AEM SM95-766 AA95-766 User manual

SPECIAL NOTICE
This product is now licensed to Anodyne Electronics Manufacturing (AEM) from Northern
Airborne Technology (NAT). AEM is responsible for all matters related to this product, including
sales, support and repair services.
Please note the transition to convert product manuals and supporting documentation is an
ongoing process and is being addressed on an ‘as needed’ basis.
All references to NAT product part numbers (and associated images) are equivalent to AEM
product part numbers.
Contact info:
Anodyne Electronics Manufacturing Corp.
#15-1925 Kirschner Road
Kelowna B.C. Canada
V1Y 4N7
Email: [e-mail]
Toll Free: 1-888-763-1088
Phone: [phone]
Fax: [phone]
www.aem-corp.com

CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
INSTALLATION AND OPERATION MANUAL
REV 3.00 June 20, 2012
Anodyne Electronics Manufacturing Corp.
15-1925 Kirschner Road
Kelowna, BC, Canada
V1Y 4N7
Telephone [phone]
Facsimile [phone]
Website: www.aem-corp.com
© 2012 Anodyne Electronics Manufacturing Corp. (AEM),
All Rights Reserved
SM95-766
AA95
-766
Single Channel Audio Controller

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
Installation and Operation Manual Page ii
ENG-FORM: 820-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
COPYRIGHT STATEMENT
© 2012 Anodyne Electronics Manufacturing Corp. (AEM), All Rights Reserved.
This publication is the property of AEM and is protected by Canadian copyright laws. No
part of this document may be reproduced or transmitted in any form or by any means
including electronic, mechanical, photocopying, recording, or otherwise, without the
prior written permission of AEM.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
Installation and Operation Manual Page iii
ENG-FORM: 820-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Prepared By:
Checked By:
Approved By:
The status of this installation and operation manual is controlled by the revision 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.
AEM MANUAL REVISIONS
Section
Revision Number
Revision Description
Date
All
Rev: 3.00
Updated drawings and template
Jun 20, 2012
Tony Pearson
Designer
Jun 20, 2012
Loen Clement
Designer
Jun 26/12
Tom Betzelt
Product Support
Manager
June 26, 2012

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
Installation and Operation Manual Page iv
ENG-FORM: 820-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Table of Contents
Section Title Page
1.0 Description
1.1 Introduction 1-1
1.2 Purpose of Equipment 1-1
1.3 Features 1-1
1.4 Specifications 1-2
1.4.1 Electrical Specifications 1-2
1.4.2 Physical Specifications 1-4
1.4.3 Environmental Specifications 1-4
2.0 Installation
2.1 Introduction 2-1
2.2 Unpacking and Inspection 2-1
2.2.1 Warranty 2-1
2.3 Installation Procedures 2-1
2.3.1 Warnings 2-1
2.3.2 Cautions 2-1
2.3.3 Cabling and Wiring 2-2
2.3.4 Adjustments 2-2
2.3.5 Mechanical Mounting 2-3
2.3.6 Post-Installation Checks 2-3
2.3.7 In-line PTT Cordsets 2-4
2.4 Continued Airworthiness 2-6
2.5 Accessories Required But Not Supplied 2-6
2.6 Installation Drawings 2-6
3.0 Operation
3.1 Introduction 3-1
3.2 General 3-1
3.3 Controls and Indicators 3-1
3.3.1 Receive Audio Select Switches 3-2
3.3.2 Transmit Selector Switch 3-2
3.3.3 ICS Functions 3-3
3.4 Emergency Operation 3-4
3.5 Direct Audio 3-4

