Friday, May 31, 2013

Zip tie repairs (!) : on a VK7 with crooked keys AND and an SY55

I don't frequently use zip ties in repairs, however I do believe they can be excellent and versatile tools. There are situations where an original part simply is not available, or cost effective. In those cases, with the customers approval, I have sometimes employed the zip tie with great success.

In this situation, I used a zip tie to secure the keys on an SY55: drilled a tiny hole through the key and used a zip tie to hold it to the chassis. The repair is permanent, sturdy, and the key behaves exactly the same as its neighbors.

notice the zip tie just visible on the Bb key

the other end of the zip tie is in a washer

On the VK7, the bushings tend to wear down, and the keys slide off. Buying new keys doesn't help much, and a new keybed can be pretty expensive. Zip ties between the keys work flawlessly at straightening the keys out, without adding any interference or resistance, and keep the keys on the bushings.. Plus, the metal casing around the keybed makes it impossible for the zip ties to fall off or move around. This is a great, permanent, and effective repair!


Juno 106 noisy chorus repair

I was able to repair crackling on the Juno 106 chorus by replacing all the tiny transistors (npn and pnp) on the jack/chorus board, as well as recalibrating the chorus section. The crackling occurred when bass heavy tones (especially chords) were played.

Some of the replacement transistors, although excellent substitutions electrically, needed to have their legs twisted since the pinouts were different.


K2000 Repair, LCD contrast capacitor added; similar to XP50 contrast issue








This Kurzweil primarily had an issue with the 220 uF capacitor right near the fet transistor  which regulated the 5 volt rail. That was causing the fet to heat up. Once that capacitor was replaced, there were still issues with the LCD contrast. Using the old trick of holding enter and turning the alpha wheel didn't really help; what ultimately fixed the issue was adding a 10 uF electrolytic capacitor between the LCD contrast voltage and ground (see photo). I found that this greatly stabilized the LCD and made the writing legible. Although there is a capacitor that is supposed to filter this voltage already, I couldn't easily find it, and adding another capacitor fixed the issue.
This was a situation where the customer did not want to spend too many resources on repairing the issue; so although this repair is not one" right out of the textbook" , it did fix the problem and the unit is working.




In my opinion, the idea of using the microcontroller and PWM to create a voltage for the LCD is a scheme which is prone to failure. When the user data containing the contrast parameter is lost or corrupted, or the PWM circuit for the LCD contrast fails (as it did here), the user is left with a blank screen. I think it is far more sensible to use a good old potentiometer to provide the LCD contrast voltage.

A similar issue occurs on the Roland XP50, another synth which uses the microprocessor to store the LCD contrast parameter. When you change the battery on an XP50, you may wind up with a blank screen In that case I used the info kindly listed here, which tells you how to ground the contrast pin in order to bypass the PWM controlled LCD contrast voltage.

Thursday, May 30, 2013

Jp8000 Repair: cracked circuit board






Sometimes an apparently tiny crack, like the one on the circuit board of this JP8000, can be a very insidious problem. I repaired this one with regular insulated, stranded, small gauge wires. The hardest part was going through each trace and locating good spots to solder the wires, and keeping everything in order. The board was restored to 100% functionality. It is good to note that on this particular keyboard, when a reset is done, the pitch wheel must be re calibrated: otherwise it will not work and the jp8000 will be out of tune





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The repaired circuit board

Sunday, March 24, 2013

Polivoks repair: dead outputs, 120 volt conversion, scaling issues

This unit came to me almost completely dead: neither oscillator working, just a power light and a slight hiss.

Bad paper and oil filter capacitors were the ultimate cause of the dead oscillators, but once they were replaced there were serious issues with the keyboard tracking.

At this point it became tricky since the only schematics that seem to be available are in Russian!

I made some headway by replacing the op-amps on the keyboard circuit board. I used a reference table found here,

Russian Ref
Europa/USA Ref
Function
KR140UD8B uA740 , uA741, LF351,... Single standart AOP
KR140UD12 uA776, MC1776, LM4250,NTE888 Programmable low power AOP
KT315G 2N3904A NPN transistor

which states that the russian op amps cross with uA741's, which are super standard monolithic op amps.

This fixed many issues, however, there was a gradual detuning of every note if the sustain was turned up.

