Eagle P178 Installation Manual

P178

AUDIO MIXER

PART 27

INSTALLATION MANUAL

MDL 7001-ML-001 Rev -- STC SR02445SE

19717 62

nd

Avenue South, Suite E101, Kent WA 98032

EAGLE COPTERS USA INC.

FAX 253-867-5619 www.eaglecopters.com

| Phone: 800-546-2210

LEGAL NOTICE

The information contained in this document is provided solely under the condition that the Recipient of this document agrees to the terms and conditions of the Non-Disclosure and Proprietary Rights Agreement listed below. By accessing this document past this page, you are agreeing to be bound by this Non-Disclosure and Proprietary Rights Agreement.

Non-Disclosure and Proprietary Rights Agreement

Recipient recognizes and acknowledges that Eagle Copters USA and its affiliates (“Eagle”) possess certain Proprietary information and materials, which constitute a valuable, special, and unique asset of Eagle. As used herein, the term “Proprietary information and materials” includes, without limitation, all information and materials belonging to, used by, or in the possession of Eagle relating to its products, processes, technology, inventions, patents, developments, and trade secrets of every kind and character, but shall not include:

(1) Information that was already in the public domain, (2) Information that subsequently becomes public domain through no act or omission by the Recipient.

Recipient hereby acknowledges that all of the Proprietary information and materials are and shall continue to be the exclusive property of Eagle, whether or not disclosed to or entrusted to the custody of Recipient. Recipient further hereby acknowledges that all Proprietary information and materials have been disclosed or made available to him solely for the purpose of assisting him in incorporating, using, or maintaining equipment provided by Eagle.

Recipient hereby agrees not to disclose, or allow to be disclosed, any Proprietary information or material of Eagle, in whole or in part, to any person or entity, for any reason or purpose whatsoever. Recipient further agrees that Recipient shall not use any Proprietary information or materials of Eagle for Recipient’s own purposes or for the benefit of any other person or entity except Eagle, whether such use consists of duplication, removal, oral use or disclosure, the transfer of any Proprietary information or materials in any manner, or any other unauthorized use, unless given prior written consent by Eagle.

Recipient further agrees that Recipient will not allow the reverse engineering of any Eagle products.

Recipient further agrees that Recipient shall use information provide, for installation or application, to one aircraft only for each product purchased, unless the purchase agreement specifically authorizes the use on more than one aircraft.

Continuing past this page constitutes acceptance of the above agreement.

(End of Agreement)

Page 1 of 1

Revision

Date

Description

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30 OCT 2014

Initial Release

Record of Revisions

7001-ML-001

Revision --

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DRAWING NO.

TOTAL

SHT

REV

DATE

DESCRIPTION

7001-MI-001

11

--

10/30/14

Modification Instructions

7001-TP-001

8

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10/30/14

EMI Test Procedure

G13120 1 --

1/13/14

Audio Mixer

Master List

7001-ML-001

Revision --

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Revision

Date

Description

--

30 OCT 2014

Initial Release

Record of Revisions

7001-MI-001

Revision --

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7001-MI-001

Revision --

Table of Contents

1. Scope ................................................................................................................................................ 4

2. Abbreviations ................................................................................................................................... 4

3. References ....................................................................................................................................... 4

4. General Information ........................................................................................................................ 4

5. Installation ....................................................................................................................................... 5

6. System Wiring .................................................................................................................................. 6

7. System Testing ................................................................................................................................. 9

8. Kit Parts List .................................................................................................................................... 10

9. Specifications ................................................................................................................................. 11

10. Weight and Balance ....................................................................................................................... 11

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7001-MI-001

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1. Scope

These modification instructions are for the installation of the Eagle Copters P178 Failsafe Audio Mixer.

