Leestereo's Restoration and Upgrade of a Sansui CA-3000

Part 9: F-2490 High Low Filter Circuit Board

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Signal Path Components
The stock ceramic capacitors in the feedback loops (C11/C12 and C19/C20) were upgraded to C0G types. The 4.7µF bipolar electrolytic output coupling capacitors at C13/C14 were upgraded to WIMA stacked film types. Similarly, the stock low-leakage electrolytic capacitors at C17/C18 were upgraded to stacked film types. The 10µF bipolar output coupling capacitors at C21/C22 were replaced with same (the schematic lists 4.7µF capacitors at these positions, the board itself had 10µF ones installed). The stock transistors at TR01/TR02 and TR05/TR06 were the failure-prone 2SA726 types; these were replaced with KSA992 transistors. Similarly, the transistors at TR03/TR04 and TR07/TR08 were the failure-prone 2SC1313; these were replaced with KSC1845 transistors.

Non-signal Path Components
The local decoupling capacitors at C55-C58 were upgraded to 100µF/35V low ESR types from the stock 47µF/25V.

Note that the F-2490 board is a double-sided type, i.e., there are copper traces on the top and bottom sides of the board. Circuit continuity from one side to the other is via solder pass-throughs (these appear as solder blobs on the board). Unfortunately, over time, these solder connections are known to fail. To remedy this situation, each pass-through connection was redone with a copper lead; the F-2490 board contained a total of 56 pass-throughs.

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Beautiful job documenting this Ben! On my not so likely to get dream list. I appreciate any detailed rebuild thread. Even better is when they get lots of comments, but people are viewing them for sure! How can anyone not appreciate the care and commitment you put into each project? Frankly, I am in awe of the work you do.
 
Part 10: F-2485 Input Circuit Board

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Signal Path Components
The input high-pass filter capacitors (C05-C10) were upgraded to WIMA 2.2µF stacked film types from the stock low-leakage electrolytic types. The ceramic capacitors, C11-C16, in the feedback loops were upgraded to C0G types. The first stage output capacitors were 22µF bi-polar electrolytic types and these were replaced with Nichicon ES types. The ceramic capacitors (C31/C32) in the low-pass filters at the preamp outputs were upgraded to C0G types. The stock input transistors at TR01-TR06 were failure-prone 2SA726 types; these were replaced with KSA992FB transistors. Similarly, the transistors at TR07-TR12 were failure-prone 2SC1313s; these were replaced with KSC1845 types. The stock output reed relay (RL02), a Hitachi HA-224N, was found to be faulty and was replaced with an Electrol RA3031-2241 (details can found in this previous AK thread).

Non-signal Path Components
The local decoupling capacitor C601 for the RL01-RL03 relay circuits was upgraded to a 470µF/63V low ESR type from the stock 220µF/50V. The stock C602 capacitor, which shunts the ZD602 zener, was 220µF and was replaced with a low ESR type. The zener itself had to be replaced due to damage from the generous application of the infamous corrosive glue on the adjacent C602. Similarly, a resistor (R607) was replaced due to glue damage. The 100µF capacitor (C603) on the regulator transistor base was replaced with a low ESR type. Similarly, the capacitors at C604, C607 and C611 (on solder side) were replaced with same capacity low ESR types. The bipolar capacitor at C605 was replaced a modern equivalent.

Note that the F-2485 board is a double-sided type, i.e., there are copper traces on the top and bottom sides of the board. Circuit continuity from one side to the other is via solder pass-throughs (these appear as solder blobs on the board). Unfortunately, over time, these solder connections are known to fail. To remedy this situation, each pass-through connection was redone with a copper lead; the F-2485 board contained a total of 59 pass-throughs.

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I need to point out in the interest of full disclosure here that the electrol is a good match (the best I've found) but is not a 100% drop in repalcmement as I originally thought.

It has the same pinout but is very slightly longer end to end versus the original, making it a slightly difficult fit in the existing PCB holes. That said, it requires far less work aound than other adaptations I've seen using other parts.

That linked ebay listing is legit, I've purchased from that seller. If you think you'll need any, probably best to get them while they are available as they are a long since disccontinued part. I've stockpiled a few for my own future needs, and the price is quite reasonable.

Edit to add that this is a phenomenal writeup on the CA-3000, and I'll be referencing it when I finally get to doing my own.
 
Part 12: Afterthoughts and Listening Impressions

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Before starting the restoration/upgrade, the CA-3000 was subjected to basic testing/measurements as well a brief listening session to evaluate its condition. No anomalies were observed in the power supply voltages, or the output signal. The left meter was non-operative (as the owner had noted). And in order to get sound on both channels, the 20Hz low filter had to be engaged, otherwise sound was only on the left channel. This last issue was probably due to the failure of one or more pass-through connections on the the filter board. And although the CA-3000 was a very good sounding unit as received, it did not distinguish itself as a TOTL design that it is.

Following the restoration/upgrade work, the CA-3000 was installed in the main system where it remained for an extended ~3 weeks before its owner had time to visit and claim it. During that time, it received approximately 50 hours of play time. The first thing that is noticeable is how quiet the background is when there is no music playing (there is essentially no background noise, even when listening on headphones). When playing music, the dynamic impact of the opening notes is often startling as it seemingly emerges from total silence. Considering the complexity of this design (e.g, selectable filters, tone controls, muting, output mode) the absence of any discernible extraneous and residual noise/hum was was a bit of a (pleasant) surprise and a testament to Sansui engineering.

