KIT81 Assembly Instructions 1. KIT81 Instructions

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1 KIT81 Assembly Instructions 1 KIT81 Instructions Adire Audio 1111 Elliott Avenue West Seattle, WA techsupport@adireaudio.com TABLE OF CONTENTS 1. INTRODUCTION PARTS NEEDED TOOLS CROSSOVER SCHEMATIC CROSSOVER ASSEMBLY THE BASICS OF CROSSOVER ASSEMBLY SUGGESTED LAYOUT STRIP INDUCTOR INSULATION MOUNT INDUCTORS MOUNT CAPACITORS MOUNT RESISTORS CONNECT COMPONENT LEADS BUILD CONNECTION WIRES TEST, TEST, TEST SECURE COMPONENTS SOLDER JOINTS SECURE INSIDE CABINETS ENJOY! SYSTEM TROUBLESHOOTING CABINET PLANS DRIVER LAYOUT SEALED CABINET PLANS Cut Lists Drawings VENTED CABINET PLANS Cut Lists Drawings TRANSMISSION LINE CABINET PLANS Cut Lists Drawings KIT81 Assembly Instructions 1

2 KIT81 Assembly Instructions 2 1. Introduction Welcome to Adire Audio s KIT81 loudspeaker system. The KIT81 is a high-performance MT system designed for home audio reproduction, as well as home theater applications. It features one Adire Audio AV8 midwoofer and a single Audax TM025F1 tweeter per side, which yield a system sensitivity of 87 db 2.83 Vrms. 2. Parts Your kit should include the following parts: Part Qty Use 4.7 uf 250VDC polypropylene capacitor 2 C1 in the tweeter crossover 5.6 uf 250VDC polypropylene capacitor 2 C2 in the tweeter crossover 5.1 uf 250VDC polypropylene capacitor 2 C3 in the tweeter crossover 12 uf 250VDC polypropylene capacitor 2 C the woofer crossover 47 uf 250VDC polypropylene capacitor 2 C5 in the woofer crossover 0.27 mh 16 GA perfect lay air core coil 2 L1 in the tweeter crossover 0.47 mh 16 GA perfect lay air core coil 2 L2 in the tweeter crossover 0.82 mh 16 GA perfect lay air core coil 2 L3 in the woofer crossover 1.2 mh 16 GA perfect lay air core coil 2 L the woofer crossover 3 ohm 10W sandcast resistor 2 R1 in the tweeter crossover 2.4 ohm 10W sandcast resistor 2 R2 in the tweeter crossover 4.3 ohm 10W sandcast resistor 2 R3 in the woofer crossover 11 ohm 10W sandcast resistor 2 R the woofer crossover AV8 8 video shielded midwoofer 2 Woofers TM025F1 video shielded tweeter 2 Tweeters SBP two-terminal circular input cup 2 Single pair input cup 14GA/2C 14GA twin conductor cable 10 Internal wiring 0.25 female FAST-ON connector 12 Terminal connectors 21cm long wire tie wrap 30 Crossover assembly Small T-nut/socket cap screw set 8 Tweeter mounting Large T-nut/socket cap screw set 16 Woofer mounting If any parts are missing, please contact the factory as soon as possible, and we ll correct the shortage. 3. Needed Tools You ll need to supply the following parts and tools to assemble the KIT81: - Mounting board (hardboard, plywood, or any other material suitable for crossover mounting) - Electrical tape - Masking tape - Pliers - Razor blade or sandpaper - Wire cutters - Soldering iron - Solder KIT81 Assembly Instructions 2

3 KIT81 Assembly Instructions 3 4. Crossover Schematic + AMP IN - C1 C2 4.7 uf 5.6 uf L mh/16ga L2 R1 3 ohm 0.47 mh/16ga C3 5.1 uf - + AVF1 R2 2.4 ohm R4 11 ohm L3 L mh/16ga 1.2 mh/16ga 12 uf C5 C4 47 uf + AV8 R3 4.3 ohm - CONSTRUCTION NOTES ALL CAPS ARE SOLEN PA POLYPROPYLENE OR BETTER ALL INDUCTORS ARE SOLEN PERFECT LAY AIR CORE OR BETTER ALL RESISTORS ARE 10W SANDCAST UNITS OR BETTER DO NOT CHANGE INDUCTOR GAUGE NOTE TWEETER POLARITY IS REVERSED LEGEND: Black solid lines are viewable edges Grey lines are normally hidden from view Red lines are for dimensions Blue lines are for construction/reference Green lines are text/labels Copyright (C) Adire Audio. All Rights Reserved. Commercial use or reproduction of this design without the express written consent of Adire Audio is strictly prohibited, and punishable by law. TITLE SIZE CAGE CODE DWG NO REV A N/A DRAWN BY DCW SCALE KIT81 CROSSOVER SHEET N/A 1 of 1 B KIT81 Assembly Instructions 3

