AkitikA GT100 User manual
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GT100
TWO CHANNEL
AUDIO POWER AMPLIFIER
ASSEMBLY MANUAL
© 2012 AkitikA, LLC
All rights reserved
Revision 1p30 June 24, 2012
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Table of Contents
able of Contents................................................................................................................ 2
able of Figures .................................................................................................................. 3
Section 1: About his Manual ............................................................................................ 4
Who Should Attempt this Project? ................................................................................. 4
ools You’ll Need........................................................................................................... 4
Project Overview ............................................................................................................ 4
Important Safety Notes ................................................................................................... 5
About Components ......................................................................................................... 5
Section 2: Building the Power Supply PCB ....................................................................... 6
Component Order............................................................................................................ 6
Install the Resistors ......................................................................................................... 6
Install the Diodes ............................................................................................................ 8
Identifying the glass body diodes ............................................................................... 9
Install the Small Capacitors .......................................................................................... 10
Install the ransistors.................................................................................................... 11
Install the Integrated Circuits........................................................................................ 11
Install the Big Capacitors.............................................................................................. 12
Final Inspection of the Circuit Board............................................................................ 12
Power Supply Final Assembly...................................................................................... 12
Attach the Power Supply Ground Wire ........................................................................ 14
Section 3: Assembling the Amplifier Circuit Boards ....................................................... 15
Install the Resistors ....................................................................................................... 15
Install the Small Capacitors and the Diodes ................................................................. 17
Last Capacitors and the ransistors .............................................................................. 18
Winding the Output Inductor ........................................................................................ 19
Final Inspection of the Circuit Board............................................................................ 20
Installing the LM3866 and Mounting the Amplifier Board to the Heat Sink............... 21
Attach the Amplifier Module Wires ............................................................................. 23
Attaching LEF Module Power Wires ..................................................................... 23
Attaching RIGH Module Power Wires .................................................................. 24
Section 4: Wiring it All ogether ..................................................................................... 25
Input Connectors........................................................................................................... 25
Speaker Binding Posts .................................................................................................. 26
Power Wiring ................................................................................................................ 26
ransformer Installation............................................................................................ 28
esting the Power Supply ............................................................................................. 30
Final Amplifier Wiring ................................................................................................. 31
Installing Amplifier Modules into the Chassis ......................................................... 31
Wiring Amplifier Power ........................................................................................... 33
Fasten the Power Supply to the Chassis ................................................................... 33
Wiring Input Connections......................................................................................... 34
Wiring Speaker Connections .................................................................................... 34
Completing Ground Connections ............................................................................. 34
Visual Inspection ...................................................................................................... 35
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Install the op ........................................................................................................... 36
Section 5: esting It Out ................................................................................................... 36
Section 6: Specifications and Schematics......................................................................... 36
Appendix 1 - Resistor Color Code................................................................................ 41
Appendix 2 - Preparing a Shielded Cable End ............................................................. 42
Table of Figures
Figure 1-Installing resistors ................................................................................................ 6
Figure 2-Form the cathodes of D4-D7 as shown (banded end denotes cathode) ............... 8
Figure 3-Black text shows C2 polarity, yellow plus sign shows C3 polarity................... 10
Figure 4-Pinout of U1, viewed from the top..................................................................... 11
Figure 5-Completed Power Supply Circuit Board awaiting Q5 installation .................... 12
Figure 6-Note the rounded brackets used for the power supply heatsink and PCB ......... 13
Figure 7-Placing thermal compound on Q5...................................................................... 13
Figure 8-Installing Q5 on the heatsink and to the PCB .................................................... 14
Figure 9-Remember to solder Q5's leads .......................................................................... 14
Figure 10-power supply with attached ground wire ......................................................... 14
Figure 11-First four resistors are installed, leads bent on the back side, but not yet
soldered. ............................................................................................................................ 15
Figure 12-leads soldered and clipped ............................................................................... 16
Figure 13-showing LED cathode orientation.................................................................... 18
Figure 14-Starting to wind the output inductor................................................................. 20
Figure 15-finishing step for the output inductor ............................................................... 20
Figure 16-Mounting assembled PCB to heat sink ............................................................ 21
Figure 17-mounting the PCB to the heat sink................................................................... 22
Figure 18-solder the LM3886 pins ................................................................................... 22
Figure 19-a completed amplifier module.......................................................................... 23
Figure 20-shielded cable for left channel.......................................................................... 24
Figure 21-installing the RCA jacks................................................................................... 25
Figure 22-positioning the RCA input jacks and ground lug............................................. 26
Figure 23-Wiring IEC power connector ........................................................................... 27
Figure 24-Power wiring with IEC connector installed into chassis.................................. 27
Figure 25-Installing power wires on the switch................................................................ 28
Figure 26-joining the secondaries..................................................................................... 29
Figure 27- oroidal ransformer Mounting ...................................................................... 29
Figure 28-connecting up the power transformer............................................................... 30
Figure 29-cable tie the red and orange wires as shown .................................................... 30
Figure 30-spread thermal compound on the 3/8" wide ridge............................................ 32
Figure 31-amps installed, wiring not complete................................................................. 32
Figure 32-I/O Wiring detail (one channel) ....................................................................... 33
Figure 33-Grounding Stud Detail ..................................................................................... 35
Figure 34-Power Supply Schematic.................................................................................. 38
Figure 35-Amplifier Module Schematic........................................................................... 39
Figure 36-Overall Wiring ................................................................................................. 40
Figure 37-demonstrating the resistor color code .............................................................. 41
Figure 38-shielded cable end, as of step 4 ........................................................................ 44
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Figure 39-Shield wired end prep completed..................................................................... 44
Section 1: About This Manual
his manual gives the information you need to build Akitika LLC’s G 100 Stereo Power
Amplifier.