2. Abbreviations

EMI ............ Electro-Magnetic Interference

3. References

7001-TP-001 EMI Test Procedure

4. General Information

4.1 The Audio Mixer provides 3 composite outputs from up to 8 input signals. Channel 1 and

Channel 2 composite outputs are failsafe relay protected for Master Caution or Essential Tones to ensure that no fault in the system or an electrical bus failure can prevent pass through of Essential Warnings or Tones. Channels 3 through 8 are for non-essential tones and will drop off line in case of fault or Avionics Bus failure.

4.2 The P178 Failsafe Audio Mixer removes the need for external relays to ensure Essential Tones

are passed to unswitched inputs on any audio system. The mixer also has internal fault detection. Upon fault, the relays go to their normally closed (Failsafe) position.

4.3 There are no restrictions as to the quantity of Audio Mixers that are installed. However, it is the

installer’s responsibility to verify that the installation of this device does not interfere with other installed equipment and to perform an electrical load analysis to verify that the aircraft electrical buss can support the installation of the Audio Mixer.

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5. Installation

5.1 The Audio Mixer is designed to be mounted in a variety of locations within the airframe,

provided it is protected from the environment. It may be mounted to a deck, bulkhead, tray, avionics shelf or other structure rated to carry a 0.50 lb load. The exact mounting location is left

to the installer’s discretion provided that the installation of the Audio Mixer does not interfere

with other installed equipment.

5.2 Mount the Audio Mixer using (4) #8-32 screws, washers and locknuts or nutplates.

5.3 When mounting into composite structure, #8-32 potted inserts (not included in kit) should be

used.

5.4 Unless otherwise specified, follow aircraft manufacturer’s standard practices and maintenance

manuals for installation of all hardware.

5.5 Maintain a minimum 2 e/d edge margin for all installed fasteners.

5.6 Refer to Figure 1 for Audio Mixer reference dimensions that may be used when planning the

installation.

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Figure 1 Audio Mixer Dimensions

7001-MI-001

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6. System Wiring

6.1 Unless otherwise specified, follow the aircraft manufacturer’s electrical wiring practices and

maintenance manuals for installation of all system wiring.

6.2 Refer to Figure 2 for cable harness fabrication instructions to connect to the Audio Mixer.

6.3 Ground Audio Shields at ONE end only.

6.4 Unless otherwise noted, all shielded wire is M27500-(ga)TG(n)T14 and all unshielded wire is

M22759/16-(ga)-9, where (ga) is the wire gauge and (n) is the number of wires inside the shield.

6.5 Unless otherwise noted, all wire is 22 GA.

6.6 Route all system cabling through existing cable runs.

6.7 Secure all cabling using nylon cable ties and/or cable clamps using standard practices.

6.8 Cable lengths are dependent on Audio Mixer installation location.

6.9 Notes for Figure 2:

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7001-MI-001

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Page 7 of 11

Figure 2 Cable Wiring

6.10 Refer to Figure 3 for Audio Mixer pin designation.

7001-MI-001

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Page 8 of 11

Figure 3 Pin Designation

7001-MI-001

Revision --

7. System Testing

Failure to follow these instructions will result in improper operation.

7.1 If the mixer is not powered or is in fault mode (Essential), Input 1 will be connected directly via

relay closure to Output 1D, and Input 2 will be connected directly to Output 2D. It is important to follow the setup instructions exactly in order for the mixer to work properly in the Essential Mode.

7.2 The mixer has internal fault detection. Upon fault, the relays go to their normally closed

(Failsafe) position and the FAIL indicator light will illuminate. Optionally, the installer may connect Pin #10 (pull low) to an external fault indicator (see note #2 in Section 6.9). There are no internal adjustments, jumpers or user serviceable parts. If the mixer fails, return it to Eagle Copters USA, Inc. for repair or replacement.

7.3 The direct inputs in essential mode are non-adjustable. The level that is present at Inputs 1 and

2 will be present at 1D and 2D respectively.

7.4 Output 3 is not relay direct protected and therefore will drop off line in unpowered or fail mode.

This output is designed to be a monitor port to a non-critical device.

7.5 Before applying power, perform a continuity check of all leads to confirm they are connected

properly.

