Sigtronics EAI Installation Instructions
Sigtronics Emergency Apparatus Intercom System (EAI)
INSTALLATION AND OPERATING INSTRUCTIONS
Models EAI-S4, EAI-S6, EAI-D4, and EAI-D6
INTRODUCTION
ATTENTION INSTALLER: To assure a trouble free Installation, please read these entire instructions through once
before beginning.
The Sigtronics EAI system, when used with Sigtronics noise
attenuating headsets provides the emergency apparatus
crew with clear, hands free, voice actuated (VOX) intercom.
The system also allows full radio monitoring at all headset
positions as well as radio transmit capability from selected
headsets via Push-To-Talk (PTT) switches.
Applications: The unit is designed for fire apparatus, rescue
and ambulance vehicles, marine emergency equipment, airport ground vehicles, and mobile emergency command
centers.
igtronics
S
Made in the U.S.A.
®
Specialists in “SOUND” Management
178 East Arrow Highway, San Dimas, CA 91773 ( 909 ) 305-9399
Voice Activated Intercom (VOX) feature allows “hands free”
communication between headsets connected to the EAI unit.
Start speaking and the intercom turns on instantly to relay
your message clearly to the other headsets. Stop talking and
it turns off to reduce background noise.
Up to Four Headset Positions can be connected to the
EAI unit. More headset positions can be achieved by wiring
additional jacks in parallel. Only one headset, however, can
be plugged into paralleled jacks at one time. This paralleled
jack scheme is most commonly used on pumper trucks at the
pump panel. In this case, the driver plugs his headset into the
engineer’s jack while driving. He then unplugs and plugs into
the pump panel when he arrives on scene.
Headphone Output: The EAI system is designed to easily
drive six or more 300 to 1000 ohm headsets.
Noise attenuating, full cushion headsets, such as the
Sigtronics SE-2, or SE-40 are recommended for best results.
The EAI system incorporates an automatic headphone limiting circuit to eliminate the possibility of painful spurious
radio or noise spikes from getting to the headsets and into
your ears.
Universal Radio Interface design to accommodate virtually
any type of communication radio.
Mike Output: Designed to be fully compatible with virtually
all mobile radios used on emergency vehicles. An adjustment
for transmit microphone level is provided to perfectly match
the EAI system to your particular radio. For applications where
a very high transmit microphone level is required (some Midland and Wilson radios), an inexpensive plug in Mic Level
Amplifier module is available.
Automatic Sidetone Generation allows everyone on the
vehicle to hear both sides of the radio conversations.
Excellent RF Immunity guarantees clean, clear, radio communications.
Standardized for use with Sigtronics single plug headsets
(ie. SE-2, SE-40, SE-41).
Model Differences: The EAI-S4 is used in applications requiring up to four persons at one time on intercom and using a
single vehicle radio. The EAI-S6 is identical to the EAI-S4 but
can intercom up to six people at one time. The EAI-D4 is used
in applications requiring four intercom positions and the use
of two separate radios. Similarly, the EAI-D6 is a six place intercom with two radio capability.
CONTROL FUNCTIONS
ON / OFF — Power Switch — In “ON” position; supplies
power to all EAI circuits. In “OFF” position; disables all unit
functions except radio receive.
VOL — Intercom Volume — Adjusts intercom volume level.
Does not affect radio volume.
SQ — Intercom Squelch - Adjusts VOX operation of the intercom for variations in background noise levels.
RADIO 1 / RADIO 2 (TALK) — Transmit Select (EAI-D4 and
D6 units only) — Used to select which radio to talk on -Radio
1 or Radio 2.
AUTO / BOTH (LISTEN) — Receive Select (EAI-D4 and D6
units only) — Used to select which radio is heard. In “BOTH”
position, you hear both Radio 1 and the Radio 2. In “AUTO”
position, only the radio selected by the RADIO 1 / RADIO 2
switch is heard.
