Beogram 4004 (5526): Restoration of the Arm Lowering Mechanism and Exchange of Tracking Sensor Bulb with a LED Assembly

I started working on the Beogram 4004 (5526) that I recently received. As usual, I rebuilt the arm lowering mechanism and installed a LED assembly to replace the original tracking sensor incandescent light source.

This shows the arm lowering mechanism consisting of solenoid (left) and motion damper (right; to gently lower the arm once the solenoid activates):

I disassembled the setup

and cleaned away all the hardened lubricants. Then I re-lubricated everything and re-assembled the mechanism. The next step was to do the same for the linkage that connects the damper to the tonearm. To get to the pivot point of the linkage, the sensor arm assembly has to be taken out. This shows the arms from the back

and after removing the sensor arm:

After removing the retaining washer and the small spring that presses the linkage towards the sensor arm post (do not loose this spring if you try this at home, it has a tendency to vanish in 'small parts nirvana' and is never seen again...;-). This shows the removed linkage:

I cleaned, re-lubricated and reassembled. Then it was time to adjust the arms to be orthogonal to the carriage and parallel to each other:

This can be a bit tricky and listening to calming music is recommended.

After taking care of the arms, I exchanged the tracking sensor light source, which is originally a small bulb that frequently burns out, disabling the Beogram. Installing a LED ensures longterm stability. This shows the original part in place:

I removed the bulb housing revealing the aperture that controls the tracking feedback by varying the amount of light that hits the light sensor in the lower part of the housing:

This shows the original part and the Beolover replacement side-by-side:

The LED sits exactly in the spot where the filament of the original bulb is located. I installed the part and also replaced the sheet metal screw that holds the aperture in place on the lateral tonearm bearing with a stainless M2x16mm screw and a corresponding nut (this makes it much easier to properly lock the aperture position in place once the tracking feedback has been calibrated):

On to restoring the electronics of the deck.

Beomaster 1900 Type 2904: Testing and wrapping up the project

This Beomaster 1900 receiver is finally ready to perform the job it was intended for.

I don't have as many options for connecting up my audio analyzer probes inside the Beomaster 1900 like I did on the Beomaster 8000 but I am able to perform the main tests I wanted to do which are a total harmonic distortion (THD) test at maximum output into my dummy 8Ω speaker load using a 1KHz sine wave source signal and a frequency response test.

Here is my newest testing apparatus, two new dummy speaker loads.

My previous dummy speaker loads were made with a single 8Ω resistor for each channel. The new test loads have a 4Ω resistor in series with two 2Ω resistors and a 0.08Ω sensing resistor.  This gives me more connection points for measurement probes to use in combination with the audio analzyer attenuators...so I can setup the measured signal at a level most suited for the analyzer.

I still expect to primarily connect up the analyzer probes differentially across the 0.08Ω sensing resistor as shown in the picture.

The DMM probes are across the full 8Ω load so I can monitor what the amplifier output level is actually at. This is especially useful on the Beomaster 1900 where you really don't get a numeric value for the volume. I find it difficult to visually tell if I have the same volume level when using the touch controls unless I can see the result on a DMM.

The connection to the QuantAsylum QA401 audio analyzer from the 0.08Ω sensing resistor is via the two differential BNC connectors.

The first tests I ran were for the total harmonic distortion (THD).  The Beomaster 1900 - Type 2904 service manual states the maximum THD should measure less than 0.2%.  I take that to mean at full power output (20W into an 8Ω speaker load).

As mentioned in other Beomaster amplifier tests here on the Beolover Blog, we can't duplicate the test setup exactly as Bang & Olufsen did when the Beomaster 1900 was manufactured. However, we should come close and we collect these new test results to use as a reference for other restoration projects of the same Beomaster models....so keep in mind that this testing is an ongoing learning experience.

Here are the Beomaster 1900 left and right channel THD measurements. The QA401 audio analyzer generated the 1KHz sine wave test signal to the Beomaster 1900 Tape input. I adjusted the volume on the Beomaster as best I could to just under 12.7Vrms (which is 20W across 8Ω).  The Beomaster 1900 is a little tricky to dial in a specific volume level value (like 12.7Vrms).  My measurements ended up being more in the range of 11.7Vrms to 12Vrms. 