7.6 With the circuit breaker to the mixer pulled (Off) and the audio system on, adjust the source to

Audio Source 1D and 2D so that the proper level is heard at both the Pilot and Co-Pilots Headsets when the source is triggered, i.e. Master Caution. DO NOT adjust the 1D or 2D outputs of the mixer; instead, adjust the source to the mixer.

7.7 With all other avionics off, push the mixer's circuit breaker In (On). Verify visually that the power

indicator (PWR) is on, and the FAIL indicator is off. The mixer is now in powered mode. Trigger the source for Inputs 1D and 2D. Adjust the mixer Output Adjustments 1D and 2D so that the proper level is heard in the Pilot and Co-Pilot Headsets. It should be the same as in the unpowered mode. Pull the circuit breaker to the mixer in order to verify this operation.

7.8 Once steps 7.6 and 7.7 are completed, turn on all avionics or other sources connected to Audio

Sources 3 through 8. Adjust the levels as required at Inputs 3 through 8 on the mixer. DO NOT change the adjustments on Outputs 1D, 2D or 3.

7.9 After Completion of Steps 7.6 through 7.8, adjust Output 3 to the desired level required by the

device connected to Output 3.

Conduct EMI test in accordance with EMI Test Procedure 7001-TP-001.

Page 9 of 11

QTY

PART NUMBER

DESCRIPTION

1

G13120

Audio Mixer

8

CCR264SS-3-02

Pull Rivet

4

MS21042-08

Lock Nut, #8-32

4

MS21059L08

Nut Plate, #8-32, Floating

4

MS35206-245

Screw, #8-32 x 1/2", Phil Pan

8

NAS1149FN832P

Flat Washer, #8

25

205090-1

Contacts

1

205165-1 **

Connector, D25F

1

165X10159XE **

Backshell

8. Kit Parts List

7001-MI-001

Revision --

P178 Failsafe Audio Mixer Kit

** Optional: use Connector Kit M2430812-8F in place of these items

Page 10 of 11

P178 FAILSAFE AUDIO MIXER SPECIFICATIONS

Number of Inputs

8 each Balanced @ 600 Ohm Impedance

Number of Ouputs

3 each Composite @ 600 Ohm Transformer Coupled. 2

are Relay Protected Channels

Input Gain Adjustment

-17dB to +10dB

Output Gain Adjustment

-6dB to +6dB

Output Signal

150mW into 600 Ohms Nominal

Output Current Limit

20mA

Voltage (Start)

20 VDC

Voltage (Hold)

12 VDC

Voltage (Max)

32 VDC

Power

250 mA

Temperature

- 40 to 80C

Finish

Gold Iridite per MIL-C-5541 Class 1A

Weight

.50 lbs.

Size

3.04 W x 5.75 L x 1.05 H inches Less protrusion of connector.

9. Specifications

7001-MI-001

Revision --

10. Weight and Balance

10.1 Weight of the Audio Mixer and mounting hardware = 0.50 lbs.

10.2 The arm will depend on the exact location that it is installed.

10.3 The installer will record the location for the Audio Mixer along with its installed weight on the

aircraft’s weight and balance record.

Page 11 of 11

Revision

Date

Description

--

30 OCT 2014

Initial Release

Record of Revisions

7001-TP-001

Revision --

Page 2 of 8

7001-TP-001

Revision --

Table of Contents

1. Scope ................................................................................................................................................ 4

2. Applicable Documents ..................................................................................................................... 4

3. Witnessing of EMI Test .................................................................................................................... 4

4. Equipment Under Test ..................................................................................................................... 4

5. Test Procedure ................................................................................................................................. 4

6. Items To Evaluate ............................................................................................................................. 5

Page 3 of 8

7001-TP-001

Revision --

1. Scope

This document is a test plan to be used to establish that newly installed electrical equipment does not interfere with essential aircraft equipment in any way that would impair safety of flight of the aircraft. Satisfactory completion of this test plan confirms that the newly installed equipment satisfies the EMI requirements of the Federal Aviation Administration. This test plan is applicable to CFR part 27 Rotorcraft.

