OSD Overdrive Special Design Builders Guide For the sole personal use of Trinity Amps Customers. February 2018, Version 1.16 Parts © Trinity Amps 2005 - 2018 www.trinityamps.com Trinity Amps OSD Builders Guide Ver. 1.16 - 1 - Table of Contents Table of Contents ................................................................................................................................................................................................... 2 Introduction ............................................................................................................................................................................................................ 6 Acknowledgements ................................................................................................................................................................................................ 6 WARNING ............................................................................................................................................................................................................. 7 Please Read this Information Carefully .................................................................................................................................................... 7 Version Control ...................................................................................................................................................................................................... 8 About the OSD .................................................................................................................................................................................................... 10 Guitar Amplifier Basics ....................................................................................................................................................................................... 11 Dumble Tone Stack – from Merlin ............................................................................................................................................................. 14 General Amplifier Operation ............................................................................................................................................................................. 16 Some DO NOTS ....................................................................................................................................................................................... 16 Some DOs........................................................................................................................................................................................................ 16 Introduction to Vacuum Tubes and Common Terms .................................................................................................................................. 17 Building an Amp................................................................................................................................................................................................... 20 Introduction ..................................................................................................................................................................................................... 20 Switches and wire............................................................................................................................................................................................ 20 Physical layout ................................................................................................................................................................................................. 20 Grounding ........................................................................................................................................................................................................ 20 Insulated jacks ................................................................................................................................................................................................. 21 Minimizing transformer interference .......................................................................................................................................................... 21 Wiring ............................................................................................................................................................................................................... 21 Assembling the amp ............................................................................................................................................................................................ 22 Before You Begin ........................................................................................................................................................................................... 22 Tools ................................................................................................................................................................................................................. 22 Soldering ........................................................................................................................................................................................................... 22 Tube Pin Numbering ..................................................................................................................................................................................... 23 Check Your Kit..................................................................................................................................................................................................... 24 OSD Build Steps Summary ................................................................................................................................................................................ 24 1. Install all the Hardware ................................................................................................................................................................................... 25 2. Install Terminal Strips ..................................................................................................................................................................................... 29 3. Install Terminal Strip Components .............................................................................................................................................................. 33 4 Install Components on the Send Return Jacks and Bias Points ............................................................................................................... 36 5 Install the ground bus ...................................................................................................................................................................................... 37 6 Connect Components to the ground bus ..................................................................................................................................................... 