Honeywell KMA28 User Manual

Installation and Operation Manual

BENDIX/KING®

KMA 28

FAA-Approved TSO C50c, C35d

JAA-Approved JTSO-2C35d, C50c

Audio Amplifier /Intercom/

Marker Beacon Receiver

Document P/N 006-10565-0000

REVISION 0, SEPTEMBER 2000

WARNING

Prior to export of this document, review for export license requirement is needed.

Honeywell International, Inc. 2000©

Copyright Notice

Reproduction of this publication, or any portion thereof, by any means without the express written permission of Honeywell International, Inc. is prohibited. For further information contact the Manager, Technical Publications; Honeywell Business & General Aviation, Olathe, Kansas 66061. Phone [phone].

Bendix/King

KMA28

Audio Amplifier/Intercom/Marker Beacon Receiver

Table of Contents

1 SECTION I GENERAL INFORMATION.........................................................................			1-1
1.1		INTRODUCTION...........................................................................................................	1-1
1.2		SCOPE .............................................................................................................................	1-1
1.3		EQUIPMENT DESCRIPTION .....................................................................................	1-1
1.4		APPROVAL BASIS - .....................................................................................................	1-2
1.5		SPECIFICATIONS ........................................................................................................	1-3
1.6		EQUIPMENT SUPPLIED.............................................................................................	1-4
1.7	EQUIPMENT REQUIRED BUT NOT SUPPLIED....................................................		1-5
1.8		LICENSE REQUIREMENTS .......................................................................................	1-5
2	SECTION II - INSTALLATION.........................................................................................		2-1
2.1		GENERAL INFORMATION........................................................................................	2-1
2.1.1		SCOPE........................................................................................................................	2-1
2.1.2		CERTIFICATION REQUIREMENTS.................................................................................	2-1
2.2	UNPACKING AND PRELIMINARY INSPECTION................................................................		2-1
2.3	EQUIPMENT INSTALLATION PROCEDURES ....................................................................		2-1
2.3.1		COOLING REQUIREMENTS...........................................................................................	2-1
2.3.2		MOUNTING REQUIREMENTS .......................................................................................	2-1
2.3.3		MOUNTING RACK INSTALLATION ...............................................................................	2-2
2.3.4		CONNECTOR ASSEMBLY .............................................................................................	2-2
2.4	CABLE HARNESS WIRING ...............................................................................................		2-2
2.4.1		NOISE ..........................................................................................................................	2-2
2.4.2		EXISTING KMA-24 INSTALLATION.............................................................................	2-3
2.4.3		EXISTING PS ENGINEERING PMA6000 INSTALLATIONS ............................................	2-3
2.4.4		POWER ........................................................................................................................	2-3
2.4.5		COMMUNICATIONS PUSH-TO-TALK ............................................................................	2-3
2.4.6		TRANSMIT INTERLOCK................................................................................................	2-3
2.4.7		"SWAP" MODE ............................................................................................................	2-4
2.4.8		BACKLIGHTING ...........................................................................................................	2-4
2.4.9		UNSWITCHED INPUTS..................................................................................................	2-4
2.4.10		INTERCOM WIRING ....................................................................................................	2-4
2.4.11		COM 3 AUDIO............................................................................................................	2-5
2.4.12		PUBLIC ADDRESS FUNCTION.....................................................................................	2-5
2.4.13		PA MUTE (J1, PIN 18)...............................................................................................	2-6
2.4.14		CONTROL OUTPUT (J2, PIN 4)...................................................................................	2-6
2.4.15		VOX OVERRIDE (J2, PIN U) .....................................................................................	2-6
2.5		MARKER INSTALLATION.................................................................................................	2-6
2.5.1		MIDDLE MARKER SENSE ............................................................................................	2-6
2.5.2		EXTERNAL MARKER LIGHTS ......................................................................................	2-6
2.5.3		MARKER ANTENNA INSTALLATION ............................................................................	2-6
2.6		ADJUSTMENTS..................................................................................................................	2-7
2.7	COMMUNICATIONS ANTENNA INSTALLATION NOTES ..................................................		2-7
2.8	WIRELESS TELECOMMUNICATIONS INTERFACE ...........................................................		2-7
2.8.1		HOOK SWITCHES.........................................................................................................	2-8
2.9		KMA 28 PIN ASSIGNMENTS ...........................................................................................	2-9
2.10 POST INSTALLATION CHECKOUT ...............................................................................			2-10
2.11		UNIT INSTALLATION ....................................................................................................	2-10

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Audio Amplifier/Intercom/Marker Beacon Receiver

