PIONEER SA-9100: Restoration
As always before I start working on a vintage unit restoration, I organize all the parts that will be changed. Further more I am sorting transistors based on the hFE factor. This is a boring job but it pays for itself. Careful with new Fairchild transistors legs disposition. Thankfully the Pioneer engineers designed these boards with triangle transistor legs dispositions. This means that it is extremely easy to mount every new transistor in place of the old ones. However one needs to carefully observe the board markings and the electrical schematics first.
This Pioneer amplifier is hard to work on due to the multitude of wires that are all wire-wrapped. These cannot be unwrapped and de-soldering the wire-wrap posts is next to impossible. The posts were mechanically fixed before being soldered. This means that you have to work on the boards in place, carefully bending all the wires at once. This operation is risky and I wouldn't bend the wires more than a few times. So a lot of patience is required.
General Considerations
Working on this unit exposes you to electrical hazards. There are lethal voltages inside. Severe accidents and possibly death by electrocution might occur. I am qualified and skilled with electronics and I have been doing audio gear repairs for over 20 years. If you lack experience, please take these articles as just a knowledge base. Do not attempt to repair something that you cannot handle as there is a high chance of doing further damage while also possibly suffering accidents.
Good tools are a must for a quality restoration. I use eutectic soldering alloy and a temperature-controlled soldering station equipped with various tip shapes. I a standard and a precision desoldering pumps and desoldering wick in various widths. To clean the flux, I use isopropyl alcohol and high purity acetone.
Empirically, I found that working with a temperature of exactly 300 °C is safe for these vintage printed circuit boards. I have never lifted any pads and I never wait more than a couple of seconds with the hot tip on any pad. While working on the chassis, I use between 360 and 440 °C. Flux fumes are extremely toxic and should be avoided at all costs.
Every replacement part is brand new, from a reputable manufacturer, ordered from the U.S.A., Japan, or Germany. In addition, I only use parts that are suitable in specific circuit sections, after inspecting and comprehending the original schematic diagrams. Last but not least, I have years of experience backing up my choices and actions.
I have not taken a lot of pictures during this restoration because the boards are hard to position for good lighting.
Chassis Restoration
On the chassis there are a few things to be done. The power supply rails filtering capacitors, the front panel indicator bulbs, and the speaker protection relay. It appears that there is not much to do here. But this assumption is plain wrong. Let's proceed then.
A technician installed some axial electrolytic capacitors: two Setton and two Roederstein -- marked ERO. The mounting hardware is missing as well. Oh no! This is how the former capacitors looked like.
Now please check the electrical connections the former technician did.
Junk capacitors are all out. One of the Roederstein parts has vented and upon measurement it was revealed that actual capacity was about 970 uF out of the rated 4700 uF. ESR was 8.1 Ω and loss was 31%.
Thankfully I was able to find Sprague Powerlytic 36DY large can series capacitors that will fit this purpose. In fact these have identical electrical specifications to the old parts. That means 15.000 uF / 50 V.
Mounting hardware is available as well. And it fits perfectly the old machined holes.
However I had to manufacture connector wires since the old ones were cut and floating around the chassis protected by electrical tape. So I took 1.5 mm stranded copper wire and soldered terminals designed for screw mount capacitor leads.
I have used thermo tube to isolate the potential short-circuit prone zone.
I have soldered the wires using a very resistant technique and then covered the joints with thermo tube.
This is how the work looks from below.
And in the end this is how the capacitors look like from above.
Moving on to the front panel indicator bulbs now. The power indicator bulb is burned out. The other one works without issues. I have decided to remove the bulbs and replace them with LEDs: yellow 5 mm LED for power indication and red 5 mm LED for protector indication. LEDs require specific current and rectified voltage. I have used a simple circuit for each LED. The parts involved are: a 390 R / 0.5 W resistor in series with a 1N4148 diode in series with each LED. I have decided to replace the wires as well since the old ones were very short. I have decided to solder each diode as close to the LED as possible and cover it with thermo tube. This makes for a very clean approach. The 390 R resistor is left uncovered and is mounted directly on the wire. Can you spot the tiny DALE resistors?