4 KIT81 Assembly Instructions 4 5. Crossover Assembly 5.1. The Basics of Crossover Assembly Crossover assembly is one of the most critical aspects of loudspeaker construction. A poorly built crossover can seriously degrade the sonic performance of a kit. Additionally, poor construction can lead to early failure of components! The key to good crossover assembly is to go slow. Take your time. Best to double-check every connection and step twice before proceeding. Remember, each part of a crossover interfaces with others. Mess up one connection, and that will ripple through the entire crossover. We recommend that you start by reading over these instructions a few times prior to actual construction. This way, you ll know what comes when, and will have a somewhat intuitive feel for the process. Also, familiarize yourself with the crossover schematic as best as possible! That way, when you re hooking parts up, you ll recognize bad connections before they become permanent. Inductors don t go in series with the tweeter; caps don t go in series with the woofer, and other basics. Get a feel for the flow of the crossover, and your assembly will go MUCH smoother. That said, let s get into the basics of crossover assembly Crossover assembly is the process of building the electrical network that goes between the amplifier and the driver(s). As such, it s VERY similar to other electrical kit assembly. If you ve soldered parts together before, and can read a schematic, you ll have no problems assembling this kit. On the other hand, if you ve never soldered, or don t understand schematics, you should the time to learn some basics of soldering, and how to read a schematic, or find a friend with some electronics experience, and you ll be set. We recommend any of the Intro to Electronics books at Radio Shack, or other electronics/hobbyist stores. Anyway, on to the assembly! KIT81 Assembly Instructions 4

5 KIT81 Assembly Instructions Suggested Layout C1 C2 R1 - F1 + AMP R2 L2 L1 - AMP C3 + F1 R4 + AMP L4 L3 + AV8 C5 C4 R3 - AMP - AV8 KIT81 Assembly Instructions 5

6 KIT81 Assembly Instructions 6 You can actually print out the layout, tape it to some ¼ thick hardboard or plywood, and use it as a drill/wiring/placement guide. If this document is printed out on US Letter or A-4 size paper (roughly 8.5 wide by 11 long), then the above layouts are in real 1:1 scale, matched for the actual component sizes. Each crossover board will be 4 wide by 6 long, and should easily fit through the woofer cutouts. As far as the crossover layout goes, we use the following marking conventions: Crosshatch is for inductors Standing inductors are labeled with a V ; i.e.: L2V indicates L2 is standing Alternating line/dashes are for capacitors Hexagons are for resistors Blue lines indicate electrical connections Red lines indicate tie wrap locations Red circles are holes bored for the tie wraps Tie wraps go through the center of both horizontal and vertical inductors Gray lines are for board edges. For the longer electrical connections, we recommend using either the extra inductor lead, or some of the supplied 14AWG wire. Alternatively, you can use some 16AWG or larger wire that you may have laying around. You may want to make the electrical connections on the back of the board, rather than the front. This will provide some more mechanical reinforcement for the components, but does require additional drilling of the mounting board. Simply drill a hole at the location of each component lead, and push/pull the leads through (this does make a neater looking crossover, but be careful when screwing the crossover down, so that you don t short out a hidden electrical connection!). Note that the driver and amplifier polarities are spelled out; follow them! KIT81 Assembly Instructions 6