The right channel measured 0.13% THD which is comfortably below the spec value of 0.2%. 
I was happy with that but then surprised when the left channel measured 0.034%. 

Both channels are obviously in spec but not having measured this Beomaster 1900 before I have no reference data whether this is typical.

To be safe I decided I would run through and recheck the no-load current settings of the output amplifiers. Perhaps that adjustment had changed.

This meant removing the Beomaster 1900 bottom cover and the tone control/FM tuning cover in order to access the measurement and adjustment points. The probe connections across the two emitter resistors for the no-load current adjustment are too difficult to reach on the component side of the board so I connect from underneath.

The adjustment trimmers are also a little hard to reach.

I ended up spending a couple of hours on the readjustments.  Initially I checked them with the amplifier cold. Both channels measured up close to 14mV across the emitter resistors (R256 and R356). Eventually they settled to the low 11mV range. I adjusted them both back to 12mV then reconnected the dummy speaker loads to drive the outputs for a while up to 20W across the 8Ω loads again. After that I lowered the volume level to zero and removed the speaker loads again to check the no-load current measurements. Since the amplifier was warmed up it took a while for the voltages to settle back down. Both channels dropped to about 11.5mV.  I adjusted them back to 12mV one more time and repeated the test. 

This time the no-load adjustment check measured close to 12mV on each channel's emitter resistor.

After all of that I remeasured the THD for 1KHz at 20W and...got the same results as before.
Right channel THD is 0.13% and the left channel THD is 0.03%.  I did try measuring the THD for both channels at a lower volume (10W).  The right channel THD dropped to 0.09% but the left channel remained at 0.03%. 

It would seem like a lot of effort for no gain but I feel better knowing that the output amplifier is adjusted as good as I can get it.

In addition, while the two channels are not identical in their THD test, both channels do meet the Beomaster 1900 spec value. I am satisfied with the THD result now.

The last performance measurement I wanted to do is a frequency response test. The Beomaster 1900 spec for frequency response on the Tape input is 20Hz to 20KHz ±1.5dB.

The frequency response measurement is another test that is an ongoing development for me with my current test equipment set up. For this first time Beomaster 1900 frequency response check I decided to try the QA401 new frequency response plotting feature. Like the THD tests I used the QA401 differential input probes across the 0.08Ω sensing resistor in my dummy speaker load.

The test automatically sweeps test frequencies from a selected range and plots the amplitude of the output signal. I selected a sweep from 15Hz to 40KHz.

Here are my results.

The frequency plot for both channels is within the ±1.5dB specified by the Beomaster 1900 spec from 20Hz to 20KHz so I am happy with that. I marked the 1KHz test signal amplitude as the zero reference to check the ±1.5dB amplitude to. I tried to lock the volume level to the same position for both channel frequency response test but I ended up with the left channel running at a slightly higher level.

Now for a final play test and this Beomaster 1900 should be ready to return home.
I decided to connect up this receiver to my spare Beosystem 8000 where the Beomaster 8000 project recently vacated from. I was interested to see how a Beomaster 1900 would do driving a pair of Beovox M100.2 speakers.

Not a problem for the "little" Beomaster 1900. 20W of maximum power is plenty for a pair of Beovox M100.2 speakers in a small listening room (12 foot x 12 foot).

The final performance evaluation is now my own ears enjoying music controlled through this great little amplifier from the seventies.

Beomaster 1900 Type 2904: Cleaning, polishing and reassembly

For about a week since the last post this Beomaster 1900 has been sitting on the workbench playing music for hours on end. No problems surfaced during that time so with the new parts broken in I am ready to reassemble the Beomaster before going into the final stretch of testing.

The trickiest part of the reassembly has to be the touch control panel.
The copper, spring leads for the touch controls must fit onto corresponding posts on the Beomaster 1900 circuit boards. A trick Martin Olsen taught me was to install this panel with the Beomaster 1900 bottom cabinet plate still removed. That way you can inspect each touch control contact from underneath and use some tweezers or probe to maneuver the contacts into place.

