SCI Panel Mount Intercom System

SCI Panel Mount Intercom System
Sigtronics SCI Panel Mount Intercom System
INSTALLATION AND OPERATING INSTRUCTIONS Models SCI-4 and SCI-6
INTRODUCTION
ATTENTION INSTALLER: To assure a trouble free
installation, please read the entire instructions through
once before beginning.
WORLDS FIRST AND ONLY VOICE ACTIVATED
INTERCOMS WITH DUAL SQUELCH INDICATORS!
Once again Sigtronics is first. First with VOX, now first with dual
Squelch lights. Get instant visual confirmation on who is breaking
squelch.
All of our products are “systems designed” to provide reliable, failsafe products at the lowest possible cost. And we stand behind our
products to guarantee your satisfaction!
The Sigtronics Models SCI-4 and SCI-6 intercom systems are
specifically designed for permanent - panel mounted installation
in aircraft. The SCI units allow both pilot and co-pilot to operate
the aircraft radios and have the convenience of voice activated
intra-cabin communication. Passenger connections are provided
that allow up to four additional intercom positions, depending on
model.
SIGTRONICS SCI
INTERCOM SYSTEM FEATURES:
VOICE ACTIVATED feature allows “hands free” intercommunication between pilot(s) and passengers. Start speaking
and the intercom instantly turns on to relay your message clearly
to the other headsets; stop talking and it turns off to eliminate
background noise. There’s no need to raise your voice or turn your
head to communicate.
UP TO FOUR POSITION INTERCOM is provided with the model
SCI-4. Model SCI-6 handles up to six positions. “H” Model units
for use in high noise aircraft.
DUAL SQUELCH CONTROL AND INDICATOR LIGHTS - Another
Sigtronics first. Know instantly who is breaking squelch, crew or
passengers.
TRANSMIT CAPABILITY allows both pilot and co-pilot to transmit
to air traffic control via their push-to-transmit switches and headset
boom mics. Depending on the mode selected, intercom function
is disabled during transmission so only the voice of person
transmitting is heard.
PILOT ISOLATE MODE - The pilot can set the intercom so that
he can transmit and receive on the aircraft radio(s) independently
from the rest of the intercom. The co-pilot and passengers can
still intercom among themselves and not be heard by the pilot.
Conversely, they won’t hear the aircraft radios or the pilot. This
can be an advantage in areas of busy radio traffic.
CREW ISOLATE MODE - The pilot can set the intercom so that
the pilot and co-pilot (crew) can intercom, transmit and receive on
the aircraft radio(s) and not hear the passenger conversations.
Conversely, passengers can intercom simultaneously and not be
bothered by radio traffic or crew conversations.
RADIO MONITORING capability allows radio output to be heard
by the pilot, whether the SCI unit is in “ALL”, “ISO”, or “CREW”
mode.
COMPATIBILITY - Sigtronics SCI intercoms operate with all
standard general aviation aircraft radios and headsets.
FAIL-SAFE feature provides the pilot with the ability to use the
aircraft radios even if power is lost to the intercom.
EASY UPGRADE - In most cases enlarge three holes, add two
more, and re-route three headphone wires in an existing SPA-400
or SPA-600 installation and get the latest technology in aircraft
intercoms.
WEIGHT: 7.3 ounces (SCI-4 intercom unit with panel and knobs).
Jacks and wiring harness weigh 6.3 ounces.
SIZE: Panel 1” x 2.5”. Chassis - 1” high x 2.5” wide x 6” deep. Can
be mounted either horizontally or vertically in the aircraft panel.
INPUT POWER: 11VDC through 32VDC. Maximum current drain
0.2 Amp (SCI-6)
DISTORTION: Less than 1% total harmonic distortion.
WARRANTY: The SCI units are constructed of high quality
components and carry a five year parts and labor warranty.
FAA TSO: C-50c
ENVIRONMENTAL: DO-160D
Environmental Catagory:
A1D1XCAAS2MXXXXXXZBBBBXXXXXXXXXXX
MADE IN THE USA
Specialists in “SOUND” Management
178 East Arrow Highway, San Dimas, CA 91773 ( 909 ) 305-9399
OPTION - PILOT TRANSMIT PRIORITY - If the pilot and the
copilot key at the same time (not a common occurrence) the
default operation is that both microphones will go out the aircraft
radio to the tower. If you prefer only the pilot’s microphone active
when both press their PTT’s simultaneously then enable this
option. Note - if only one of the pilots presses his PTT only his
mic will go out over the radio regardless if this option is selected
or not.