7 KIT81 Assembly Instructions Strip Inductor Insulation The first thing you ll need to do is strip all of the varnish insulation off the inductor leads. This is what the razor blade or sandpaper is for. If you re using the razor blade, you ll need to scrape the insulation. Hold the razor blade perpendicular to the inductor lead, and scrape. Rotate the lead a bit, and scrape. Repeat as necessary. For the sandpaper, you re best bet is to wrap a small piece of paper around the inductor lead and twist. This will allow you to sand off the insulation in no time! 5.4. Mount Inductors Reading Inductor Values: All inductors are labeled with their value, such as 1.2 mh. All are 16 gauge units, so simply pay attention to the value on the inductor label. Now mount the inductors. All the locations are shown in section 5.2. Note that we ve labeled two of the inductors with a V. This means to stand the inductor up on end (like a standing tire or inner tube). Pull the leads through the mounting board. Give them a quick bend to hold the inductors down. Now use the masking tape to temporarily hold the inductors in place. Go ahead and be liberal with it, and don t worry about a perfect mount; we ll replace the tape with the wire ties later Mount Capacitors Reading Capacitor Values: All capacitors are marked with their nominal capacitance, such as 6.2 uf. All capacitors are 250VDC units, so, don t worry about matching up the voltage rating. Also, note that all the capacitors you received are non-polar. You don t have to worry about connecting the capacitor backwards, like you do with polarized capacitors. Lay out the capacitors on the board. As with the inductors, pull the leads through the mounting board then tape the capacitors down with the masking tape Mount Resistors Reading Resistor Values: Resistors are labeled WWSQP10JXRY, where XRY is the resistor value. X represents the whole ohm value, and Y the fractional ohm value. For example, a 7.5 ohm resistor would be 7R5, while an 11 ohm resistor would be 11R. The 10J represents the power handling; all resistors are rated for 10W, so as with the capacitors, don t worry about searching the kit for different power ratings on the resistors. Lastly, put the resistors on the board. Pull the leads through, and tape down the resistors with the masking tape Connect Component Leads Using the pliers, twist the component leads together as needed. You should be able to have all the leads contact each other as needed. No extra wire is necessary. Once each connection is made, give it a quick wrap in electrical tape, to avoid shorting out during the testing phase. KIT81 Assembly Instructions 7

8 KIT81 Assembly Instructions Build Connection Wires Now we ll build the connection wires. For this step, you ll need to use the wire cutters and the supplied internal cable and FAST-ON connectors. For each speaker, you ll need two 12 long pieces and one 36 piece. Use the 12 pieces to connect the drivers to the crossovers, and the 36 long piece to connect the input cup to the crossovers. Now strip ~0.5 of insulation off all ends of the cable. One end of each cable will ultimately be soldered to the crossover. The other ends we re going to attach to the Twist the raw ends of the cable on to the crossover inputs and outputs. Cover in electrical tape (for protection while testing the crossover) TEST, TEST, TEST Connect the connection wires to the drivers. For the tweeter, the wide terminal is the positive side; the narrow terminal is the negative side. Now mount the crossovers in the cabinets; lay them down on any suitable brace, or strap them to the wall of the cabinet with masking or duct tape. Mount the drivers into the cabinets. Now connect the crossover input wires to the terminal cup. Connect the terminal cup to your amp, and TURN THE VOLUME ALL THE WAY DOWN. Start playing some music. Turn the volume up VERY slowly. Put your ear in front of the tweeter, to make sure no bass is coming from it. Likewise, listen to EACH woofer to make sure no really high frequencies are coming from them. SLOWLY increase the volume a bit more. Listen to the soundstage, frequency response, and general timbre of the speaker. If all sounds OK, then continue on to the next step. Otherwise, see section 6 for details on tracking down a potential crossover problem Secure Components Now comes the fun part: strapping down all the components! Start by removing the crossovers from the speaker. Then use the supplied wire ties to strap the crossover components tight to the mounting board. Use one wire tie for each capacitor and resistor. Use two wire ties for the inductors, as they re pretty heavy. Go ahead and pull fairly tight; you don t want the components moving around. Don t pull so tight as to crush the capacitors, though that can damage the components. Just pull the ties tight enough that it takes a good amount of effort to get the components to move Solder Joints Unwrap the electrical-taped joints. Solder each joint, and inspect for cold solder joints. Then re-wrap each joint with electrical tape Secure Inside Cabinets Mount the crossovers inside the cabinets. Typically a pair of drywall screws are used to hold the crossover to a brace or side panel. Make sure you do NOT put a screw through a wire, or through the center of an inductor! Enjoy! We trust this step is self-explanatory KIT81 Assembly Instructions 8

9 KIT81 Assembly Instructions 9 6. System Troubleshooting So you encountered a few problems in testing the crossover. Here are some common tips to check over: 1. Double-check all component values. The resistors all look the same, and can only be differentiated by the markings! Likewise, check the capacitors and inductors. 2. Make sure the polarity of the drivers is observed. Reverse connections will create a deep suck-out in the midrange. 3. Triple-check all component values. 4. Make sure all joints are electrically isolated from each other. 5. Make sure you ve connected the positive tweeter output lead to the wide terminal of the tweeter. 6. Make sure the drivers are wired to the outputs of the crossover 7. Quadruple-check all component values. 8. Contact us! We try to answer all questions within one business day. You can reach us at techsupport@adireaudio.com, phone at , or FAX us at KIT81 Assembly Instructions 9