With no circuit descriptions (that were in English), I was ultimately able to use the international language of schematics to find the sample and hold circuit on that keyboard circuit board. It consists of a fet, and an op amp and a few capacitors. Essentially, while the key is depressed the voltage flows through the fet and charges the .22 capacitors. Then the key is let up, the fet opens up and the capacitor remains charged to the same voltage, and continues to flow through the op amp (a7 on the schematic below). Since the op amp has super high impedance, the capacitor discharges so slowly that it holds at the same voltage for a long time, and the op amp output stays at the sampled voltage for quite a while. A good description is available here.

The sample and hold circuit thus demands a fet based op amp, so that it doesn't draw too much current from the capacitor and cause the sample voltage to decay too quickly. The 741 op amp worked perfectly everywhere else as a pin for pin substitution for the russian op amp, but not in this sample and hold circuit!  I replaced it with an original russian one, and everything worked fine. (I am sure I could have replaced it with any fet based op amp, but I had russian ones left over since I had replaced quite a few on this circuit board, having use a shotgun approach.)

Interestingly, here is a website which shows a sample and hold circuit using the 741... notice the addition of the 10k resistor, which probably helps the 741 work without drawing too much from the capacitor. 

Here is a picture of the circuit in question


Once all this was settled, the keyboard worked well. I installed the mods located here for external CV and Gate, and I also swapped out the transformer with one that can convert 120 volts down to the 34 volts, center tapped, that the polivoks needs for power (thus you can run it off from regular wall power). I installed an IEC connector and it is all set!






Wednesday, February 20, 2013

Rheem Mark VII Organ Repair

 

This gorgeous instrument would shut down unpredictably, or sometimes there would be excessive distortion on the outputs. My first suspicions were with broken solder joints, or perhaps failing electrolytic caps in the power section or on a circuit board. Sure enough, over time, I was able to detect low voltages from the power supply, as well as some AC on the DC rails. I replaced the filter capacitors, the rectifier, however the problem still persisted. This was an unregulated power supply,so there wasn't that much to replace or check.

I then disconnected,  board by board, each of the various circuit boards from the power supply, to see which area was loading it down, but there seemed to be no particular issue with any of the different rails.

This was a real mystery, until I decided, finally, to check the resistance across the terminals of the power switch. Although the switch was working mechanically...opening and closing as it should, there was a 30 - 70 ohm resistance across the contacts of the switch even when the unit was turned on.

I was able to disassemble the switch, and spray it with some cleaner and used my new fiberglass cleaning brush to clean the contacts, and all was fine. It has not usually been my experience that AC power switches can fail in that manner, but after 30 years or so of service, I suppose anything can fail.



Thursday, January 31, 2013

OBERHEIM TVS-1 DIGITAL KEYBOARD AND SEM REPAIR



Although the schematics are easily found for the TVS-1, an actual circuit description of the digital keyboard circuitry is hard to locate. Having just fixed issues with this circuitry in two separate synthesizers, I decided to write my own.  In case anyone else is crazy enough to delve into this and sort it all out, this could be useful information, even if incomplete.


There are four purposes to the digital keyboard circuitry: one is to provide the correct  control voltage "cv", a voltage which will produce the correct frequency oscillation in the SEM module(pitch), the second produce is the "gate" voltage, a voltage which tells the SEM card that it is in use... enabling it to produce sound. The third purpose is to activate the sem cards in the right sequence (in unison, or right first and then left, etc). The fourth purpose is to astonish and stymie the repair technician with a brilliant, yet complex, array of logic gates.

The circuitry is designed to process two note polyphony, so after holding down one note, any second note played is sent to the other sem module.

This circuitry uses CMOS chips with a supply voltage of 9 volts... unlike many later logic chips (TTL) which only work with up to 5 volts.

1) the heartbeat of the circuit is A8, which is designed to produce a clock pulse which drives the other logic gates. It uses some RC components and a 4001 logic "or" gate. It's output, labeled "clock", should like like a clean square wave.

2)this "clock"  pulse is routed to A8, a "counter" device which sequentially routes pulses among 6 outputs, labelled "a1 -a6".

