lorne said:
ilimzn: Your post snagged my attention: thanks! Do you have a source for the details concerning the upgrade of the SonyS-7? And could I apply them to my 222ES?
Of course, that would be me

AFAIK the motherboard in the S7 is virtually identical to the one in the 222.
lorne said:
I am interested in the apparent debate or difference of opinion about new and old CDP. I lean towards the idea that the new chips are better (borrowed opinion, not empiricly supported) but WAF/SAF would not support a new machine to take advantage of the newest DAC's etc., hence my interest in the 222.
On the whole I would tend to agree the DACs are better today. however, the one used in the 222/229 (with minor changes and/or selection it was used up to 1994 or so, including in the 777s, 779s and 707s) is no slouch either. Today, the digital filter and DACa re integrated into one chip, and we get faster and more accurate DACs. The big question is, does ths improve red book playback? Since this is 44.1k 16 bit, does it pay to use a 192k capable DAC with 22-23 bits effective resolution, instead of the 21 bit effective you already have? I would say that it would be more prudent to upgrade things around the DAC - clock generator, filters, power supplies.
Of course, that is a totally different ballgame compared to designing a DAC from scratch, even for RB playback. Any designer worth their salt would not use obsolete (or nearly) chips, if nothing else because the supply might run out just as the product is going to market.
lorne said:
Any details like components, chips, op amps, values, changes in voltage measurements, PS mods etc would be great. BTW, I have managed to get a photo-copy of the 222 schematic. Cheers — Lorne
If you can scan the power supply and audio part of the schematic, i can be very exact. As it is, i can tell you what the ideas behind the mods were, and you can find the relevant sections of the circuit yourself.
1) Power supply
The S7 uses a single transformer for both analog and digital, but uses two windings to get 5V for the logic and servos, and +-5 (iirc) for the analog section and outputs. The purpose of a power supply mod would therefore be to isolate the two power supplies as much as possible without going into extravagances (though given a different or even custom wound transformer or transformers, would make this easyer). The power lines use small inductors and resistors and capacitors to form filters. In order for these to work properly, it is essential that the capacitors behave like proper low impedances for the widest spectrum of frequencies. The S7 generates interferences well into the 100MHz range and ordinary electrolytics will not stop that from spreading. Here is what was done:
a) The power supply caps were increased in size, chosen for low ESR and additionally bypassed with foil type caps (the red rectangular WIMAs you can see in the pics). There is an additional smaller capacitor that powers the servo circuits, this was changed to a low ESR switching PSU cap and bypassed by both a WIMA and a chip NPO ceramic cap. The idea was to better separate the digital power and the servo power (servo power is taken before the digital section regulator).
b) The main clock is generated by the DAC chip and it has a separate power supply pin, which is decoupled from the main digital supply via a small feritte bead followed by a ceramic cap. This was changed to a double LC filter replacing one jumper that supplies power from the PSU to the spod before the feritte with a proper inductor, and adding a cap to ground under the board, then changeing the feritte by another inductor and the nearby caps (one electrolytic and one ceramic) were changd to a low ESR electro (normally used on PC motherboards for the switching core voltage regulators), in parallel with a WIMA foil, in parallel with a NPO ceramic chip cap. The PCB is well designed and the caps form the required local power supply and ground for the ocillator. This was done because a dirty power line to the osc will produce dirty (jittery) output and signifficantly degrade the DAC accuracy. The best way to do this (and I've done it on one 229) would be to use a separate low power regulator just for this, but on the S7 it would have been very awkward.
c) The DAC chip is a pulse DAC, which outputs current pulses from it's internal regulator. In order to prevent the internal regulator being fed by dirty power, both the analog and the digital side of the DAC decoupling caps (noninductive foil caps originally) were upgraded with low ESR electrolytics, with wima foils in parallel, and then on the digital side and the analog voltage reference pin, chip NPO ceramic caps. Note the black electrolytics and red WIMAs around the DAC chip outline on the picture.
d) The power supply lines to the output OP-AMPs are quite long and there is very limited decoupling right next to the OP-AMP chips themselves. This was again upgraded to low ESR electros with WIMA foils right on the pins of the chips under the board.
e) In some cases it is necessary to put wire links strategically placed between some ground points on the PCB. Grounding is exceptionally important for DA converters and their outputs, and using a single layer PCB does not always make it possible to optimally route ground lines. However, the S7 is better than most here and did not need this mod (it is also quite difficult to measure ground inductance, bounce or loop problems, you need proper tools and instruments).