To enable this option,
remove the four screws
on the bottom of the
SCI unit and remove
the cover. Refer to
Figure 1. To enable
pilot transmit priority
solder a small jumper
between pad “B” and
pad “G”. Replace the
cover and the four
screws and tighten.
Removing this jumper
will deactivate the
option.
UNIT PLACEMENT
The SCI unit has been designed to mount either horizontally or
vertically in your aircraft panel.
The location selected for the SCI unit requires a minimum front
panel area of 2 1/2” by 1”. Depth required behind panel is 6” plus
cable access.
CAUTION: Move the aircraft flight controls through the limits of
travel while observing the selected area and making sure that the
rear of the intercom and cable will not interfere with any aircraft
control components.
PANEL PREPARATION:
1. Position the adhesive drill template on the aircraft panel in the
selected area.
2. Center punch each hole at the cross lines. (Five holes are in a
straight line and equally spaced 0.4” apart, two holes are 0.8”
apart).
3. Drill 1/8” pilot holes in all seven places.
4. Enlarge two holes to 9/16”, one hole to 7/16”, and two holes to
3/16” per the template.
CHASSIS INSTALLATION
To upgrade an existing SPA-400 installation to a SCI-4 or a SPA600 to SCI-6 skip to the “UPGRADING A SPA INSTALLATION TO A
SCI” section on page 4. For a completely new intercom installation
continue below.
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HARDWARE SUPPLIED
Besides the intercom unit and these instructions, each SCI system
comes with the following hardware:
SCI-4
SCI-6
4
6
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Headphone Output Jacks - Accept standard
0.250” aircraft headphone plugs.
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Microphone Input Jacks - Accept standard
0.206” aircraft microphone plugs. (U93 plug
compatible jacks can be used in place of the
MOUNTING CHASSIS (See Figure 2)
jacks provided).
4
6
Mic Jack Insulating Washers, Flat
4
6
Mic Jack Insulating Washers, Shoulder
4
6
Intercom Panel - lettered on both sides.
1
1
Intercom Control Knobs
4
4
Mounting Screws 4-40 x 1/2
2
2
pattern for drilling aircraft panel.
1
1
Aircraft/Intercom Interface Cable (4 feet long)
1
1
1
1
Drill Template - Adhesive backed hole size
Headphone/intercom Interface Cable (4 feet
long)
1. Remove the knobs from the Volume and Squelch controls using
a 0.050” Allen wrench. NOTE: DO NOT REMOVE the nuts from
the Volume/Squelch, or ALL/ISO/CREW controls.
2. Insert the SCI unit from the rear of the aircraft panel with the
appropriate arrow on the unit chassis pointing upwards. Make
sure the squelch indicator lights have unrestricted movement
through aircraft panel.
3. Install the printed SCI panel and lightly thread the two 4-40
screws through the holes in intercom panel. The nuts on the
Volume/Squelch and OFF/ALL/ISO controls will fit inside the
9/16” and 7/16” diameter holes.
4. Tighten the two screws.
5. Install the knobs on the Volume (VOL) and Squelch (SQL)
control shafts and tighten the Allen screws.
page 2
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3. Connect one end of a wire to the barrel terminal of the mic jack
and connect the other end to Point “A”.
4. Install insulating washers as necessary if the barrel of the mic
jack is mounted in metal.
For the headphone jack, remove any existing wires from the
tip connection. Connect the green wire (J2 pin 1) to the tip
connection.
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2. Connect the intercom white/black wire to the ring terminal.
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Figure 3
WIRING INSTRUCTIONS
MOUNTING HEADPHONE AND MICROPHONE JACKS (See
Figure 3)
1. Locate the mounting areas. (One mic and one headphone jack
required for each headset). Again, make sure that the jacks will
not interfere with any aircraft control components. (Note that the
jack contacts will expand when a plug is inserted into the jack.)