3) These signals (a1-a6) from A8 are routed through a1, then the keyboard, then a2, which essentially produces a type of serial output which contains information about which keys were pressed. This output is shown in figure 1... it essentially is a serial synchronous data signal, which produces voltage spikes which reflect which of the 37 keys were pressed. Ultimately, these spikes lines up with the "dac" signal, and depending where the spike falls along the dac signal, an analog voltage is produced for EACH key that is pressed, these voltages are higher if the higher keys are pressed. Note that the voltage spikes are recurring, synchronous with the DAC signal, and thus line up in the same spot each time with with the recurrent dac signal, as long as the key is held. See figure 2.

4)Now the beauty of the design can be seen... an analog voltage for EACH key can be produced, and by manipulating the "dac" signal, you can make that voltage be higher or lower, or if necessary you can curve the dac signal slightly making the voltage difference across the keyboard non-linear.


5)the "dac" signal is produced using the outputs "a1-a6", by Ic's a16 and a17, and a series of resistors making a voltage "ladder"... an old fashioned "dac". The signal,when all is right, should be a 3 volt sawtooth as seen in figure 1 and 2. Conveniently, the signal can be modulated up and down by 3 volts by using the transpose switches, and adjusted using the trimmers on the board. The length of one "DAC" wave corresponds exactly to the time period of the output on the "data" rail.

6)It is useful to note here that any issues in the circuitry described thus far will produce intonation problems for BOTH left and right voices.... issues with the "clock" signal, the "dac" signal, or with the circuitry used to produce the "data" signal.
Most of the next section addresses the circuitry that effects each voice seperately.



7) "LGate and Rgate are signals which are either high or low, low signalling the "gate is open", and the voice is in use.

8) "RTAKEN and LTAKEN are signals which go High when the right or left voice is taken.

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When a key is pressed on the keyboard, a voltage spike is present on the "data" signal. Let us suppose that left voice first is selected. In this case, A11 pin 12 and 13 will be high, allowing  pin 11 to go low.

9) A12 pin 13 can now go High, which represents a clock pulse to latch A6.

10) The whole purpose of A6 and the network around it, is to "record" the position of the data pulse at that  time of the key press, and to repeat it each DAC signal. A6 takes that recording when a12 pin 13 goes high, which moves the clock on the latch. After that, at each  point when data lines a1-a6 are in that position, the network of logic gates a5,7,9, 8 and 11 will create a pulse which should line with the dac signal in the right position, so that the correct CV is produced by A18 pin 2. This voltage is stabilized by the small cap, and then run through op amp A6, which does not produce a voltage gain, but a current gain.

11) The gate is opened (goes low) on the first press of a key when a12 pin 13 goeshigh, a14 pin 4 goes low, then a15 pin 10 goes high. This, when synchronized with a data pulse at A14, causes a14 pin 12 to go low (and a14 pin 13 to go high. This happens at the first keypress, and initially opens the gate. After that, A15 pin 11 goes high with each successive DAC cycle,a15 pin 4 goes low, and a15pin 10 goes high.  and as long as there is a concurrent data pulse at 14 pin 9 (ie the key is held down), L gate stays open, and a sound is played from the left SEM. when the key is let up, the data pulse is no longer present at pin 9, and the gate is allowed to go high again. now a11 pin 13 is high, and the process can start again.

The process is essentially mirrored on the circuitry which corresponds to the Right Gate.


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Some other things:

Some issues with a weak resonance effect in the VCO's came down to a weak 3080, a transconductance op amp.

The customer was also concerned about driving the sequencer with an external clock,which did not produce the correct voltage for the TVS logic... for example a standard TTL square wave, from a 5 volt clock,  may not drive the TVS CMOS logic chips properly.These chips are designed to see logic highs above 7 volts (see http://www.allaboutcircuits.com/vol_4/chpt_3/10.html). Thus in the signal path between an external clock jack which I installed,   I added the small circuit below, which was effective in buffering the external clock input, and allowing it to accept a wide range of voltages. The second transistor is added to make the output square wave in phase with the input (as the first stage turns it upside down). The high value collector resistors mean that the circuit wont draw much current... you may notice it is not a wonderfully designed amplifier circuit, and more biasing could be done... however the transistors are either off or completely saturated, so I think all that extra biasing would be unnecessary.