2.11.1		OPERATIONAL CHECKOUT ......................................................................................	2-10
2.11.2		RECEIVER SENSITIVITY...........................................................................................	2-11
2.12 CELLULAR INTERFACE CHECKOUT ...........................................................................			2-11
2.13		FINAL INSPECTION.......................................................................................................	2-11
3 SECTION III KMA28 OPERATION .................................................................................			3-1
3.1		AUDIO SELECTOR ............................................................................................................	3-1
3.1.2		SPEAKER AMPLIFIER...................................................................................................	3-1
3.1.3		PUBLIC ADDRESS (PA) FUNCTION .............................................................................	3-2
3.2		POWER SWITCH /EMERGENCY (EMG) OPERATION.....................................................	3-2
3.3		MICROPHONE SELECTOR................................................................................................	3-2
3.3.1		SWAP MODE (SWITCH FROM COM 1 TO COM 2 REMOTELY) ......................................	3-3
3.3.2		SPLIT MODE ................................................................................................................	3-3
3.3.3		TELEPHONE MODE......................................................................................................	3-3
3.4		INTERCOM SYSTEM .........................................................................................................	3-4
3.4.1		INTELLIVOX® VOX-SQUELCH....................................................................................	3-4
3.4.2		VOLUME CONTROL .....................................................................................................	3-5
3.5	MARKER BEACON OPERATION ......................................................................................		3-7
3.6	TELEPHONE OPERATION (IF EQUIPPED WITH APPROVED SYSTEM).............................		3-7
4 APPENDIX A – INSTALLATION DRAWINGS ................................................................			A
5 APPENDIX B BOTTOM CONNECTOR INTERCONNECT...........................................			B
6 APPENDIX C TOP CONNECTOR INTERCONNECT.....................................................			C
7 APPENDIX D- INSTRUCTIONS FOR FAA FORM 337 AND CONTINUING
AIRWORTHINESS......................................................................................................................			D
7.1	INSTRUCTIONS FOR FAA FORM 337 ................................................................................		D
INSTRUCTIONS FOR CONTINUING AIRWORTHINESS, AUDIO PANELS .................			D
APPENDIX E RTCA DO160C (EUROCAE ED-14) ENVIRONMENTAL
QUALIFICATION FORM..........................................................................................................			E

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KMA28

Audio Amplifier/Intercom/Marker Beacon Receiver

Section I GENERAL INFORMATION

1.1INTRODUCTION

The KMA 28 represents the next step in cockpit audio control and intercommunications. Using proprietary IntelliVox® design, this unit eliminates the requirements for intercom squelch adjustments. The unit is designed for outstanding ergonomics and visually defined mode annunciation and selection.

Before installing and/or using this product, please read this manual completely. This will ensure that you will take full advantage of all the advanced features in the KMA 28.

1.2SCOPE

This manual provides detailed installation and operation instructions for the Honeywell, Inc. KMA 28 Audio Selector Panel/Intercom System

Model	Description	Part Number
KMA 28	Stereo Audio Panel with Marker	066-01176-0101

1.3EQUIPMENT DESCRIPTION

The KMA 28 is a state of the art audio isolation amplifier and audio selector that contains an automatic voice activated (VOX) intercom system. It can switch up to three transceivers (Com 1, Com 2 and Com 3) and six receivers (Nav 1, Nav 2, ADF, DME, MKR and AUX).

The TEL mode allows the KMA 28 to act as an audio interface between aircraft headphone and microphones and specific aircraft approved (FAA/FCC) cellular telephone equipment.

Warning: Use of non-aviation approved cellular telephone equipment may be prohibited by regulation. Honeywell, Inc. is not responsible for unauthorized airborne use of cellular telephones.

There are two unswitched inputs, for autopilot disconnect, and/or radar altimeter warning. Push buttons select the receiver audio source provided to the headphones. A SPR button allows the user to listen to the receiver(s) selected on the cabin speaker. Except for the unswitched inputs, all speaker audio is muted during transmit.

A rotary switch selects one of the three communication transceivers for the pilot and copilot position, and allows radio transmission. In "Split Mode" the KMA 28 has the ability to allow the pilot and copilot to operate different transceivers independently. The TEL mode allows the pilot to use the cellular telephone interface. External switches permit telephone operation for the copilot and passengers.

An emergency mode connects the pilot headphone and microphone to COM 1 if power is removed for any reason, or if the power switch is placed in the Off (emergency ) position.