Who Should Attempt this Project?
You can build this kit if you can:
1. solder (using normal rosin core solder and a soldering iron).
2. use simple hand tools like screwdrivers, wire cutters, and pliers.
3. read and follow directions.
It helps if you:
1. know a bit about electronics, or
2. have a friend who knows a bit about electronics
3. can get to You ube to watch a few helpful videos about the assembly process (not
available as of this version of the manual)
Tools You’ll Need
You’ll need the following tools:
1. flat blade screwdriver for #6 screws
2. Phillips screwdriver (#2)
3. pliers or nut drivers suitable for #6 hardware (5/16” nut driver or hex wrench)
4. needle nose pliers (helpful, but not strictly necessary)
5. pencil type soldering iron of 25 to 50 Watts (no huge honking soldering guns or
blowtorches)
6. wire cutters and strippers
7. multi-meter (helpful, but not strictly necessary)
8. magnifying glass, if you’re over 42!
Project Overview
he project consists of the following steps:
1. Build the Power Supply Regulator Board
2. Build left and right channel amplifier circuit boards.
3. Install and wire the circuit boards, switches, and connectors into the chassis.
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Important Safet Notes
By purchasing, using, or assembling this kit, you have agreed to hold AkitikA, LLC
harmless for any injuries you may receive in its assembly and/or use. o prevent injuries:
• Wear safety glasses when soldering to prevent eye injuries.
• Always unplug the power before working on the amplifier.
• Large capacitors hold lots of energy for a long time. Before you put your hands
into the amplifier:
o Pull the AC plug!
o Wait 1 full minute for the capacitors to discharge!
• Remove jewelry and rings from your hands and wrists, or anything that might
dangle into the amplifier.
• If working in the amplifier, keep one hand in your pocket, especially if you’re
near the power supply or power supply wires. his can prevent serious shocks.
• Build with a buddy nearby. If you’ve ignored all the previous advice, they can
dial 911 or get you to the hospital.
About Components
We reserve the right to make design/or component changes at any time without prior
notification.
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Section 2: Building the Power Supply PCB
his section details the process of building the circuit board. We start with an overview
on this page. he specifics you need to start building begin on the next page.
In general, you’ll start with the components that lay closest to the board, working your
way towards the taller components. You will:
1. Install the resistors
2. Install the diodes
3. Install the capacitors
4. Install the transistors
5. Install the integrated circuits.
6. DO NO INS ALL HE LARGE PASS RANSIS OR (Q5) A HIS IME!
Component Order
You’ll notice that the component designations in the directions don’t go exactly in order.
We have grouped them so that all components with the same value appear together. his
makes assembly easier. You’ll find in the parts kit that similar parts, e.g. 3 1K resistors,
are typically (though not always) taped together.
Install the Resistors
In general, you install the resistors by placing the body on silk screen side of the board,
and the leads through the indicated holes. Bend the leads over on the back of the board to
keep the resistors from falling out until your solder them in place. ry to bend the leads in
a direction that won’t lead to solder bridges between traces that should remain
disconnected.
Figure 1-Installing resistors
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We recommend the following procedure:
1. Insert all the resistors of the same value, e.g. R2, R3 and R4.
2. Bend the leads as described above.
3. Solder the leads on the back of the board.
4. Clip the leads.
rack your progress by placing a check-mark in the done column as you install each
resistor. Check resistor values with a meter, or by reading the color code
1
. Orient the
resistor with the fat brown band on the right, then you can read both the Color Code
column and the resistor from left to right.
