OPERATION AND INSTALLATION MANUAL / Aincrart intercom /| iG-=COM MODEL 500 Peat ci ca) \ David Clark company INCORPORATEDCONTENTS General oration ns _] Spectains insallaton ae + WarnnglCations Seting Options echnical Mounting {iver Adsment Side Lovel Ada Ray Bod raya Pity Sich Location ee ep fear View " ee ener Dust Aodo Panel Wing pelea Hert Pir VolalSquich On CoplovPassengor Volumelsauich Rosiarcrow Al Switch Com 1/Com 2/Com 3 Switch... ea 20) ‘Aux. Input. : 20 Pilot PrioryiNo Priority 2 Failsafe. 2 Final Check. 2 Troubleshooting, 23 Pullout Section Center of Manual ‘Warranty/Registration/Owner Record/Drill Template * Please Read Before Installation/Disassembly GENERAL INFORMATION DC-COM MODEL 500 VOICE ACTIVATED INTERCOM Based on the input of experienced pilots, the David Clark Company designed and engineered the all-new, noise-free DC-Com Model 500 Voice-Activated Intercom...the only intercom specifically designed to satisfy the complex needs of today’s pilots. fering many features exclusive to the DC-Com Model 500 Voice-Activated Intercom, the highly flexible, state-of-the-art unit provides total ‘communication freedom for pilot, copilot and passengers. ‘The DC-Com Model 500 is sized to fit into the instrument panel or bracket mounted, horizontally or vertically. Solid-state electronics and 5-year guarantee ensure years of dependable service. aFEATURES 00 cou Ad iia ft 8 ee ru Catt pear @) i oe) ee 1. VOLUME AND SQUELCH CONTROLS Pilot has own volume and squelch control, while passengers and copilot have a separate volume and squelch control. x AUX. (AUXILIARY) / STEREO INPUT The intercom has two AUX. inputs. One is accessible at the rear of the unit, the other on the front panel of the unit. The input at the rear is for hardwiring to a permanent auxiliary source. The front input is for plugging, inportable tape or CD players or other auxiliary sources and takes priority ‘over the rear input. ee RADIO/CREW/ALL SWITCH Pilot, copilot, and passengers can be isolated from each other in various combinations of talking, hearing AUX. inputs, and using com radios. 4. DUAL-COLOR LED Green (power on) and red (transmit); red is illuminated when a Push-To- Talk switch is activated for external transmission. 5. COM 1/COM 2/COM 3 SWITCH Provides pilot and copilot the ability to monitor two different com radios simultaneously or independent. PLUS..... THESE ADDITIONAL FEATURES ACCOMMODATES UP TO 6 PLACES Each place (aviation headset) has its own independent VOX circuit; the individual mics are on only when speaking, while the others remain silent (off) cutting down on background noise. VOX OVERRIDE Full clockwise rotation of the Pilot and Copilot Squelch knobs overrides the VOX feature and provides an open microphone circuit (hot mic) for inter- cabin communication. PRIORITY TRANSMISSION ‘The DC-Com 500 is shipped preset at the factory to allow Pilot Priority of transmission which mutes the copilo’s transmissions. ‘An internal switch is provided (see Relay Board, Pilot Priority/No Priority Switch Location drawing and Disassembly drawing) that, when reset, will allow both pilot and copilot to transmit and receive simultaneously. TRUE STEREO SYSTEM The unit is factory set for mono at all locations. True stereo, with left and rightchannels at any location, is accomplished during installation by resetting jumpers within the unit. Frequency response 20 Hz to 10 KHz. OPTIONAL ATC/AUX SWITCHES The DC-Com Model 500 has built into it the muting of AUX. upon com radio reception. To override this feature, add optional ATC/AUX. switches (not supplied) external to the DC-Com 500. In the ATC mode, the com radio reception mutes the AUX.; in the AUX. mode, com radio reception is heard in addition to the AUX. TRUE FAIL-SAFE DC-Com 500 has a built-in Fail-Safe. If power is removed from the unit or the unit is tured off, the Fail-Safe