10 KIT81 Assembly Instructions Cabinet Plans We provide three basic cabinet plans for you to consider: a sealed box, a vented box, and a transmission line box. Also provided is the basic driver layout, if you decide to build your own box design Driver Layout Note that this layout is what we designed around. Keep the baffle width the same as shown here, and the driver locations the same with respect to the upper right hand corner, and you can rest assured that the crossover will function fine. There s really no reason to change the XO if the baffle is longer, or the box alignment changes; those effects will only make a difference in the sub-200 Hz range, where the crossover has no impact. All dimensions in inches Maintain baffle layout with respect to top edge for proper crossover operation One channel shown; mirror image other channel Minimum baffle length is 1ches; maximum is not defined CONSTRUCTION NOTES R1 in 3 in Copyright (C) Adire Audio. All Rights Reserved. Commercial use or reproduction of this design without the express written consent of Adire Audio is strictly prohibited, and punishable by law. SCALE N/A DRAWN BY DCW 1 of 1 SHEET A N/A LEGEND: TITLE Black solid lines are viewable edges Grey lines are normally hidden from view KIT81/KIT81M BAFFLE LAYOUT Red lines are for dimensions Blue lines are for construction/reference Green lines are text/labels SIZE CAGE CODE DWG NO REV 6 in R3.5 in 2.5 in 1.5 in 9 in 4.5 in KIT81 Assembly Instructions 10

11 KIT81 Assembly Instructions Sealed Cabinet Plans The Sealed Cabinet KIT81 is a net 14 liters, stuffed with 8 ounces of polyfill. This alignment is designed to provide bass extension to 67 Hz anechoic, with a system Qtc of 0.8. The result is a slight bump in the midbass, which is recommended for limited-bandwidth systems. The higher-qtc value, in combination with the 67 Hz anechoic extension, will yield typical in-room extension into the 40 Hz range. Maximum in-room SPL (driven with 100W) will be in excess of 105 db SPL (at 1 meter) from 60 Hz and up, which makes this system well suited for satellites in a home theater applications. In addition, the system will handle 100W continuously above 80 Hz, the typical crossover point for home theater applications Cut Lists Panel cuts QTY SIZE USE 2 14 x 9 Front and back 2 9 x 10.5 Top and bottom x 10.5 Sides x 10.5 Internal brace Hole/baffle cuts QTY SIZE USE 1 7 diameter Midwoofer cutout; cut in front panel 1 2 diameter Tweeter cutout; cut in front panel 1 4 diameter Internal air flow; cut in internal brace KIT81 Assembly Instructions 11

12 KIT81 Assembly Instructions Drawings Copyright (C) Adire Audio. All Rights Reserved. Commercial use or reproduction of this design without the express written consent of Adire Audio is strictly prohibited, and punishable by law. SCALE N/A DRAWN BY DCW 1 of 1 SHEET A N/A Cabinet is 9" wide, 12" deep, 14" high (external dimensions) Cabinet constructed of 3/4" thick MDF stock or better Drivers are not rabbeted in Cabinet assumes 8 ounces of stuffing for optimal performance Internal brace is perforated with a single 4"d hole CONSTRUCTION NOTES LEGEND: TITLE Black solid lines are viewable edges Grey lines are normally hidden from view KIT81/KIT81M Sealed Cabinet Red lines are for dimensions Blue lines are for construction/reference Green lines are text/labels SIZE CAGE CODE DWG NO REV FRONT VIEW SIDE VIEW 7.5 in BRACE 5.5 in 8.5 in R3.5 in 1 6 in R1 in 3.25 in 7 in 2 in 8.5 in 3.25 in 10.5 in 7.25 in 3.25 in R2 in 2.5 in 3.75 in 3.75 in in 1.5 in 4.5 in 12 in 9 in KIT81 Assembly Instructions 12

13 KIT81 Assembly Instructions Vented Cabinet Plans The Vented Cabinet KIT81 is a net 35 liters, tuned to 32.5 Hz (2 ID by 4.75 L vent), and stuffed with 16 ounces of polyfill (8 ounces behind the midwoofer, with the remainder in the lowest chamber of the cabinet, below the vent). This alignment is designed to provide bass extension to 42 Hz. The system will approximate a Q=0.707 second order response down to 26 Hz (fit within ±1 db). This low-q response, in combination with the 42 Hz anechoic extension, will yield typical in-room extension into the 35 Hz range. Maximum in-room SPL (driven with 100W) will be in excess of 105 db SPL (at 1 meter) from 28 Hz and up, which makes this system well-suited for wide-band audio applications Cut Lists Panel cuts QTY SIZE USE 2 31 x 9 Front and back 2 9 x 10.5 Top and bottom x 10.5 Sides x 10.5 Horizontal internal brace Hole/baffle cuts QTY SIZE USE 1 7 diameter Midwoofer cutout; cut in front panel 1 2 diameter Tweeter cutout; cut in front panel 6 4 diameter Internal air flow; two cut in each horizontal brace 1 2 diameter Vent mounting KIT81 Assembly Instructions 13

