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H.C. Andersensvej 56
or Gert Frederiksen
+45 6062 9017
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800XE Build Example
Here is an example of building a complete ZapPulse 800XE amplifier into a 35*18*5cm aluminum enclosure.
The used drilling template for this specific project can be downloaded here: Drill Drawing. Scaled to fit an A4 - make sure to verify the measurements!
Front Panel View
Simple front with a white 5mm LED (we've used a 12kohm series resistor to 12V) and a mains switch.
Inside the Enclosure
Looking inside the box: The transformer is fitted with a rubber washer under and over the transformer and fastened with a bolt, giant washer and nut. Be careful not to over-tighten the nut! In addition to potentially bending the chassis plate, the transformer will also transfer more mechanical hum to the cabinet if the bolt/nut is too tight.
The original wires from the transformer are double insulated and are also used (cut) for the power entry filter and mains switch (see configuration examples for 230V mains or 115V mains (wiring etc.)). The ground wire from the power entry filter is soldered to a ring terminal which is attached to the cabinet with a toothed washer, 4mm bolt and double nut (so it can not be unscrewed from the outside). If the enclosure is made with ie. anodized aluminum or painted panels: Be sure to sand/scratch the contact area down to bare metal before mounting the ground connection. This is important to get a proper electrical contact!
The Predator 800XE supply rectifiers are mounted with a little thermal grease and 3mm screws. The PCB is fastened with a 4mm bolt. The two large capacitors has been given a blob of glue from a glue gun - it's usually not necessary, but makes sure there's no rattle when played loud. The power cable to the 800XE module has in been soldered directly to Predator 800XE board. Using the screw terminals is equally good.
The 800XE module (with buffer) is fitted with thermal paste on the contact surfaces ("cooling towers") and fastened with 3mm bolts. Use the included 200mm micro-match ribbon to connect the buffer module and the regulated low voltage supply of the Predator 800XE supply. Please note the small polarisation holes in the PCBs; the taps on the connectors fit those...
Rear Panel View
The rear panel shown is fitted with Neutrik XLR connectors and Teflon insulated alu RCA sockets. The connections to the buffer of the 800XE module are made with some short, twisted stripline cables. Speaker terminals are mounted on the supplied plastic backing, which makes it easier to get nicely aligned. The supplied speaker cable for the 800XE module is cut so it fits nicely. Short and especially away from the input cables is good! All connections are soldered using our 4% silver solder. In this model we have also soldered the speaker wires in the terminals (please note that this requires a powerful soldering iron!) - they can also be fastened using the screws.
ZapPulse 800XE Essentials Kit
The ZapPulse 800XE Essentials Kit contains almost everything needed to build a complete high-end 2*230W in 8ohm amplifier into your preferred enclosure:
- ZapPulse 800XE amplifier module with buffer (supplied with screws / nuts and supply/speaker cables with the appropriate connectors)
- Predator XE supply of 2 * 15000uF capacitors and + /-12V supply (supplied with screws / washers / nuts)
- 220VA toroidal transformer (2*42VAC and 1*15VAC) "pancake" (supplied with mounting hardware)
- 2 sets of our speaker terminals
- 1 set of alu/Teflon RCA chassis terminals (input)
- 2 Neutrik Gold XLR female chassis terminals (input)
- approx. 1m Teflon-insulated Stripline silver cable for signal connections
- Schaffner IEC power entry filter with fuse holder
- 2 x 3.15A slow blow fuses
- Ring terminal, a piece of ground wire and 4mm bolt, toothed washer and two nuts
|ZapPulse 800XE essentials kit||EUR 483.22||Order Now
|Taking DIY to the next level!|
To assemble the kit you'll also need:
- A fitting enclosure
- Mains switch
- Some thermal paste
- Optionally a LED, resistor and some wire
Naturally, some tools are also required:
- Soldering iron & solder
- Wire cutters (and possibly. Stripper)
- Torx screwdrivers (T10, T20)
- Spanners or wrenches for transformer bolt / nut
- Drill, punch, drill bit (approximately 3.2 mm and 4.2 mm)
- Tools for making the holes/cut-outs in front and rear panels.
- Multimeter for checking connections, etc..
The kit might be supplemented with:
- DC filter (removes mechanical hum of the transformer due to DC on the mains)
- Soft Start (limits start-up current of transformer and capacitor bank)
- IEC mains cable (power)
- 2 pcs 3-pole screw terminal (for inputs)
- 1 pcs 4-pole screw terminals (for the PredatorXE supply power output)