is automatic. In Fail-Safe, the pilot is connected directly to the COM 1 port of the intercom. There is no inter- cabin communication when the unit is in Fail-Safe mode. GUARANTEE DC-Com 500 Aircraft intercom is made in the U.S.A. and carries our standard 5-Year Guarantee, backed by David Clark Company's “unbelievable” customer service policy.POWER REQUIREMENTS SPECIFICA TIONS #1130 VOC SUPPLY CURRENT ‘+ 200 mA max with 6 headsets, OUTPUT POWER ‘© 50mW (per headset) TEMPERATURE RANGE #30 deg F to +150 deg F CONTROLS * Three position mode switch * Locking three position Com switch * Pilot volume and On/Off switch * Pilot squelch control '* CopilotPassenger volume control * Copilot/Passenger squelch control * Sidetone Adjust for two com radios + Equalization Adjusts for two com radios * Level Adjusts for left and right AUX. inputs * Internal jumpers for selectable Pilot/Copilot/Passenger mono or stereo * Internal Pilot Priority/No Priority switch INDICATORS ‘= Bicolor LED: green indicates power on, red indicates transmit INPUTS Up to 6 standard carbon equivalent microphones '* Two AUX. inputs, pins in back connector, or jack on front panel + Two com radios or audio panels * Optional external Pilot ATC/AUX. select switch * Optional external Copilot ATC/AUX. select switch + Three EXT inputs: one each for Pilot, Copilot, and Passengers © Pilot PTT * Copilot PTT ourPuTs. Up to 6 standard aviation headsets ‘Two com radios or audio panels WEIGHT 15 02. DIMENSIONS * Height 1.705 in. fdth 2.795 in, * Length 6.125 in. (excluding front panel and rear connectors) 5INSTALLATION INSPECTION Unpack the equipment and visually inspect it for shipping damage and report any such damage to your dealer. Inspect the contents to make sure each unit, has the following items: DC-COM Model 500 Operation and Installation Manual (This document) Warranty Card (Pullout Section in Manual) ‘Mounting Kit P/N 40318G-01 Consisting of: 11 ea, bracket ea. #6 screws 4 ea, lock washers 5. Connector Kit P/N 40319C-01 Consisting of: 1 ea. male connector DBM25?. 11a, female connector DBM25S 2 ea, back shells M85049/48.3-3F 2 ea. packs of screws and nuts for cable strain relief on the back shells. 4ea, screws for fastening the connectors to the unit Beep Report any shortage immediately to your dealer or the David Clark Co. Inc., ‘Attn, Customer Service Warnines/CauTions: * Do not position this equipment next to any other equipment with strong alternating magnetic field such as motors, blowers, and inverters. Audio interference may result. © Do not bundle any wire going to or from this unit with any other wires, especially wires going to transmitters, 400 Hz synchro wiring, or AC power lines. ‘© Use shielded cable as shown on the Panel Wiring diagrams and described ‘on page 7 (Cabling). Ground exactly as shown. Failure to do so may cause Unacceptable levels of crosstalk, hum, or ground loop noise. ++ When disassembling the unit, be sure to remove the black nylon screw on the left side of the unit. Failure to do so will cause damage to Q3 on the Relay Board when you try to remove the boards from the case. Damage to Q3 will cause the unit not to work. + When opening the unit on the bench, do not over flex the 30 wire ribbon cable connecting the two main boards together. Over flexing the cable will cause the leads to break where they enter the board. ‘+ When reassembling the unit, ensure that the insulator is in place between Q3 of the Relay Board and the case. Not having this insulator in place will damage the unit. 6‘SETTING OPTIONS STEREO/MONO- If the installation is a mono installation, no changes need to be made. The unit comes from the factory set for mono at all locations. To wire for mono, use the left channel audio outputs for all stations. Ifthe installation is to be stereo at any location, jumpers must be set within the unit. (See Disassembly