Electrolytic capacitors in vintage equipment
After being contacted by a number of contributors to this thread........I guess I owe it to them to chime in. Although my first impulse these days is to simply ignore these discussions because those that logically look at the facts and science of electronics don't need to be convinced, and those that want to ignore the same..........won't be convinced in any case. Also, after so many years of spreading the information and providing the "proof" that some have asked for.........it really gets redundant posting the same information over and over.
This thread reminded me of one of my first posts here at AK. So, to save a lot of typing and if you'd like to see that Echowars used to be almost on the other side of this argument read this thread:
http://audiokarma.org/forums/showthread.php?t=5739
Now then (did you read the linked thread???????), I've noted a couple of major issues mentioned in this current thread:
1) Performance and aging of electrolytic capacitors
2) The "if it ain't broke...don't fix it" mindset
3) "Original" Sansui sound
So, let me try to introduce some "proof" and information to these 3 main topics. First up..........electrolytic capacitors!
The life expectency and failure rate of electrolytic capacitors has been studied extensively. It is truely the "achilles heel" of modern electronics. I'd wager a hefty sum that the guy who invents a component that does what an electrolytic capacitor can do as cheaply that DOESN'T fail due to age or that can last much longer could match Bill Gates in personal wealth! They exist in virtually every electronic device, and the cheaper the device........the more likely it is FULL of electrolytic capacitors.
The reality is that no one has thus far, and today most designers are concentrating on trying to minimize or eliminate them completely. You might ask Why?
Take a look at this chart from Nichicon:
For those of you that are not technically inclined, concentrate on looking at line (1) for 85C 2000 hour capacitors.......because that is what is used in our Sansui (and all other vintage audio) equipment. Note that Nichicon rates these capacitors for "2000 hours of use". A little simple math will tell you that works out to about an hour a day for 5 and a half years (2007 hours) OR 15 years of non-powered storage at an ambient temperature of 45C (113F). So, this gives us our first "fact":
FACT: Most of our Sansui equipment is over 20 years old (check your serial number date code!).......therefore according to the MANUFACTURER of the electrolytic capacitors they are beyond their useful life whether the unit has been in continuous service OR unused and still new in the box!
Of course.........many of you that enjoy Sansui equipment might say "it sounds great" and still functions perfectly! And, luckily for all of us you're not entirely wrong! Because otherwise....ALL of our units would be completely non-functional and we'd never have become addicted to the looks and sound of vintage audio! The reality is that yes our beloved equipment "still works" at least mostly! All you have to do is follow the threads of failure after failure, and look at the trends of failures to start getting clues to the true reality and condition of our gear. At this point I really want to avoid "opinion" though and try to stick to the facts and science as much as possible. Which isn't easy as I've yet to find solid scientific research on "the aging of audio components" and the effects of that aging on both sound quality and reliability. Because the industry that supports us and would be best qualified to research it........would much rather simply sell us "new" equipment!!
Therefore.........lets look a little closer at the uses of electrolytic capacitors in our equipment, which for the most part falls into two main categorys:
1) Operating Voltage stabilizers
These are your power supply caps, both large and small. They include the main filter caps as well as the lower voltage dc power supplies and the stabilizer found in each circuit to maintain steady voltage for ICs and transistors. Their primary purpose is to hold a steady DC voltage for other components to operate from........much like a battery.
2) Signal path filter caps
These are found throughout the audio signal path and provide DC blocking....allowing only the audio signal to pass.
Now let's take a look at what happens to these caps when they are well past their useful rated life and see what impact that has on the unit itself. Let's start with 1) above........the electonic batteries:
Their ability to "hold a charge" drops....and their charge/discharge time slows (they are not as reactive). Which means that SLOWLY over the years........their "fully charged" voltage drops. This can be measured.
Amplifier rail voltages that for example should be +/- 75 volts DC, begin to drop..........73, 72, 71....etc. Luckily, in the best designs these voltages can be calibrated so we can compensate for the drop by raising the supply voltage. But, in most of OUR equipment.........it is fixed and non-adjustable. So, you might think that being as the drop is only slight its actual affect won't be that great. And, for the most part you'd be right. But, this brings us to our second fact:
FACT: James Joule defined the relationship between Power (in watts) and voltage/current in what we now refer to as Joules Law:
Electric power, like mechanical power, is represented by the letter P in electrical equations. The term wattage is used colloquially to mean 'electric power in watts'.
