Northern Airborne Technology AA9x User Manual

Installation and Operation Manual

AA9x Series

Single Channel Audio Controller

SM56

ISSUE 4.01

Northern Airborne Technology Ltd.

1925 Kirschner Road

Kelowna, BC, Canada.

V1Y 4N7

Telephone [phone]

Facsimile [phone]

Issued on the authority of Northern Airborne Technology Ltd.

Copyright 2002

AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

IMPORTANT INFORMATION

This manual has been produced to provide information unique to the AA9x Series Single Channel Audio Controller. Some of this information has been published previously in the SM01 Service manual (AA90/AMS40 Series Audio Controllers).

The information presented in this manual is for reference purposes only, and is intended to provide general information that can be used by the installer/technician to gain a fundamental understanding of the respective product. It is not intended to cover all variations of the AA9x Series audio controllers. Drawing packages for specific AA95, AA96 and AA97 units can be requested from NAT by contacting the Product Support Department.

Earlier versions of the AA9x Series (prior to Serial number 6000) may not be covered by the information in this manual. Please refer to SM01, or contact the Product Support Department at NAT Ltd.

Installation and Operation Manual	Page ii
ENG-FORM: 820-0115.DOT

CONFIDENTIAL AND PROPRIETARY TO NORTHERN AIRBORNE TECHNOLOGY LTD.

AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

Prepared By:	Checked By:	Approved By:

The status of this installation and operation manual is controlled by issue shown on the title page. The status of each section is controlled by revision shown in the footer of each page. All revisions affecting sections of this manual have been incorporated into the latest issue.

ISSUE/REVISION RECORD

	Manual Issue	Section		Revision Description	Issue Date
	Number	Revision Number
1.00		N/A		Initial Issue	Oct 23, 2002
4.00		N/A		Split Manual	Nov 10, 2003
4.01		Section 1	Rev: 1.00	Update to current templates.	Sept 05, 2008
		Section 2	Rev: 1.00
		Section 3	Rev: 1.00

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

Table of Contents

Section	Title	Page

1.Description

1.1	Introduction	1-1
1.2	Product Description	1-1
1.3	Design Features	1-1
1.4	Specifications	1-2
1.4.1	Electrical Specifications	1-2
1.4.2	Physical Specifications	1-3
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	Continued Airworthiness	2-1
2.4	Installation Procedures	2-2
2.4.1	Warnings	2-2
2.4.2	Cautions	2-2
2.4.3	Cabling and Wiring	2-2
2.4.4	In-line PTT Cordsets	2-2
2.4.5	Post Installation Checks	2-4
2.5	Adjustments and Connections	2-5
2.5.1	Left Side Panel Adjustments	2-5
2.5.2	Right Side Panel Adjustments	2-6
2.6	Accessories Required But Not Supplied	2-6
2.7	Installation Drawings	2-7

3.Operation

3.1	Introduction	3-1
3.2	General Information	3-1
3.3	Controls and Indicators	3-1
3.3.1	Receive Audio Select Switches	3-2
3.3.2	Transmit Selector Switch	3-3
3.3.3	ICS Functions	3-3
3.4	Optional Features	3-4
3.4.1	ICS ISO and/or PLT ISO Annunciators	3-5
3.4.2	ICS CALL Annunciator	3-5
3.4.3	ICS CALL Switch	3-5
3.4.4	PAT ON/OFF Switch	3-5
3.4.5	ICS TIE/SPLIT Switch	3-5
3.5	Emergency Operation (AA95 and AA97 models only)	3-5
3.6	Audio Alerting Functions (AA95 and AA97 models only)	3-6
3.6.1	Direct Audio	3-6
3.6.2	Internal Alerting	3-6
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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

Section 1 Description

1.1Introduction

Information in this section consists of product description, design features and specifications for the AA9x Series Single Channel Audio Controller. All derivative product information shall be contained in the applicable manual supplement, which may be obtained from NAT as required.

Review all notes, warnings and cautions.

