Sigtronics RES-400 - Manual (Page 2)

INSTALLATION FOR COMPLETE SPA-400 pIus RES-400 SYSTEM
(If RES-400 is to be added to existing SPA-400 installation, proceed to Installation Retrofit.)
SPA-400 CHASSIS INSTALLATION
Hardware Supplied: (SPA-400, RES-400)
Four Headphone Output Jacks — Accept .250” stereo headphone
plugs.
Four Microphone Input Jacks — Accept standard .206” aircraft
microphone plugs.
Mike Jack Insulating Washers: 4 shoulders and 4 flat.
Transcom Panel: Lettered on both sides.
Control Knobs (2), Switch Nuts (3), 4-40 Screws (2)
Switcher Panel and harness
Template (Hole size pattern)
Aircraft/Intercom interface cable (4 ft. long)
Connectors for fabricating extension cable
The location selected requires a minimum front panel area of 21/2” by
1”. Depth required behind panel is 4” plus cable access.
Allow approximately 1” by 11/2” space nearby to mount the RES-400
switcher panel.
CAUTION: Move aircraft flight controls through limits of travel while
observing selected area to make certain intercom components will
not interfere with aircraft control components.
PANEL PREPARATION:
1. Position adhesive template on aircraft panel in selected area.
2. Center punch each hole at cross lines. (The five holes are in a
straight line and equally spaced 0.4” apart.)
3. Drill 1/8” pilot hole all five places.
4. Enlarge holes to 1/4” and 3/8” per template.
MOUNTING CHASSIS: See Figure 1
1. Remove nut from Transcom ON-OFF switch bushing.
2. Remove knobs from VOL and SQ controls using .050 Allen wrench.
DO NOT REMOVE nuts from VOL and SQ control potentiometers.
3. Remove two 4-40 screws and remove panel from TRANSCOM
chassis.
4. Insert Transcom from rear of aircraft panel with appropriate arrow
pointing upwards.
5. Install panel and lightly thread nut on to ON-OFF switch. Nuts and
washers on VOL and SQ controls should fit inside the 3/8” diameter
holes drilled in aircraft panel.
6. Install two 4-40 screws through holes in Transcom panel. Tighten
ON-OFF switch nut.
7. Install knobs on VOL and SQ control shafts.
MOUNTING HEADPHONE AND MICROPHONE JACKS
1. Locate mounting areas. (One mike and one headphone jack for
each headset.)
2. Drill 3/8” diameter holes for headphone jacks and install.
3. Drill 1/2” diameter holes for mike jacks and install with insulating
washers supplied. (See Figure 2)
4. Terminals on the stereo phone jacks may be identified per the mike
jack shown in Figure 2. The phone jack bushings (sleeve terminal)
must be grounded to airframe or wired to aircraft ground.
RES-400 SWITCHER CHASSIS INSTALLATION
1. As in mounting the intercom, select a mounting location which will
not cause interference with flight controls. (If space allows, mounting
of the Switcher within a few inches of the intercom will allow
connectors J1 and P1 to be mated directly. Otherwise, an extension
cable may be fabricated, from the connectors provided, to permit
mounting the switcher chassis elsewhere.
2. Remove the four corner panel screws and remove unit from case.
3. Drill aircraft with same hole pattern as in the switcher case. Use a
#27 drill. (Clearance drill for 6/32”)
4. Secure case to aircraft with screw heads inside switcher case for
circuit board clearance. (Care should be taken not to crush
grommets while applying torque to screws.)
5. Replace unit in the case and secure.
SWITCHER HARNESS INSTALLATION
1. Select area on panel and drill ¼” diameter holes for Music (On/Off)
and Mode (Pilot/All) Switches.
2. Mount switches with bushing key slots down.
3. Route harness to Switcher to clear aircraft controls and secure with
suitable ties.
INSTALLATION RETROFIT
If the Transcom SPA-400 has been previously installed, the RES-400
Switcher may be added as follows:
1. Mount the RES-400 chassis per paragraph “RES-400 Switcher
Chassis Installation”
2. Install the Music and Mode Switches and route the harness per
paragraph “Switcher Harness Installation”.
3. Unplug SPA-400 from its wiring harness and insert Connectors J1
and P2 on the RES-400 as shown in Figure 3. Connect remaining
plugs per Figure 3.
4. Remove the headphone jacks from the pilot, co-pilot, and passenger
positions in aircraft. Wires which had been connected to the phone
jacks should be cut, insulated and tied back. If two or more wires
appear on a single jack terminal, they should be cut free of the jack,
then spliced together before insulating and tying back. Do Not Dis-
turb Microphone Jacks.
5. Replace headphone jacks with three-terminal type “stereo” jacks
supplied with the RES-400 switcher. Connect wires to the stereo
jacks per Figure 3. Terminals on the stereo phone jacks may be
identified per the mike jack shown in Figure 2. The jack bushings
(barrel terminal) must be grounded to the airframe or wired to
aircraft ground.