Bose T5 Service Manual
T5 Tactical Headset
©2016 Bose Corporation
Service Manual
Reference Number 350006-SM Rev. 00
CONTENTS
Electrostatic Discharge Sensitive (ESDS) Device Handling .........................................................3
Part List Notes...................................................................................................................................3
Specifications....................................................................................................................................4
Product Description.................................................................................................................... 5-10
Single Comm Module Controls........................................................................................................6
Dual Comm Module Controls...........................................................................................................6
Manufactured Versions ..................................................................................................................11
Packaging Part Lists, T5 Headset, All Versions ...........................................................................11
User Replaceable Parts List...........................................................................................................11
System Configurations............................................................................................................. 12-13
Cables and Replacement Parts......................................................................................................14
Disassembly Procedures ......................................................................................................... 15-19
Test Procedures ........................................................................................................................ 20-26
Definitions........................................................................................................................................20
Troubleshooting........................................................................................................................ 27-29
Service Manual Revision History...................................................................................................30
IMPORTANT NOTE: These products are RoHS compliant. Use ONLY lead free solder when
making repairs.
®
CAUTION: The Bose
warranty infractions, refer servicing to warranty service stations or factory service.
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF
FOR THE PURPOSE OF SERVICING THE IDENTIFIED BOSE
PRODUCT BY AN AUTHORIZED SERVICE CENTER AND SHALL
NOT BE REPRODUCED OR USED FOR ANY OTHER PURPOSE.
T5 Tactical Headset contains no user serviceable parts. To prevent
PROPRIETARY INFORMATION
BOSE CORPORATION WHICH IS BEING FURNISHED ONLY
2
ELECTROSTATIC DISCHARGE SENSITIVE (ESDS)
DEVICE HANDLING
This unit contains ESDS devices. We recommend the following precautions when repairing,
replacing or transporting ESDS devices:
• Perform work at an electrically grounded work station.
• Wear wrist straps that connect to the station or heel straps that connect to conductive floor
mats.
• Avoid touching the leads or contacts of ESDS devices or PC boards even if properly grounded.
Handle boards by the edges only.
• Transport or store ESDS devices in ESD protective bags, bins, or totes. Do not insert unprotected devices into materials such as plastic, polystyrene foam, clear plastic bags, bubble wrap
or plastic trays.
PART LIST NOTES
1. The individual parts located on the PCB are listed in the part list.
2. This part is referenced for informational purposes only. It is not stocked as a repair part.
Refer to the next higher or lower level assembly for a replacement part.
3. This part is critical for safety purposes. Failure to use a substitute replacement with the
same safety characteristics as the recommended replacement part might create shock, fire and/
or other hazards.
3
SPECIFICATIONS
Bose® T5 TECHNICAL INFORMATION OVERVIEW
Mono and stereo available Single Comm and Dual Comm options
Weight (on head)
Control Module W eight
Dual Comm radio or intercom cables
Nominal Headband Clamping Force
Ear cup to Control Module Cable Length
Push-to-talk (PTT) on control module One momentary PTT switch for single comm
Live Mic Switch
ANR ON/OFF on control module 2-position (on/off) toggle type switch, powers headset in
Talk-through (TTC switch
Batter y Po w er
Current Draw
Operating noise environment Full ANR performance up to 123 dBSPL.
Earphone sensitivity 104 ± 3dB SPL (active) for a 0±0.1 dBV input
Input Impedance
Attenuation Performance will vary depending on the vehicle noise
Boom microphone Electret or Dynamic
Temperature Rating -40
EMI MIL-STD-461F
455g
300g
120g (max/each)
2.1 +/- 0.1 lbs.
420 +/- 50 mm
Two momentary PTT switches for dual comm
2-position (on/off) toggle type switch, used to transmit
continuously within the intercom
dismounted operations
User-selectable, 4 position rotary, Binaural
Position one: off
Position two: 0db gain
Positio n three: medium gain
Position four: high gain
2 AA batteries
ANR Only: 40 hours minimum
TT Only: 100 hours minimum
ANR and TT: 30 hours minimum
16 mA RMS nominal at 24v
Reduced ANR from 124dBSL u p to 130 dBSPL Max
94 ± 4dB SPL (bypass)
1000±10% per channel (binaural)
500±10% (monaural)
profile and crew position.
o
C to +65oC Operating
o
C to +71oC Storage
-57
4
PRODUCT DESCRIPTION
OVERVIEW
The Bose® T5 Tactical Headset (T5TH) offers an unsurpassed combination of full-spectrum
noise reduction, comfort and clear audio in an ergonomic and rugged form factor that is compatible with a variety of helmets, intercoms and radio systems. The optional dual-communications
designed control module provides additional mission flexibility, which allows soldiers to easily
adapt the headset to fit specific mission needs.