1.2Product Description

The AA9x series provide control for all aircraft audio, allowing selection of transmit and receive audio, LIVE, KEYED, or VOX intercom, interface for an additional hand held transmit microphone (hand mic), and pilot isolation/emergency operation.

Transmit and PA functions are controlled with a single rotary switch. Receive audio, ICS operations and tape audio are controlled with toggle switches. Receive volume, ICS volume and ICS VOX squelch are individually adjusted with rotary controls. Sidetone (S/T) level is adjustable internally and the AA97 also has an individual RX level control for each transceiver.

1.3Design Features

The AA9x series are Dzus rail mounted units with lighted faceplates. Transceiver interfacing is accomplished through directly switched microphones. To ensure maximum radio compatibility, it has a ground-referenced keyline that incorporates no diodes or other steering components.

Independent control is provided for each audio channel within the controller, allowing sidetone, ICS audio and RX audio to be independently set.

Boom mic support is provided for the pilot and co-pilot, with both ICS and XMIT functions via cyclic or yoke switching. In some models, a third ‘transmit capable’ boom mic is added. Live (Hot Mic) and VOX ICS are also provided, with a ‘transparent’ function, allowing immediate transmission via this mode without further control panel switching and immediate return to ICS operation on completion. The ICS (intercom) function is achieved using dynamic noise reduction and active filtering. This provides the clearest possible ICS audio under high ambient noise conditions by rejecting airframe and wind noise and passing only voiceband information.

All audio, except the S/T of the radio in use and certain DIRECT AUDIO input signals, is muted during transmit for clarity. ICS operation allows transmit during any ICS mode by using the transmit PTT switch.

All switches, relay contacts and external connections are gold plated for maximum reliability. Switches and relays are sealed. G10-FR flame retardant circuit boards are postcoated for maximum moisture resistance and corrosion prevention. Relays are sealed, high vibration rated (50g shock), dry nitrogen filled units.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

1.4Specifications

1.4.1Electrical Specifications

Input Power
Nominal	27.5 Vdc Nominal @ 0.50 A Max.
Lighting	27.5 Vdc @ 160 mA
Alert Power	27.5 Vdc Nominal @ 150 mA Max.
Input Signals
Quantity	13 receive channels
	7 mic channels
	1 ICS tie channel
	1 or 2 direct channels
Audio level	2.5 Vrms for receiver inputs
	0.25 Vrms for mic inputs
	2.5 Vrms for direct audio inputs
Impedance	1 kΩ ±10% for receive inputs
	1 kΩ ±10% for mic inputs
	1.6 kΩ ±10% for ICS tie input
	1.3 kΩ ±10% for Direct Audio1 input
	100 Ω ±10% for Direct Audio 2 input
Circuit Type	All are single ended inputs
Coupling	<-40 dB
Keylines	Pilot & copilot transmit PTT
	Rear hand mic transmit PTT
	Pilot & copilot ICS PTT
	3 Alerts - active low
Output Signals
Quantity	6 Headphone outputs
	Up to 7 Transmitter mic outputs (incl. PA)
	Up to 7 Transmitter keyline outputs (incl. PA)
Headphone	7.7 Vrms or 100 mW (20 dBm) into 600 Ω nominal
Direct Audio 1	10 mW (10 dBm) into 600 Ω nominal
Direct Audio 2	0.1mW (-10 dBm) 0.25 Vrms into 600 Ω nominal
Alert	90 mVrms ±10% into 600 Ω nominal
Circuitry Type	Headphones are balanced
	Mic and ICS Tie are single ended
Distortion	<10% THD @ nominal power output
Audio Noise Level	>50 dB down from rated output (no signal)
Coupling	<-40dB
Output Regulation	<10% distortion @ 3 dB max. of rated output power at 400% and
	75% of rated load
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	AA9x Series Single Channel Audio Controller
	SM56 Installation and Operation Manual
Bi-directional Signals
Quantity	1 ICS tie channel
Audio level	0.34 Vrms for NAT ICS tie
Impedance	1.8 kΩ ± 10% for NAT ICS tie input
Circuitry Type	Single ended
Miscellaneous
Annunciators	Green LED will light for transmit operation