RADIO TRANSMIT MIC LEVEL — Sets the transmit mic audio
level for the radio(s).
EAI INSTALLATION
Standard Equipment Included
Besides the Intercom unit and the Radio Adapter unit, each
EAI system comes complete with the following:
EAI-S4/D4 EAI-S6/D6
Intercom Drill Template 1 1
Intercom Panel 1 1
(printed on both sides)
Intercom Control Knobs 2 2
Intercom Switch Nut 1 1
Intercom Panel Screws 2 2
Headset Jack Box 6 6
Headset Jack Box Cover
with Pre-mounted Headset Jack 4 6
with Pre-mounted Headset Jack
& Splash Cover 1 1
with Pre-mounted PTT Switch 1 1
PTT Switch with Hardware
(loose, not in boxes) 2 2
Jack Box Cover Screws 12 16
Jack Box Mounting Screws 12 16
Wire Grommets 6 8
Jack Insulator Washer, Flat 5 7
Jack Insulator Washer, Shoulder 5 7
Radio Adapter Mounting Screws 4 4
Radio Adapter Mounting Nuts 4 4
Male Connector Housing 1 1
Male Crimp Pins 13 15
Female Connector Housing 1 1
Female Crimp Pins 13 15
4 ft. Headset Jack
& PTT Switch Cable 1 1
4 ft. Radio 1/ Power
Interface Cable 1 1
4 conductor hook-up wire 1 Roll 1 Roll
4 ft. Radio 2 Interface Cable 1* 1*
Radio Select Switch Cable 1* 1*
Radio Select Panel 1* 1*
* Supplied with Dual Radio EAI-D4 and EAI-D6 units only.
INSTALLATION OVERVIEW
Sigtronics has simplified the installation process, to assure
perfect operation. Refer to the EAI Wiring Diagram (for EAIS4 or EAI-S6 see Figure 4 on page 6 for EAI-D4 or EAI-D6 see
Figure 5 on page 7). If you have any installation questions or
problems that are not addressed in this manual, feel free to
call our installation hot line number located on the last page
of this manual.
Installation of the Sigtronics EAI System is a five step process:
I. Mount the intercom unit. (Intercom Chassis Installation)
II. Install the Radio Adapter unit. (Radio Adapter Chassis
Installation)
Ill. Install the headset jacks and PTT switches. (Headset Jack
and PTT Switch Installation)
IV. Wire the jacks and PTT switches. (Headset Jack and PTT
Switch Wiring)
V. Wire the radio(s). (Radio Hook Up)
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I. INTERCOM CHASSIS INSTALLATION
Intercom Placement:
There are a few factors to consider when selecting a mounting location for the EAI Intercom chassis unit:
1. The unit should be placed in such a way that its controls
can be easily seen and operated. Most commonly, this will
be near the vehicle’s communication radio controls.
2. The Intercom unit is primarily designed to be panel or dash
mounted. Above and below dash mounting, however, can
be accomplished by fabricating an inexpensive bracket.
3. The intercom unit has been designed to mount either
horizontally or vertically. The printed panel is reversible
for this purpose.
4. The location selected requires a minimum front panel area
of 2 1/2˝ by 1 1/16˝.
5. The intercom unit normally mounts though the panel or
dash. The maximum allowable panel thickness is 5/32 of
an inch. If the panel is thicker than this, the volume and
squelch knobs will not attach on the unit.
6. The depth required behind panel is 4 3/16˝, plus cable
access. Verify that the rear of intercom unit and cable will
not interfere with the normal operation of any vehicle
controls or the operation of vehicle compartment doors.
7. The Radio Adapter part of the EAI system plugs into the
intercom unit. Therefore, they are usually mounted near
each other. If necessary, however, an extension between
the two units can be fabricated. Connectors for this are
included with the system.
8. For dual radio systems (EAI-D4 or EAI-D6), allow for an additional panel space of 1˝ x 1-1/2˝ near the Intercom unit for
the radio selection switches.