drawing and the Logic Board Jumper Location drawing.) The DC-COM Model 500 allows for stereo to be available for some stations and not others. You can set the pilot for stereo, but all other stations for mono; or the passengers to be stereo, but not the crew. Three jumpers are located on the Logic Board. (See Logic Board Jumper Location drawing.) For pilot stereo, move jumper J6 from 1+2 to 2+3. Wire stereo jack at pilot position. For copilot stereo, move J3 from 1+2 to 2+3. Wire stereo jack at copilot position. For passenger stereo, move J4 from 1+2 to 2+3. Wire stereo jacks at passenger positions. PILOT PRIORITY/NO PRIORITY ‘The DC-COM Model 500, as it comes from the factory, has Pilot Priority of transmission. If the pilot is transmitting, the copilot can not transmit; if the pilot wishes to transmit, he can preempt the copilot’s transmission. I you wish to have No Priority on transmit, ie., the pilot and copilot can transmit simultaneously, you must set the switch on the Relay Board. (See Relay Board, Priority/No Priority Switch Location drawing and the Disassembly drawing.) The switch must be moved from the position itis shipped in to the rearward position marked No Priority on the Printed Circuit Board This option is recommended for dual audio panel wiring only. PILOT AND COPILOT ATC/AUX SWITCHES The DC-COM Model 500 has built into it the muting of AUX. upon.com reception. If you want to override this feature you may add switches, external to the unit, that will bring pin 1 of the Logic Board connector for the pitot and pin 2 of the Logic Board connector for the copilot to GND. (See Single and Dual Audio Panel Wiring drawings.) CasLinc All wiring should be at least 24 AWG, except power and ground which should be at least 22 AWG. Shielded wire must be used on all input lines and is recommended for use on all lines. Ensure that ground connections are clean and secure, and do not share electrical paths with other equipment that may cause noise on the system, e.g., fans, 400Hz synchro, or inverters. Power should be provided through a 1 amp circuit breaker or slo-blo fuse.Mecuawicat Mounting ‘The DC-COM Model 500 can be mounted through the panel or under the panel with the bracket provided. tan be mounted horizontally or vertically with the face plate reversed. (See Page 9.) For through-the-panel mounting, place the drilling template on the desired location on the panel and drill through the locations indicated. The appropriate hole sizes are shown on the drilling template. Remove the knobs, ruts, screws, and lock washers from the face plate. Remove the face plate and enlarge the stereo jack hole from 17/64" to 1/2". Slide the controls through the holes in the panel and reinstall the front panel. Mount case to aircraft panel and fasten 4 ea. #6 screws with lock washers; torque to 8 in/Ibs. to secure. Replace the washers, nuts, and knobs. Forbracket mounting, mount the bracket to the desired location in the aircraft. Fasten the bracket to the sides of the case with 4 ea. #6 screws with lock ‘washers and torque to 8 inJ/ibs. Levet ADJUSTMENTS: RADIO EQUALIZATION To equalize the receive audio level, start with the unit turned OFF. Adjust the volume of the radio connected to the COM 1 input for a comfortable level in the pilot headset. Turn the unit ON. Adjust the radio equalization for radio 1 on the intercom so that you hear the same level with the ur n or off. Set the volume control for the other radio at the same position and the radio equalization for radio 2 at the same position. (See Side Level Adjustments drawing) SIDETONE lf the radios provide sidetone, then the unit should have its sidetone turned off. This is done by turning the appropriate potentiometer counterclockwise. Gee Side Level Adjustments drawing.) If the radio does not provide sidetone, turn the corresponding potentiometer clockwise to