Original bulbs were Stanley 8 V / 50 mA. Very nice! Stanley is still in business now and makes automotive tail lights and bulbs. Should you want to take an original restoration approach, please find similar bulbs. I didn't have any similar bulbs around and 5 mm LEDs fit the rubber casing very well.
Final result.
Next up, is dealing with the speakers protection relay. It is located in the lower left part of the steel chassis, next to the Power Supply B assembly. In addition to extreme heat exposure, it is also probably unusable by now due to the contacts being clogged with oxide and carbon deposits resulted from electric arcs. These arcs are generated when the mobile armature opens or closes the circuit while music is being played at a consistent volume.
Mounting a new relay requires a little bit of ingenuity. But everything is possible as you will quickly see. Let's examine the old relay next to the new OMRON part. The first thing that screams incompatibility is the position of the mounting ears. The old one has the ears on the bottom while the new one has the ears on the top.
The quickest method to mount the new relay in place of the old one is to use some computer-grade hex standoffs. The ideal length would be 33 mm. I already had some hex standoffs in my junk parts box so I used those instead. I have joined a 20 mm standoff with a 15 mm one to provide a 35 mm standoff. A little bit taller but nothing to be scared off.
The wires under the relay are particularly short and difficult to work on. My approach was to suck all solder from the old relay terminals with my solder pump and then push the wires as far down as I could. I have individually clipped the tips of each relay terminal for about 2 mm to expose the U shaped cavity. Then I have extracted all wires effortlessly. Soldering them is easy. In addition, I have added small lengths of protective thermo tube over the insulation of each wire next to the soldering point.
All is good now. The new relay will last a lifetime if you make sure you lower the volume while you power on or off the amplifier. Or at least, stop the music.
Equalizer Amp Assembly Restoration
The equalizer amplifier is built on two different printed circuit boards which are located on the far bottom-right side of the steel chassis. It is very difficult to work on these two boards because of the connection wires that are wrapped on two diametrically opposing sides. I decided to de-solder the top four wire wrapping posts of the right outer PCB, taking great care not to damage them.
The schematic doesn't entirely correspond to what can be found on the printed circuit boards but I am posting it here anyway.
This is before.
And after.
Control Amp Assembly Restoration
The control amplifier implements the tone controls and can be found under the black front main Faraday shielding cage.
Here is the electrical schematic.
Originally I thought this would've been the hardest board of them all since the number of wrapped wires is just outstanding. An entire array of wires spanning throughout the entire PCB length. But once I removed the two screws I was able to flip the board upside-down and get access to all the parts. I have shotgun replaced every transistor and capacitor on this board.
Pictures as follows.
Working my way through the component forest.
While adding small glass beads on stacked film capacitor leads.
And tubular glass beads on the collector terminal of each small-signal transistor.
All good on the solder side.
Metal can transistors are off as well. Modern Fairchild replacements are in place.
Filter Amp Assembly Restoration
The filter amplifier is accessible from underneath the unit. There are four transistors and a few capacitors to replace.
Here is the electrical schematic.
Removing it from the plastic securing posts is easy if you have patience. Servicing this PCB does not raise any problems.
Before the restoration.
After the restoration.
And this is the solder side. On this board I have not touched any other solder joints than necessary.
Power Amp Assembly Restoration
There are two power amplifier printed circuit boards in this unit. Both are bolted to their appropriate power transistor heatsink. There are four screws per board. The two on the top are easy to remove but in order to get out the two on the bottom you need to disassemble the heatsink and get out the power transistors themselves. The wires leading to these boards are fairly short and it is difficult to work on the boards and also to take pictures.
