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Akai AA-1030 recap project and problems. Help needed.

bitomaxsp

Member
Hi AK members.

I own 1030 for about a year. Bought it for 130EUR and enjoyed so far. I knew it was in original state and untouched inside. Only lamps were changed. My dirty hands started itching and I decided to check main PSU voltages. They were quite off, more than 10%. I decided I'd do the recap and also replace PSU board and filter board with new ones. Seems like fun project to play :)

What I discovered along the way, heh... Schematic was not precise for PSU. Main AMP has quite different static either. Filter board (in the protection side) absolutely different except FM muting and filters itself.

I have experience doing stuff in Kicad, so I decided to contribute to open source a bit.
If anyone interested in having new PSU pcb you can use it for free (https://github.com/bitomaxsp/aa-1030-psu). All you need to do is to check it matches you schematic, modify if needed, make berbers and order.
I ordered rev.A and it works in my receiver very well. (in the repo there is rev.B which is more friendly for mounting. Made it after spent some time with rev.A at hand).

I also made new PCB for filter P.C. board, but not ready to make it open source. I'll put schematic here, as I noticed people incorrectly replace WZ-033 for diodes there :) NOTE: Mind the PCB number in the Title!
I made schematic from PCB and then double, triple checked it. Now new PCB work in my receiver. (will post repo link soon). PDF is attached to the post.

I also made transistor matcher, to match diff amp transistors. I replaced 2SA640 with KSA992. My 640were just fine , but I checked how they matched, and they were off ~2mV, I matched mine to sub mV.
For transistor matcher I also made PCB, but this time myself. Will open source it soon too.
I used this video:
and this fantastic article: https://dragonflyalley.com/synth/images/TransistorMatching/ianFritz-transmat0011_144.pdf

I also made 200W dummy load (with fault detection circuits) to test output power. Just bunch of 8)hm res on the big heatsink. Nothing special.

Anyway, this project is still going.
 

Attachments

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My replacement list (what has already been done so far)

Power:
C1,7,8,9,10: S103M69Z5UP63K7R
C2: 330/63 -> EKYA630ELL331MJ25S (or 390uF EKYB630E391MK20S) (I used 390)
C3: 330/63 -> EKYA630ELL331MJ25S (or 390uF EKYB630E391MK20S) (I used 390)
C4: 470/10 -> EKYB500E471MK20S(50V)
C6: 220/16 -> EKYB500E221MJ16S(50V)
C11: 1000/50 -> EKYA630E102ML25S
C12: 220/50 -> EKYB500E221MJ16S

TR2: 2SC945L -> KSC2383
TR1,3: 2SD234O -> KSC2073H2TU x2


AMP:
C1: 1uF 50V -> UKL2A010KDD1TDx2
C4: 220uF 10V -> UKL1A221MPDANA x2
C5: 100uF 50V -> UKL1H101KPD x2
C12: 330/63 -> EKYA630ELL331MJ25S (this one I part of negative ripple killer)

TR1,2: 2SA640 -> KSA992FBTA x4 (matcher to sub mV)

2sc1628 -> KSC3503 x4 (on order, not done yet)
2sc1222 -> KSC1845 x4 (on order, not done yet)
2sc1625 -> ksc2073 x2 (on order, not done yet)
2sa815 -> ksa940 x2 (on order, not done yet)

Filter board: (Numbering according to my schematic is the attachment)
C3: 2u2 -> UKL2A2R2KDD
C4: 3u3 -> UKL1H3R3MDD1TA
C6: 47uF -> ELXZ500ELL470MFB5D


Tone board:
C3: 22uF (powerline) -> ELXY250ELL220ME07D x2
C4: 1 uf 50V -> UKL2A010KDD1TD x2
C6: 2.2uf -> UKL1H2R2KDDANA x2
C9: 3.3uF -> UKL1H3R3MDD1TA x2
C12: 47uF -> UKL1H470KPD1TAx2
C13: 2.2uf -> UKL1H2R2KDDANA x2
C14: 4.7uf -> UKL1H4R7MDDANA