14 KIT81 Assembly Instructions Drawings Tune with a 2"d by 4.75" long vent Flare vent with a 1/2" 45 degree chamfer Cabinets constructed of 3/4" thick stock (MDF or better) Cabinets are 31" tall, 9" wide, 12" deep external Driver rabbets are not required FRONT VIEW SIDE VIEW 7.5 in 8.5 in 8.5 in 13.5 in 10.5 in R1.5 in R1 in 31 in 9 in R3.5 in 7.25 in 8.25 in 4.75 in 2 in 7 in 7.25 in 8.25 in 3.25 in 2.5 in 6 in R1 in 3 in 9 in 1.5 in 4.5 in 2 in 12 in 3.25 in Copyright (C) Adire Audio. All Rights Reserved. Commercial use or reproduction of this design without the express written consent of Adire Audio is strictly prohibited, and punishable by law. LEGEND: Black solid lines are viewable edges Grey lines are normally hidden from view Red lines are for dimensions Blue lines are for construction/reference Green lines are text/labels C O N S T R U C T I O N N O T E S 2.75 in BRACES 10.5 in 5 in R2 in R2 in 3.75 in 3.75 in 7.5 in 2.75 in SCALE N/A DRAWN BY DCW 1 of 1 SHEET A N/A SIZE CAGE CODE DWG NO REV KIT81 VENTED CABINET BAFFLE DETAIL 13.5 in R1.5 in R1 in 31 in 9 in R3.5 in 6 in R1 in 3 in 4.5 in 1.5 in 9 in 2.5 in KIT81 Assembly Instructions 14

15 KIT81 Assembly Instructions Transmission Line Cabinet Plans The Transmission Line Cabinet KIT81 is a net 76 long line, tapered from 4.5 width at the top to 3 width at the terminus. This results in a line tuning 44 Hz. The line is stuffed with 16 ounces of polyfill in the 4.5 width section, 10 ounces of polyfill in the middle 3.25 wide section, and 6 ounces of polyfill in the front 3 wide section. This alignment is designed to provide anechoic response to 40 Hz, with typical in-room response down to 30 Hz. Maximum SPL (driven with 100W) will be in excess of 105 db SPL (at 1 meter) from 38 Hz and up, which makes this system well-suited for most home audio applications. In addition, the system will handle 100W continuously from 45 Hz and up, resulting in linear operation over 95% of the audible bandwidth Cut Lists Panel cuts QTY SIZE USE 2 38 x 9 Front and back 2 9 x 12.5 Top and bottom x 12.5 Sides x 7.25 Horizontal front brace x 7.5 Rear line vertical divider x 7.5 Front line vertical divider Hole/baffle cuts QTY SIZE USE 1 7 diameter Midwoofer cutout; cut in front panel 1 2 diameter Tweeter cutout; cut in front panel x 3.25 Line terminus; cut in front panel KIT81 Assembly Instructions 15

16 KIT81 Assembly Instructions Drawings Copyright (C) Adire Audio. All Rights Reserved. Commercial use or reproduction of this design without the express written consent of Adire Audio is strictly prohibited, and punishable by law. Cabinets constructed of 3/4" thick stock (MDF or better) Cabinets are 31" tall, 9" wide, 12" deep external Driver rabbets are not required Stuff with 32 ounces of polyfill throughout line LEGEND: Black solid lines are viewable edges Grey lines are normally hidden from view Red lines are for dimensions Blue lines are for construction/reference Green lines are text/labels C O N S T R U C T I O N N O T E S FRONT VIEW SIDE VIEW 3.25 in 7.5 in 3.5 in 3.25 in 3.5 in 3 in 23.5 in in 29.5 in 38 in 2.75 in in 7.25 in R3.5 in in 6 in R1 in 3 in 4.5 in 1.5 in 7 in 2 in in 4.5 in 3.75 in 1 9 in 2.5 in SCALE N/A DRAWN BY DCW 1 of 1 SHEET A N/A SIZE CAGE CODE DWG NO REV KIT81 TRANSMISSION LINE CABINET HORIZONTAL BRACE REAR LINE DIVIDER 7.25 in 7.5 in FRONT LINE DIVIDER in in 7.5 in 7.5 in KIT81 Assembly Instructions 16