Connections should be made as shown in Figure 4 and indicated
in Table 1 and 2. If longer wire lengths are required, use a good
quality hook-up wire - 22 gauge or larger. Although not necessary,
shielded audio wire can be used if desired. This can simplify the
wiring process.
2. Drill 3/8” diameter holes for headphone jacks and install.
3. Drill 1/2” diameter holes for the mic jacks and install with the
insulating washers supplied. (See Figure 3)
Note: If the aircraft already has pilot headset jacks, they can be
used for intercom, however, the mic jack must be re-wired as
follows:
1. Remove any existing wires from the tip, ring, and barrel
connections.
page 3
UPGRADING A SPA INSTALLATION TO A SCI
TABLE 1 - P1/J1 - See Wiring Instructions
PIN
WIRE COLOR
FUNCTION
CONNECT TO
1
White/Black
Pilot Mic Input
Ring Terminal of Pilot Mic Jack
2
White/Red
Pilot Transmit Switch
Input
Pilot Transmit Switch (PTT)
(Switch to Ground to Transmit)
3
Blue *1
Radio Headphone Input
Radio Headphone Output
4
Black *2
Intercom Central
Grounding Point “A”
Aircraft Chassis Ground
5
White
Radio Transmit Key
Output
Tip Terminal of Aircraft Hand
Mic Jack, or Key Input of Aircraft
Radio or Audio Panel
6
Brown
Transmit Mic Audio
Output
Ring Terminal of Aircraft Hand
Mic Jack or Mic Input of Aircraft
Radio or Audio Panel
7
Red *3
12 through 28 VDC
Power Input
Intercom Circuit Breaker
8
Tan *4
Passenger #1 Mic Input
Ring Terminal of Passenger #1
Intercom Mic Jack
9
Tan *4
Passenger #2 Mic Input
Ring Terminal of Passenger #2
Intercom Mic Jack
10
White/Blue
Co-Pilot Transmit
Switch Input
Co-Pilot Transmit Switch (PTT)
(Switch to Ground to Transmit)
11
White/Orange
Co-Pilot Mic Input
Ring Terminal of Co-Pilot Mic
Jack
12
N/C
None
No Connection
13
Tan *5
Passenger #3 Mic Input
Ring Terminal of Passenger #3
Intercom Mic Jack
14
Tan *5
Passenger #4 Mic Input
Ring Terminal of Passenger #4
Intercom Mic Jack
15
N/C *5
None
No Connection
Chassis Mounting
The SCI-4 is specifically designed to easily replace a SPA-400.
Similarly, the SCI-6 can replace a SPA-600. The panels are exactly
the same dimensions (1” x 2.5”), however the SCI units are 1 3/4”
longer than the SPA units. You will have to make sure that you
have the extra depth required behind your panel. Five mounting
holes are exactly in the same positions. The center hole will have
to be enlarged from 1/4” to 7/16”, the two outer holes will have to
be enlarged to 9/16”, and two additional holes drilled to 3/16” (As
per template).
To upgrade, first remove the SPA unit from the aircraft panel. This
is done by unscrewing the two Phillips head screws and the nut on
the ON/OFF switch. Remove the printed SPA panel. Pull the SPA
unit out and unplug the white connector from the wiring harness.
Next, drill the center hole in the aircraft panel out to 7/16”. Then drill
the two outer holes to 9/16”, then use template to mark the position
of the final two holes and drill. Finally mount the SCI chassis (see
Figure 2 on page 2):
1. Remove the knobs from the Volume and ALL/ISO/CREW
controls using a 0.050” Allen wrench. NOTE: DO NOT REMOVE
the nuts from the Volume/Squelch (VOL/ SQ) or ALL/ISO/CREW
controls.
2. Insert the SCI unit from the rear of the aircraft panel with the
appropriate arrow on the unit chassis pointing upwards. The
squelch indicator lights (LED’s) should easily fit through their
respective holes.
TABLE 2 - P2/J2 - See Wiring Instructions
PIN
WIRE COLOR
FUNCTION
CONNECT TO
1
Green
Pilot Intercom
Headphone Output
Tip Terminal of Pilot Headphone
Jack
2
Gray
Co-Pilot Intercom
Headphone Output
Tip Terminal of Co-Pilot
Headphone Jack
3
Yellow
Passenger Intercom
Headphone Output
Tip Terminal of Passenger
Headphone Jacks
3. Install the printed SCI panel and lightly thread the two 4-40
screws through the holes in intercom panel. The nuts on the
Volume/Squelch and ALL/ISO/CREW controls should fit inside
the aircraft panel holes.