I reinstalled the indicator masks for the bass, treble and balance slide controls at this time.
I also used some plastic cleaner and aluminum cleaner on the touch panel as I installed it.

The next piece to install is the other part of the top cover. The grooved section for the heatsinks and the access door hinge had a lot of dirt and grime from wherever this Beomaster was stored.

I cleaned it with mild cleaning solution and a couple of brushes to get into the channels.
The right side hinge of the access door was loose and came off so I reattached it with some epoxy.
Before reinstalling the base of the cabinet I gave the Beomaster a quick test to make sure all of the electrical connections were still good.

Finally I could install the cabinet base. This cabinet was missing all four of its feet so I used the replacement feet I recently got from Martin Olsen.

While the Beomaster 1900 was upside down I noticed that the Phono DIN jack is a 7-pin DIN connector.  There isn't anything wrong with that but the Beomaster 1900 will never utilize the number 6 and 7 pins of that connector. The Beomaster 2400 is the receiver with a remote control and can control Play/Stop functions of a Beogram 4004 via the 7-pin DIN. Except for the remote control the Beomaster 1900 and 2400 share the same circuit board so I guess Bang & Olufsen just started installing the same source connectors on both receiver models.

The Beomaster 1900 is all assembled again so I turned it over and started another play test session.

This week I will connect it up to my audio analyzer and make some measurements. After that I will hook it up to a Beogram and Beocord to round out the functional testing.

Beogram 4004 (5526): A New Arrival From New York State - A First Look

A Beogram 4004 (5526) arrived for restoration from New York State. Shipping went well, and I had a first look:

This spring revealed itself during unpacking:

Looks like one of the two springs that hold up the mounting screws for the hinge in the back. The unit has decent aluminum panels without major damages, the keypad is also in pretty good shape:

So are the plinth corners up front:

Like most 400x we receive, this unit also has a scratched up hood:

Unfortunately, the MMC 4000 cartridge that came with it is missing the tip:

I took a look under the aluminum panels:

As far as I can tell at this point things look pretty original. That is always a good starting point for a restoration. 

I plugged it in, and pressed START. The carriage started moving, but passed by the LP set-down point and went all the way across to the center and then returned. Since the 33-to-45 switchover occurred during this trip, the carriage position sensor seems to work. This suggests that the record detection circuit has an issue. Another obvious issue with this deck is the DC platter motor. It emitted a knocking sound while it was running, a clear indication that the bearings need to be re-infused with oil. This is a common issue with this Beogram vintage. 

Beogram 4002: DC Motor Restoration

A Beogram 4002 DC motor recently arrived for restoration from Iowa. This shows the motor as received:

I took it apart to get the bearings out. Most Beogram 4002 and 4004 motors need their Oilite bearings re-infused with oil. Such bearings are made from porous brass, and after operating the motor for some time the oil in the pores is drawn out and the bearings run dry. This causes RPM variations and eventually the motor will seize and stop running. This shows the motor disassembled:

The bearings are the two small donuts on the black pad upfront. I immersed them in motor oil and pulled a vacuum:

Immediately vigorous bubbling started. This indicated that the air in the pores of the bearing material was pulled out by the vacuum. This process creates space for the oil to diffuse into the bearing. After about 24 hrs the bubbling stopped, which indicated that the infusion process had completed. I extracted the bearings

and re-installed them into the motor housing:

I use a specially made 3D printed tool for pressing the tabs of the ring that holds the upper bearing in place back into their original shape.

This shows both bearings back in place:

I put the motor back together and installed it into one of my Beogram 4002s for a 24 hrs RPM stability test with my BeoloverRPM device:

The BeoloverRPM device allows logging the RPM in 10s intervals for extended periods of time, perfect for spotting intermittent RPM issues. This motor passed with flying colors:

This is as good as it gets for the Beogram 4002 DC motor. This motor is back in business! Time to send it back to Iowa!