IntelliVox® is a trademark of PS Engineering, Incorporated, and used with their permission

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A six-station voice activated (VOX) intercom is included in the KMA 28. This system has the advanced IntelliVox® circuitry that eliminates manual adjustments. The system contains six separate VOX mic circuits, and only opens the microphone channel in use.

The intercom system incorporates pilot isolate and crew modes, two stereo (or mono depending on unit) music inputs with "Soft Mute," and LED indicators for swap and transmit indications. Intercom control is through front panel-mounted knob and 3 position mode switch. A single volume controls intercom level for the pilot and copilot. Passenger headphone volume is factory set, and adjusted in flight with headset-mounted volume controls. Passenger volume control is further adjustable through screwdriver access in the top of the unit. Intercom squelch is automatic.

A 3-light Marker Beacon receiver is integrated in the KMA 28. This provides the necessary Marker Beacon lights and audio indications necessary for an Instrument Landing System (ILS) approach.

1.4APPROVAL BASIS -

TSO Approval.

The KMA 28 Audio Selector Panel is FAA approved under TSO C50c (Audio Amplifiers) and TSO C35d (Marker Beacon Receivers). In addition, they are approved by the Joint Airworthiness Authorities under JTSO C50C and JAR-TSO 2C35d. The TSO holder and manufacturer is PS Engineering, Incorporated, Lenoir City Tenn., USA.

The KMA28 complies with relevant portions of EUROCAE RTCA MPS WG No. 7/70, DO-143 and (Marker Beacon Receivers), ED-14C/DO-160C (Environmental Conditions and Test Procedures for Airborne Equipment), ED12B/DO-178B (Software Considerations for Airborne Equipment) and ED- 18/DO-214 (Audio Systems Characteristics and Minimum Operational Performance Standards for Aircraft Audio Systems).

Operation is subject to the following conditions: This device may not cause harmful interference.

This device must accept any interference received, including interference that may cause undesired operation.

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Audio Amplifier/Intercom/Marker Beacon Receiver

1.5 SPECIFICATIONS

TSO COMPLIANCE
Marker Beacon:	C35d, Class A
Audio Selector/Intercom:	C50c, Class A
APPLICABLE DOCUMENTS:	RTCA/DO-214
	RTCA/DO-143
	RTCA/DO-160C
	RTCA/DO-178B
ENVIRONMENTAL Qualifications:	A1D1/CA(MN)XXXXXXBBBBTBKXX
Temperature Range:
Operating:	-15º C to +55ºC
Storage:	-55º C to +85ºC
Altitude:	Up to 50,000 feet in an non-pressurized area of
	the cockpit.
DIMENSIONS:	Height: 1.3 in. (3.3 cm) Width: 6.25 in. (16.9 cm)
	Depth: 6.8 in. (17.3 cm)
WEIGHT (With Rack & Connectors):	1.5 lb. (0.54 kg)
POWER REQUIREMENTS (Including Internal Lighting):
Voltage:	11 to 33 VDC
Maximum Current:	2.5 Amp (Externally protected by a 3 Amp circuit
	breaker.)
Typical operating current:
Speaker off:	350 mA
Speaker on, 28V, full radio volume	1.5 A
Audio Selector Specifications
Audio selector panel input impedance:	510 Ω
Input Isolation:	-60 dB (min.)
Speaker Muting:	-60 dB (min.)
Speaker Output (into 4 Ω ) with no clipping	3 Watts (min.)
14 VDC:
28 VDC:	10 Watts (min.)
Receiver Inputs:	9
	(Com 1, Com 2, Com 3, Nav 1, Nav 2, ADF,
	DME, MKR, AUX)
Unswitched Inputs:	2
	(examples: GPS WPT, Value, Autopilot Discon-
	nect, Altimeter DH)
Transmitter Selections:	6
	(Com 1, Com 2, Com 3
	Com1/2, Com2/1, Telephone)
Speaker Impedance:	4 Ω
Headphone Impedance:	150 - 1000 Ω
Headphone Output:	38 mW each headset, no clipping <1% THD
	70 mW each headset with < 10% THD into 150Ω
Microphone Impedance:	150 - 600 Ω