*1. The blue wire from Pin 3 must be connected to the aircraft radio
headphone output - NOT the speaker output.
*2. Connect all intercom mic jack grounds to a single aircraft
chassis ground point - Point “A” - as shown in Figure 4. (Use
the black washers supplied to insulate the intercom mic jacks
from aircraft chassis ground). Note this intercom central
grounding point is used to eliminate any unwanted electrical
noises, such as alternator whine or strobe noise, from being
induced into the intercom system through the grounds. All
intercom mic jack barrels must be insulated from ground where
they are mounted and connected back to Point “A” on their own
individual ground wire. Similarly, both intercom ground wires
(pin 4) and the push-to-transmit switch grounds must also be
connected back to Point “A”. It is not necessary, however, to
connect the headphone jack barrels to Point “A”. They can
either be grounded where they are mounted or some place
nearby.
*3. The red wire may be connected to either 12V (14V) or 24V
(28V) power source. No switching or adjustments are required
to operate from either source.
*4. Tan wires (pins 8 and 9) are only used on installations that
require extra intercom positions.
*5. Provided on SCI-6 units only.
Skip down to the INSTALLATION CHECK OUT AND ADJUSTMENTS section on this page.
4. Tighten the two screws. Make sure LED’s have unrestricted
movement in aircraft panel holes.
5. Put the knobs on the Volume and Squelch control shafts and
tighten the Allen screws.
Wiring Change
The wiring changes to an existing SPA installation is as follows.
Re-wire the pilot, co-pilot, and passenger(s) headphone lines. You
will not need the 4 foot interface cable (12 or 15 pin) that comes
with the SCI system. You will use the SPA harness already in the
aircraft and the 4 foot headphone/intercom interface cable (3 pin).
In an SPA installation, the tip terminals of the pilot, co-pilot, and
passenger headphone jacks are wired to the blue wire (pin 3).
They need to be disconnected from there and connected to their
respective pins on the headphone/intercom interface harness. (see
Figure 4 on page 3). Make sure that the blue wire (pin 3) is still
connected to the tip of the radio headphone line.
INSTALLATION CHECK-OUT AND ADJUSTMENTS
After the unit is installed, again check that the SCI unit chassis,
jacks, and wiring harness are clear of all aircraft operating controls
and cause no interference with them. Next, to check out the SCI
unit installation plug in all the headset mic and phone plugs into the
respective intercom jacks. Put on the pilot’s headset and position
the boom mic close to the mouth, as is the practice with a hand-
page 4
held mic. Voice clarity is best when the mic is at one side of the
mouth and 1/4” from the lips.
To assure that the aircraft radios, pilot’s headset, and PTT switch
are connected and functioning properly, remove power to the SCI
by pulling intercom circuit breaker. If applicable, set the aircraft
audio panel to “Headphone” position. Then turn on the aircraft
radio(s) as usual, and verify that the pilot can hear the radios and
can transmit using his push-to-transmit switch and headset. Aircraft
radio(s) and audio panel should operate exactly as they did before
the SCI system was installed. Aircraft radio reception should not be
heard in the co-pilot or passenger headsets. There should be no
intercom between headsets with no power to the SCI unit.
Next restore power to the SCI unit. Switch ALL/ISO/CREW
control to the “ALL” position. Set the SCI volume controls to midposition. Set both SCI squelch controls fully clockwise. Verify that
all headset positions can now intercom with each other, including
the passengers. Verify that both pilot and co-pilot can operate the
aircraft radio(s). In this mode all headsets on the intercom will hear
the aircraft radio(s).
It may be necessary at this time to adjust the SCI unit mic output
to the aircraft radios. A small adjustable potentiometer is provided
inside the unit for this purpose. It is accessible through a hole
in the side of the SCI chassis. It is marked “Mod. Adj.”, and can
be adjusted with a small blade screwdriver. In the event of overmodulation (garbled) or reports of weak transmissions over the
aircraft radio, an appropriate adjustment can be made. Clockwise
rotation increases the output level to the aircraft radio mic input.