obtain a comfortable level of sidetone. (See Side Level Adjustments drawing.) ‘AUX LEVEL ‘The DC-COM Model 500 AUX. input is designed for line level signals, but may be adjusted for higher or lower levels. (See Side Level Adjustments drawing.)DRAWINGS SIDE LEVEL ADJUSTMENTS RADIO, SIDETONE RADIO. SIDETONE, EQUALIZATION “ADJUST EQUALIZATION “ADJUST (Radio 1) (Radio 1) (Radio 2) (Ratio 2) = i |__orwrores 5 ——— AUX LEVEL, AUX LEVEL MOUNTING (fight) (lek) ‘SCREWS PANEL MOUNTING FRONT PLATE CASE. oy acrart——— | PANEL BRACKET MOUNTING AIRCRAFT PANELRELAY BOARD PRIORITY/NO PRIORITY SWITCH LOCATION é 2 6 ‘SHOWN IN PRIORITY POSITION Hulse Boe eld |e Calvan ale, 8 ras eat og Hise See | Eee Tools \eevsjoume| {Tes _}++ rsa [2 eesoee oF [eee = 4ntzp—41 Rev 1 0 2220000000000 4 4OPC0000C0000 10LOGIC BOARD JUMPER LOCATIONSREAR VIEW RELAY BOARD PIN OUT MALE CONNECTOR (PINS) EXTERNAL PIN VIEW 1 - COM1 AUDIO 9 - COPILOT MIC 18 - COPILOT PTT 2 - COM2MIC 10 - PASS 4 MIC 19 - COM 2PTTLO 3 - COMI MIC 11 = PASS 3 MIC 20 = COM2MICLO 4 POWER GRND 12 - PASS 2 MIC 21 - COM1PITLO 5 - + POWER 13 - PASS T MIC 22 - COM 1 MICLO 6 - POWER GRND 14-PILOTAUDIOR 23 - COM2 PTT 7 -MICCOM(GRND) 15- PILOTAUDIOL = 24 - COM 1 PTT 8 - PILOT MIC 16 -N/C 25 - COM2 AUDIO 17 - PLOT PTT O° Oo Oo oO 1 - PILOTATC/AUX SW 10 - PASS EXT IN 19 - PILOT AUDIO 2 = COPILATCIAUXSW 11 - GRND. COM (GRND) 3 - AUXL 12 - GRND 20 - GRND 4 = AUXCOM(GRND) 13 - GRND. 21 - PASS AUD L 1/3 5 - AUXR 14 - GRND 22 - PASS AUD L 2/4 6 - GRND. 15-COPILAUDIOL —_23 - PASS AUDIO 7 - GRND. 16 - COPIL AUDIO COM (GRND) 8 - PILOT EXT IN ‘COM (GRND) 24 - PASS AUD R 1/3 9 -COPILOTEXTIN _17-COPILAUDIOR —25 - PASS AUD R 2/4 18 - GRND LOGIC BOARD PIN OUT FEMALE CONNECTOR (SOCKETS) EXTERNAL PIN VIEW 12BLOCK DIAGRAM oe hod |_6 vamos owouy OK cour coredSINGLE AUDIO PANEL WIRING PLTAUDIOL PLT AUDIOR PLTAUDIO COM COPLT AUDIOL COPLTAUDIOR COPLT AUDIO CoM PASS AUD 1/3 PASS AUD 2/4 PASS AUD 1/3 R PASS AUD 2/4R PASS AUDIO COM vosicso | 24 pour | 38 suraronuxsw | 1 5] Seutarenuesw | 2 ae" e geo | Be owe 7 more | 8 [Ue exraraneTne Lever nPUTSTOENGH comorextin | 8 FATS [Recrecnve rom crane rier axe NOT AfseoteD y tae sabioonEWnlL Sito axe |s bY A [ouRUTRGAT ARE |S oureur ts? Akeow | $ RF Sotanon MATING MALE ‘ MeO AN Pot convecTory [CONNECTOR DBM.25° 14Dc-COM MODEL 500 SINGLE AUDIO PANEL WIRING [SUGGESTED WIRING FORA COMPLETE STEREO | [ FOR MONO HDPH [SYSTEM AND ONE AUDIO PANEL Repiace STEREO €-cOM 500 USE SHIELDED WIRE ON ALL AUDIO LINES. OPH JACKISWITCH. (TERCOM UNIT CONNECTOR KIT er gewesne PIN 409196-01 = oc-com tt90v0e ene MALE CONNECTOR| EXISTING renmmcon ie 5 44. AIRCRAFT : 4 sacks | auDIo . Y PANEL 3 2 ty 4 Mic mic 2 2 rey Mickey come 2 » o PHONES IPHONES. | RADIO 2 2 eno {com GND 2 ine Reaver | 2 a Z ImcKer |cone pwour |B 2 pac ee | cone, 3 2 [cow cn. 7 a CoPiLoT Mic. Mic com 7 PASSi MIC PASS2MIC PASS3MIC. PASSAMIC. 15DUAL AUDIO PANEL WIRING So a TESA ETAT 44 | [PLTAUDIOR 4 10 | [Petauoiocom [19 15 | |coptraunio | a5 17 | |coptrauiorn | 17 16 | |coptraupiocom | 16 a | |passauoisr | 21 2 | |passauozar | 22 None <— tosicso | 24 | |passauoiar | 24 cscs 25 | |passau24R | 25 ‘See Foe fone pour | 23 | |passauoiocom | 23 5 PLT ATCIAUX SW CPLTATCIAUX SW “GRND isl Sole oe aah 1 2 6 canon | 7 PILOT EXTIN aa! 8 1 » COT ARETRETEVET BUTE TOES coruoresrin | 8, FETS [REcrachwe nore CHnaneL TY ORE nor eeeeree 0 AFFECTED BY THE RADIO/CREWIALL SWITCH. wuce | s Sop axe | § Ef CylSireurcer Abou | 3 esti ARONRED ADK) 16DC-COM MODEL 500 DUAL AUDIO PANEL WIRING [SUGGESTED WIRING FOR A COMPLETE STEREO SYSTEM AND TWO] | FOR MONO HOPH REPLACE [AUDIO PANELS. USE SHIELDED WIRE ON ALL AUDIO LINES. STEREO HDPH JACKISWITCH po-con $00 WITH MONO JACKAS INTERCOM UNIT ‘CONNECTOR KIT SHOWN. me Pm 403196-01 won 1130voe rosin one PANEL [—[COMt PHONES |—]COM 2 RELAY 8D PIN OUT. KEY coms ral oO 10) BBY R-Re Aupio |—|¢om2, 2 1 8 1 8 7 aeDISASSEMBLY