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Pioneer DV 600-AV, -575-A, -578-A, -585-A, -588-A and -696-AV
Hires SACD and DVD-A digital output DIY-Kit
(New version V 2.0) 

Scope of delivery for Extended Kit

Digital output (S/PDIF) of SACD and DVD-A players is restricted due to copyright reasons. This means at the digital output of your DVD-A/SACD player you get PCM signals in a restricted output quality:

CD :  44.1 kHz
SACD : -- 
DVD-A 96 : 48 kHz
DVD-A 192 : 48 kHz

For those who want to use an external (maybe better) D/A converter instead of the D/A converter built-in the player this restriction is a big drawback.

Installing the offered
"Hires SACD and DVD-A digital output DIY-Kit" 
inside your Pioneer player the digital S/PDIF output is no more restricted.
The kit works with Pioneer DV 600-AV, 575-A, -578-A, -585-A, -588-A.
It also should work with Pioneer DV-696AV
(not yet tested)

Player with Hires-Kit installed Player with Hires-Kit installed

All other functions of your player will work as before, even Dolby-Digital or other digital output. With this kit installed you will get Stereo-PCM signals with their original output quality at the S/PDIF output of your player:

Standard Kit
CD : 44.1 kHz
SACD :  88.2 kHz
DVD-A 96 : 96 kHz
DVD-A 192 : 192 kHz

The output rates above are output rates of the Standard Kit (see "Scope of delivery and pricing" below). 
Beside the Standard Kit an Extended Kit is offered with the some additional modes of operation: 
  • Limit output rate for DVD-A 192 to 96kHz
  • Provide a constant output rate of 96kHz no matter what kind of media is played
  • Low jitter operation at constant output rate if tentlabs XO DIY oscillator (24.5760MHz) is used
  • Input for synchronisation to an external (256 x fs) superclock (e.g. from Apogee Big Ben)
  • Seamless operation with Tentlabs XO-3 for best jitter performance
Extended Kit
  Normal  Limit to 96kHz    Constant  External superclock   XO-3
 CD : 44.1 kHz 44.1 kHz 96 kHz superclock / 256  XO-3 clock / 256 
SACD :  88.2 kHz 88.2 kHz 96 kHz superclock / 256  XO-3 clock / 256 
DVD-A 96 : 96 kHz 96 kHz 96 kHz superclock / 256  XO-3 clock / 256 
DVD-A 192 : 192 kHz 96 kHz 96 kHz superclock / 256  XO-3 clock / 256 

Features

  • The kit is real DIY. Only standard components despite the CS8606 and AD1896 were used.

  • No changes at the housing of the player. All output is sent to the standard digital output.

  • If superclock input should be used an additional BNC connector has to be built inside the player.

  • The kit outputs SACD with 88.2 kHz and DVD-A with 96 kHz and 192kHz. 

  • Using three kits a PCM 5.1. output can be realized. 

  • On the board there is a multiplexer which passes all other outputs despite the hires signals (44,1 kHz, 48kHz, 5.1, DD, ) unchanged to the digital output of the player. This is especially important for Audio CDs recorded with emphasis and for all surround formats. (Not for the 'Constant', 'External superclock' or 'XO-3' option of the Extended Kit)

  • Despite the standard output via multiplexer a S/PDIF output (0,7V for coax) directly behind the CS8406 is available (direct out). 

  • The Extended Kit offers different modes of operation regarding the output rate (see table above). The modes of operation could be selected by setting jumpers (see Powerpoint presentation for details)

 


LEGAL STUFF

Please read the following paragraphs carefully. They are part of the act of sale. Ordering the offered DIY-kit you state that you have read, understood and agreed with the following paragraphs. 
You have understood that anything regarding order, installation and use of the kit is at your own risk! 

Do not order the kit if you did not agree with all paragraphs below!

The only thing I take responsibility on is that you receive a functional kit after ordering and paying. Anything beyond that is at YOUR OWN RISK!

CAUTION:
The installation of the kit inside the player is dangerous! There are current-carrying parts inside the player. Opening the player is at your own risk. Be sure that the player is disconnected from power and all other equipment before opening it. Do not reconnect the player to power while it is open! I will not assume liability for any injuries or death while opening the player or installing the kit. All you do with the player is at your own risk!

