AE Techron Service

Expert Product Service You’ll Almost Never Need

Amplifier Rebuild Process

(This process is available for most Techron and AE Techron amplifiers built in the last 30 years. Although the specific details will differ from model to model, the basic rebuild process is the same:

1. Replace parts that are worn or may be worn,
2. Test to verify amplifier performance, and
3. Place the amplifier under the coverage of a “parts and labor” factory warranty.

The following example details the AE Techron process of rebuilding a Model 7796 amplifier.

Amplifier Check-in
After being received and unboxed, an initial inspection is done to verify that your unit has arrived safely. Once the incoming inspection is complete, the amplifier is assigned to a technician.

Initial Disassembly
The technician performs an initial disassembly by removing the chassis top cover (photo 1), followed by the fan panel (photo 2).

During this initial disassembly process, the technician also begins examination of your amplifier. The technician makes note of your amplifier’s revision level and determines what extra parts will be needed to bring the amplifier up to the latest revision level. Any unusual wear or contamination will also be noted.

Core Disassembly
Technician will then remove the output stack assembly and top rails from the chassis (photo 3). The top output PC board is carefully removed from the stack and inspected for damage (photo 4).

Unit Cleaning & Parts Replacement
All the output transistors are removed (photo 5) and both the heat sink and boards are cleaned. The transistors are replaced with our latest-revision parts (photo 6) and new Heat sink compound is applied. This process is performed for each output PC board.

With this work done, the amplifier is returned to the assigned service technician. While the amplifier core has been cleaned and rebuilt, the service technician has been working on the main circuit board. The technician has upgraded the board to the latest revision and has replaced worn parts. Other parts that have been known to have the potential to cause reliability problems in that model of amplifier are also replaced. In the case of the Model 7796, this includes the trimmer pots, which are replaced with precision resistors. Certain brands of electrolytic capacitors, if found in the amplifier, are also removed and replaced.

Initial Testing
Output stack is then tested prior to being returned to the chassis. Testing begins by verifying that no accidental shorts exist. These checks will include verification of impedances between output transistors, emitter resistors and ground.

Amplifier Reassembly
Output stack is reinstalled in the chassis and all cables reconnected. After this initial testing, the amplifier is powered up and additional tests and adjustments of DC offset, bias, and protection circuits are performed.

Final Testing
When everything checks out, the amplifier moves on to the burn-in station (photo 7), where the amplifier undergoes a comprehensive, computer-controlled, 24-hour burn in. The burn-in time is divided into eight, four-hour cycles, alternating between pulsed and continuous power.

Pulsed cycles are timed so that the amplifier goes from cold to just short of thermal shut-off. This type of testing will expose any undiscovered issues that could be aggravated by thermal expansion (i.e., cracked traces on a PCB).

The continuous power testing checks the amplifier’s long-term thermal performance (photo 8). This testing will verify that all output transistors have been mounted with the correct torque and have sufficient heat-sink compound.

The burn-in testing is the same testing as is done with any AE Techron remanufactured amplifier. Due to this rigorous testing, AE Techron is confident with the results and places all rebuilt amplifiers back under warranty.

Proof of Performance and Shipping
With testing complete, the Proof of Performance or PoP sheet is created (photo 9), and the newly rebuilt amplifier is packaged for shipment back to you, to provide many more years of reliable service.

If you are interested an amplifier rebuild, you can contact AE Techron via phone, email or our online Contact Form. Tech Support is available via phone or email from 8 AM – 5 PM EST. Our response goal is for you to hear back from us within 1 business day.

Email us at: [email protected] 
Or, call us at: +1 574-295-9495