1.4.2Physical Specifications

	AA95		AA96		AA97
Height	1.90" (48.3 mm)		1.90" (48.3 mm)		3.00" (76.2 mm)
Depth	6.82" (173.2 mm)		6.82" (173.2 mm)		6.82" (173.1 mm)
Width	5.00"(127.0 mm)		5.00" (127.0 mm)		5.75" (146.1 mm)
Weight	2.1 lbs. (955 g)		2.1 lbs. (955 g)		2.5 lbs (1.14 kg)
Mounting			Dzus rail
Faceplate		Engraved acrylic edge lit panel
Material/Finish	Chassis & cover are 5052-H32 brushed aluminum with chromate conversion finish
Connectors	Male 50 pin & 37 pin D-submin connectors with slide locks

1.4.3Environmental Specifications

Temperature	-20 to +55°C (ambient)
	-55 to +85°C (survival)
Altitude	25,000 feet max.
Humidity	95% Non-condensing
Vibration/Shock	Conforms to DO-160C Cat. ‘N’

1.5Unit Nomenclature

AA95-512 VHF 1, VHF 2, RT1, RT2, RT3, RT4 XCVRs NAV, AUX switched Nav-Aids

2 unswitched alerts provided RX and ICS level controls

ICS Call LED from rear controller ICS Tie/Split switch

AA95-728 Full pilot and co-pilot support

2 Comm, 2 FM and AUX XCVR positions

5 Nav-Aids plus music input

KEYED, LIVE, VOX ICS with front panel control 3-level alerting

ICS CALL annunciator Illuminated TX selector knob 1 Direct Audio input

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

AA95-729 Full support for Doctor, Nurse and Attendant ICS only for 2 positions plus patient

2 Comm, 2 FM and AUX XCVR positions ADF, Doppler and music inputs.

1 Direct input

ICS CALL switch, PLT ISO annunciator 5 Nav-Aids plus music input

KEYED, LIVE, VOX ICS with front panel control Illuminated TX selector knob

AA96-001 TX 1, TX 2, TX 3, TX 4, TX 5 and PA XCVRs 2 NAV and 2 ADF unswitched RX inputs

No internal alerting

VOX/LIVE ICS with squelch adjustment Pilot/Co-pilot boom mic support with pilot priority 4 PAX ICS only support

Front panel master RX and ICS level controls

AA96-400 Full support for Jumpmaster and observer VHF 1, VHF 2, FM1, FM2, INT and PA XCVRs 2 NAV and 2 ADF unswitched RX inputs KEYED/LIVE ICS operation

4 PAX ICS only supported

Front panel RX and ICS level controls

PIL ISO annunciator and ICS CALL pushbutton

AA97-402 VHF 1, VHF 2, TAC1, TAC2, TAC3, TAC4 XCVRs and PA Each XCVR has independent RX level adjustment

NAV1, NAV2, ADF1 and DME switched Nav-Aids 1 Direct Audio input

3 Audio alerts installed

TX/PA and locking ISO/EMR switches No hand mic connection

Pilot/co-pilot boom mic support with pilot priority 4 PAX ICS only supported

Front panel RX and ICS level controls

Section 1 ends

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

Section 2 Installation

2.1Introduction

Information in this section consists of unpacking and inspection procedures, installation procedures, postinstallation checks and installation drawings for the AA9x Series Single Channel Audio Controller.

Note: The AA95, AA96 and AA97 series single channel audio controllers are customized units and may have unique operational features that are different to the options described, or are not covered in this manual. Any questions should be directed to the NAT Product Support Department.

Review all notes, warnings and cautions.