CAUTION:
Opening the player you will loose all warranty for the player! Opening the player is at your own risk! Installing the kit in your player may destroy the player. I will not assume liability for destroyed players or players being defective after trying to install the kit.

CAUTION:
The DIY Kit offered is only for people being able to build up the kit by their own. You have to be experienced in perfectly soldering even very small (SMD) parts. The kit is not suited for people having never soldered before! The kit is given away as described in "Scope of delivery" below. I did not offer complete built-on PCBs nor do I offer a service to build the kit for you. I also do not install the kit in your player nor do I sell players with preinstalled kit. This is a kit only for experienced electronic and electric DIYers. No additional service will be offered.

CAUTION:
Building the kit and installing it in your player may violate copyright laws of the country you live in. Worldwide it is forbidden to copy copyright protected material for any use. So take a close look at the copyright laws of your country. It even may be prohibited in your country installing the kit in your player. To be sure not to incur a penalty ask a layer before installing the kit. I will not assume liability for any copyright violation you perform building and installing the kit in your player.


Theory of operation 

Playing SACD and DVD-A the Pioneer player delivers hires digital signals in I2S format to the built in D/A converters. These signals were taken, amplified (74HCT244) and delivered to a CS8406 S/PDIF transmitter. The clock for the transmitter is generated by a custom programmable logic device (CLOCK-GAL22V10). One output of the CS8406 is delivered to the S/PDIF output on the PCB (direct out) and the other to a multiplexer (MUX-GAL16V8). The multiplexer acts like a switch between the original S/PDIF signal from the player and the output of the CS8406. The output of the multiplexer leads to the S/PDIF output of the player.

Receiving a standard signal (<88.2kHz) the multiplexer transmits the original S/PDIF signal from the player to the digital output of the player. Receiving a high resolution signal (>=88.2Khz) the multiplexer switches to the output of the CS8406 where a high resolution signal will be output. 

At the "direct out" output of the board a S/PDIF signal is present for all transmission speeds. Only the emphasis signal is not transmitted correctly. This means CDs with emphasis (there are only very few at the market) have too much hights at the "direct out" output.

Schematics of the kit

For external D/A converters which do not cope with a 192kHz input signal an additional AD1896 can be installed (see Extended Kit below). This will decrease 192Khz output rate to 96Khz and allow all the other modes of operation.
The quality of the output signal is indicated by two LEDs. A blue LED is on for 88.2kHz and 96kHz operation and a white LED is on at 192kHz. For lower sample rates both LEDs are off.

For those who want to get real 5.1 PCM output three boards may be cascaded.


Scope of delivery and pricing

There are two kits available:

Hires standard Kit - 88 Euro - consisting of: 

  • Professional double layer PCB (V2.0)
  • MUX-GAL (GAL16V8 programmed and tested)
  • CLOCK-GAL (GAL22V10 programmed and tested)
  • CS8606 S/PDIF transmitter
  • Cooler for the 7805 power regulator
Scope of delivery for Extended Kit

Hires extended Kit - 148 Euro - consisting of:

  • Professional double layer PCB (V2.0)
  • MUX-GAL (GAL16V8 programmed and tested)
  • CLOCK-GAL (GAL22V10 programmed and tested)
  • CS8606 S/PDIF transmitter
  • Cooler for the 7805 power regulator
  • AD1896 Sample rate converter
  • LM2936-3.3V low noise power regulator
Scope of delivery for Extended Kit

Tentlabs XO DIY low jitter Oscillator - 35 Euro:

All prices include handling, taxes and shipping.


Order and payment

To order please send a mail with your name, your shipping address and the type of kit you like to order to:

 

Receiving your mail you will get an order confirmation with delivery time and a request for PayPal payment. For PayPal use the mail address above.
I ONLY accept payments via PayPal! 
The DIY-Kit will be delivered after payment but not before the denoted delivery time.

Parts list and additional parts

The kit does not include all parts needed for PCB equipping and final assembly. 

