Total solder points: 500

Difficulty level:
beginner 1o 2o 3o 4o 5 advanced

HIGH-END VALVE CONTROL AMPLIFIER

K8020

8020
Valve Control Amplifier

+6dB

Aux

CD

Tuner

AV

Monitor

ILLUSTRATED ASSEMBLY MANUAL

H8020IP-1

VELLEMAN KIT NV
Legen Heirweg 33
9890 Gavere
Belgium
http://www.velleman.be

Assembly hints
1. Assembly (Skipping this can lead to troubles ! )
Ok, so we have your attention. These hints will help you to make this project
successful. Read them carefully.
1.1 Make sure you have the right tools:
A good quality soldering iron (25-40W) with a
small tip.
Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to
the tip, to give it a wet look. This is called thinning and will protect
the tip, and enables you to make good connections. When solder
rolls off the tip, it needs cleaning.
Thin raisin-core solder. Do not use any flux or grease.
A diagonal cutter to trim excess wires. To avoid injury when cutting
excess leads, hold the lead so they cannot fly towards the eyes.
Needle nose pliers, for bending leads, or to hold components in place.
Small blade and phillips screwdrivers. A basic range
is fine.

For some projects, a basic multi-meter is required, or might

be handy

0.0
00

1.2 Assembly Hints :

Make sure the skill level matches your experience, to avoid disappointments.
Follow the instructions carefully. Read and understand the entire step before
you perform each operation.
Perform the assembly in the correct order as stated in this manual
Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
Values on the circuit diagram are subject to changes.
Values in this assembly guide are correct*

Assembly hints
Use the check-boxes to mark your progress.
Please read the included information on safety and customer service
* Typographical inaccuracies excluded. Always look for possible last minute
manual updates, indicated as NOTE on a separate leaflet.
1.3 Soldering Hints :

1- Mount the component against the PCB surface and carefully solder the leads

2- Make sure the solder joints are coneshaped and shiny

3- Trim excess leads as close as possible to the

solder joint

AXIAL COMPONENTS ARE TAPED IN

THE CORRECT MOUNTING SEQUENCE !
REMOVE THEM FROM THE TAPE ONE AT A
TIME !

Aran-

Giallo

Verde

Blu

Viola

Grigio

Bianco

Naran-

Oranssi

Brun

Svart

Orange

Bl

Grn

Kulta

B Oro

Dourado Oro

Gr

Guld

Silver

Valkoinen Vit
Hopea

Blanco

Harmaa

A Argento Prateado Plata

Branco

Sininen

Vihre

Morado Purppura Lila

Azul

Verde

Cinzento Gris

Violeta

Azul

Verde

DK

4K7= ( 4 - 7 - 0 - 1 - 1 )

1%

Rd

Brun

Sort

Guld

Slv

Hvid

Gr

Violet

Bl

Grn

Gul

Guldl

Slv

Hvidt

Gr

Violet

Bl

Grnn

Gul

Orange Orange

Rd

Brun

Sort

FRG FARVE- FARGESCHEMA KODE

KODE

Punainen Rd

Ruskea

Musta

VRI
KOODI

SF

Amarelo Amarillo Keltainen Gul

Laranja

Rojo

Rosso

Encar-

Marrone Castanho Marrn

Negro

Preto

Nero

C CODICE CODIGO CODIGO

O COLORE
DE
DE
D
CORES COLORE
E
S

4K7= ( 4 - 7 - 2 - B )

5%

GB

NL

Gold

Silber

Weiss

Grau

Violet

Blau

Grn

Gelb

Orange

Rot

Braun

Gold

Silver

White

Grey

Purple

Blue

Green

Yellow

Orange

Red

Brown

Schwarz Black

Or

Argent

Blanc

Gris

Violet

Bleu

Vert

Jaune

Orange

Rouge

Brun

Noir

Goud

Zilver

Wit

Grijs

Paars 7

Blauw 6

Groen 5

Geel

Oranje 3

Rood

Bruin

Zwart

FARB COLOUR CODIFI- KLEUR C

KODE
CODE CATION KODE O
D
DES
E
COU-

COLOR= 2 5

Color code table

Construction
CONSTRUCTION
The unit consists out of two PCBs, one is the main PCB, P8020B and the other
is the left channel input section P8021L.
First we will start with the small P8021L, then we assemble the P8021B.