RIAA:
C1: 100uF/35V -> EKYB101E101MJ20Sx2
C2: 10uF/16V ->UKT1E100MDD1TD x2
C6: 10uF/16V ->UKT1E100MDD1TD x2
C7: 0.47uF/50V -> MKS0C034700E00KSSD
C8: 3.3uF/25V -> UKL1H3R3MDD1TA x2

Tuner:
C15: 220uF/10V -> UKT1C221MED
C17: 47uF/6.3V -> UKL1H470KPD1TA
C23: 22uF/16V -> ELXY250ELL220ME07D
C24: 47uF/6.3V -> UKL1H470KPD1TA
C28: 2.2uF/25V -> UKL1H2R2KDDANA
C29: 4.7uF/25V -> UKL1H4R7MDDANA
C32: 1uF/25V -> UKL2A010KDD1TD
C35: 22uF/16V -> ELXY250ELL220ME07D
C36: 0.1uF/16V -> UVR2A0R1MDD1TA
C37: 0.47uF/25V -> RFS50VR47ME3
C38: 10uF/16V -> UKT1E100MDD1TD
C47,48: 2.2uF/25V -> UKL1H2R2KDDANA x2
C51: 1uF/25V -> UKL2A010KDD1TD
C52: 0.22uF/25V -> UFG1HR22MDM1TD
C53: 0.47uF/25V -> RFS50VR47ME3
C55: 220uF/16V -> UKT1C221MED
C57: 0.47uF/25V -> RFS50VR47ME3
C58: 1uF/25V -> UKL2A010KDD1TD
C59: 47uF/6.3V -> UKL1H470KPD1TA
 
So far it worked ok. But I decided to test each channel with dummy load, measure it's maximum power and to the frequency sweep tone.
I tested each channel separately. Effect the I found is on both channels.

So when frequency reaches ~15500Hz output is absent. It does not depend on volume, bass, treble, Loudness. It's sine before that frequency and nothing (straight line at 0V on scope) when it passes that frequency.

I honestly duo not know where to look. Initially I suspected that it maybe some capacitor shunting signal to ground but how could it be for both channels on the same frequency? (chances are very low imo)

So if you know how to debug it, or you know where to look, what to measure, I'd be very glad for suggestions.

Thank you
 
Initially I suspected that it maybe some capacitor shunting signal to ground but how could it be for both channels on the same frequency? (chances are very low imo)
Certainly reads like that's happening. Maybe incorrect capacitor replacement? Review caps you've replaced on the audio path, candidate would be C2 in power amp stage. Failing that, set your signal generator to 16kHz and use your scope, ie, divide the circuit in half, test at input to power amp stage (pin 2) then depending on the result move forward or back, eg, Bass or Trebble wiper or base of driver transistors...
 
Certainly reads like that's happening. Maybe incorrect capacitor replacement? Review caps you've replaced on the audio path, candidate would be C2 in power amp stage. Failing that, set your signal generator to 16kHz and use your scope, ie, divide the circuit in half, test at input to power amp stage (pin 2) then depending on the result move forward or back, eg, Bass or Trebble wiper or base of driver transistors...

thanks. You would laugh. Initially i used my lapton as audio signal gen. Easiest way was to play something from youtube. I wouldn’t have imagined that tones higher than 15khz are not reproduced by my laptop. I don’t know what is the problem. Probably its HW. I decided to hook the scope in and use HP signal generator. everything works as expected.
 
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Also replaced following transistors on main amp board:

2SA640 -> KSA992FBTA x4
2SC1628 -> KSC3503 x4
2SC1625 -> KSC2073 x2
2SA815 -> KSA940 x2

And main transistors:
2SD428 -> 2N3055 x2
2SB558 -> MJ2955 x2

Now it is sound very differently. And I noticed no more low hum.
 
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