Northern Airborne Technology AA85 User Manual

SM38

AA85

InterVOX II™ Intercom

INSTALLATION AND OPERATION MANUAL

REV 4.10 June 9, 2004

Northern Airborne Technology Ltd.

1925 Kirschner Road
Kelowna BC, Canada

V1Y 4N7

Telephone [phone]

Facsimile [phone]

Copyright 2004 by Northern Airborne Technology

CONFIDENTIAL AND PROPRIETARY TO NORTHERN AIRBORNE TECHNOLOGY LTD.

SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

Performed at factory

Performed at factory

Periodically NAT will release manual amendments. In order to maintain the most
accurate and up to date manual these amendments should be carried out immediately
upon receipt and recorded on the following amendment record.

AMENDMENT RECORD

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INSTALL_OPS
MANUAL AMENDMENT

Manual: SM38_AA85 Amendment #: 2
Document #: SM38\Install_Ops\809-0002 Amendment Date: Apr 11, 2006

The purpose of this amendment is to correct the voltage/resistance checks section.

Amendment Instructions:

1

2-7 and 2-8 Rev 4.10 Amendment # 1 2-7 and 2-8 Rev 4.10 Amendment # 2

2 Update the Amendment Record sheet at the front of the manual.

3 Insert this page into the manual after the Amendment Record sheet (page ii).

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Amendment # 2 Apr 11, 2006 Page 1

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INSTALL_OPS
MANUAL AMENDMENT

Manual: SM38 (AA85-001) Amendment #: 1
Document # SM38\Install_Ops\809-0001 Amendment Date: Jan 18, 2005

The purpose of this amendment is to update Cable and Wiring statement, section 2.3.4,
paragraph 1.

Amendment Instructions:

1

2-3 and 2-4 Rev 4.10 2-3 and 2-4 Rev 4.10 Amendment #1

Note: Ensure that all drawings are inserted in the order shown on the latest drawing lists.

2 Update the Amendment Record sheet at the front of the manual.

3 Insert this page into the manual after the Amendment Record sheet (page ii).

Manual Amendment ends after the following amended pages

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Amendment #1 Jan 18, 2005 Page 1

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SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

Table of Contents

Section Title Page

1 Description

1.1 Introduction 1-1

1.2 Purpose of Equipment 1-1

1.3 Features 1-1

1.4 Specifications 1-2

1.4.1 Electrical Specifications 1-2

1.4.2 Physical Specifications 1-2

1.4.3 Environmental Specifications 1-3

1.5 Unit Nomenclature 1-3

2 Installation

2.1 Introduction 2-1

2.2 Unpacking and Inspection 2-1

2.2.1 Warranty 2-1

2.3 Installation Procedures 2-1

2.3.1 Warnings 2-1

2.3.2 Cautions 2-2

2.3.3 Notes 2-2

2.3.4 Cabling and Wiring 2-3

2.3.5 Installation Options 2-4

2.3.6 Adjustments 2-6

2.3.7 Adjustment procedure 2-7

2.3.8 Mechanical Installation 2-8

2.3.9 Post-Installation Checks 2-8

2.4 Continued Airworthiness 2-9

2.5 Accessories Required 2-10

2.6 Installation Drawings 2-10

3 Operation

3.1 Introduction 3-1

3.2 General 3-1

3.3 Controls and Indicators 3-1

3.3.1 Mode switch 3-2

3.3.2 VOX Controls 3-2

3.3.3 Volume Controls 3-3

3.3.4 TX/ICS Indicator 3-3

3.3.5 ICS Mute Functions 3-3

3.3.6 Music Mute Functions 3-4

3.4 Intercom Adjustments 3-4

3.4.1 Receive Level 3-4

3.4.2 Music Mute 3-4

Jun 9, 2004 Page iii

ENG-FORM: 820-0109.DOT

CONFIDENTIAL AND PROPRIETARY TO NORTHERN AIRBORNE TECHNOLOGY LTD.

SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

Section 1 Description

1.1 Introduction

This manual contains information on the AA85-001 Intervox II Intercom.

Information in this section consists of purpose of equipment, features, specifications,
and unit nomenclature.

1.2 Purpose of Equipment

The AA85-001 InterVox II Intercom provides full radio and intercom capabilities for the
pilot and copilot, plus intercom and receive radio functions for up to four passengers.
The music input provides entertainment audio at all positions.

1.3 Features

The AA85-001 has been designed to be backward compatible with the AA80. This
allows simple upgrades to existing installations. The AA85-001 can be configured to
simulate any of the following AA80 InterVox units:

- AA80-001

- AA80-020

- AA80-060

- AA80-062

Stereo music source is selectable between portable cassette tape/CD players and
remote CD changers/am/fm cassette players.

Receive audio and microphone input will mute the music to an adjustable level.

Both crew and passenger receive audio controlled by trimpots.