2.2Unpacking 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. Check that all items listed below are present before proceeding and report any shortage immediately to your supplier:

-Warranty Card

-Operators Manual

-Certificate of Conformity or Release Certification

2.2.1Warranty

All Northern Airborne Technology Ltd. products are warranted for 2 years from date of installation by an authorized NAT dealer, to be free of defects in workmanship or performance. This warranty covers all materials and labour, but is exclusive of any transport to deliver the defective unit to and from NAT or its designated warranty repair center, or any labour to remove or re-install the defective unit in the aircraft. Contact NAT for any questions regarding this warranty, its applicability to your units and/or for return authorization. NAT is the final arbitrator concerning warranty administration. Units which have been physically damaged, burned, immersed in water or otherwise abused beyond the scope of normal use will not be considered for warranty. WARRANTY IS VOID UNLESS THE PRODUCT IS INSTALLED BY AN AUTHORIZED NAT DEALER. Product for which a warranty card is not returned shall be warranted from date of manufacture.

2.3Continued Airworthiness

Maintenance of the AA9x Series Single Channel Audio Controller is ‘on condition’ only. Periodic maintenance of this product is not required.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

2.4Installation Procedures

2.4.1Warnings

WARNING:

High volume settings can cause hearing damage.

Set the headset volume control to the minimum volume setting prior to conducting tests, and slowly increase the headset volume to a comfortable listening level.

2.4.2Cautions

CAUTION:

Failure to follow the installation and wiring instructions provided in this manual for power and ground connections, including the rating of the circuit breaker, may lead to damage in the power input circuitry of the unit.

2.4.3Cabling and Wiring

All wire shall be selected in accordance with the original aircraft manufacturer's Maintenance Instructions or AC43.13-1B Change 1, Paragraphs 11-76 through 11-78. Unshielded wire types shall qualify 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 connector map in Section 2.7 as required.

Allow 3" from the end of the shielded wiring to the shield termination to allow the connector hood to be easily installed. Reference the interconnect drawing in Section 2.7 for shield termination details. Note that the hood is a "clamshell" hood, and is installed after the wiring is complete.

Maintain wire segregation and route wiring in accordance with the original aircraft manufacturers Maintenance Instructions.

Unless otherwise noted, all wiring shall be a minimum of 22 AWG, except power and ground lines, which shall be a minimum of 20 AWG. Reference the Interconnect drawing for additional specifications. Check that the ground connection is clean and well secured, and that it shares no path with any electrically noisy aircraft accessories such as blowers, turn and bank instruments or similar loads.

2.4.4In-line PTT Cordsets

In-line, push-to-talk (PTT) cordsets (also known as drop cords) can be used to create/provide PTT capability for the user headsets that do not have yoke or cyclic mounted PTT switches. For headsets connected to the PILOT or COPILOT inputs/outputs of the AA9x series, ICS and TX keylines are needed to properly activate the associated PTT circuitry inside the AA9x series. For headsets connected to the PASSENGER inputs/outputs of the AA9x series, a method of controlling the microphone on the headset is needed because of the 'hot mic' circuitry. This is best accomplished with a 'mic interrupt' switch in the PTT cordset.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

There are numerous manufacturers of in-line PTT cordsets, offering many 'electrical' variations to accomplish different functions. To meet the operational requirements for headset stations supported by the AA9x series, NAT recommend the dual switch type: a 3-position (momentary/center-off/locking) slider switch for the ICS functions and a momentary push-button switch for the Transmit functions. Both switches provide a ‘mic interrupt’ function. The 3-position ICS switch will allow the user to change the switch settings to match the operational intercom mode that has been selected at the AA9x series

(e.g., LIVE, KEYED or VOX). The cable should have 6 conductors with the MIC and PHONE pairs shielded (MIC wires must be shielded as a minimum). To ensure proper shielding, the shield(s) should be terminated to the MIC LO connection at the airframe connector of the PTT cordset. See Figure 1 below for details.

Figure 1: PTT Cord for Use with NAT Audio Controllers (XMIT and ICS)

To avoid complications in the aircraft, it is recommended that the same type of PTT cordsets be used for all headset locations in the aircraft. It is not good practice to create a situation where a specific cordset is needed for the copilot, which might cause operational errors if moved to a passenger location.

Although in-line PTT cordsets can be used to conveniently address a number of requirements for microphone and PTT control, they can also be a source of trouble if incorrectly configured, or improperly shielded.