38 7 Build the RELAY board .................................................................................................................................................................................. 42 8 Install the Power Transformer and Output Transformer ......................................................................................................................... 45 Wire the Output Transformer ................................................................................................................................................................. 45 Wire the Impedance Selector and Output Jacks ................................................................................................................................... 47 9 Wiring the Power Transformer Primary Leads ........................................................................................................................................... 48 120V Mains ...................................................................................................................................................................................................... 48 240V Mains ...................................................................................................................................................................................................... 49 Test the Power Transformer .................................................................................................................................................................... 50 Test the Overdrive RELAY Board ......................................................................................................................................................... 52 10 Build the Eyelet Board. Install it in the Chassis ....................................................................................................................................... 53 Eyelet Board General Assembly Notes ...................................................................................................................................................... 55 Eyelet Board Assembly ............................................................................................................................................................................. 57 11 Connect Eyelet Board Ground Points ........................................................................................................................................................ 63 12 Connecting the Eyelet Board to Tube Sockets ......................................................................................................................................... 64 13 Connecting the Eyelet Board to the Controls ........................................................................................................................................... 69 Trinity Amps OSD Builders Guide Ver. 1.16 - 2 - Shielded Cable ............................................................................................................................................................................................. 69 14 Wire the RELAY Board to the Foot Switch Chassis Socket. ................................................................................................................. 77 15 Complete the Power Transformer Secondary Wiring. ............................................................................................................................. 78 16 Complete Output Transformer Wiring....................................................................................................................................................... 81 17 Wire the Heaters ............................................................................................................................................................................................. 82 18 Double Check. ................................................................................................................................................................................................. 84 19 Build the Footswitch Box, Cable and DIN connector. ........................................................................................................................... 85 20 Start-Up Procedure ......................................................................................................................................................................................... 86 Making a Voltage Measurement ................................................................................................................................................................... 86 Discharging the Power Supply ..................................................................................................................................................................... 86 Quick OSD Setup ................................................................................................................................................................................................ 89 Using the OSD Controls..................................................................................................................................................................................... 90 Trinity Amps OSD OSD 6V6 Voltage Chart ................................................................................................................................................. 91 Trinity Amps OSD 6L6 Voltage Chart ............................................................................................................................................................ 92 WARNING ........................................................................................................................................................................................................... 93 Read This Information Carefully............................................................................................................................................................. 93 Troubleshooting ................................................................................................................................................................................................... 94 Hum .................................................................................................................................................................................................................. 94 Volume Test .................................................................................................................................................................................................... 94 Faulty tube ....................................................................................................................................................................................................... 95 Severely unmatched output tubes in a push pull amplifier ..................................................................................................................... 