Individual VOX detector on each of the microphone inputs and on the ICS tie line.

In Crew Isolate mode, the crew and passengers have separate headset audio with
independent music muting and the passenger's radio receive audio is muted
continuously.

Number of passenger headsets, ICS Tie Line and ICS Key Line configuration are
selected by configuration switches.

DIP switches accessible through the side of the unit control the ICS gain for multiple unit
installations.

June 9, 2004 Page 1-1

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AA85 InterVOX II™ Intercom Manual SM38 Rev. 4.10

1.4 Specifications

1.4.1 Electrical Specifications

Input Power +12.4 to 30.3 Vdc at 400 mA to 1.5 A max

Input Signals

Microphone 6 inputs (2 crew and 4 Passengers),
250 mVrms @ 150 Ω.

Radio 2.5 Vrms @1 kΩ.

Music:
Portable CD/Cassette 250 mVrms to 700 mVrms @ 1kΩ
400 mVrms @ 1kΩ (Nominal)

Multi Disk CD Changer 850 mVrms to 2.4 Vrms @ 3 kΩ

1.4 Vrms @ 3 kΩ (Nominal)

Keyline Transmit capability for pilot and copilot, with

pilot priority. One ICS key for all microphones.

Output Signals

Phones 6 outputs (2 crew and 4 Passengers), 100 mW

into 600 Ω nominal (each headset)

ICS Tie Channel One input, bi-directional, 340 mVrms ±10% into 2

kΩ. Frequency response 350 Hz to 3 kHz.

Audio Frequency Response 350 - 6 kHz ± 3dB with ≤ 1% THD

Crosstalk:

Input - Input < 60 dB
Input - Output < 55 dB
Input - Mic < 1.0 mVrms

1.4.2 Physical Specifications

Height 1.3 inches (33 mm).

Length 5.8 inches (147 mm).

Width 2.6 inches (66 mm).

Weight 0.7 lb (315 g).

Mounting Through front panel; 3 X 6-32 black brass screws.

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SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

1.4.3 Environmental Specifications

Temperature:

Operating -20 C to +55 C
Survival -55 C to +85 C

Altitude 50,000 ft

Humidity 95%

Shock :

Operational 6 g
Crash Safety 15 g

Qualification:

DO-160C Env. Cat. A1/D1-BA[BMN]XXXXXXZBABAUZXXX

TSO Compliance

TSO C50c, RTCA DO-170 Class 1b
(Only applicable to units Serial # 3000 and above)

1.5 Unit Nomenclature

Model Description / Distinction

AA85-001 Selectable 4 or 6 place operation.

Music muted during ICS and radio operations.
Individual mic gating.
Two color LED.
ICS volume, Music volume and VOX Squelch controls.
Live, Keyed and VOX Intercom modes.

End of section 1

June 9, 2004 Page 1-3

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SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

Section 2 Installation

2.1 Introduction

Information in this section consists of: unpacking and inspection procedures, installation
procedures, post-installation checks, and installation drawings.

Note: To meet TSO compliance for serial numbers 3000 and above, follow

interconnect drawing Revision 2.00 or higher. Ensure the installation is
completed using the metal ‘hood’ to enclose the AA85 connector.

2.2 Unpacking and Inspection

Unpack the equipment carefully and locate the warranty card. Inspect the unit visually
for damage due to shipping and report all such claims immediately to the carrier
involved. Note that each unit should have the following:

- AA85-001 InterVOX II™ Intercom

- Install Kit (with metal ‘hood’)

- Warranty Card

- Operators Manual

- Release certification

Verify that all items are present before proceeding and report any shortage immediately
to your supplier.

2.2.1 Warranty

Complete the warranty card information and send it to NAT when the installation is
complete. If you fail to complete the warranty card, the warranty will be activated on
date of shipment from NAT.

Note: An appropriately rated facility, e.g. Certified Aircraft Repair Station, must install this

equipment in accordance with applicable regulations. NAT Ltd’s warranty is not
valid unless the equipment is installed by an authorized NAT Dealer. Failure to
follow any of the installation instructions, or installation by a non-certified individual
or agency will void the warranty, and may result in a non-airworthy installation.

2.3 Installation Procedures

2.3.1 Warnings

Do not bundle any lines from this unit with transmitter coax lines. Do not bundle any
audio or DC power lines from this unit with 400 Hz synchro wiring or AC power lines. Do
not position this unit or wiring from this unit next to any device with a strong alternating
magnetic field such as an inverter, or significant audio interference will result.

June 9, 2004 Page 2-1

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AA85 InterVOX II™ Intercom Manual SM38 Rev. 4.10

2.3.2 Cautions

In all installations, use shielded cable exactly as shown and ground as indicated. Significant
ground loop and noise problems may result from not following these guidelines. Ensure
chassis is grounded to provide proper shield terminations.

Ensure microphone and headphone jacks are isolated from the airframe ground.