2) DAC output and filter mods. The DAC used has differential output which is combined into single ended using one half of the dual output OP-AMP. The DAC output is also filtered at this point using a simple 1st order RC filter. There is a simple 2nd order filter made out of the second half of the OP-AMP. The output is fed to the connectors via electrolytic caps (fortunately bypassed by foil caps) and a series damper resistor.
a) It is exceptionally important for the 1st order filter cap to be of high quality and low loss as well as the resistors being as equal as possible. This part of the circuit sees harmonics in excess of 100MHz and is the point where these are filtered out. It is also helpful if the left and right channel caps are matched. For this I replaced the rather large tolerance ceramics with a selected pair of either HF silver mica caps or styrene caps. In theory, NPO ceramics would be a candidate as well, curiously the originals were not of that kind even though they are widely available and inexpensive. The resistors were changed from regular carbon to metal film.
b) Due to the way the differential to single ended converter operates, it is prudent to eliminate bias current mismatch of the Op amp inputs, as the bias current 'leaks' back into the DAC. The DAC outputs are thus unewually loaded, which decreases DAC linearity for various reasons. The way I chose to solve this, was to replace the OPamp with something that has the least bias current possible - a FET input OP, the BB OPA2604 (there are many other candidates that could fit). The resistors in the diff to single ended converter were also changed to 1% metal film. Since all of these resistors are fairly high values for the original NE5532 OPamp, using a FET OP instead also lowers the noise floor, so you catually have a chance to see those lowest bits out of your DAC chip!
c) Caps and resistors in the output filter were changed to foil WIMAs (non-inductive, nothe blue squares near outputs) and 1% metal film. Caps were matched between channels to reduce interchannel phase shift at HF - this would count into somewhat extreme stuff but it only takes a few minutes to do, so why not.
d) Output caps are necessary for the NE5532 due to fairly large offset, but can be removed when a OPA2604 is used. Still, not knowing what this CDP was going to be connected to (it was for a customer), I elected to keep them in circuit, just upgrade them. Low ESR switcher caps were used again, with the capacitance about 20x higher than the low 47u Sony selected. They were also bypassed with 1u foil caps. The reason for the increase in capacitance is that it's really the only sure way to reduce capacitor distortion at LF if a low impedance component is connected to the output. Quality bipolar caps (bypassed with foils of course) would be even better but it is quite difficult to find some with the required form factor. Also, if normal electrolytics are used, it frequently pays off to use higehr voltages (50-100V) even if the application does not call for this, because these tend to have lower ESR and less distortion.
3) Mechanics
The case of the S7 is a combination of metal panels and fiber filled plastic. It is quite heavy on it's own but has large undamped metal surfaces. The power transformer is rigidly couled to the chasis, fortunately it is impregnated and welded for vibration reduction. Still, it could be heared. The rear panel required cutting of a hole for the digital output (see below).
a) All undamped surfaces larger than about 3x3 inches got damping foil applied to the inside (similar to what is used on the insides of car doors to stop the speakers from rattling them). The top and bottom got double layers.
b) Not for the faint-hearted as it requires partial dissasembly of the mechanism, the meta base also got a specially tailored cutout of the damping foil applied on both sides. Not absolutely necessary and may require some adjustment of the springs used to mount the mechanism to ensure it all fits properly.
c) The sides form cavities with the rest of the case. In order to prevent midrange resonances in these, they were filled with rubber foam (self sticking kind).
d) Power tranbsformer was mounted on rubber grommet dampers (salvaged from old hard disk!).
4) Miscellaneous: The board has provision for optical output, which was not installed originally. Since I had the required optical transmitter, I installed it, and connected it to the proper place on the board (note brown shielded cable and addition of oprical output). This also required cutting a hle on the back panel for it.
I also have some pics of a 229 mod, which will probaly be more similar to the 222, but i need to find that. The ideas behind that one, however, are the same as the mods for the S7 so the description is the same...