The T5 Tactical Headset is designed to be used by infantry and other military personnel who are
primarily operating in and around tactical wheeled vehicles. These users engage in missioncritical communications and require effective noise reduction. Interpersonal communication and
situational awareness are paramount, so they value products that are operationally flexible for
mounted and dismounted use cases without sacrificing hearing protection.
KEY BENEFITS
• Clear, two-way communication provides increased situational awareness via intercom, radio
and Talk-Through feature.
• Reduction of both continuous and impulse noise provides hearing protection and allows for
increased focus on mission-critical tasks and information.
• Certain configurations can support simultaneous communications with two different devices.
• Improved ergonomic design supports both mounted and dismounted operations, and the
seamless transition between the two.
• Designed to fit securely and comfortably under combat helmets to support longer mission
profiles.
• Designed for rugged combat use while being intuitive and easy to use with limited training.
• Easily field-repairable and upgradeable.
5
PRODUCT DESCRIPTION
Single Comm Module Controls
Dual Comm Module Controls
6
PRODUCT DESCRIPTION
The T5 headset is capable of working in noise environments with sound pressure levels up to
115dB(C) SPL which means it is most useful in small and large wheeled vehicles as well as
many fixed and rotary wing aircraft.
The T5 headset consists of four main assemblies:
1. An active noise canceling headphone (two ear cups with ear cushions)
2. A suspension system (Napeband with over-the-head Velcro straps to support the weight)
3. A control cable assembly which provides power management, houses the necessary user
interface controls and adapts the headphone to the customer’s needs (by changing cables
to be compatible with desired source). The control cable assembly can be removed from the
earcups and replaced in the field.
4. A noise canceling boom microphone enabling communications. The microphone can be
easily replaced in the field.
The earcups each contain external-facing microphones and circuitry to allow Talk-Through, or
the ability to monitor external sounds such as speech without having to lift the earcups off of the
ear. This talk-through (TT) circuit limits external sounds to be no greater than 85dB at the ear.
The T5 headset has a volume control for the talk-through feature with volume settings will be
OFF; unamplified, medium amplification and high amplification. In all settings, the above mentioned 85dB limit is enabled.
The ear cushions used on the headset contribute to the performance as well as the overall
comfort of the headset. The ear cushions consist of polyurethane foam inside a polyurethane
film.
The napeband consists of a single, arc shaped spring formed to tuck behind the nape of the
user’s neck and head and to provide the desired clamping force. Two yokes connect the spring
to the earcups. The assembly is adjustable to fit most head sizes. The yokes and earcup
interface allow for rotation in 2 axes in order to allow optimum fit for performance as well as for
comfort. Additionally, the assembly includes a soft pad to provide cable routing and a comfortable fit behind the head for extended wear periods. The napeband / yoke assembly can be
completely disconnected from the earcups for replacement.
The control cable mates to the bottom of the left ear cup via a connector and housing that is
screwed to the earcup for robustness. This housing also mounts the flexible gooseneck boom
with integral noise canceling boom microphone. The control module contains a smart power
management system which can power the headset off of an external (vehicle) power source or
can use the on-board 2 AA batteries. In either case, the headset is fully functional to provide
active noise reduction (ANR), clear two way communications and talk-through capability. The
headset is also configured to provide passive noise reduction and clear two way communications when there is no power source (fail safe mode). The control module is configurable via
cable selection to enable connection of up to two input sources at any one time including intercoms, portable communication radios or other auxiliary audio or communication devices.
The control module also includes an integrated clothing clip that enables the module to be
securely mounted to a variety of clothing or equipment in a variety of orientations that best suit
the application at hand. The clothing clip can be mounted on both the front and the back face of
the control module in order to facilitate operation with either the left or the right hand or to cater
to different user preferences.
7
PRODUCT DESCRIPTION
The control module switches and buttons are designed to be easily operated while wearing
typical work gloves with a material thickness of up to 3mm. They are also designed to provide
tactile feedback during operation and configured such that the mode of the switch can be
recognized visually or by feel.
The switches and their functions include:
1. Push to Talk (PTT) switch(es) (Momentary-Off)
2. 4-position rotary switch Talk Through (TT) control. The Talk Through circuit can be
powered by either the intercom (if applicable) or the 2-AA batteries in the control module.
3. Battery powered Active Noise Reduction (ANR) Switch (On-Off)
4. ICS Mic live Switch (Live-Mic, Mic-Off) This switch is used to enable continuous active
(latched) PTT mode for Intercom communications.
The boom microphone is serviceable and replaceable in the field. It is a dynamic microphone
which consists of a flexible gooseneck boom and a noise cancelling dynamic microphone
capsule. The Boom Microphone output is specific to the device it is attached to and is achievable by selecting the appropriate cable. Some options may include a pass-through while others
may include a +24dB gain to simulate an electret microphone’s output level. If gain is needed,
the power is provided by the input device OR from the control module depending on the specific
input cable. Some options may include a pass-through dynamic 150 ohm, single ended or
differential microphone.