Counter-clockwise rotation decreases modulation level. This
adjustment sometimes needs to be made after the initial installation
of the intercom or if a new radio is installed. (The output is set for
unity gain at Sigtronics).
It may also be necessary to adjust the SCI unit radio receive input
from the aircraft radio. A small adjustable potentiometer is provided
inside the unit for this purpose. It is accessible through a hole in the
side of the SCI chassis. It is marked “RX Adj.”, and can be adjusted
with a small blade screwdriver. In the event of low aircraft radio
volume in the “ALL” or “CREW” mode relative to “ISO” mode, an
appropriate adjustment can be made. Clockwise rotation increases
the input level to the SCI radio receive input. Counter-clockwise
rotation decreases input level. This adjustment sometimes needs
to be made after the initial installation of the intercom or if a new
radio is installed that has a low output impedance or low output
power. The adjustment is best made with the pilot and co-pilot
headsets plugged in. (The input is set full CCW which is unity gain
for 500Ω radios).
If everything checks out, refer to the OPERATING INSTRUCTIONS below for proper use and other operating modes
of the Sigtronics SCI intercom system. If something does not
work as above, carefully go over the intercom wiring again. If
something is still not right or you have any questions regarding
the installation and operation of the Sigtronics SCI intercom or any
other Sigtronics product feel free to contact us directly or email us
at [email protected] Technicians are available Monday though
Friday 8 am to 4:30 PM Pacific time.
This concludes the installation check-out.
OPERATING INSTRUCTIONS
The Sigtronics SCI-4/SCI-6 is a voice activated (VOX) intercom
for aircraft with “transmit through the aircraft radio capability” using
your push-to-transmit switches. Three controls are provided on the
SCI units:
ALL/ISO/CREW Switch - Sets the intercom mode of operation.
PILOT/CO-PILOT VOL - Volume Control - Controls the intercom
volume for pilot (except in ISO mode) and co-pilot. (Does not affect
aircraft radio volume. Set radio volume on radio as normal.)
PILOT/CO-PILOT SQ - Squelch Control - Sets the pilot (except
in ISO mode) and co-pilot intercom turn-on threshold for voice
activated intercom (VOX) mode.
PASSENGER VOL - Volume Control - Controls the passenger
intercom volume. (Does not affect aircraft radio volume. Set radio
volume on radio as normal.)
PASSENGER SQ - Squelch Control - Sets the passenger intercom
turn-on threshold for voice activated intercom (VOX) mode.
CAUTION - As is standard practice with all aircraft avionics
equipment, be sure that the aircraft radio master switch is turned
off when you start up the aircraft engine.
INTERCOM OPERATION
Intercom operation and adjustment can be performed by the
following procedure:
1. With aircraft power on, set the SCI ALL/ISO/CREW switch to the
“ALL” position - the preferred mode for setting the squelch.
2. Turn the SCI unit volume controls to the 10 o’clock position.
Turn the crew squelch control full clockwise and the passenger
squelch control full counter-clockwise. Inform passengers to
remain silent until you finish setting the intercom squelch.
3. To adjust the intercom squelch control for voice activated
operation (VOX), it is helpful to have some background noise
present. Turn intercom crew SQuelch control all the way
counter-clockwise. Now, without speaking, rotate the Squelch
control clockwise until you hear the background noise in your
headset, at this point the crew squelch indicator light will be
on. Next, rotate it counter-clockwise a small amount and wait
(approximately 1 second) until the background noise disappears
and the squelch indicator light is off. Finally, make small
adjustments until your voice triggers the unit at comfortable
speaking levels. This procedure is necessary because the
squelch is a “Fast-on, Slow-off” system. Now with the crew
squelch set, repeat step 3 for the passenger squelch.
Once set, the intercom stays silent until someone speaks in their
headset microphone (mic). Then it instantly turns on and relays the
conversation. After about a second of no conversation the intercom
goes silent again.
In most aircraft the squelch level won’t need to be set again until
the next flight. In some high noise aircraft it is better to set the
squelch during climb or cruise.