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		KMA28
	Audio Amplifier/Intercom/Marker Beacon Receiver
	Intercom Specifications
Intercom Positions:		6 places (with individual IntelliVOX® circuits)
Music Inputs:		2 (Stereo)
Music Muting:		>-30 dB "Soft Mute" when Com or intercom active.
Distortion:		<1% THD @ 38 mW into 150Ω
		<10% THD @ 70mW into 150 Ω
Mic Freq. Response, 3 dB:		300 Hz - 6000 Hz
Music Freq. Response, 3 dB:		100 Hz - 18kHz
	MARKER BEACON RECEIVER
Frequency:		75 MHz Crystal Controlled
Sensitivity:		Capable of:
Low:		1000 µ Volts (Hard)
High:		200 µ Volts (Hard)
		(preset at factory for field application)
Selectivity:		-6 dB at ±10 kHz
		-40 dB at ±120 kHz
External Lamp Output:		9.0 (±2.5 unloaded, at maximum brightness) VDC posi-
		tive when active, max. current 125 mA
MM Sense:		Active high (4.7 VDC ± 0.5V) during Middle Marker
		acquisition, for autopilot use.
1.6 EQUIPMENT SUPPLIED
1 ea. of the following:
	Model		Part Number
	KMA 28		066-01176-0101

KMA 28 Installation Kit, 050-03613-0001, contains the following parts.

	Description	Quantity	Part
			Number
KMA28 install rack		1	071-00164-0001
Top Molex Connector Shell w/key, 44 pin, key 4/5		1	120-425-4402
Bottom Molex Connector Shell w/key, 44 pin, key 7/8		1	120-425-4400
Gold Plated Crimp Pins		88	425-001-0002
4 40 X 7/16 screw w/nyl patch		4	475-440-0007
Grounding strap		1	430-007-0001
6-32	X 3/4 screw php	2	475-632-0038
6-32	Nut Flat	2	475-632-0003
6-32	Lock Nut	2	475-632-0004
Cable Clamp		1	625-001-0002
#6-32 x ½” FHP screw		6	475-632-0012
#6-32 Clip Nut		6	475-630-0002

The KMA 28 install rack may be purchased separately under part number 071-00164-0001.

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Audio Amplifier/Intercom/Marker Beacon Receiver

1.7EQUIPMENT REQUIRED BUT NOT SUPPLIED

a)Circuit Breaker: 1 ea. 3 amp

b)Speaker, 4 Ω

c)Headphone Jacks (Stereo, as Required)

d)Microphone Jacks (as Required)

e)Headphones, 150 Ω (Stereo), up to 6 as required

f)Microphones, up to 6 as required

g)Marker Antenna (75 MHz, VSWR <1:1.5, 50 ohm, and cable (RG400 R/U)

h)Interconnect Wiring

1.8LICENSE REQUIREMENTS

None

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KMA28

Audio Amplifier/Intercom/Marker Beacon Receiver

Section II - Installation

2.1GENERAL INFORMATION

2.1.1 SCOPE

This section provides detailed installation and interconnect instructions for the Honeywell, Inc. KMA28 Audio Selector Panel/Intercom System with internal Marker Beacon. Please read this manual carefully before beginning any installation to prevent damage and post-installation problems. Installation of this equipment requires special tools and knowledge.

2.1.2 Certification Requirements

When the digital audio warning system is installed in a certified aircraft, certification basis is the installer’s responsibility. Due to the variety and options available for interface, Honeywell will only provide manufacturers’ data for our equipment interface.

2.2Unpacking and Preliminary Inspection

Use care when unpacking the equipment. Inspect the units and parts supplied for visible signs of shipping damage. Examine the unit for loose or broken buttons, bent knobs, etc. Verify the correct quantity of components supplied with the list in Section 1.6. If any claim is to be made, save the shipping material and contact the freight carrier. Do NOT return units damaged in shipping to Honeywell. If the unit or accessories shows any sign of external shipping damage, contact Honeywell to arrange for a replacement. Under no circumstances attempt to install a damaged unit in an aircraft. Equipment returned to Honeywell for any other reason should be shipped in the original packaging, or other UPS approved packaging.

2.3Equipment Installation Procedures

2.3.1 Cooling Requirements

Forced air cooling of the KMA 28 is not required. However the unit should be kept away from heat producing sources (i.e. defrost or heater ducts, dropping resistors, heat producing avionics) without adequate cooling air provided.

2.3.2 Mounting Requirements

The KMA 28 must be rigidly mounted to the instrument panel of the aircraft structure and within view and reach of the pilot position(s). Installation must comply with FAA Advisory Circular AC 43.13-2A. The unit may be mounted in any area where adequate clearance for the unit and associated wiring bundle exist.

Avoid installing the audio panel close to high current devices or systems with highvoltage pulse type outputs, such as DME or transponders.

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Audio Amplifier/Intercom/Marker Beacon Receiver

2.3.3 Mounting Rack Installation

Set the unit aside in a safe location until needed. Install the tray using six FHP 6-32 x ½" screws. The audio selector panel must be supported at front and rear of the mounting tray.