OF UNIT @OPERATION Pitot VotumeSauetcH/On/Orr The pilot has control of his volume through the smaller of the two knobs on the let side of the unit. This knob is also the ON/OFF switch for the intercom. Full counter-clockwise rotation of this knob turns the intercom off, and puts it into Fail-safe mode. In Fail-safe, the pilot can stil use the radios, but there is no inter-cabin communications via the intercom. The larger of the two knobs is the PILOT SQUELCH. This controls the level at which the pilot’s VOX turns on the pilot’s mic. When the squelch is set properly you should be able to talk at a comfortable level and have the microphone turn on without clipping the first syllable. When not speaking, the microphone should turn off, after about one second, cutting down on the level of background noise entering the system. —Copior/PASsENGER VotumE/SQUELCH (On the right side of the intercom are the COPILOT/PASSENGER VOLUME and SQUELCH controls. The smaller knob is the VOLUME control which sets the volume for the copilot and all of the passengers. If your headsets have volume controls, then the best way to set volume is to turn the intercom volume up high and then adjust each headset volume for the desired level If your headsets, do not have volume controls, then you can just set the to a comfortable level. The larger of the two knobs is the COPILOT/PASSENGER SQUELCH control. See the PILOT VOLUME/SQUELCH/ONIOFF section for a description and setting recommendations. Raoio/CREWALL SwitcH ‘The RADIOICREWIALL switch isolates the pilot, copilot, and passengers. In ALL mode, the pilot, copilot, and passengers can talk to and hear each other. Everyone can hear the AUX. and everyone can hear com radio reception. The AUX. will be muted upon com radio reception if the optional ATC/AUX, switches have not been installed. The pilot and copilot can both transmit. Only the pilot and copilot microphones will be connected to the radio, Only what they say will go out over the radio. In the CREW mode, the pilot and copilot are isolated from the passengers. ‘The passengers can talk to and hear each other but cannot talk to or hear the pilot and copilot. The passengers still hear the AUX., but do not hear the ‘com radios. The pilot and copilot can talk to and hear each other but do not hear the passengers. The pilot and copilot do not hear the AUX. The pilot 19Ranio/CREwALL SWITCH cow. and copilot can receive and transmit over the com radios. In the RADIO mode, the pilot is isolated from the copilot and the passengers. The copilot and the passengers can talk to and hear each other but cannot talk to or hear the pilot. The copilot and the passengers hear the AUX., but do not hear the com radios. The copilot cannot transmit in this mode. The pilot cannot talk to or hear the copilot or passengers. The pilot can transmit and receive the com radios. Com 1/Com 2/Com 3 SWITCH ‘The locking COM 1/COM 2/COM 3 switch allows the pilot and copilot to monitor and transmit over two different radios at the same time. (See Single ‘Audio Panel Wiring drawing for this discussion.) In Com 1, the pilot and copilot are connected to the COM 1 port of the intercom. ‘Both the pilot and the copilot transmit and receive through the ‘Audio Panel. Whatever is selected on the Audio Panel will be heard; the transmit will also be selected on the Audio Panel. In the Com 2 position, the pilot is connected to the COM 1 port of the intercom, and the copilot is connected to the COM 2 port. The pilot will hear and transmit through the Audio Panel. The copilot will now be connected directly to the Com 2 radio and transmit and receive through it. This allows the pilot to monitor ATC while the copilot can use the other radio. The pilot and copilot can still talk to and hear each other depending on the position of the RADIO/CREW/ALL switch. In Com 3, the pilot and