The CA-3000's low noise floor compliments its excellent low level resolution. For example, it easily portrays the recording space (e.g., its obvious that the background singers in Lou Reed's "Walk On the Wild Side" are getting louder as a result of approaching the microphone rather than it just being a mixing level manipulation). In many recordings, the small incidental sounds that are buried deep in the sound mix that are somewhat obscured by the noise floor are clearly heard with the CA-3000.

With the tone controls and filters switched out, the overall sound of the CA-3000 can be characterized as neutral and balanced, with excellent dynamics. It never seemed to impose its sonic signature on the music but rather allows one to listen through a recording, equally revealing its good and not so good aspects. For example, the ECO (Standage)/Four Seasons recording and the Nishizaki/Beethoven violin sonatas are both known to have an aggressively recorded high range and were heard as such: these recordings were indeed bright sounding, but I wouldn't characterized them as sounding overly harsh as played through the CA-3000. With excellent recordings (e.g., the DMP Big Band, Wynton Marsalis, The Great Jazz Trio) the treble range is very natural sounding with lots of detail (e.g., different percussion instruments are easily identified). The midrange reproduction, to which human hearing is most sensitive, was exemplary: the sound of brass (e.g., Maurice Andre; Duke Ellington), violins/violas (e.g., Brandenburg Ctos.), and acoustic guitars (e.g., Eric Clapton) have a very realistic "bite". Vocals were rendered with startling clarity: singers sound "live" with easily heard vocal "ticks" and 'hiccups" (e.g., Buddy Holly), and "mangled" (e.g., Elton John vocals) or mumbled lyrics (e.g., Springsteen) are easier to decern. I thought that the bass range reproduction to be both powerful and "tight" sounding: the 2019 remix of "Abbey Road" sounded particularly good. Other examples of such are are the Joe Morello's drum breaks on "Time Out," the synthesizer bass on Sarah McLachlan's "I Love You" and Nick Mason's drum work on "Shine On You Crazy Diamond."

The dynamic and transient response of the CA-3000 is also notable: the close-miked guitar of Clapton on "Unplugged" was well rendered as was that of Jack Johnson on "In Between Dreams." Also in the Clapton recording, the applause sound in the smallish venue was realisticly portrayed (this is often difficult to portray accurately). The power and dynamics of Backhaus' interpretation of Beethoven Piano Sonatas was well conveyed. In terms of stereo/spatial presentation, the CA-3000 produced a wide soundstage and very good image depth/height (e.g., Beethoven Symphonies). Recordings of solo instruments or small ensembles (e.g., Bach Cello Suites or Mozart Violin & Piano Sonatas) were very realistically rendered with a plausible "live-in-the-room" quality. The listening sessions used CD and LP recordings that I'm very familiar with and often use to evaluate equipment (listed below). The CA-3000 phono stage in particular deserves special mention: it is a stellar performer and features selectable sensitivity and cartridge loading (resistance and capacitor).

When fully restored (and upgraded with the latest passive component technology), the CA-3000 delivers on the promise of a TOTL model. There is a cohesiveness and accuracy to the sound that this preamplifier produces that is truly "high-end" and further, it remains sonically competitive with anything available today (or yesteryear).

Some of the recordings (CD and LP) used during the listening sessions (in no particular order): Buddy Holly/From the Original Master Tapes; The Doors/L.A. Woman; Steely Dan/Aja (1999 Remaster); Bruce Sprinsteen/Born To Run (2005 Remaster); Miles Davis/Kind of Blue; Eagles/Hell Freezes Over; DMP Big Band/Carved In Stone; Elton John/Goodbye Yellow Brick Road; Jacques Loussier/Plays Bach; Dire Straits/Love Over Gold; Eric Clapton/Unplugged; Beatles/Abbey Road (2019 Remix); Elton John/Goodby Yellow Brick Road; Sarah McLachlan/Surfacing; Beethoven (Nishizaki and Jando)/Violin Sonatas No.5 and No. 9; Dave Brubeck/Time Out; ECO (Leppard)/Bach Brandenburg Ctos; Duke Ellington Orchestra/Digital Duke; VPO (Böhm, 1972)/Beethoven Symphonies no. 6 & no. 9; Pink Floyd/The Wall (1994 Remaster); Pink Floyd/Wish You Were Here; Beethoven (W. Backhaus)/Piano Sonatas no. 8, 14 & 23; The Great Jazz Trio/Standard Collection; Jack Johnson/In Between Dreams; Bach (Gendron)/Cello Suites; ECO (Pinnock)/Vivaldi Four Seasons; Wynton Marsalis/Standard Time Vol. 3; Maurice Andre/Trumpet Ctos.
 
Thx again Ben , words can't describe how it sounds . Stay tuned folks as I am still gettting it set up properly with the NewForm Research V 645 s speakers purchased from Rich Pa and the Sota Sapphire. Going to do a few videos of some of my favorite music , then you could hear it and see it live . Going to be a few weeks if not sooner . I might get lucky and get a glimpse of the restored Ba- 3000 Ben did all so at the same time .
 
...I see in spots you were using KSC945(G) transistors to sub the 2SC1313s... I see the G version has more hfe versus the other c945s... Is it okay to use a lower hfe C945s in these spots? Like this one: https://www.digikey.com/product-detail/en/on-semiconductor/KSC945YTA/KSC945YTAFSTB-ND/1047215...

The use of the "G" rank KSC945Cs was in deference to the high gain 2SC1313s specified by Sansui. Its unfortunate that Mouser and Digi-Key only have the "Y" gain variant in stock. However, since there is some overlap between the "Y" and "G" rankings, one can measure the "Y" transistors and use the ones that have a hFE are >200.
 
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