INTERCOM MODES
ALL MODE - When the SCI is in the “ALL” mode, transmitting
from both pilot and co-pilot positions is possible. As normal, the
pilot selects the appropriate radio he wishes to use. When the pilot
presses his PTT switch, his headset mic is automatically routed
through the intercom to the radio. Only his mic will be live. The microphones of the co-pilot and any passengers will be muted when
the pilot transmits. Similarly, when the co-pilot transmits, only the
page 5
co-pilots mic will go out on the radio. Depending upon which priority mode is selected, only the pilot or both will go out when both
PTT switches are pressed at the same time. When transmitting,
everyone on the intercom will hear the transmitting pilots voice via
the SCI sidetone return.
hear intercom and cannot talk to the other headsets. The co-pilot
and passengers still have intercom, but do not hear the radios. If
the radio does not provide transmit sidetone, then the pilot will not
hear his voice in the “ISO” mode.
SOLO FLIGHTS
CREW MODE - When the SCI is in the “CREW” mode, transmitting
from both pilot and co-pilot positions are possible. The pilot selects
the appropriate radio he wishes to use. When the pilot presses his
PTT switch, his headset mic is automatically routed through the
intercom to the radio. Only his mic will be live. The microphone of
the co-pilot will be muted when the pilot transmits. Similarly, when
the co-pilot transmits, only the co-pilots mic will go out on the radio.
Depending upon which priority mode is selected, only the pilot or
both will go out during simultaneous keying of the PTT switches.
When transmitting, the pilots will hear their own voice via the SCI
sidetone return. In this mode, the passengers will still have the
ability to intercom among themselves and not be bothered by radio
traffic interruptions or crew intercom conversation. Similarly, the
pilots will not hear the passenger’s conversations.
ISO MODE - When the SCI is set to the “ISO” mode, only the pilot
can transmit and receive on the aircraft radio(s). The pilot will not
Since the intercom is not needed during solo flights, it may be
turned to the “ISO” position. The pilot will still hear the aircraft
radio(s), since this circuit is always active, and may transmit to
ATC via his headset and push-to-transmit switch. If radio does not
provide sidetone, then switch intercom mode to “CREW”.
FAIL-SAFE
If power to the SCI unit fails, the pilot can still transmit and receive
on the a/c radio(s) (assuming the radio(s) are still functioning).
Additionally, if a problem is ever suspected in the intercom, switch
to “ISO” mode or remove power to unit. In this mode you will still be
able to transmit and receive on the aircraft radio(s) from the pilot’s
position. If the radio does not provide sidetone, then the pilot will
not hear his voice in the “FAIL-SAFE” or “ISO” mode.
Congratulations, you have purchased one of the finest intercom systems available for your aircraft.
Why not use headsets designed with the same quality and performance? No headset works better with
Sigtronics intercom systems than a Sigtronics headset!
Sigtronics headsets are designed like no other headset for top-notch performance even in the noisiest of environments.
Sigtronics manufactures the lightest full-size noise-attenuating headset line available in the aviation market. Our ear
seals (gel or foam), earcup style and cushion design keep unwanted sound to a minimum, resulting in a 24db Noise
Reduction Rating (NRR) on every headset. Durable polyurethane ear seals are impervious to perspiration and ultra violet
deterioration. Speaker elements are high efficiency, tailored to the conversation bandwidth, and are not affected by changes
in temperature or humidity. Sigtronics headsets are guaranteed to be RFI and EMI immune in any type of aircraft, even in
fabric or composite aircraft or when used with handheld radios. 105 strand, stop break high-flex cords can withstand up to
95 lbs. of strain.
Along with our standard general aviation headsets, Sigtronics also manufactures full stereo headsets. These headsets
utilize an infinite baffle system to deliver true high fidelity sound and offer an integrated stereo / mono switch and dual
volume controls for the ultimate in quality, comfort and sound reproduction for the discriminating pilot. Stereo headsets are
also recommended for those with unequal hearing abilities in each ear.
All Sigtronics headsets can be custom fit by choosing one of the available three headband sizes; regular, large, or petite /
children.
For more information on our line of headsets or any other Sigtronics product see your local Sigtronics Dealer or visit our full
service web site at www.sigtronics.com.
Made in U.S.A.
Sigtronics Corporation
178 East Arrow Highway
San Dimas, Ca 91773
909) 305-9399
www.sigtronics.com
…when it counts!
SCI4INST
REV C
1-8-2007
P/N 700110
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