Operation Modes (Power Compatibility)
The power modes listed below are determined by the combination of cables plugged into the
device as well as voltages that are present in different locations or vehicles. Any combination of
power modes based on input connections or signals can be configured within the electronics of
the control module including but not limited to the following scheme.
External Power Source
• Unpowered (0 – 6.0 VDC )
• Battery powered ANR (2-AA batteries)
• Gain switchable Talk Through only
• Selectable Output Level and Frequency Response (Both parameters follow the state
of ANR and/or Talk-Through)
• Boom Microphone Output is specific to device it the is attached to and is configured
inside the input cable. Some options may include a pass through while others may
include a +24dB gain to simulate an electret microphone’s output level. If gain is
needed, the power is provided by the input device OR from the control module
depending on the specific input cable.
Low Power (6.1 - 13.5 VDC)
• Battery powered ANR
- ANR Switch position has no effect
• Gain switchable Talk Through
8
PRODUCT DESCRIPTION
Operation Modes (Power Compatibility) (continued)
Intercom Power (13.6 – 32.0 VDC)
• Battery powered ANR
- ANR Switch does not operate
• Selectable Gain switchable Talk Through
• Boom Microphone Output is specific to device it is attached to and is configured inside the
input cable. Some options may include a pass through while others may include a +24dB
gain to simulate an electrets level. If gain is needed, the power is provided by the input
device OR from the control module depending on the specific input cable.
Battery Power (2x 1.5V AA ;1.8 – 3.2 VDC)
• ANR Switch OFF and Talk Through Switch OFF
- ANR off
- Talk Through off
- Unpowered Output Level and Frequency Response
- Boom microphone output depends on cable and device it is attached to.
• ANR Switch ON and Talk Through Switch OFF
- ANR on
- Talk Through off
- Powered Output Level and Frequency Response
- Boom microphone output depends on cable and device it is attached to.
• ANR Switch ON and Talk Through Switch in any ON position
- ANR on
- Talk Through on
- Powered Output Level and Frequency Response
- Boom microphone output depends on cable and device it is attached to.
• ANR Switch OFF and Talk Through Switch in any ON position
- ANR off
- Talk Through on
- Powered Output Level and Frequency Response
- Boom microphone output depends on cable and device it is attached to.
Operation Modes (Audio Management) Dual Comm Versions:
The headset is designed to support multiple audio sources through ports located at the bottom
of the in-line control module. The behavior of each port has been designed to support a wide
range of applications. Any combination and presentation of input and output audio signals can
be configured within the electronics of the control module, including but not limited to the following scheme.
Port 1 is intended to be the primary communications port and can support binaural or monaural sources. When the source is monaural, the cable for that device is wired such that the
monaural signal is paralleled so that it is made compatible with the binaural connection and the
user will always hear the audio from Port 1 in both ears. Whenever Port 1 is connected, pressing PTT 1 shorts the control line to the Port 1 source which enables transmission of the boom
microphone signal to the Port 1 source. If there is no source connected to Port 1, nothing
happens when PTT 1 is pressed.
9
PRODUCT DESCRIPTION
Operation Modes (Audio Management) Dual Comm Versions (continued):
Port 2 is intended to be a secondary communications port. The presentation of this source’s
audio to the headset depends upon the presence of a cable plugged into Port 1.
If Port 1 has a cable plugged in, the audio from the Port 2 device will only be presented to the
left earcup. In order to properly mix the audio between the multiple sources while maintaining
the dynamic range of the headset, the two signals will each be reduced by 6dB. The reduction
will occur as soon as the second cable is attached to the port on the bottom of the control
module .
If Port 1 does not have a cable plugged in, the audio from the Port 2 device will be presented to
both earcups and will not be reduced by 6dB.
Binaural devices may be connected to Port 2, however the cable connecting this type of source
to the control module will mix the two separate channels onto one signal line and present the
device as a mono device to the headset. Whenever Port 2 has a cable connected to it, pressing
PTT 2 shorts the control line to ground of the Port 2 source which enables transmission of the
boom microphone signal to the Port 2 source. If there is no cable connected to Port 2, nothing
happens when PTT 2 is pressed. The “Mic live” switch has no effect on any Port 2 device under
any configuration.
The table below describes how the headset manages the multiple audio sources based on what
cables are connected as well as how the PTT buttons function. An N/A in a cell means there is
no cable connected or there is no function. There are many variations of this that are possible.
Mode of operation Port 1 Port 2 Left Earcup Right Earcup
Unpowered X N/A Port 1 Port 1
Unpowered N/A X Port 2 Port 2
Unpowered X X Port 1 + Port 2 Port 1 + Port 2
Battery Powered X N/A Port 1 Port 1
Battery Powered N/A X Port 2 Port 2
Battery Powered X X Port 1 Port 2
ICS powered 6-32 V X N/A Port 1 Port 1
ICS powered 6-32 V X X Port 1 + Port 2 Port 1
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