2. Applicable Documents

CFR 27.1309(c) and 27.1351(b)(1)(i).

3. Witnessing of EMI Test

This test shall be witnessed by someone who is authorized by the FAA to return the aircraft to service. This would include an FAA licensed Avionics Technician, A&P Mechanic, Inspector of Airworthiness, or the Repair Station’s Director of Maintenance. In addition, an FAA representative, such as a DAR or DER may witness the test.

4. Equipment Under Test

The newly installed Equipment Under Test (EUT) by this test plan shall be in proper working order throughout the test. If the EUT fails during this test, then this test shall be repeated with the EUT in proper working order.

5. Test Procedure

Testing shall normally be conducted with the aircraft running on the ground, or with battery or external ground power where appropriate. In the event that an aircraft system or component can only be evaluated for the effects of interference with the aircraft in flight, then the evaluation of that system or component shall be conducted with the aircraft in flight. Testing conducted with the aircraft in flight shall be performed with safety of flight in mind and with only necessary personnel on board.

Testing shall be conducted on the aircraft with all aircraft systems and equipment operating normally, and cycled as necessary to conduct the test. The EUT shall be operated normally. The EUT shall be cycled on and off. The EUT shall also be cycled through all of its operating modes.

Each aircraft system or component being evaluated for the effects of EMI will be observed as the EUT is cycled. A transient motion or flicker is acceptable provided no permanent deviation is established. There can be no stand-off conditions displayed on an instrument. In the case of audio equipment being evaluated for the effects of EMI, a change in the audio (such as background noise) that does not interfere with the intended purpose of the audio is acceptable.

For each aircraft system or component being evaluated for the effects of EMI, mark the item as PASS or FAIL based upon the outcome of this test procedure.

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7001-TP-001

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If an aircraft system or component being evaluated for the effects of EMI Fails this test procedure, then corrective action must be taken to reduce the interference to an acceptable level which allows the aircraft system or component being evaluated for the effects of EMI to PASS this test. When re-testing after corrective action, the only tests to be repeated are the tests that Failed previously. Items that previously Passed do not need to be re-tested, unless the method of corrective action results in changes to the EUT, which might cause the EUT to Fail previously Passed items. Mark the N/A __ field on the retest test plan for the items that previously Passed and are not being re-tested.

6. Items To Evaluate

Engine Temperature Indicator N/A __ Pass __ Fail __ Engine RPM Indicator N/A __ Pass __ Fail __ Engine Torque Indicator N/A __ Pass __ Fail __ Engine Fuel Control N/A __ Pass __ Fail __ Engine Oil Pressure Indicator N/A __ Pass __ Fail __ Engine Oil Temperature Indicator N/A __ Pass __ Fail __ Rotor RPM Indicator N/A __ Pass __ Fail __ Fuel Quantity Indicator N/A __ Pass __ Fail __ Fuel Pressure Indicator N/A __ Pass __ Fail __ Generator Voltage Indicator N/A __ Pass __ Fail __ Battery Voltage Indicator N/A __ Pass __ Fail __ Directional Gyro / Heading Indicator N/A __ Pass __ Fail __ Attitude Indicator N/A __ Pass __ Fail __ Turn and Bank Indicator N/A __ Pass __ Fail __ Annunciator Indicators N/A __ Pass __ Fail __ Flight Time Hour Meter N/A __ Pass __ Fail __ Warning Horn N/A __ Pass __ Fail __ Outside Air Temperature Indicator N/A __ Pass __ Fail __

Transponder N/A __ Pass __ Fail __

Set controls to mode C code 1200, or other code assigned by ATC. Cycle EUT and confirm proper data transmitted, either by use of transponder ground test equipment, or by confirmation from ATC of proper reception of correct data. Check for proper operation of reply light.