2.3.4 Connector Assembly

The unit connectors mate directly with the circuit boards in the KMA 28. The connectors are a Molex crimp-type, and require the use of a Molex hand crimp tool, EDP P/N 11-01- 0203, CR6115B (or equiv.). The connectors are mounted to the unit tray with #4-40 screws, from the inside of the tray. Ensure that proper strain relief and chafing precautions are made during wiring and installation.

2.4Cable Harness Wiring

Referring to the appropriate Appendix, assemble a wiring harness as required for the installation. All wires must be MIL-SPEC in accordance with current regulations. Twoand three-conductor shielded wire must be used where indicated, and be MIL-C-27500 or equivalent specification. Proper stripping, shielding and soldering technique must be used at all times. It is imperative that correct wire be used.

Refer to FAA Advisory Circular 43.13-2A for more information. Failure to use correct techniques may result in improper operation, electrical noise or unit failure. Damage caused by improper installation will void the warranty.

2.4.1 Noise

Due to the variety and the high power of radio equipment often found in today's general aviation aircraft, there is a potential for both radiated and conducted noise interference.

The KMA 28 power supply is specifically designed to reduce conducted electrical noise on the aircraft power bus by at least 50dB. Although this is a large amount of attenuation, it may not eliminate all noise, particularly if the amplitude of noise is very high. There must be at least 13.8 VDC present at the bottom connector, pin 20, of the KMA 28 for the power supply to work in its designed regulation. Otherwise, it cannot adequately attenuate power line noise. Shielding can reduce or prevent radiated noise (i.e., beacon, electric gyros, switching power supplies, etc.) However, installation combinations can occur where interference is possible. The KMA 28 was designed in a RFI hardened chassis and has internal Electromagnetic Interference (EMI) filters on all inputs and outputs.

Ground loop noise occurs when there are two or more ground paths for the same signal (i.e., airframe and ground return wire). Large cyclic loads such as strobes, inverters, etc., can inject noise signals onto the airframe that are detected by the audio system. Follow the wiring diagram very carefully to help ensure a minimum of ground loop potential. Use only Mil Spec shielded wires (MIL-C-275000, or better).

Radiated signals can be a factor when low level microphone signals are "bundled" with current carrying power wires. Keep these cables physically separated. It is very important

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that you use insulated washers to isolate the ground return path from the airframe to all headphone and microphone jacks.

2.4.2 Existing KMA-24 Installation

If the installation replaces a KMA-24 (series –00, -01, -02 or -03), the existing 44 pin connector can be used for the bottom connector of the KMA 28 tray as is, providing it is properly installed and wired. No other changes are required except for external marker lights (see Appendix B for details). The "key" in the existing connector must be located between pins 7 and 8. This connector will be used in the bottom connector position. (See Appendix for complete wiring harness details.)

The existing ground bus may be reused for radio shield connections, if it was constructed so it can be relocated to the KMA 28 tray.

2.4.3 Existing PS Engineering PMA6000 installations

In 28-Volt aircraft, the dropping resistor may be removed, however, the 2 Amp breaker should be changed to 3 Amp. If either old unit is stereo (PMA6000S or PMA6000MS), no rewiring is necessary unless additional features are added.

2.4.3.1Stereo KMA 28 installations into existing monaural PS Engineering PMA6000, PMA6000M.

Installations replacing PMA6000 or PMA6000M require re-wiring of the top connector to accommodate the stereo configuration. See appendixes for detailed interconnect information.

2.4.4 Power

The KMA 28 is compatible with both 14 and 28 Volt DC systems. A two (2) Amp circuit breaker is required for 14 VDC installations, and a three (3) Amp breaker for 28 VDC aircraft. Power and ground wires must be a twisted #18 AWG pair. Connect airframe power ground to J1 (bottom connector) Pin Z only. No dropping resistors are required.

2.4.5 Communications Push-to-Talk

An important part of the installation is the PTT (Push-To-Talk) switches that allow the use of your aircraft communications radio for transmissions. Only the person who presses their PTT switch will be heard over the radio. If the pilot and copilot both use the PTT, only the pilot position has access to the radio. The pilot position will have PTT control regardless of the mic selector switch or copilot PTT when the KMA 28 is in the

EMERGENCY mode.

2.4.6 Transmit Interlock

Some communications transceivers use a transmit-interlock system. To fully utilize the Split Mode feature, this function must be disabled. Consult that manufacturer's installation manual.

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