10watt Amplifier Assembly instructions

Etching the Circuit Board

1) 2) 3) 4) 5) 6) 7) 8) Obtain the copper clad board from the instructor. Steel wool the board to ensure it is free of grease or any other foreign material. Obtain the Amplifier Circuit Board Layout design from the instructor. Turn on the T-shirt Press and ensure the temperature is set to 3500. Place the copper clad board in the centre of the T-shirt Press with the copper facing up and the Amplifier Circuit Board Layout on top of the copper so the design is against the copper. Press the copper clad board and the Amplifier Circuit Board Layout together for 1 minute using heavy pressure. Remove the board after 1 minute. CAUTION: The board will be hot. Using running water and soap, scrub the board gently with your finger until the paper dissolves away and the copper clad board is left with just the Amplifier Circuit Board design on it. NOTE: check that all the paper has been removed, ESPECIALLY in the centre of each pad, as any paper left will not allow the board to be etched properly and drilling the pads will be more difficult. Print your name on the board using the special etchant resist pen. At the same time you are printing your name, inspect the board for any breaks in the traces and fix them. Let the resist pen ink dry for a couple of minutes before putting it in the etching solution. Drill a #55 hole in one of the corners of the board and string a 4piece of wire through it. Twist the wire together to form a loop. Turn on the etching tank (the lid must be down and the power light on) and ensure that sufficient time has been given for the heater to heat up the etching solution (the heater light will turn off). NOTE: A circuit board takes longer to etch with cold etching solution. With protective gloves and an apron on (Etching solution on clothing is PERMINANT!!!), open the lid of the etching tank and hang your board in the tank. Close the lid. Turn the timer on to about 2 3 minutes to etch the board. It will take longer if the etching solution is not warm. Once the timer has finished, using protective gear, open the lid of the etching tank and do a visual check to see if the board is completely etched. You know it is etched when the circuit board design is clearly defined and the board has a yellow/green appearance. Using protective gear remove your circuit board from the tank and IMMEDIATELY place it in the plastic container without dripping all over the tank and floor. Take the board, in the plastic container, to the sink and wash the etching solution off the board. Dry the board off with paper towel and inspect it. If it looks good you can begin drilling holes ONCE you know what size holes to drill. Clean off the toner material that is left after the etching process with steel wool. The board should be back to the original copper shine or you wont be able to solder to it properly.

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Parts Placement

Using the 10 Watt Amplifier Schematic above, figure out where the parts are to be placed on the board below. You will not get any parts until you can show me the proper parts placement.

Drilling and Soldering 1) Using a #55 drill bit, drill the holes for the TDA2003 chips, speaker wires, power wires, resistors, diode, 470uf and 2000uf capacitors. 2) Using a #60 drill bit, drill the holes for the remaining parts (small capacitors, jumper wire, test jumpers, incoming audio signals) 3) Begin assembling the components on the board. Start with all the components that are not very tall ( watt resistors, jumper, diode, .1uf and 10uf capacitors). 4) Next solder in the TDA2003 amplifier chips. Be VERY CAREFUL when soldering in these chips to NOT overheat them. The suggestion is to alternate between each chip, soldering 1 pin at a time. This gives the chip time to cool between soldering pins. 5) Solder in place the last components (470uf and 2000uf capacitors). 6) Find 2 stranded wires about 8 inches long for your positive and negative power and solder them in place. 7) Obtain two 8 inch pieces of 18 gauge speaker wire from the instructor and solder them in place. Make sure the copper coloured wire is connected to the 2000uf capacitor and the silver colour is attached to negative. 8) You need 2 pairs of solid core breadboarding wire 6 long to solder into the Test Jumper holes. DO NOT connect them together as they will be used later for testing purposes. 9) Finally, get the 3 conductor shielded wire from the instructor. Strip back as little as needed of the shielding to expose the 3 wires (left - black, bare ground, right - red). Solder in place the 3 wires. 10) The board is now complete for now. 11) Check every solder joint to ensure that they are good and that there is not a single trace or solder touching another. Once you are sure everything is good, you are ready for the testing phase of the project.

DO NOT PUT POWER TO THE BOARD!!!!!

The testing phase of the project requires you to setup a power supply (supplies voltage), ammeter (to measure current), frequency generator (provides an input signal), and the oscilloscope (to measure the input signal and the amplified output).

Testing your Amplifier to ensure it is working properly

1) Connect a power supply to your circuit and ensure the voltage is set to ZERO. Do NOT turn it on. 2) Connect an analog ammeter to the left side of the circuit using the 500mA setting. Take the 2 test point wires on the left side of the board and connect the ammeter between them. Ensure the leads on the ammeter are connected in the correct direction the positive lead it connected towards positive and the negative lead is connected towards the negative. 3) Turn the power on. Increase the power supply voltage slowly and monitor the current flow. Idle current should start to appear at 6V and reach about 60mA when you get to 12V. If it is not, you could have parts in incorrectly or bad solders or a short circuit. IF AT ANY TIME THE NEEDLE ON THE AMMETER GOES PAST 60MA, SHUT THE POWER OFF IMMEDIATELY!!!

Your actual Left Channel Idle current reading ____________

4) Repeat sets 2 and 3 for the right side of your board

Your actual Right Channel Idle current reading ____________

You have now established that the Idle current for both channels in the circuit is correct. 5) Now that you have checked the idle current you may install a dummy load across the speaker wires (The dummy load is a 3.9ohm 2watt resistor and it replicates a 4ohm speaker. The amplifier cant tell the difference). This test is to check to see that the idle current remains the same when the output is loaded. Since idle current is dealing with a DC level (no input signal- flat line) it should not be affected by adding the load since the load is only supposed to have AC levels (Output signals) placed upon it. No DC level should appear across the output load. Remeasure the idle current using the previous procedure (Steps 2 and 3) including starting at ZERO voltage. Idle current should remain the same. If the current changes IMMEDIATE TURN OFF THE POWER Left Channel Idle current loaded _________ Right Channel Idle current loaded _________