In direct current resistive circuits, instantaneous electrical power is calculated using Joule's Law, which is named after the British physicist James Joule, who first showed that electrical and mechanical energy were interchangeable.
P=IV
where
P is the power (watt or W)
I is the current (ampere or A)
V is the potential difference (volt or V)
The key for our purposes here is that Voltage and Current are inversely proportional in a circuit to produce a given Power. And, also that a given CIRCUIT OR OTHER COMPONENT which draws or needs a certain power will be affected by Joules Law. So when a given Sansui power supply that for example is rated at 75volts and 5 amps sees a drop in voltage........the current "draw" will increase to compensate and maintain the power required by the circuit. This is also why our units have fuses in them that are rated in "amps" (current). As voltage drops..........current increases!
And, just what does that mean in our equipment?
In the worst case scenario........blown fuses. But what about those "vintage" electrolytic caps that haven't failed totally yet.......but cannot maintain the voltage they were designed for? It means a slight and ever increasing (over time) current draw. And, as that current draw approaches the maximum rating of the OTHER components in the circuit.....we can start to see the results of the "cancerous" electrolytic capacitors:
1) Resistors.........increased current can cause them to physically get hot (should I define Ohm's Law now?........Google it!). Their overheating and being subjected to higher than designed current causes them to change value.
2) Transistors.............increased current causes them to fail (worst case), or become non-linear (pops, distortion, etc.)
3) ICs..............increased current most commonly simply causes failure as they short internally.
4) Pots (variable resistors).......increased current causes the same effects as fixed pots.......but more commonly causes "burned" windings and contact points.
5) Switches/Relay points.......increased current can actually melt the contact points and minimally causes pitting and carbon buildup.................
Which brings us to another important factor....."carbon buildup". When individual components are stressed from an over current condition they will discolor and develop a carbon "trail". So, let's apply this "theory" to our Sansui equipment. Take a look at a new IC or transistor. Note that the legs of the transitors and pins of the IC are a dull "bare" metallic color. Now take a look inside your favorite Sansui unit (the one you listen to ALL the time

). Look at the IC pins.........look at the legs of the small (low voltage) transistors in the preamp or phono sections. Are they bare metal color? Or, are they a dull black "carbon" color? Now you know Why!
If yours is still a nice metallic color...........congrats!

You have a "low milage" unit. It simply means that it hasn't been run enough to show visible damage yet..........but it certainly doesn't mean that you're "safe" and don't have anything to worry about! If you put the unit into regular service now with the original caps installed.............all of the above applies and they will suffer the damage NOW rather than already exhibiting it.
Not enough proof for you skeptics? Let's apply this to what we commonly see TODAY in our vintage equipment:
Sansui amplifier driver pcbs - Changed values of emittor resistors (causing DC imbalance and protection circuits to activate)
Control Pots - Carbon buildup on contact surfaces causes "scratchy controls". And, yes DeOxit is wonderful stuff.............but you are ONLY treating the symptom, not curing the root problem! And, I suppose you thought those controls were "dirty". From what? Smoke? Dust? Then explain why even SEALED controls exhibit the same symptoms! Explain why a "new" piece of gear can be used in the filthiest environment and not exhibit the same symptoms? Or for that matter why the over 50 QRX-9001's that I've totally recapped over the last 10 years don't need their controls cleaned every yearl! (Oops.........I wanted to stay away from anecedotal evidence!!......stick to the facts QB!).
Which brings us to my original points 2) and 3). I'm going to hold number 3 for another post. But I think this post adequately covered number 2) as well!
Because running a unit with original 20+ year old caps in it..........IS DAMAGING IT SLOWLY BUT SURELY EVERYTIME YOU TURN IT ON. And, while "new" caps may be cheap and a pain to replace labor wise.....what about those transistors, ICs and controls that we just don't have new anymore?
Luckily.......the life expectency of a transistor, IC, resistor or mechanical control is easily in the hundreds of years......so long as:
1) It isn't physically damaged or destroyed
and
2) The VOLTAGE AND CURRENT it is rated for stays within its designed parameters.
So.............next note, we delve into sound quality and what if any affect old caps have on that!
QB