Repairing Nuraphones "Entering Deep Sleep" Broken Capacitive Sensor

For fixing the "deep sleep" issue, feel for the cup that has a flexible ring (capacitive sensor) around the face-side of the cushion. It should be the right cup.

Grip the hard outer shell of the ear cup you want to disassemble.

Completely cover the soft padding area with your other hand, squeeze to grip, and twist like opening a jar.

Twist the left cup clockwise to open, and turn the right cup anticlockwise to open.

Remove 9 Torx T7 screws from the ring of the cup

When reinstalling any plastic screw, insert the screw in the hole and rotate backwards (unscrew direction) with slight downward pressure until you feel a click - that locates the original thread and prevents stripping. Begin screwing it back in where you feel the click.

Separate the two halves of the cup, revealing the skin mounting

Fold back the skin, revealing the ear cup foam and (if fixing the Deep Sleep issue) the broken wire leading to the capacitive ring

The capacitive sense wire will likely be buried halfway through the foam. Your job is to get it back through.

It may help to squish the foam flat and fish the wire through the smaller, squished distance.

Litz wire has enamel (insulation) wrapping every tiny strand individually. Thus, you need to melt it off the bundle at the tip - it should form a dark brown blob with some smoke, assisted by adding excess fluxed solder (and cleaning your soldering tip while doing so).

After you have a tinned segment, you may wish to trim it to a clean, tinned tip (remove fraying at the end), then simply attach it back to the pad on the capacitive ring.

You're done! Reverse the disassembly steps to re-assemble.