Panel Preparation:
1. Once the location is selected, remove the protective paper
from the back of the adhesive drill template. Then stick it
down on the vehicle dash or panel in the selected area.
2. Center punch each hole at the cross lines. (The five holes
are in straight line and equally spaced 0.4˝ apart).
3. Drill 1/8˝ pilot hole at all five places.
4. Enlarge ON / OFF switch hole to 1/4˝ and the volume and
squelch control holes to 3/8˝ per template.
Mounting Intercom Unit: See Figure 1
VEH I CL E
PAN E L
DO N OT RE M OV E
THE S E N UTS
INT E RCOM
INT E RCOM
PAN E L
SWI TCH
NUT
FIGURE 1
KNO B
4– 40 S CR EW S
KNO B
1. Remove the nut from the Intercom unit ON / OFF switch.
2. Remove the two small black Phillips head screws (#4-40)
located on either side of the ON / OFF switch.
3. Remove both knobs from the Volume and Squelch controls
using a standard .050˝ Allen wrench. CAUTION: DO NOT
REMOVE the nuts from the Volume and Squelch controls.
4. Insert the Intercom unit from the rear of panel. Arrows on
the top and side of the intercom unit chassis indicate which
way is up. One for horizontal mounting and the other for
vertical.
5. Install the printed Intercom panel and lightly thread on
the ON / OFF switch nut. The nuts on Volume and Squelch
controls should fit inside the drilled 3/8˝ diameter holes.
6. Reinstall and tighten the two small black screws through
the holes in intercom panel. Tighten ON / OFF switch nut.
7. Turn both Volume and Squelch controls fully clockwise.
Reinstall the knobs on Volume and Squelch control shafts.
Without moving the control shafts, align the white line on
the knobs to the five o’clock position. Tighten with the
Allen wrench.
II. RADIO ADAPTER CHASSIS INSTALLATION
Placement:
The Radio Adapter part of the EAI system is designed to
be remote mounted (behind the dash) with four screws
mounted through the grommets on the back of the chassis. Because the Adapter connects to the radio(s), select a
mounting location near the emergency radio controls. Also,
if space allows, mounting this Adapter within a few inches of
the Intercom unit allows connectors P1 and J1 to be mated
directly. An extension can be fabricated if necessary to connect the two together.
Make sure that the transmit mic level adjustment hole(s) on
the side of the Radio Adapter chassis can be easily accessed
for adjustment with the Adapter in place. As usual, with the
Adapter in place, it or its cables should not interfere with the
normal operation of the vehicle.
Mounting Radio Adapter Chassis:
1. Remove the four corner panel screws (the smaller ones)
from the top of the Adapter unit. Remove the unit from
the chassis.
2. Set the Adapter chassis in the intended mounting place.
Using a small point pen or marker, mark the hole pattern
through the four grommets located on the bottom of the
Adapter chassis.
3. Drill four holes using a 5/32 inch drill (clearance for a 6-32
screw).
4. Secure the Adapter chassis to the vehicle using the four
screws and locking nuts supplied. Be sure to install the
screws with the screw heads inside the Adapter chassis.
This should assure that these mounting screws will not
touch the Adapter circuit board when in place. Do not
tighten the nuts and screws so tight as to excessively crush
the grommets.
3
5. Replace the Adapter circuit back into the chassis. Make sure
that the transmit mic level adjustment(s) lines up with the
hole(s) in the Adapter chassis. Be sure not to pinch any
wires under the panel. Replace the 4 corner panel screws
and tighten.
6. Plug the Intercom unit plug P1 into the mating connector
J1 on the Radio Adapter unit.
If you are installing an EAI-D4 or EAI-D6 continue on with
the following. Otherwise, for a EAI-S4 or EAI-S6 skip down to
“Headset Jack and PTT Switch Installation” below.
Dual Radio Select Switch Cable Installation (EAI-D4 or EAID6):
The dual radio units have an additional switch cable that
allows radio selection. The switches on this cable are designed
to be panel or dash mounted. The other end of this four foot
cable plugs into the Radio Adapter unit.