FTip: The pictures on the packaging can be

used as a guideline.
However, due to possible changes it is not
100% reliable.

P8021L

1. Diodes (check the polarity)

2. Resistors (check the color code)

D...
CATHODE

q
q
q
q
q
q

D1: 1N4148
D2: 1N4148
D3: 1N4148
D4: 1N4148
D5: 1N4148
D6: 1N4148

R...

q
q
q
q
q
q
q
q

R1: 10K (1-0-3)

R2: 10K (1-0-3)
R3: 10K (1-0-3)
R4: 10K (1-0-3)
R5: 10K 1-0-3)
R6: 10K (1-0-3)
R7: 1K (1-0-2)
R8: 1K (1-0-2)

Construction
3. Capacitors

6. RCA connectors.
Mount them straight and
against the PCB

C...

q
q
q
q
q
q

C1: 220p (221)

C2: 220p (221)
C3: 220p (221)
C4: 220p (221)
C5: 220p (221)
C6: 220p (221)

4- Reed relays (check the position

q
q
q
q
q
q

SK1: MJ-523AG/B BLACK

SK2: MJ-523AG/B BLACK
SK3: MJ-523AG/B BLACK
SK4: MJ-523AG/B BLACK
SK5: MJ-523AG/B BLACK
SK6: MJ-523AG/B BLACK

of the notch)

7. Pin connector. Mount it exactly

as indicated

RY...
q
q
q
q
q
q

RY1: VR05051AS or eq.

RY2: VR05051AS or eq
RY3: VR05051AS or eq
RY4: VR05051AS or eq
RY5: VR05051AS or eq
RY6: VR05051AS or eq.

5. transistors
q SK7: HDR20/26

q
q
q
q
q
q

T1: BC557
T2: BC557
T3: BC557
T4: BC557
T5: BC557
T6: BC557

Construction
P8020B Assembly

Construction
1. Jump wires

3. Resistors (check the color code)

R...

q J1... J26

2. Diodes (check the polarity)

D...
CATHODE

q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q

D1: 1N4148
D2: 1N4148
D3: 1N4148
D4: 1N4148
D5: 1N4148
D6: 1N4148
D7: 1N4148
D8: 1N4148
D9: 1N4148
D10: 1N4007
D11: 1N4007
D12: 1N4007
D13: 1N4007
D14: 1N4007
D15: 1N4007
D16: 1N4007
D17: 1N4007
D18: 1N4007
D19: 1N4007
D20: 1N4007

q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q

R01: 10K (1-0-3)

R02: 10K (1-0-3)
R03: 10K (1-0-3)
R04: 1K (1-0-2)
R05: 10K (1-0-3)
R06: 10K (1-0-3)
R07: 1K (1-0-2)
R08: 10K (1-0-3)
R09: 680R (6-8-1)
R10: 1M (1-0-5)
R11: 27K/0.6W (2-7-3-9)
R12: 10K (1-0-3)
R13: 3K6 1% (3-6-0-1)
R14: 100K (1-0-4)
R15: 5K6 (5-6-2)
R16: 680R (6-8-1)
R17: 3K6/1% (3-6-0-1)
R18: 33K/1% (3-3-0-2)
R19: 10K (1-0-3)
R20: 1M (1-0-5)
R21: 27K/0.6W (2-7-3-9)
R22: 10K (1-0-3)
R23: 3K6/1% (3-6-0-1)
R24: 100K (1-0-4)
R25: 10K (1-0-3)
R26: 3K6/1% (3-6-0-1)
R27: 33K/1% (3-3-0-2)
R28: 680R (6-8-1)
R29: 5K6 (5-6-2)
R30: 1K (1-0-2)
R31: 1K (1-0-2)
R32: 27K/0.6W (2-7-3-9)
R33: 27K/0.6W (2-7-3-9)
R34: 27K/0.6W (2-7-3-9)
R35: 1R (1-0)
R36: 10K (1-0-3)

Construction
q
q
q
q
q
q
q
q
q
q
q
q

R37: 4K7 (4-7-2)

R38: 10K (1-0-3)
R39: 4K7 (4-7-2)
R40: 10K (1-0-3)
R41: 1K (1-0-2)
R42: 10K (1-0-3)
R43: 10K (1-0-3)
R44: 10K (1-0-3)
R45: 1K (1-0-2)
R46: 1K (1-0-2)
R47: 10K (1-0-3)
R48: 1K (1-0-2)

5. IC sockets

q IC1: 18P

6. Capacitors
4. PCB pins

C...

q Mount 9 pins in
each hole for the
valve supports
V1 and V2.