  • All parts tagged with a '*' are part of the kit. 
  • The parts tagged with '*E' are only delivered with the extended kit. 
  • The parts tagged with '*E' and 'E' have be installare i for Extended Kit only

All other parts you have to buy at your local electronic store. These parts shouldn't  cost more than 20 Euro.

Additional Parts

Hires Digital Output V1.0 PCB
IC1 74HCT244 Driver
* IC2  GAL16V8 MUX GAL
* IC3  GAL22V10 Clock GAL
* IC4  CS8406  S/PDIF transmitter
*E IC5  AD1896 AYRS ASRC
*E IC6  LM2936-3.3 3.3V Regulator
IC7  7805  5V Regulator 
E IC8 7808 8V Regulator
E IC9 XO DIY 24.5760MHz or other XTAL  Only needed for 
operation mode 'Constant'
E C1  100uF 16V
C2  100uF 16V
C3  100uF 16V
C4  100uF 16V
C5  0.1uF Keramics
C6  0.1uF Keramics
E C7  0.1uF Keramics
C8  0.1uF Keramics
E C9  0.1uF Keramics
C10  0.1uF Keramics
C11  0.1uF Keramics
C12  0.1uF Keramics
E C13  100uF 16V
E C14  0.1uF Keramics
E C15  100uF 16V
E C16  0.1uF Keramics
E C17  0.1uF Keramics
R1  1K
R2  1K
R3  3.3K
R4 330 Ohm
R5 91 Ohm
E R6 10 Ohm
E R7 10 Ohm
E R8 22k
E R9 56K
E R10 1k
E R11 10k
E L1 10uH
D1  1N4148
E T1  BC547B
LED1  white LED
LED2  blue LED
J1  3-pin male connector
J2  3-pin male connector
J3  3+3+2-pin male connector
J4  1-pin male connector
J5  3-pin male connector
CO1  14-pin (2x7) male connector
CO2  2-pin male connector
E CO3  2-pin male connector
some jumper
one ribbon cable 20cm
14-pin female connector 
for ribbon cable
two screws 3mm diameter 10mm long with nut
one screw 3mm diameter 15mm long with nut
* small cooler for 7805 
5mm spacer for 3mm screws
10mm spacer for 3mm screws
two 20pin sockets (0.75)
one 24pin socket (0.75)


Populating the PCB step by step:

  • Tin-plate the pads for the SMD parts
    This is the first of the two most difficult tasks. For training purposes start with the pads of the CS8406. Then put the tin-solder on the pads for the AD1896 (you can omit this if you are building the standard kit). Be sure there is no interconnection between the pins. Interconnections will kill the kit. Take a magnifying-glass and carefully check your work
    .

    Tin on the pads of the SMD semiconductors

     
  • Solder in the SMD-Parts
    Start with the CS8406. Use a very thin soldering tip. Look for the dot on top of the CS8406. Turn the CS8406 around till this dot is in the upper left corner of the IC. Having the dot at the wrong position will kill the kit. Press the CS8406 with a finger on the tin-plated pads. Adjust the CS8406 till the circuit points directly lay above the pads. Heat one corner pin with the soldering iron while pressing down the chip. Now heat the pin in the opposite corner. Having fixed these two pins check the position of the chip again and adjust if necessary. Having reached the perfect position, heat all pins one after another. Do not use tin-solder while heating the pins. If you build an extended kit perform the same procedure with the AD1896. The dot of the AD1896 has to be in the upper right corner! Soldering the AD1896 is much more difficult!! So take time, good light and a magnifying-glass.


    Soldered CS8416 Soldered CS8416 Soldered AD1896 PCB populated with Rs and D1

     
  • Solder the sockets, Rs and the diode D1
    This is quite straight forward. Localize the right resistors and solder them in. For the diode watch the white stripe on the PCB print (left in the image). The black stripe of the diode has to be placed above it.

    PCB populated with the sockets

     
  • Insert the connectors and the strip for the jumper

    PCB populated with the keramics Cs

     
  • Now insert the ceramic and electrolyte Cs and the 3.3V regulator
    Inserting the wires of the electrolyte Cs look for the little + sign on the PCB print. This is where the long wire of the Cs had to be inserted. Using Cs with wires of the same length, locate the positive side of the C and insert it correctly. The photo shows how to insert the 3.3V regulator if the extended kit is built. 