VOR N/A __ Pass __ Fail __ Set Voice/Ident to Voice. Check frequencies for audible interference sounds. Set local VOR frequency for full needle displacement. Adjust course select knob for gradual reduction of needle displacement to half, fourth, and zero. Note stability at each displacement and that zero can be achieved without a standoff.

DME N/A __ Pass __ Fail __ Perform self test with EUT cycled. Note that no skips in miles display occurs. Observe that mile indications do not drift and there is no audible interference in Ident tone.

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7001-TP-001

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Magnetic Compass N/A __ Pass __ Fail __ Swing compass and adjust with EUT operating normally. If EUT causes erratic operation of magnetic compass, then mark compass as Fail.

VHF Communications System N/A __ Pass __ Fail __ Tune each comm receiver to a low, middle, and high frequency within its frequency range. Listen for audio interference. Transmit on low, middle, and high frequencies. Listen on an external receiver for audio interference.

GPS Navigation Receiver N/A __ Pass __ Fail __ Check for proper operation. Observe signal to noise ratio readings to determine if reception is interfered with.

Crew Interphone System N/A __ Pass __ Fail __ Check for normal operation of the interphone system. Listen for excessive background noise.

ADF N/A __ Pass __ Fail __ Check for needle offset. Listen for audio interference.

Glide Slope/LOC N/A __ Pass __ Fail __ Check for needle offset. Perform test using TAC/30b or equivalent ground test equipment, or during flight while established on an ILS glide slope.

Radio Altimeter N/A __ Pass __ Fail __ Perform test with appropriate ground test equipment, or check reading in flight.

The space below is provided to include additional systems or devices not listed previously. These would include any Transceivers, Nav Aids, Radar, or Auto Pilot systems. Use the Manufacturers test procedures for each component listed with the EUT operating normally.

Other Equipment: __________________ N/A __ Pass __ Fail __ Describe test: _________________________________________________________________________ _____________________________________________________________________________________

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7001-TP-001

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Other Equipment: __________________ N/A __ Pass __ Fail __ Describe test: _________________________________________________________________________ _____________________________________________________________________________________

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7001-TP-001

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Aircraft Tested:

Model _______________, Registration ___________, Serial Number ______

Location of Test _______________________, Date _____________

Equipment Under Test:

List: MODEL, PART NUMBER, SERIAL NUMBER

_________________________________________________________________

__________________________________________________________________

Test performed by ________________________________________________ Name Credentials

Test witnessed by ________________________________________________ Name Credentials

I hereby certify that I have witnessed the above documented test and that the results documented above reflect my observations.

_______________________ _______________________ Signature Date

Page 8 of 8

1.050

J1

5.750

3.040

5.250

1.750

.188

INPUT

OUTPUT

PWR

FAIL

3 4

5 6 7 8

1D 2D

3

--

1:1

GA182

G13120

AUDIO MIXER

1/13/14

CLB

1/13/14

CLB

--

G13120 AUDIO MIXER

WEIGHT = 8 OZ MAX

VOLTAGE = 20 VDC MIN TO START 12 VDC TO HOLD 32 VDC MAX

POWER = .25 AMP MAX

NOTE: DIMENSIONS SHOWN ARE FOR REFERENCE ONLY

REVISIONS

REV

DESCRIPTION

APVR/DATE

ANGLES

2

DECIMAL

.X

.050

.XX

.030

.XXX

.010

FRACTIONS

1/8"

TOLERANCES ARE:

UNLESS OTHERWISE

SPECIFIED DIMENSIONS

ARE IN INCHES

BREAK SHARP EDGES

DATE

APPROVED

DESIGNED

CHECKED

DRAWN

THIS DOCUMENT INCLUDES INFORMATION PROPRIETARY

TO GENEVA AVIATION AND SHALL NOT BE USED OR DUPLICATED BY

ANYONE WITHOUT THE WRITTEN PERMISSION OF GENEVA AVIATION, INC.

REV

Sheet of

Scale:

SIZE

Pro No:

Drawing Number

Title

B