V1
1

V2

q Mount 3 pins in
the holes for
VR1.

VR1

10

q
q
q
q
q
q
q
q
q
q
q
q
q
q
q

C01: 220p (221)

C02: 220p (221)
C03: 220p (221)
C04: 220p (221)
C05: 220p (221)
C06: 220p (221)
C07: 220p (221)
C08: 100n (104, 0.1, u1)
C09: 100n (104, 0.1, u1)
C10: 100n (104, 0.1, u1)
C11: 100n (104, 0.1, u1)
C12: 100n (104, 0.1, u1)
C13: 100n (104, 0.1, u1)
C14: 100n (104, 0.1, u1)
C15: 100n (104, 0.1, u1)

7. Female header

10. Reed relays (check the position

of the notch)

SK..
J...
RY...

q SK7: 20P (type 96120205)

q
q
q
q
q
q
q
q

8. transistors

q
q
q
q
q
q
q
q
q

Construction

RY1: VR05051AS or eq.

RY2: VR05051AS or eq
RY3: VR05051AS or eq
RY4: VR05051AS or eq
RY5: VR05051AS or eq
RY6: VR05051AS or eq.
RY7: VR05051AS or eq.
RY8: VR05051AS or eq.

11. RCA connectors.

Mount them straight and
against the PCB

T01: BC557
T02: BC557
T03: BC557
T04: BC557
T05: BC557
T06: BC557
T07: BC557
T08: BC557
T09: BC557

q T10: BC547

q
q
q
q
q
q

9. Power relay

SK1: MJ-523AG/R RED

SK2: MJ-523AG/R RED
SK3: MJ-523AG/R RED
SK4: MJ-523AG/R RED
SK5: MJ-523AG/R RED
SK6: MJ-523AG/R RED

RY...

q RY9: VR5C122C

11

Construction
12. Valve socket mounting

V...

8
5

q V1: B9A
q V2: B9A
The valve socket is mounted on top of the allready mounted PCB pins.
First position the socket over the pins and solder one lead.
Check the hight of opprox. 23mm (0.9)

13. Push button

Mount them straight against
the PCB surface !

14. Capacitors

C...

q
q
q
q
q

SW1: TS-04PV
SW2: TS-04PV
SW3: TS-04PV
SW4: TS-04PV
SW5: TS-04PV

Remark: The metal part of these buttons are used as jump wire.
Be sure not to test or use the unit
without soldering these push buttons.

12

q
q
q
q
q
q
q

C16: 2,2uF( 2u2, 225 )

C17: 2,2uF( 2u2, 225 )
C18: 68nF/630V (0.068, 683)
C19: 68nF/630V (0.068, 683)
C20: 22nF/630V (0.022, 223)
C21: 4,7uF/160-250V( 4u7)
C22: 4,7uF/160-250V( 4u7)

Construction
15. Voltage regulator.
The back side corresponds to
the thick line.

17. Transformer.

VR...

TRAFO...

q VR2: UA7805
VR1 will be mounted later

16. Electrolytic capacitors.

Check the polarity !

C...

q TR1: TR8020, 2x18V, 12V, 220V/

16VA
First fix the transformer using four
6mm M3 screws and nuts (nuts at
solder side), then solder his connections.
Tip: It is advisable to secure the
nuts using a drop of glue.

q
q
q
q
q
q
q
q
q
q
q
q

C23: 100
C24: 470
C25: 1000
C26: 1000
C27: 1000
C28: 47/350V
C29: 47/350V
C30: 47/350V
C31: 47/350V
C32: 47/350V
C33: 47/350V
C34: 47/350V

13

Construction
18. Volume potentiometer.