¼ Watt, 1% resistors
Designation
Value Color code Done? ()
R2 1K Brown, Black, Black, Brown, Brown
R3 1K Brown, Black, Black, Brown, Brown
R4 1K Brown, Black, Black, Brown, Brown
R6 10K Brown, Black, Black, Red, Brown
R26 10K Brown, Black, Black, Red, Brown
R27 10K Brown, Black, Black, Red, Brown
R8 20K Red, Black, Black, Red, Brown
R9 20K Red, Black, Black, Red, Brown
R1 15K Brown, Green, Black, Red, Brown
R5 140K Brown, Yellow, Black, Orange, Brown
R7 5K76 Green, Violet, Blue Brown, Brown
R11 3K48 Orange, Yellow, Gray, Brown, Brown
R22 165K Brown, Blue, Green, Orange, Brown
R23 100 Brown, Black, Black, Black, Brown
R24 95K3 White, Green, Orange, Red, Brown
R25 NO LOAD
2 Watt, 5% resistor
Designation
Value Marking Done? ()
R12 0.1 0.1
1
See “Appendix 1 - Resistor Color Code” on page 41 to see how to read resistor color codes.
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Install the Diodes
Now install the diodes. Be careful to observe the polarity markings on the diodes. You’ll
notice that one end of the diodes has a band. Match the banded end of the diode with the
banded end of the silk screen.
Warning: Don’t cut the leads of D4-D7 until after the leads have been formed and the
diodes have been soldered into the PCB.
Form the leads of D4-D7 as shown in Figure 2. Solder one lead of each diode while
attempting to keep the body perpendicular to the plane of the board. he anodes of the
diodes can sit on the board.
Figure 2-Form the cathodes of D4-D7 as shown (banded end denotes cathode)
Designation ype, Package Description Done? ()
D1 BZX55B33, DO-35 33 Volt 2% zener diode
D14 BZX55B33, DO-35 33 Volt 2% zener diode
D2 BZX79-B10, DO-35 10 Volt 2% zener diode
D8 1N4148, DO-35 0.2 A, 100 PIV, switching
diode
D9 1N4148, DO-35 0.2 A, 100 PIV, switching
diode
D10 1N4148, DO-35 0.2 A, 100 PIV, switching
diode
D11 1N4148, DO-35 0.2 A, 100 PIV, switching
diode
D12 1N4004, DO-41 1A, 400 PIV, rectifier
diode
D13 1N4004, DO-41 1A, 400 PIV, rectifier
diode
D4 6A4, R-6 6A, 400 PIV, rectifier
diode
D5 6A4, R-6 6A, 400 PIV, rectifier
diode
D6 6A4, R-6 6A, 400 PIV, rectifier
diode
D7 6A4, R-6 6A, 400 PIV, rectifier
diode
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dentifying the glass body diodes
he glass body diodes have the following identifying marks. If your vision is like mine,
you may need good light and a magnifying glass.
• 1N4148, D8-D11, has the number 48 visible
• BZX55B33B, D1 and D14, has the number 33 visible
• BZX79-B10, D2, has the number 10 visible
Also, typically when these diodes are packed, you can preliminarily identify the types
because:
• he 4 1N4148 diodes will typically be taped together
• he 2 BZX55B33B diodes will typically be taped together
• he 1 BZX79-B10 diode will be by itself
D4-D7, opaque
black plastic
package
D3, D12, D13,
DO-41, opaque
black plastic
package
D1, D1, D8-
D11, D14,
DO-35 glass
package
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Install the Small Capacitors
Now install the capacitors:
Designation Value Description Done? ()
C1 10 µF 100V electrolytic (polarized),
cylindrical shape
C2 10 µF 100V electrolytic (polarized),
cylindrical shape
C3 10 µF 100V electrolytic (polarized),
cylindrical shape
C4 100 nF 50V, Z5U, +/- 20%, marked 104
C5 10 nF 400V, film, 20%, box shaped
Notes:
1. C1 is polarized, showing a minus sign (-) on the negative end of the capacitor.
Make sure that the minus sign faces away from the plus sign (+) marked on the
silk screen for C1.
2. C2 is also polarized. he Rev A PCB’s have a silk screen error in the drawing for
C2. he shape is shown as a rectangle; but there is no no polarity designation. Use
the drawing below to properly install C2. he bottom of C2 should be about ¼”
above the PCB to avoid stressing the leads.
3. C3 is also polarized. Rev A PCB’s are missing the polarity sign. See the yellow
plus sign added to Figure 3.
Figure 3-Blac text shows C2 polarity, yellow plus sign shows C3 polarity
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