Many in-line PTT cordsets use the PHONE LO connection as the ground reference for the ICS and TX PTT keylines. The PHONE LO connection in the AA9x series is floating, which will lead to incorrect keying of the intercom and radio systems if this type of cordset is used.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

In-line PTT cordsets can be a source for crosstalk if the MIC wire pair in the cordset is not shielded. The source of the crosstalk is the high level Phones audio being coupled on to the MIC HI/LO pair in the in-line PTT cordset, because of the lack of shielding for this wire pair. Once the mic line is contaminated, the undesired audio can be sent into the audio system as ‘mic audio’, then processed and distributed to all other audio controllers via the ICS Tie Line.

2.4.5Post Installation Checks

2.4.5.1Voltage/Resistance Checks

Do not attach the AA9x Series until the following conditions are met.

Check the following:

a)Check P101, pins <16> and <17> for +28 Vdc relative to ground.

b)Check P101 pin <34> for continuity to ground (less than 0.5Ω).

c)Check P102 pin <19> for lights buss voltage.

d)Check all Mic, phone, music and key lines for shorts to ground or adjacent pins.

2.4.5.2Power On Checks

Power up the aircraft’s systems and confirm normal operation of all functions of the AA9x Series. Refer to Section 3 (Operation) for specific operational details.

a)Begin with only the Pilot's headset installed, no hand mic. Confirm correct radio operation, both receive and transmit. Check yoke (or cyclic) switch action. Check radio audio inputs and selection of same.

b)If there is a music source in the system turn it on and verify that music is muted in the CREW mode and removed in the PLT ISO mode. Check for proper mute operation. Do not proceed until the radios are functioning correctly. The S/T (sidetone) trimpot accessible through the left side of the controller and the transceiver internal trimpot may have to be adjusted for correct balance for the pilot. Adjustment of the individual radio RX levels should be set first with the AA9x series in Pilot ISO mode; then adjust the AA9x series front panel RX master volume control level in NORMAL mode.

c)Unusual buzzes, hums or other background audio are symptomatic of multiple grounds, or noisy external systems such as blowers or pumps sharing wiring with the audio system. Failure to key or correctly modulate a transmitter is often the result of forgetting to connect all required grounds to the radio or external audio system.

d)Check the ICS Modes (ALL, CREW, PLT ISO), and the manual Fail-safe operation.

e)Plug in the Co-pilot's headset. Check for correct ICS and SPLIT transmit operation. Check that the Co-pilot loses transmit capability during PLT ISO. Check yoke switch functions.

f)Plug in the hand mic, if installed, and test for correct operation in all modes. (Hand mic activation does not illuminate the TX light.) Note that wiring faults for this accessory may cause peculiar loss of ICS or TX functions because it has over-riding priority in the system.

g)Plug in any remaining headsets, and check for correct ICS operation. Note that an incorrect cordset (drop cord) or improper jack wiring may cause a wide range of problems from loss of audio to a tone heard in the headset. For further information, see section 2.4.4 above.

i)To verify proper operation, all functions and levels shall be checked in-flight.

j)Check preset adjustments are completed before aircraft departure.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

Upon satisfactory completion of all performance checks, make all required log book entries, electrical load, weight and balance amendments and other documentation as required by your local regulatory agency before releasing the aircraft for service.

2.5Adjustments and Connections

The unit is shipped from the factory with all internal adjustments set to the normal test levels. Once installed in the aircraft, it may be desirable to change some of these settings to best suit the local operating environment. The internal adjustments are located on the sides of the unit and are shown in Figure 2 and Figure 3.

2.5.1Left Side Panel Adjustments

The trimpots on the left side panel shown in Figure 2 are used to adjust the levels of audio in the user’s headphones. Rotating the trimpots clockwise (cw) increases the level and counter clockwise (ccw) reduces it.

Figure 2: Left Side Panel Adjustments

2.5.1.1ALERT LEVEL

The ALERT LEVEL trimpot is used to adjust the level for the internally generated Alert signals. Other parameters relating to these signals are adjusted from the right side panel.

