The three
places where tweaks to an inexpensive player
can make the most difference are the power supply, the
power supply, and the power supply. Okay, that may be a
slight overstatement, but it's a fact that the power in
your home is often corrupted by air conditioners, dimmer
switches, halogen lights, and other noisy
appliances—yours and your neighbors'. Cleaning up and
filtering out this noise on the line will help any
player perform better.
Essentially all low-cost DVD players these days use a
switching power supply. It converts the line's ac
voltage to dc, at, for instance, the 3.3, 5, and 12
volts needed by chips, motors, and other internal
components. Switching power supplies use switching
transistors and other devices to, in effect, chop the
50- or 60-hertz line frequency into an ac signal at tens
or hundreds of kilohertz. The advantage of this higher
frequency signal is that it can be filtered, and its
voltage changed, with small and light capacitors and
transformers. The high-frequency transformer also easily
provides multiple output voltages and isolates the dc
from the input voltage.
The supply consists of a power-input receptacle, a
bridge rectifier to convert ac to dc, capacitors for
smoothing the resulting pulsed dc waveform and for
storing the energy needed by the other sections, MOSFET
transistors to chop up the dc into the high-frequency
ac, and the high-frequency transformer with multiple
secondaries to produce the various desired voltages. For
each secondary coil, there are rectifiers and filter
capacitors to yield the desired dc output. Besides being
smaller and lighter, switching power supplies are
typically more efficient than other types. The tradeoff
is that they tend to generate more high-frequency noise
on the power line. Sufficient filtering becomes
important—especially in audio circuits.
Before you begin, a few words of caution. You will be
playing with a system that runs on real ac current, so
make sure the unit is unplugged while you are working on
it. If you are new to the world of building and
troubleshooting electronics, read this excellent guide
before proceeding:
http://repairfaq.ece.drexel.edu/REPAIR/F_appfaq2.html.
Be careful and patient. Oh, yeah, this will definitely
void your warranty, too.
To open the Toshiba SD4960, remove the three screws
on the back panel; then slide off the lid. Snap off the
front panel, being careful not to break the fragile
plastic clips that hold it in place. Unplug the ribbon
cables where they attach to the main printed-circuit
board and unplug the wire running from the electrical
cord to the board. Unscrew the board, and lift it gently
out of the case.
On the board (See photo, "Inside the Toshiba
SD4960"), you will notice lots of insectlike
components, their bent leads splayed like little legs on
the surface of the board. You will be leaving these
surface-mount parts alone. They are too small to fuss
with, and their would-be replacement parts too big to
fit in their place. Also, they have been
machine-soldered to the top of the board and would be
hard for you to remove and replace without damaging
other circuitry.
Starting with the power supply section (indicated in
yellow), first identify all of its capacitors and their
values. You should replace all of these capacitors with
higher-quality capacitors with the same voltage value
but about 20 percent more capacitance. (See table,
".") There are various measures of
a capacitor's quality; one is ESR, or Equivalent Series
Resistance. A low ESR means low resistive losses inside
the device, and therefore better ability to deliver
power to the sort of fast-changing loads presented by
the clock and other high-frequency digital circuitry.
There will also be one relatively large capacitor just
after the rectifier or diode bridge (indicated in pink);
you can double the capacitance value of this one, from
82 microfarads (µF) to about 180 µF, or whatever you can
fit in the available space.
Basically, by using better-quality parts, like Sanyo
Oscon, Panasonic FC, or Nichicon UHE or FG/KZ
capacitors, and increasing their values, you will
improve the power delivery to the other circuits. That
in turn will increase the dynamic range and enhance the
all-important bass performance. Besides low ESR, such
high-end capacitors have tighter tolerances and use
better materials (the Nichicon leads, for example, are
copper, not steel).
The one constraint you'll face in replacing capacitors
is the space on the board—capacitors with larger values
are bigger, so make sure you have enough real estate for
them. And don't forget to note the polarity of the
capacitors you are removing so you know which way to
solder in the new ones. Polarity is usually indicated on
the board, but go slow and be cautious.
To take your upgrade a step further, replace the diode
rectifier bridge with "soft" recovery FREDs (fast
recovery epitaxial diodes) or Schottky diodes. These
fast-action diodes have what is known as soft recovery.
What that means is that when the voltage across them
changes polarity, causing them to go from forward- to
reverse-biased, the plot of current versus time slopes
smoothly back toward zero current, rather than
overshooting the zero axis and wobbling briefly around
it, or "ringing." Basically, the lack of ringing means
less noise.
Buy replacement diodes with higher amperage ratings
than the original ones. The original diodes are designed
to tolerate high-peak surge currents, which occur when
the power-supply capacitors are charging (and don't
forget, you added more capacitance!). Chances are, your
replacement diodes aren't designed for high current
surges; in my case, replacing the specced 1-ampere
600-volt diodes with the same value FREDs smoked them.
So I used 4-A 600-V diodes and they worked fine.
You may have to be a bit creative with the
installation of these replacements, because diodes with
this increased rating are usually only available in a
TO-220 type package instead of the original DO-41
package. Note that the TO-220 package has a metal tab at
the top; this tab is generally connected to the cathode
and should therefore be insulated with heat-shrink
tubing to avoid any shock hazard.
Again, be very, very careful of the orientation of
these diodes. By putting a faster, soft-recovery
rectifier in the power supply, you will allow the power
supply to respond more rapidly to the demands of the
downstream circuitry with less switching noise.
Taking the modification yet further, you can also
replace both of the X-rated capacitors (indicated in
orange)around the transformer with 0.47 µF 600-V
Auricaps. These will set you back about $13 apiece.
X-rated capacitors are standard components that meet
Underwriters Laboratories Inc. (UL) standards for use on
ac mains lines. These capacitors are designed to be
self-extinguishing in the event of a big surge on the
power line. They're potted in fire-retardant
compositions, and are designed to fail open, rather than
closed, so components up- and downstream will be
protected. Auricap capacitors, a brand of high-end
capacitor favored by audiophiles, are not rated against
UL standards for ac current.
While this tweak is widely used in audio modification
circles and no problems have ever been reported on the
audio tweak Web sites (as far as I know), it could
potentially lead to damage in other parts of the system,
so you might say it's risky. But, to my ears anyway, it
does noticeably improve audio quality. If you're
squeamish about replacing the X-rated capacitors, you
might try a compromise, such as replacing the stock
X-rated capacitors with a good-quality safety-rated
polypropylene capacitor, such as the MKP series from
Illinois Capacitor (part number 474MKP275K).