    PCB populated with electrolyte Cs and 3.3V regulator mounting direction of the 3.3V regulator

     
  • Next power regulators and LEDs and CO2 and CO3
    The LEDs have a long and a short wire on their bottom side. Insert the LEDs the way that the short wire get inserted at the outer side of the PCB (right side at the image). The 7805 power regulator is inserted with the cooler and tightened with one of the 3mm (length 10mm) screws. Insert the 7808 regulator as deep as possible in the big holes.

    PCB populated 5V regulator and LEDs

     
  • Finally the integrated circuits have to be inserted
    The top 20 pin socket is for the HCT244 and below of it the MUX-GAL16V8 has to be inserted. The lowest socket with the 24 pins is for the CLOCK-GAL 22V10. Beware of the dots on top of the ICs. They show the position of pin 1. This dot has to be in the lower left corner for all three ICs! Putting the ICs into the sockets in opposite direction will kill the kit!!
     
    Finalized PCB front view Finalized PCB rear view

  • Final check
    Take a close look to the PCB. Watch for shortened pins. Check if the ICs are at the right position. Also check if the dots of the ICs are at the right position. If you are satisfied with your work and the PCB looks like the photos above the PCB should be operational.

Setting the Jumpers

Now you have to decide in with mode your Kit should operate. For the correct juper setting I have prepared a Powerpoint presentation showing you the modes of operation and the corresponding juper setting.

Jumper setting for the different modes of Operation

Only for only the operation mode 'Constant' IC9 is necessary. If you did not operate your Kit in this mode IC9 may be omitted but it will cause no harm if IC9 stays in its socket at all other operation modes.

CAUTION!

For the operation modes 'Constant', 'External superclock' and 'XO-3'
jumper J1 has to me omitted. 
If not the MUX-GAL may be destroyed!


Preparing the ribbon cable

For preparing the ribbon cable you need a vice, scissors and a cutter. First insert the cable in the connector. Check that the red side of the wire is above the pin 1 marking of the connector. Put the connector and the cable in the vice and press. Now take the scissors shortening the ribbon cable as displayed in the picture. Finalize the work skinning the wires.

Inserting the ribbon cable in the connector Compressing the connector Finished connector Assembled ribbon cable Bared wires


Opening the player

Now you have to open the player. Here a last warning before you open the player.

CAUTION:
The installation of the kit inside the player is dangerous! There are current-carrying parts inside the player. Disconnect the player from power before opening the player. Opening the player is at your own risk. Opening the player you will loose all warranty for the player! Installing the kit in your player may destroy the player. I will not assume liability for destroyed players or players being defective after trying to install the kit. All you do now is at your own risk!

To open the player, first disconnect it from ALL wires. In the pictures below you see the screws to be opened are marked with a red circle.

Screws to open in the rear of the player Screw to open at the side of the player Screw to open at the side of the player

Having unscrewed the screws open the player by lifting the rear side 45 degrees and remove the top cover.


Installing the ribbon cable for Pioneer DV 575-A and DV 578-A

The images below show you where the ribbon cable has to be connected to the PCB of the player. The first image gives you an overview. The others show the details. For soldering put the wires of the cable in the right holes on the PCB. Heat the pin and the wire with a very sharp soldering tip and touch it with tin-solder.

Near the connection point of pin 2 a wire on the PCB of the player has to be disconnected (see image in the middle). Best use a sharp cutter to disconnect the wire. Be careful to cut only this wire and damage noting else.

How to connect the ribbon cable Pin 1 is connected to the power regulatur Pin 2 connection and disconnection of the PCB wire Pin 3 connection Connection for the rest of the pins


Installing the ribbon cable for Pioneer DV 585-A and DV 588-A

The fotos below show where the ribbon cable has to be connected. The first foto gives you an overview the second shows the details.

The holes on the PCB are very small. Therefore I recommend to fix the ribbon cable with hot-melt adhesive on top of the big processor chip before soldering the wires. You need a very fine soldering tip for this step!