2.5.1.2S/T LEVEL

The S/T LEVEL trimpot adjusts the overall sidetone level of all selected transceivers (from the front panel).

2.5.1.3VOX LEVEL

The VOX LEVEL trimpot sets the sensitivity level for the front panel VOX control (the level of audio required to activate microphones).

2.5.1.4POWER ON

The POWER ON LED will illuminate to indicate that the unit is connected to the power supply.

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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

2.5.2Right Side Panel Adjustments

A variety of different signals can be selected to trigger the internal Alert signals. The trimpots on the right side panel shown in Figure 3 are used to adjust the characteristics of the audible signals that the user will hear.

Figure 3: Right Side Panel Adjustments

2.5.2.1DIR AUD LEVEL

The DIR AUD LEVEL trimpot is used to adjust the audio level of the devices connected to the DIR AUD 1 input.

2.5.2.2AUDIO ALERTS

AUDIO ALERT 1 is a single tone signal and AUDIO ALERTS 2 and 3 are two-tone signals.

2.5.2.3TIME

The duration of AUDIO ALERT 3 can be adjusted from one to three seconds using the TIME trimpot.

2.5.2.4TONE

The pitch of the signals can be adjusted using the relevant TONE trimpot.

2.5.2.5RATE

The cycling rate of the two-tone signals can be adjusted using the RATE trimpots.

Note: The number and type of adjustments is dependent on the features specific to the particular AA95, AA96 or AA97 configuration.

2.6Accessories Required But Not Supplied

Installation kit p/n AA90-IKC (crimp) (NAT Part No. D50S37SL-IKC) is required to complete the installation. The kit consists of one 50-Pin D-min Female Crimp Kit (D50SL-IKC) and one 37-Pin D- min Female Crimp Kit (D37SL-IKC):

D50SL-IKC consists of
Quantity	Description	NAT Part No.
1	D-min 50 Socket Housing	20-21-050
50	MS Crimp Socket	20-26-901
1*	Jack Screw Set	20-27-002
1*	Lock Clip Set	20-27-004
1	50 Pin Connector Hood	20-29-051
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AA9x Series Single Channel Audio Controller

SM56 Installation and Operation Manual

D37SL-IKC consists of
Quantity	Description	NAT Part No.
1	D-min 50 Socket Housing	20-21-037
37	MS Crimp Socket	20-26-901
1*	Jack Screw Set	20-27-002
1*	Lock Clip Set	20-27-004
1	37 Pin Connector Hood	20-29-038

*Use as required.

2.7Installation Drawings

Note: There are multiple versions of the AA95, AA96 and AA97. For this reason, the documents listed below are supplied for reference only for units with Serial numbers 6000 and above. If specific model information is required, please contact the Product Support Department at NAT.

DOCUMENT	REV.	DESCRIPTION	TYPE
AA95 and AA96 (All versions)
AMS43\922-0	1.01	Audio Controller	Mechanical Installation
AA95-728
AA95\728\403-0	1.01	Audio Controller	Interconnect
AA95\728\403-1	1.01	Audio Controller	Interconnect
AA95\728\403-2	1.01	Audio Controller	Interconnect
AA95\728\405-0	1.01	Audio Controller	Connector Map
AA95\728\905-0	1.02	Audio Controller	Faceplate
AA95-729
AA95\729\403-0	1.00	Audio Controller	Interconnect
AA95\729\403-1	1.02	Audio Controller	Interconnect
AA95\729\403-2	1.01	Audio Controller	Interconnect
AA95\729\405-0	1.02	Audio Controller	Connector Map
AA95\729\905-0	1.02	Audio Controller	Faceplate
AA96-001
AA96\001\403-0	1.00	Audio Controller	Interconnect
AA96\001\403-1	1.00	Audio Controller	Interconnect
AA96\001\403-2	1.00	Audio Controller	Interconnect
AA96\001\405-0	1.00	Audio Controller	Connector Map
AA96\001\905-0	1.11	Audio Controller	Faceplate

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