95 Faulty power supply filter caps ..................................................................................................................................................................... 95 Faulty bias supply in fixed bias amplifiers .................................................................................................................................................. 96 Unbalanced or not-ground-referenced filament winding ........................................................................................................................ 96 Defective input jack........................................................................................................................................................................................ 96 Poor AC grounding ........................................................................................................................................................................................ 96 Induced hum.................................................................................................................................................................................................... 96 Poor internal wire routing ............................................................................................................................................................................. 97 Poor AC Chassis Ground at Power Transformer .................................................................................................................................... 97 Defective internal grounding ........................................................................................................................................................................ 97 Hiss .................................................................................................................................................................................................................... 97 Metal Film Resistor Substitutions ................................................................................................................................................................ 97 Squealing/Feedback ....................................................................................................................................................................................... 98 Radio Interference .......................................................................................................................................................................................... 98 Scratchy Sounds on Potentiometer(s) ......................................................................................................................................................... 98 Amp Buzz or Rattle When Installed in Cabinet ........................................................................................................................................ 98 Tone Tweaking ................................................................................................................................................................................................... 101 General Tips for fine tuning your amp ..................................................................................................................................................... 101 Appendix 1 - Running 6L6 Tubes in the OSD ............................................................................................................................................. 102 Calculating Power Tube Bias ...................................................................................................................................................................... 102 Appendix 2 - Installing the Buffered Effects Loop ..................................................................................................................................... 103 Appendix 3 - How to read Resistor Color Codes ........................................................................................................................................ 106 First the code ............................................................................................................................................................................................ 106 How to read the Color Code ................................................................................................................................................................. 106 Appendix 4 - How to read Capacitor Codes ................................................................................................................................................. 107 Appendix 5 - FAQ ............................................................................................................................................................................................. 109 Appendix 6 - Cliff Jacks Explained ................................................................................................................................................................. 111 Appendix 7 – Additional Mains Wiring Schematics .................................................................................................................................... 112 Appendix 8- OSD Bill of Materials ................................................................................................................................................................. 114 ADDENDUM – Eyelet Board Mounting ..................................................................................................................................................... 116 ADDENDUM – FOOTSWITCH - RELAY BOARD CONNECTION ............................................................................................. 117 Trinity Amps Schematics and Layouts ........................................................................................................................................................... 