I am targeting all small signal and medium power transistors, all small signal diodes, all variable resistors, and some of the standalone resistors. I chose Dale resistors with a higher wattage than the original specs. The variable resistors are Bourns. Transistors are either ON Semiconductor or Fairchild. Capacitors are all Nichicon FG series electrolytic types or Nichicon film types. The 1N4148 small signal replacement diodes have been mounted on glass standers. The replaced pre-driver transistors have received thermal compound between them and their heatsinks.
The Pioneer glue used to mechanically bind capacitors to the printed circuit board assembly is easily removable with 100% acetone and cotton swabs. No mechanical removal approach is required.
Here is the electrical schematic for one channel.
Let's start with the right channel which is located in the rightmost side of the steel chassis.
Before the restoration.
During the restoration.
After the restoration.
The power transistors received new mica insulators and a drop of quality non-conductive thermal compound.
I am continuing with the left channel which is located in the leftmost side of the steel chassis.
Before the restoration.
During the restoration.
After the restoration.
As before, these power transistors also received new mica insulators and a drop of quality non-conductive thermal compound.
Protection Circuit Assembly Restoration
This board implements the speaker protection circuit. It is easily serviceable and it is mounted directly underneath the big can power supply filtering capacitors. It is secured by plastic posts. On this board I am targeting all transistors and two capacitors. In my unit the two capacitors were 220 nF / 25 V tantalum capacitors. I have replaced them with Nichicon film capacitors rated 220 nF / 50 V. In addition, I have added a flyback diode to protect the relay driver transistor from inverse transient voltages generated by the relay coil when it de-energizes.
This is the electrical schematic.
Before the restoration.
After the restoration.
Flyback diode.
Power Supply Circuit-A Restoration
I think this is the easiest board to work on from the entire amplifier. There are only two capacitors and eight diodes to replace. Normally the diodes are not prone to failure but since this amplifier is very hard to disassemble, I have chosen to overhaul it in terms of inaccessible semiconductors.
The electrical schematic as follows.
Before the restoration.
ON Semiconductor power diodes are mounted on the PCB assembly.
And mounted back in its place. You can spot the two axial capacitors.
Power Supply Circuit-B Restoration
This is probably the worst power supply construction that I have ever seen in an audio amplifier. Hot transistors, small heatsinks, cooked capacitors, scorched resistors, mismatched power dissipation coefficient on certain resistors. Drifted resistor values and cracked resistors. But even with all these design flaws the power supply was still running OKish.
I have shotgun replaced a bunch of resistors that appeared damaged or on their way out. I have chosen Dale resistors with higher power dissipation factors in order to ensure some derating. As for capacitors, all of them were replaced high temperature Nichicon BT series parts that can withstand temperatures of +125 °C while still doing their job. These capacitors also have an unusually long life if they are exposed to ambient temperatures -- think 30 to 40 °C -- while operating. The transistors were all replaced with better ones. The two power transistors used as regulators were moved somewhere else on the steel chassis so they can better dissipate heat.
The electrical schematic as follows.
Before the restoration. Notice the massive heat damage to the printed circuit board. I think these CEM (?) boards are 94V-1 flame retardant certified. It really stood the test of time and heat but it doesn't look pretty. However the tracks are intact and the solder pads are in excellent condition. Heat discoloration is the only issue I can see here.
New capacitors.
New resistors with a big power dissipation reserve.
During the restoration. Some of the transistors have already been changed. All capacitors were replaced and some of the resistors are still pending replacement. You can see the two regulator power transistors mounted on weak heatsinks. As I previously said, I am going to relocate these power transistors somewhere else where they can better dissipate heat.
I have used some heavy duty wires that were originally built for military high frequency transceiver constructions. These have a very thin PTFE (Teflon®) insulation. I was keeping them for tube amplifier construction but I decided to use them in this unit as well. Thermo tube was used for insulating each transistor terminal.