1. Select a location for the RADIO 1/ RADIO 2 select switches
near the Intercom unit.
2. Use the printed RADIO 1/ RADIO 2 switch panel as a template to mark the two switch holes. Drill both holes using
a standard 1/4’ drill.
3. Remove the switch nuts and mount the switches from
the back of the panel or dash with the key slots down. The
smaller of the two switches is the AUTO / BOTH switch and
it mounts on the right.
4. Install the printed switch panel, thread on the switch nuts
and tighten.
5. Plug the switch cable plug P5 into the Radio Adapter J5
connector.
6. Secure the switch cable to the vehicle with suitable ties.
Again, make sure that the cable does not interfere with
anything on the vehicle.
Ill. HEADSET JACK AND PTT SWITCH INSTALLATION
Headset Jack Placement:
It is assumed that it has already been determined which
positions on the vehicle will have headsets. At this stage, it is
helpful to have a headset handy to physically gauge the best
place for the jack. There are several things to consider when
selecting a place to mount the headset jacks:
1. In general, for headset positions inside the vehicle, the
jacks should be placed towards the middle between the
user’s positions. They should also be placed up above and
towards the back of the user’s head. This will assure that
the headset cord will not hang between the user and the
vehicle door.
2. The headset jack should be out of the way so that the
headset plug can’t be hit during use or when entering or
exiting the vehicle.
3. The jack position should also take into account how the
headset cord will hang when the headset is in use. The cord
should hang out of the way and should not interfere with
vehicle controls.
4. Verify that the jack placement and headset cable do not
interfere with the normal operation of vehicle doors or
compartments.
5. In vehicles with intercom headset positions installed in
open jump seat locations, the combination of wind, road,
and engine noise, picked up by these jump seat headsets,
can in some cases produce excessive background noise
in the intercom system. Additionally, wide variations in
engine noise (from idle to high RPM) can falsely trigger the
intercom VOX (voice activated) feature. This is especially
true for older vehicles with open jump seats located right
next to the vehicle engine. There are two solutions for this
situation. The first one is the recommended one:
a) Order an additional Push-To-Talk (PTT ) switch (and
mounting box if needed) for each open jump seat
position. These switches can be conveniently mounted
at each jump seat location and wired so that the jump
seat headset microphone is disabled until the switch is
pressed. See Figure 2 below. The firefighter then uses the
PIT button to talk on the intercom instead of the VOX
(voice activated) intercom feature. PTT buttons wired in
this way only activate the intercom. They do not let the
FIGURE 2
TAN
INTERCOM PTT SWITCH
OPEN JUMP SEAT WIRING DIAGRAM
jump seat locations talk on the vehicle radio(s).
b) Order Sigtronics headsets (Models SE-2P, SE-40P, or SE-
41P) with the intercom PTT switch already mounted on
the ear cup for the open jump seat positions. The fire
fighter then uses the PIT button on his headset ear cup
to talk on the intercom instead of the VOX feature. The
advantage of this method is that it eliminates having to
mount and wire in additional PIT buttons for the jump
seats. Note, however, most departments prefer to have
all the headsets on the vehicle(s) the same so that any
headset can be used in any position. The headsets with
intercom PTT switches on them cannot easily be used
in a position that has radio trans-mit capability such as
the driver or officer position.
Sigtronics provides two ways to mount the headset jacks for
the EAI unit:
1. Mount the jacks in the supplied blue jack boxes.
Advantages:
a) Little or no “behind the panel” space required.
b) No vehicle panel thickness limitation.
c) Smaller holes are required to be drilled — a real advan-
tage on vehicles with thick metal panels.
d) Complete electrical isolation of the jacks from the
vehicles chassis, because the jack box is fabricated out
of non-conductive high impact plastic.
TIPRING
BARREL
HEADSET JACK
BLUE
BLACK
4
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