the copilot are both connected to the Com 2 radio and do not hear or transmit through the Audio Panel. AUX Inpur- ‘The DC-COM Model 500 has two AUX. inputs. One is accessible at the 25 pin Logic Board connector on the rear of the unit. The other is located on the front of the unit. The input on the back of the unit is meant for hardwiring toa permanent AUX. source. The input on the front of the unit is for plugging in portable CD players or other AUX. sources. The input on the front of the unit takes priority over the input in the rear. 1f-you plug a source into the front, that source will be heard instead of the rear source. 20‘Pi.or Priority/No Priority ‘The DC-COM Model 500 comes from the factory set for Pilot Priority. When the pilot presses his PTT he takes priority over the copilot. The copilot will be cutoff if he is transmitting, or he will not be allowed to transmit while the pilot is transmitting. f you wish to allow the pilot and co at the same time, you must set the Pilot Priority/No Priority switch to the No Priority position. (See Setting Options, page 7.) This option is recommended for dual audio panel wiring only. FAIL-SAFE ‘The DC-COM Mode! 500 has a built in Fail-Safe. If power is removed from the unit, or the unit is tumed Off, the fail-safe is automatic. In Fail-safe, the pilot is connected directly to the COM 1 port of the intercom. There is no. inter-cabin communication through the unit in FailSafe mode. 21FINAL CHECK Ater the installation is complete, check the function of the unit to ensure that it performs in accordance with Operation section (Pg.19). Check to ensure that all microphones can talk and all headsets can hear. Check the Failsafe by removing power from the unit and working the radio. Check the function of the RADIO/CREW/ALL switch and the COM 1/COM 2/COM 3 switch. Check to make sure AUX. is present and that it mutes on radio reception (if ATC/AUX. switches have not been installed), Start and or fly the aircraft to ensure that the level settings are correct for the level of noise expected in the aircraft during flight. Ensure that all screws for mounting the unit and the connectors are secure. Ensure that all wiring has been secured so as not to fail due to vibration. neTROUBLESHOOTING The first step to troubleshooting is to check the wiring. Check to insure that the wiring is in accordance with the wiring diagrams. Ring out all lines to ensure that they are correctly connected. Check to make sure that all ‘connections are secure, No Power On Indicator * Power not present at pin 5 of Relay Board connector. * Ground not present at pin 6 of Relay Board connector. * Unit not turned on. * Fuse not installed in power line. No Audio * Not using Audio Left for Mono installation. * Stereo/Mono Jumper not set properly. * Volume on headset or intercom not set properly. No Microphone * Vox daughter boards in the unit were loosened or became unplugged during setting of options. * Squelch Controls not set properiy. Noise On System * Squelch controls not set properly. * Wires routed with other aircraft wires. * Wires routed too close to other aircraft wiring. * Wires or unit too close to noisy equipment or equipment with strong electromagnetic fields. * Wires or unit too close to antenna. * DC power line needs to be filtered. * Intermittent connections. No Com Audio or Transmission ‘+ Bad connection between intercom and audio panel or radios. ‘Audio panel not set properly. * Com radio not set properly. * Side level Adjustments not set properly. 23GUARANTEE The DC-COM Model 500 Aircraft Intercom is made in the U.S.A., and carries our exceptional § year guarantee, backed by the David Clark Company's “unbelievable” customer service policy. ce Poa ce . David) Clark comeany INCORPORATED 19514-22 (07-85) (01995 David Clark Company ncorpraodDRILL TEMPLATE rw y o Snr © Brew @HOLES OSTHRU 4HOLES