Originally I was going to go simple with the screw directly through the transistor heatsink mounting tab as pictured below. Then I quickly realized the tab is electrically wired to the collector. This spells disaster. So I have used a PTFE washer that dresses the screw so that there is no electrical contact between the collector and the heatsink. Note that the heatsinks will be attached directly to the steel chassis for better heat dissipation. And while the chassis is connected to ground... you figure out the rest.
I went one step further and used thermo tube to protect all three wires. It was fun to shrink it with my mini-torch.
I have labeled the terminal wires as E (emitter), C (collector), and B (base) with this simple color code: RED = E, BLACK = C, NOTHING = B. Easy to remember and dumb-proof.
They go in like this. One transistor.
Both regulator transistors are connected.
But where are the transistors? I was seeking for a place on the steel chassis where to mount them. Normally there is a lot of place should you want to drill 3 mm holes. I didn't want to do this so I had to improvise. I have searched for already existing screws that could accept the heatsink pre-drilled hole. I found one next to the MODE switch. This screw is part of an array of three machine screws that hold the steel chassis in place. One of them now also holds the heatsink for one of the regulator transistors.
And the other one? Check the image below. It is mounted to one of the screws that holds the tone control amplifier in place. The thermo tube covered wires are routed through the middle of the chassis to the exit point which is directly under the Power Supply Circuit-B printed circuit board.
Which is pictured here.
After the restoration.
Switch-B Assembly Restoration
Easy to locate but damn hard to work on it. I used some medical pliers to extract and place the new components in position. It is also very hard to photograph. So there you have it: I took only one picture.
The electrical schematic as follows.
After the restoration.
Solder joints were touched with eutectic solder.
Aftermath
Old parts that have been removed from this amplifier.
Electrical Settings
The restoration cannot be complete without performing the electrical settings as illustrated in the service manual. Thus, there are two main settings that I need to touch before putting the case back on.
- Idle Current
- Neutral Potential
On this unit both procedures are very simple. First, commute the Speakers selector to OFF position. Switch the input selector to AUX1. Ground each AUX1 RCA terminals through a 4.7 kΩ resistor. Let the unit warm-up for at least 20 minutes.
To set the the idling current, connect a DC voltmeter between terminals 9 and 13 on left channel power amplifier module. Set the scale of the DC voltmeter to 200 mV. Adjust VR2 up until the voltmeter reads 25 mV. Repeat this step for the right channel.
Adjusting the neutral potential of the power amplifier is done by connecting the DC voltmeter between ground (either GND signal or steel chassis) and terminal 23 on the left power amplifier module. Adjust VR1 for a reading of 0 mV ±10 mV. Repeat this step for the right channel.
Here's the unit in tests. All electrical parameters seem to be OK. I have obtained a very steady 24 mV reading for idle current adjustment and 0.1 mV neutral potential on each channel.
Wires, wires, wires everywhere.
Cleaning the Front Panel
I have dismantled the panel and cleaned it with a cotton rag and some natural BIO degreasing substance. This is after the job.
Detailed view.
The knobs of this unit were particularly dirty. It appeared to be some kind of nicotine slime combined with dust and some oily residue. I didn't took before pictures but why should I lie? I have thoroughly cleaned them with a window cleaning solution based on ammonia and Q tips. Besides the smell, everything went smooth and a couple of hours later, the buttons were all shiny again. It is a marvel that these buttons don't have any dents or scratches on them. I am pleased to finally see these knobs after 3 years since I bought this amplifier as defect.
Then there is also this part. It is the LEVEL SET selector knob which is mounted on the same shaft as the volume control knob.
Knobs are all in.
I have then cleaned the wooden case.
But it is suffering from time patina.
When I will have time I will restore the missing chunk with epoxy rosin then I would sand it down and reapply veneer. But this is a whole different project that I will tackle somewhere in the future.
This concludes the restoration of this unit. I hope it will work great for a long time.
♫
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