As you see on the first foto the shielded wire from the main pcb to the power pcb has to be disconnected and soldered to pin 2 und pin 3 of the ribbon cable.

Interconnections overview Interconnections details


Installing the ribbon cable for Pioneer DV 696-AV

The instructions are the same as above. See the photos below for the connection points.

Interconnections overview Interconnections details

 


Installing the ribbon cable for Pioneer DV 600-AV

The instructions are the same as above. See the photos below for the connection points.

Interconnections overview Interconnections overview Interconnections overview Interconnections overview

Interconnections overview Interconnections overview Interconnections overview Interconnections overview


First test

After having installed the ribbon cable close the player, connect power and digital output and switch the player on. If the player starts insert a CD and press PLAY. There should be no signal at the digital output of the player. If there is a signal check if you have correctly disconnected the wire on the PCB of the player. 


Installing the PCB for Pioneer DV 575-A and DV 578-A

Two holes have to be drilled in the base plate of the player for installation of the PCB. Use a 3.5mm drill bit for this step. The two holes must have a distance of 88mm. The right hole lies deeper than the left one. 

Holes to drill


To assemble the PCB of the kit put the two 3mm screws screws bottom-up in the holes and slip the spacers over the screws. Use the 15mm screw and the 10mm spacer on the right side.

Holes equiped with screws and spacers

Now attach the PCB on the spacers and fasten it with the screws.
At last connect the ribbon cable to the PCB.

Player with Hires-Kit installed Player with Hires-Kit installed Player with Hires-Kit installed


Installing the PCB for Pioneer DV 585-A, DV 588-A and DV 696-AV

To install the kit you need two screws M3 15mm and two screws M3 10mm. Furthermore you need two 5mm and two 10mm spacers, two circlips and two aluminium bars (30mm each) with a square profile 5x5mm. At the end of the aluminium bars two holes with a M3 thread have to be drilled.

Two 3.5mm holes have to be drilled in the bottom plate of the player before installation . These two holes must have a distance of 88mm between each other and have to be 15mm away from the player's PCB (less is better than more!).

Mounting the aluminium bars Aluminium bar detail Aluminium bar detail

The fotos show the assembly of the aluminium bars on top of the bottom plate. Watch the circlips between the spacers and the aluminium bars. 

Now the PCB of the kit is fastend on top of the aluminium bars with the 5mm spacers and the two 10mm screws.

Mounted PCB

 

 


Installing the PCB for Pioneer DV 600-AV

For the installation a 10mm spacer tube and a 20mm long M3 screw. 

With the spacer and the screw the kit is fastened at the main PCB of the player.

Interconnections overview


Testing

Now close the player, connect power and digital output and switch the player on. If the player starts insert a CD and press PLAY. There should be a digital signal at the S/PDIF output of the player. Hearing this signal means the Hires-Kit is functional! With a normal CD playing none of the both LEDs should be on.

Now insert a SACD and press PLAY. There also should be a digital signal at the S/PDIF output of the player, a signal with 88kHz sample rate (blue LED is on). Redo this with a DVD-A for 96kHz (blue LED is on) and 192kHz (white LED is on).

Attention!

For the operation mode 'External superclock' the superclock has to be provided before the player is turned on. If not the player would not syncronize and nothing would be output at its S/PDIF output.


PCM 5.1 output

Both the Standard and the Extended Kit transmit a highres Stereo PCM signal out of the S/PDIF output of the player. Those who wish to get 5.1 digital PCM output have to use three kits. The schematic below shows how these three Kits have to be connected.

Connection schematics for PCM 5.1

As you see all pins except Pin 3 and Pin 9 are interconnected between the three kits. Pin 9 is the input pin for the second and third kit. Therefore a wire has to be fastened and connected to the corresponding pins on the PCB of the player.

Connection pionts for 2. and 3. Kit

For PCM 5.1 output the signals have to be taken from the "direct out" output of the kits (left in the schematics above). Also three cynch coax connectors must be built in the housing of the player.


Support

For questions regarding the kit please first check the forum. If you do not find answers to your questions there please send a mail to: