digital Board Power Supply Connections In this section we will make the connections between the digital Power supply (small red board) and the Digital DAC board (green board). This is quite straightforward and shouldn‟t present any problems. Please refer to the following wiring table: Power Supply Pad Digital Board Pad AGND...
Page 58: Section 9: Line Board Construction
Section 9: Line Board Construction In this section we will be building the 5687 line board that is used to drive the output transformers in your DAC Kit 3.1. You can begin by securing the board spacers (shown in the first picture below).
Page 59: Installing The Resistors
Installing the Resistors Resistors R1, R11 R3, R4, R5, R6 R7, R8 R9, R10 R2, R12 You will want to bend the resistors to the correct length for easy insertion into the board – I suggest that you place all the resistors into position and bend the legs gently on the under side of the board to make sure they stay in one place –...
Page 61: Installing The Electrolytic Capacitors
Installing the Electrolytic Capacitors Capacitors (Electrolytic) 470uf 16v C1, C2, C3, C4 The next step is to solder in the 4x 470uf 16v capacitors. These capacitors are electrolytic and they are polarized which means they have to go in a certain way - the capacitor has a long leg and a short leg - the short leg is the negative side and the long leg is the positive side.
Page 62: Board Orientation
Board Orientation The above pictures show the correct installation of the new 5687 line board into the chassis. 5687 Filament Wiring There are two pairs of filament wires coming from the M2 power supply boards. Each pair connects to one of the 5687 valve bases.
Page 63: Section 10: Installing I/V Transformers
Section 10: Installing I/V transformers In this section we will install the IV transformers into the DAC. Secure the IV transformers in their clamps with their leads facing upward and so they are flush with the bottom of the clamp where the fixing holes are situated. Then fix the clamps into position in the chassis as shown in the following picture.
Page 64: Wiring The I/V Transformers
Wiring the I/V Transformers All you need now to do is connect the Red lead from the Left I/V transformer to the LSIG and the Black lead from the left I/V transformer to the LGND on the Digital Board. Repeat for the Right I/V transformer. RSIG RED (right I/V) RGND BLK (right I/V) LSIG RED (left IV)
Page 65: Section 11: Connecting The 5687 Output
Section 11: Connecting the 5687 Output Connecting the 5687 HT to the power supply First, we need to connect the 5687 board to the M2 Power Supply board. The connections for this can be seen in the diagram shown opposite. Take a red wire and connect between the HT pad on the 5687 board and one of the B+ pads on the M2 Power Supply board.
Page 66: Output Transformer Type 1 (Single-Ended Only)
Output Transformer Type 1 (Single-ended Only) As you can see from the diagram, the Black leads from each of the transformers connect to a B+ pad on the M2 Power Supply board. The Red lead from the Right output transformer connects to the R TX pad on the 5687 board.
Page 67: Output Transformer Type 2 (Single-Ended Or Balanced)
Output Transformer Type 2 (Single-ended or Balanced) Above we can see the pair of output transformers used in the DAC output stage We are now ready to connect the output transformers to both the output of the 5687 analog board and to the RCA (single- ended) or XLR (balanced) outputs.
Page 68: Section 12: Source Selection And Switching
Section 12: Source Selection and Switching The DAC3.1 Digital Board has two inputs on it – CON1 and CON2. A selector switch is used to select which input source will be used. This allows switching between two different digital input type sources. You may choose between any two of the following input types: RCA.
Page 69: Input Connections
This picture shows how the pins on the back of the switch are connected to their relevant position on the digital board. Here you can see the wiring between the switch and the Digital Board. This will now allow us to toggle between the CON1 input and the CON2 input.
Page 70: Connecting The Rca Input
Connecting the RCA Input To connect the RCA input you will want to use the Coaxial cable length supplied. Strip the outer casing to expose the grounding shield as shown opposite. Separate the ground shield and twist together. Copyright © 2006-2011 AudioNote Kits Page 70 www.AudioNoteKits.com audionotekits@rogers.com...
Page 71 Now TIN the shield by adding solder to it. Now repeat this process at the other end of the cable. This picture shows how the solid core will fit into CON1 and the shield will be soldered to the pad beside it. This picture shows how the other end of the cable will connect to the RCA connector.
Page 72: Connecting The Usb Input
Connecting the USB Input If using the USB input then you will want to examine the three holes in the “XLR” footprint on the Digital Board. You will notice that there are three holes that the XLR would normally fit into – this is where we are going to hook up the USB inputs.
Page 73: Connecting The Xlr Input
Connecting the XLR Input For XLR Operation you will mount the XLR connector in the back rear position and then connect the wires from the XLR to the digital board – just the same way that you connected the switch. Copyright ©...
Page 74: Section 13: Turn-On Procedure
Section 13: Turn-on Procedure At this point we should be finished – we have two working power supplies – Perform the following checks: Make sure that the Digital Power Supply is connected correctly to the Digital Board. At this point we can try the turn on – we should see the 3 LED‟s on the Digital Board Light up – If they do not then I would suggest rechecking the inter-wiring to the digital board and the power supply and or measuring the voltages again.
Page 75: Final Thoughts
Final Thoughts The kit is fairly complex and we would welcome any feedback on the manual/ instructions, parts list, build instructions – Any omissions etc… If you feel that you can take some really good pictures of your build process or even final build we would like to see your work.
Page 76: Appendix
Appendix The appendix contains auxiliary information. That is information that is either common to most project manuals or any last minute pieces of information that did not make it into the manual in time. It may also contain pull-out circuit diagrams that may be handy to have outside the manual etc.
Page 77: Resistor Color Code Reference
Resistor Color Code Reference You can also find an 'Interactive Resistor Color Code Calculator' on our website (available from the Links page). Copyright © 2006-2011 AudioNote Kits Page 77 www.AudioNoteKits.com audionotekits@rogers.com...

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Audio Note DAC Kit 3.1 Instruction Manual

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