RV...
q RV1: STRK27103 (2x50K ALPS)
CAUTION:
This is a high quality
potentiometer, handle it with care.
Follow the mounting instructions
exactly and in order!
1.Mount the support bracket onto the
potentiometer. Tighten the nut
carefully.
2.Mount the potentiometer onto the
PCB, using two 6mm (0.23)
screws and M3 nut.
Only slightly tighten the nuts !
Do not solder the potentiometer
connections yet !

19. Mains voltage selection

Use a piece of isolated brown wire to

select the mains (outlet) voltage, as
indicated on the PC board.
q For 115Vac (100 to 120Vac)
A jumper between A-B, and a jumper
between C-D.
A

q For 230Vac (220 to 240Vac)

A jumper between B-C.
B

Using a black marker, erase the

not used voltage at the back of the
unit.

20. Mains voltage connection

preparation

q Connect a 10cm blue wire to the

point N of SK8.
q Connect a 10cm brown wire to the
point L of SK8.
q Connect a 10cm yellow/green
wire to the earth point of SK8.
Later these connection will be
soldered to the mains connector.

14

Construction
21. Mounting the LEDs. Check the polarity ! Short lead = Cathode or - !

CAUTION: After
bending the
leads the long
appearing lead
will be the cathode!

LD...

CATHODE

First: Bend the leads exactly like

the drawing.
Next: Solder one lead, and check
the position, if necessary correct
by heating the soldering.

IMPORTANT
Mount these LEDs exactly like in the
drawing, otherwise some LEDs will not
fit correctly in the front panel.
Please also use the front panel as a positioning reference.

Last: Solder the

second connection.
3mm

q LD7 L-424YDT
FIG. 1

q
q
q
q
q
q

LD1 L-424YDT
LD2 L-424YDT
LD3 L-424YDT
LD4 L-424YDT
LD5 L-424YDT
LD6 L-424YDT

3mm

12mm

FIG. 2
7mm

q LD8 L-424YDT
FIG. 3

15

Construction
22. Mounting the sub PCB support

q Mount four 2cm (0.8)

M3 spacers at the indicated positions using
four 6mm (0.23) M3
screws.

16

Enclosure preparation
23. Enclosure preparation
q Cut the thread in the holes for the enclosure feet in one of the aluminum
profiles, using the supplied special
M4 screw as a tap.

FIG. 1

q Cut the thread in the front and

back of the aluminum profiles,
using the supplied special M4
screw (4 holes per piece)

FIG. 2

q Mount the feet on the aluminum profile, using four M4 hexagonal Allen
screws. Use the supplied Allen
wrench. It is advisable to stick the protection adhesive onto the feet.

FIG. 3

q Mount the valve protection covers on one

of the aluminum profiles. Use four M4 hexagonal Allen screws.
FIG. 4

17

Enclosure preparation

q Position the main PCB in the

aluminum profile that is prepared with the feet.

FIG. 5

Align pcb with profile !

q Mark the center position of the three fixation holes on the aluminum.

18

Enclosure preparation

q Remove the pcb and use a

knife or a screwdriver to
scratch the paint from the aluminum fixation, from the hole
closest to the back end. This
fixation will be used later to
connect the ground and
earth.
FIG. 6

q Mount the 3, 5mm

(0.14) spacers like in
the drawing. Using
three hexagonal
5mm M3 spacer
screws and a
washer. Do not tighten
the spacers yet.

FIG. 7
M3 hex. nut
Washer

q Position the PCB in the enclosure and check if the position of the spacers is
correct, if so, remove the PCB and tighten the spacers.

FIG. 8

0.0
00

q Using an ohmmeter, measure between the edge of the aluminum profile and
the back spacer, if there is a good electric contact (0 ohm). If not, repeat the
above step to remove the paint under the spacer.

19

Final assembly
24. Potentiometer assembly and final PCB mount
q Mount the PCB into the enclosure like before.
Tip: Check if the
pcb does not have
to much play at the
potentiometer posiPlay? tion.
If there is too much
play, put a piece of
tape round the edge of the pcb to remove
FIG. 1 the slack.

q Fix the pcb using a

5mm spacers next to
C9.