120 Trinity Amps OSD Builders Guide Ver. 1.16 - 3 - Trinity Amps OSD Builders Guide Ver. 1.16 - 4 - Thank You Thank you for purchasing your OSD kit from Trinity Amps. We truly hope that you enjoy building it and that it will be enjoyed for many years. If you have any questions please do not hesitate to contact us and. Please be sure to check the package contents in case there are any missing items. We are always looking for feedback form our Customers on our products. We have checked the build instructions over thoroughly and are confident in our product. However, mistakes do happen so our advice is that as you connect each wire and part according to the layout, cross-check against the schematic. If you find any inconsistencies, or have any concerns, please let us know. Do not hesitate to contact us! We want this build to be successful for you and for Trinity Amps! We’re confident that you will like our product and our support and when you’re completed, we’d appreciate your comments posted on any of the internet forums such as thegearpage.net, 18watt.com, AX84.com or trinityamps.com. You will find some extra business cards in the package. Please keep one and pass the rest around. We know you have a choice in suppliers and do appreciate your business. If there is any other product we can provide to you or your associates, please get in touch and we will be happy to discuss requirements. Sincerely, Stephen Cohrs, Trinity Amps Web site: www.trinityamps.com email: [email protected] Trinity Amps OSD Builders Guide Ver. 1.16 - 5 - Introduction This guide has been prepared for builders of Trinity Amps Kits. It is always being improved and we would appreciate your feedback and comments to: [email protected] Accordingly, content and specifications are subject to change without notice. We do try to make it as accurate as possible, but it is sometimes hard to keep up with the changes. Therefore, if you do find an error, please let us know about it and we will correct it. Suggestions are welcome so if you have one, please get in touch with us. Sources of help. Forums: Please use the various forums to get help. They are an excellent resource and can be found at trinityamps.com, AX84.com, the Gear Page etc.. Color assembly pictures and the latest drawings, tips, techniques are all in the Trinity Amps Forum, in the Resources Forum. To view the Resources, you need to sign up so go to www.trinityamps.com and click on the Forum button. Email: We can’t help with every problem but if you can not get your problem resolved, email us and we’ll do our best to help. Phone Call: If your problem can’t be solved, email for a phone appointment. Acknowledgements Much of the content in this document is original. Rather than reinvent content, some parts are based on content from other excellent sources and are hereby acknowledged. R.G. Keen’s site www.geofex.com - Tube Amp FAQ, Tube Amp Debugging AX84.com site www.AX84.com - Gary Anwyl's P1 construction guide version 1.0 GM Arts website http://users.chariot.net.au/~gmarts/index.html - Guitar Amp Basics www.18watt.com - website for various content and diagrams – Richie TMB Aron from diystompboxes.com Parts © Trinity Amps 2005. No part of this document may be copied or reprinted without written permission of Trinity Amps or contributing authors listed above. Trinity Amps OSD Builders Guide Ver. 1.16 - 6 - WARNING Please Read this Information Carefully The projects described in these pages utilize POTENTIALLY FATAL HIGH VOLTAGES. If you are in any way unfamiliar with high voltage circuits or are uncomfortable working around high voltages, PLEASE DO NOT RISK YOUR LIFE BY BUILDING THEM. Seek help from a competent technician before building any unfamiliar electronics circuit. While efforts are made to ensure accuracy of these circuits, no guarantee is provided, of any kind! USE AT YOUR OWN RISK: TRINITY AMPS EXPRESSLY DISCLAIM ALL LIABILITY FOR INJURY OR PROPERTY DAMAGE RESULTING FROM THIS INFORMATION! ALL INFORMATION IS PROVIDED 'AS-IS' AND WITHOUT WARRANTY OF ANY KIND. REMEMBER: NEVER OPERATE YOUR AMP WITHOUT A LOAD. YOU WILL RUIN YOUR OUTPUT TRANSFORMER! Trinity Amps OSD Builders Guide Ver. 1.16 - 7 - Version Control Version Date Change 1.0 14Dec17 FIRST RELEASE 1.01 26Dec17 Note added to modify terminal strips and mounting ground lugs 1.02 27Dec17 Added description of Power/Stand-by switch installation with washer; Tone Tweaking note enhanced. 1.03 29Dec17 Mod instructions around installing 5K Trim Pot and PI components section (A. McKay) Added addendum for insulating the mounting screw in PI section close to Trim Pot. 1.04 31Dec17 Added note on tying off 100V Black/White and White / Black when not use in 120 or 240V implementations 1.05 29Jan18 Updated Relay testing procedure (J. Ianieri) 1.06 30Jan18 Corrected SEND JACK connection to Master Volume (not eyelet board) (C. Gwyn) 1.07 5Feb18 Updated orientation of Relays on board. (K. Matsumoto) 1.08 12Feb Removed jumper on mid control pins 2-3 . (C. Gwyn) 1.09 9Mar Corrected parts list for Preamp Components (2) section to 2- 10uF bypass caps and 1 – 150K 1% resistor. (B.Manker) 1.10 14Mar Corrected Rock/Jazz switch terminal numbers to “Solder a jumper between pins 1 and 4 on the DPDT switch”. Corrected description and quantity of DPDT Mini Toggle Switch to ‘3’ in BOM (M. Johnson) 1.11 19Mar18 Updated jumper wires p.54 (M. Johnson) 1.12 22Mar18 Changed procedure to connect lead from DPDT JAZZ/ROCK switch terminal 2 (was 3) to PAB RELAY 2, NC terminal (B. Manker). Corrected 240V hook-up and PT schematics. Appendix with all mains voltages supported (N. Kehlet) 1.13 1.14 7Aug18 Updated BOM per feedback from R. Vaivads 1.15 9Aug18 Corrected TRIM Control pot wiring and FX board installation Trinity Amps OSD Builders Guide Ver. 1.16 - 8 - Trinity Amps OSD Builders Guide Ver. 1.16 - 9 - About the OSD Dumble amplifiers are synonymous with the rarest finest boutique amplifiers. Alexander “Howard” Dumble started building the legendary amplifiers in the 60’s in southern California. Over time he designed and hand-built and tweaked many amps that were used by Stevie Ray Vaughn, Eric Johnson, Carlos Santana, John Mayer, Robben Ford, Larry Carlton etc.. The Overdrive Special (ODS) is by far Dumble’s most well-known and popular amp. As a result they are Dumble’s most produced amp with approximately 250 built. With previously owned ODS’ easily selling for over $100,000 USD these days online they are not your average basement rockers amp. The Trinity Amps OSD is modelled after the 100W Dumble ODS #124 with just a few less frills. It boasts a nominal 24W output in a compact format of only 15-1/2 in W X 7-1/2” in H X 9-1/2 in D and 25 lbs., two channels - Clean and Overdrive. The amp uses using 6V6 output tubes in fixed bias mode. Since most on-stage set-ups are miked, 100 watts power is almost never required and 24 watts is both sufficient and surprisingly loud even for medium gigs, especially in this design. This lower wattage helps keep volume levels manageable and makes it very useful in a studio. There is also an option to run 6L^ for slightly higher (33 watts)power. The preamp has three 12AX7 tubes which are used for the Clean channel, Overdrive channel and the Phase Inverter. On the back of the amp there is a control to configure Overdrive channel Trim. The Overdrive channel and Pre-Amp Boost (PAB) are activated with a footswitch connected to the back of the amp. There is also a passive effects loop, like in the originals. This is very effective if, for example, you want to inject some reverb. We have used a Holy Grail Reverb pedal here and it works very well. The “spanky” clean preamp has a percussive nature is extremely inspirational. This preamp stays nice and clean and allows you to crank the power amp to achieve a highly percussive tone that taps into the compression and sustain of the power amp tubes. The magic of the OSD comes from the Overdrive channel sound. The Overdrive channel provides a very smooth, sweet sustaining distorted tone. Activating the Overdrive circuit adds two additional gain stages and the result is an Overdrive that ranges from clean and harmonically rich to smooth and thick with ample saturation. Trinity Amps OSD Builders Guide Ver. 1.16 - 10 -