Use caution when routing microphone and ICS Tie Line wiring, as they are low level
signals prone to coupling from other sources.

Do not take a ground from the instrument panel or similar location that shares a ground
return with a turn and bank, horizon or other motor driven instrument. This may cause
the unit to pick up the sound of the motor as ground loop interference.

2.3.3 Notes

The AA85-001 has been manufactured and delivered in both TSO'd (serial # 3000 and
above) and non-TSO'd versions (below serial # 3000). There are critical differences in
the interconnect between the two types, which must be observed to ensure compliance
with the TSO requirements.

TSO'd units are shipped from the factory with 'jack posts' installed at the chassis connector.
The install kit supplied with the AA85 contains a metal 'hood' that must be used on the
airframe connector to ensure compliance with the stated TSO qualification requirements.

Earlier generations of the AA85 (non TSO'd, below s/n 3000) used V5, 'spring lock'
mounting hardware for the chassis connector, with jack posts as an alternative.

If installing this unit into an existing aircraft harness, ensure that the harness connector
does not have the ‘tabs’ shown in figure 1. If the harness connector does have ‘tabs’,
replace the existing harness connector with the one included in the install kit.

Tab

Harness Connector

Figure 1

Important

: Although it is possible to install and operate a new TSO'd unit in an

older installation, the system will not be compliant with the stated
TSO requirements due to the differences in the interconnect.

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SM38 Rev. 4.10 AA85 InterVOX II™ Intercom Manual

2.3.4 Cabling and Wiring

All unshielded wire shall be selected in accordance with AC43.13-1B Change 1,
Paragraphs 11-76 through 11-78. Wire types should be to MIL-W-22759 as specified in
AC43.13-1B Change 1, Paragraphs 11-85, 11-86, and listed in Table 11-11. For
shielded wire applications, use Tefzel MIL-C-27500 shielded wire with solder sleeves
(for shield terminations) to make the most compact and easily terminated interconnect.
Follow the wiring diagrams in Section 2.6 as required.

Allow 3 inches from the end of the wire to the shield termination to allow the hood to be
easily installed. Note that the hood is a ‘clamshell’ hood, and is installed after the wiring
is complete.

Note: When replacing a previous AA80 series Intercom with an AA85 serial # 3000 and

above, harness changes are necessary to ensure compliance of the AA85 with
the approved TSO configuration. Refer to Section 2.3.3 for further details.

Group the mic audio shields

Metal Hood

separately from all other audio
shields.

Utilizing Raychem solder sleeves,
create up to 6 shield pigtails in the

Raychem

Solder Sleeves

wiring harness, as shown in the
Interconnect Diagram
(AA85\001\403-x, Rev 2.00 or
higher). Each pigtail should be no
more than 3.0” long.

Bring the pigtails through the

Rubber

Grommet

rubber grommet and strip off 0.5”
of insulation.

Bend the stripped portion back
onto the grommet as shown and

Stripped

Pigtail

sandwich the pigtails between the
connector hood and the grommet.

Note: The hood is a ‘two-piece’

unit, and is assembled after
the wiring is complete.

All wiring should be at least 24 AWG, except power and ground lines, which should be
at least 20 AWG. Ensure that all ground connections are clean and well secured.

To prevent system failure or inadequate equipment protection, supply power from a
dedicated 2.0 A circuit breaker.

Jun 9, 2004 Page 2-3

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AA85 InterVOX II™ Intercom Manual SM38 Rev. 4.10

2.3.5 Installation Options

The AA85-001 can be configured to simulate any of the following AA80 InterVOX™
units:

AA80-001

Single unit installation (no ICS tie line) providing radio and intercom capabilities for
the pilot and copilot, plus intercom and radio receive functions for two passengers.
The unit provides left and right stereo music inputs (note stereo input mixes
internally and outputs as mono). ICS PTT functions are not available.

AA80-020

Multiple unit installation (includes ICS tie line) providing radio and intercom capabilities
for the pilot and copilot, plus intercom and radio receive functions for two passengers.
The unit provides only one mono music input. ICS PTT functions are available.

AA80-060

Single unit installation (no ICS tie line) providing transmit and intercom capabilities
for the pilot and copilot, plus intercom and radio receive functions for four
passengers. The unit provides left and right stereo music inputs (note stereo input
mixes internally and outputs as mono). ICS PTT functions are not available.

AA80-062

Multiple unit installation (includes ICS tie line) providing radio and intercom capabilities
for the pilot and copilot, plus intercom and radio receive functions for four passengers.
The unit provides only one mono music input. ICS PTT functions are available.

The unit ships from the factory with the switches set to simulate an AA80-001,
with a portable cassette/CD player music input and the crew music unmuted.

The switches that determine the configuration installed are AA80 SIM, H/S and CONFIG
switches 1, 2 and 5, accessible through the left-hand side of the unit. Refer to figure 2
to determine the correct switch settings.

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