FIG. 2

q Mount the knob onto the potentiometer. (check the notch position)
FIG. 3

FUse the supplied Allen wrench

MIN

20

MAX

Final assembly

q Now carefully mount the front panel, using two M4 Allen screws. Check the position of the LEDs.
q Check if the potentiometer turns smoothly
without touching the front panel, otherwise correct his position or the position of
the front panel.
FIG. 4

F Use the supplied Allen wrench

q Remove the front panel and fix the nuts of the potentiometer bracket.
q Remove the PCB from the enclosure and solder the potentiometer connections.

IMPORTANT:
q Slide an M3 hexagonal screw into the profile
side. Position the screw about in the center of
the profile.
q Again mount the pcb into the enclosure.
q Fix the pcb using a 2cm (0.8)
spacer at the position next to
SK07 and use 5mm spacers to
fix the other two positions.
Measure, using an ohm meter
(or continuity beeper) if the
2cm spacer is electrically connected to the ground wire
(yellow green wire). If not, recheck if the paint of the aluminum is correctly removed.

FIG. 5

SPACER

FIG. 6

q Mount the left channel PCB onto

the spacers, check that the connector is correctly inserted. Fix the
PCB using five 6mm M3 screws.

FIG. 7

21

Final assembly
25. Final assembly and connection

Mounting the voltage regulator:

q VR1: 7812 (isolated plastic type)
First bend his leads like in the drawing
Then mount him onto the previously inserted hexagonal screw, at the appropriate position according to the PCB. Use a
5mm spacer screw.
FIG. 1

Last solder his connections.

FIG. 2

q Mount (insert) the

mains connector onto
the rear panel. Insert a
250mA fuse into the
connector (there is also
room for a spare fuse).
q Mount the rear panel
onto the enclosure, using two M4 Allen
screws.

22

FIG. 3

Test
q Connect the mains wires to the
mains connector, Blue= Neutral,
Brown= Live, and green/yellow=
Earth. Use a piece of 1.5cm (0.6)
shrink tube to isolate each connection.

FIG. 4

q Mount the front panel onto the

front, using two M4 Allen
screws.

FCheck the position of the

LEDs and check if all buttons
are working correctly.
It could be that paint rest over
in the holes, is preventing the
buttons from smooth operation.

FIG. 5

23

Diagram
26. IC and Valve mounting

Insert the IC into his socket. Watch the position of the notch!
q IC1 VK8020 / PIC16C54RC

Insert the valves into their socket (watch the position)

q V1: ECC82, 12AU7, CV491, 6189, 8136
q V2: ECC82, 12AU7, CV491, 6189, 8136
27. Test

Connect the power cord to the mains connector.

Connect the power cord to the mains output

CAUTION: Some points on the PCB are connected to the dangerous mains voltage or high DC voltage.

Push the power button (or one of the input selection buttons)
Check if the power supply LED LD08 is lit. This means that the high voltage is
correct.
Normally the valves filaments (or heaters) must also work.

Disconnect the mains plug.

Check the user manual to test all functions and operation of the unit, then the
aluminum cover can be mounted.
Please note that the user manual is also used for the ready assembled version.
Some remarks may not be related to the kit version.

24

Diagram

VR1

21V@230Vac in

D10

GND

uA7812P
O
I

+12.5V
C24

C13

115V

B+C

A+B
C+D

Mains selection

C10

TR1

18V
100n

1000

1000

100n
1N4148

230V

1N4007

RY9

100n

470

D11

C26

C27

C12

D09

1N4007

100n

SK10

18V

C11
R35
1R

12V

+12V
PWR

22n/630V

C
D

220V

C20

SK09
265V@230Vac in

R30

+300V

1N4007 D13

R31

C08

1K

C28

C29

47/350V

47/350V

D14

D15

R09
680R

1K
C30

1N4007
D12

100n

47/350V
1N4007

R34

SK08
N

1N4007

L
MAINS

LD8

27K/0.6W
R33

R32

27K/0.6W

27K/0.6W

L-424YDT

+5V

O
C14

100

100n

D16

+12V

D18

D17

I
GND

C23

POWER SUPPLY SECTION

D19 1N4007

1N4007

uA7805 VR2

1N4007

C15

C25

100n

1000

1N4007

+12V
+5V

1N4007
D20
BC557

PWR
R37

T10

4K7
BC547

T09

R36
+5V

10K
R41

R38

1K

10K

R46
1K

R48
1K

R45
1K
+5V

R39

Input4
+6dB
Mute
Monitor

CONTROLLER SECTION

PIC16C54RC

5 VSS

Input3

IC1
OSC1/CLKIN OSC2/CLKOUT
T0CKI
RA1
MCLR/VPP
RA0
RA3
RB7
RB0
RB6
RB1
RB3
RB2
RB4
RB5
RA2

10K

Input2

16
3
4
2
6
7
8
11

100n

10K

L-424YDT

Input1

+5V

R40 R42 R43 R44 R47

C09

10K

L-424YDT

LD6

4K7
220p

10K

L-424YDT

LD4

C07

10K

LD7

VDD 14

LD5

L-424YDT

L-424YDT

L-424YDT

LD2

LD3
L-424YDT

LD1

SW4
15
18
17
13
12
9
10
1

REC
SW3
TUNER
SW2
CD
SW1
PU/LINE
SW5
STBY / MUTE

Velleman Kit

25

Diagram

PU/LINE

RY1

SK1
+5V

C1
BC557

220p
D1
T1
1N4148
CD

R1
10K

RY2

SK2
+5V

C2
BC557

220p
D2
T2

SK7

1N4148
TUNER

R2
10K

RY3

SK3
+5V

C3
BC557

220p
D3
T3
1N4148
REC

R3
10K

RY4

SK4
+5V
C4

+5V

20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

BC557

220p
D4
T4
1N4148

R4
10K

MONITOR
RY5

R7

SK5
1K
BC557

C5

+5V

220p
D5

T5
R5

1N4148

10K
LINE OUT L
R8
SK6

330R
C6

RY6

220p

+5V

BC557

D6
1N4148

T6

R6
10K

LEFT INPUT / OUTPUT SECTION

Velleman Kit

26

Diagram

+300V

PU/LINE

RY1

SK01

170v

+5V
BC557

C01

100K

T01

C32

R01
10K

1N4148
C17

RY2

ECC82

SK02

+5V
BC557

C02

2.2uF

RV1A

R03
10K

1N4148
Input3
REC

RY4
+5V
BC557
C04
T04

220p
D04

4u7/160V

+5V
T08

RY8

R17

D08
R19
10K

3K6 1%

R11

R15
5K6

1N4148

Line out L

+6dB
Line out L

Input1
Input2
Input3

+300V

Input4
Monitor
Mute

R24
+5V

100K

47/350V
C34

Input4

R27

10K

1N4148

33K 1%

R05
10K

C21
BC557

27K/0.6W

T03

+5V
BC557
C03

20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

115V
R16 R10
680R 1M

3K6 1%
+12.5V

SK07

RY3

Input2

SK04

R13

1N4148

D03

68n/630V

50K

R02
10K

220p

C18

7V -4V 3

D02

SK03

V1

T02

220p

TUNER

47/350V
220V

130V - 100V

CD

C31

R12

Input1

R18

10K

D01

33K 1%

220p

R14

47/350V

C33

R22

47/350V

MONITOR
RY5

R04

C16

+5V

1K

ECC82
2.2uF

C05

RV1B

T05

220p
D05

BC557

SK05

V2

C19 68n/630V

50K

R06
10K

1N4148
3K6 1%
+12.5V

C22
BC557

R07
SK06

Line out R

1K

R26

RY6

220p

BC557

3K6 1%

+5V

4u7/160V

+5V
RY7

T07
D07

R25
10K

27K/0.6W

C06

R28 R20
680R 1M

LINE OUT R

R23

Monitor

R21

R29
5K6

1N4148
T06
D06
1N4148

R08

+6dB
Mute

10K

RIGHT INPUT / OUTPUT SECTION

AND AMPLIFIER SECTION

Line out R

Velleman Kit

27

VELLEMAN KIT NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
Info ?: http://www.velleman.be
Questions ?: support@velleman.be

Modifications and typographical errors reserved

Velleman Kit nv
H8020IP - 2000 - ED1