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 1-1
ENG-FORM: 800-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Section 1.0 Description
1.1 Introduction
This manual contains information on the AA95-766 Single Channel Audio Controller. Information in this
section consists of purpose of equipment, features and specifications.
1.2 Purpose of Equipment
The AA95-766 is a Dzus mounted audio panel with built in intercom and lighted faceplate. The unit provides
full headset transmit (TX), receive (RX) and intercom (ICS) functions for the pilot and co-pilot users. Only
intercom and receiver audio are provided for passengers. The front panel controls permit user adjustment of
frequently needed signals.
The users have control of five transceiver positions, six receiver inputs, and one PA output. The unswitched
inputs are direct audio and tape player.
The AA95-766 supports only one lo-z mic input and five hi-z mic inputs per box. All phone outputs are hi-z.
Connection to other stations in the system is made through the ICS Tie line. The AA95-766 is plug compatible
with most AA95 and AMS40 series AEM audio panels.
The small size and extensive radio and ICS functions make this unit an excellent choice for multi-station
aircraft.
1.3 Features
Transceiver interfacing for the AA95-766 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.
The ICS tie line is fully compatible with other AEM systems including the AA80, AA82, AMS4X and AA9X
series units.
Boom mic support is provided for the pilot and co-pilot, with both ICS and TX functions via cyclic or yoke
switching. The AA95-766 has a built-in dynamic microphone amplifier for an M87- type mic. The Live
(Hot Mic) and VOX ICS functionality allow immediate transmission via these modes without further control
panel switching, and immediate return to ICS operation on completion. The ICS 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 voice band
information.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 1-2
ENG-FORM: 800-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
All audio, except the S/T of the radio in use and the DIRECT AUDIO input signal, 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 replays are sealed. G10-FR flame retardant circuit boards are postcoated for maximum moisture
resistance and corrosion prevention. Relays are sealed, high vibration rated (50 g shock), dry nitrogen
filled units.
1.4 Specifications
1.4.1 Electrical Specifications
Input Power Reverse and over-voltage protection provided.
Voltage 27.5 Vdc Nominal 0.50 A max.
Lighting 27.5 Vdc @ 160 mA
Input Signals Channels 5 aircraft transceiver radio inputs
6 navigational receiver inputs
1 direct audio input (Type ‘E’)
2.5 Vrms/10 mW input signal for full headset output
1 kΩinput impedance
Type ‘E’ Input
Direct channel Freq. Response ±6 dB from 370 to 2800 Hz
Distortion 1% THD max
Isolation/crosstalk 65 db min
Rated Level Direct Audio 10 mW (10 dBm) into 600 Ω
Signal/noise ratio 67 db min. Or less than 5 mV into 600 Ω
Quantity 13 receive channels
7 mic channels
Audio level 2.5 Vrms for receiver inputs
0.25 Vrms for co-pilot and passenger mic inputs
0.25 mVrms for pilot mic input
2.5 Vrms for direct audio input

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SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 1-3
ENG-FORM: 800-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Impedance 1 kΩ±10% for receive inputs
1kΩ±10% for co-pilot and passenger mic inputs
(150Ωamplified dynamic Industry standard ‘carbon
equivalent’ type. 250 mVrms for rated output)
5±1Ωfor pilot mic input (5 Ωdynamic Military M87
or equivalent, 0.1 to 1.0 mVrms 250 uVrms for
rated output)
1.3 kΩ±10% for Direct Audio input
Circuitry Type All are single ended inputs.
Coupling <-50 dB
Key lines Pilot & co-pilot transmit PTT
Rear hand mic transmit PTT
Pilot & co-pilot ICS PTT
Output Signals: Quantity 6 Headphone outputs
6 Transmitter mic outputs
5 Transmitter keyline outputs
Headset Rated level 12.3 Vrms or 250 mW (24 dBm) into 600 Ω
Circuitry Type Single-ended, except for phones, which are
balanced.
Freq. Response
Sidetone <6 dB from 370 Hz to 2800 Hz
Receive inputs <6 dB from 370 Hz to 2800 Hz
Intercom <6 dB from 350 Hz to 2800 Hz
Distortion <10% THD+N @ rated power output
Audio Noise Level >50 dB down from rated output (no signal)
Coupling <-50 dB
Output Regulation at 400% <10% distortion / ∆3 dB max of rated output power
and 75% of rated load.
Keylines Transmit key is active low
Intercom keyline is active low

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SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 1-4
ENG-FORM: 800-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Bi-directional Signals:
Quantity One NAT ICS tie channel
Audio level 0.34 Vrms
Impedance 1.8 kΩ±10%
Circuitry Type Single ended
Miscellaneous: Annunciators Green LED will light for transmit operation
1.4.2 Physical Specifications
Height 1.91" (48.5 mm) max.
Depth 7.05” (179.1 mm) max. behind panel
Width 5.78" (146.8 mm) max.
Weight 2.1 lbs (1.0kg) max. excluding harness and mating
connectors
Mounting Standard Dzus rails
Connectors One male 50-pin and one male 37-pin D-min connector
1.4.3 Environmental Specifications
Operating Temp -40qC. to +70qC
Survival Temp -55qC. to + 85qC
Vibration/Shock DO-160B category “P”, panel mounting 6g.
Humidity 95% Non-condensing
Altitude 35,000 feet
End of Section 1.0

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-1
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Section 2.0 Installation
2.1 Introduction
Information in this section consists of: unpacking and inspection procedures, installation procedures,
post-installation checks, and installation drawings.
2.2 Unpacking and Inspection
Unpack the equipment carefully. Inspect the unit visually for damage due to shipping and report all such
claims immediately to the carrier involved. Note that each unit should have the following:
- AA95-766 Single User Audio Controller
- Product Information Card
- Certificate of Conformity
Verify that all items are present before proceeding and report any shortage immediately to your supplier.
2.2.1 Warranty
All Anodyne Electronics Manufacturing Corp. (AEM) products are warranted for 2 years. See the website
www.aem-corp.com/warranty for complete details.
2.3 Installation Procedures
2.3.1 Warnings
Do not bundle any lines from this unit with transmitter coax feed lines. Do not bundle any logic, audio, or
DC power lines from this unit with 400 Hz synchro wiring or AC power lines. Do not position this unit next
to any device with a strong alternating magnetic field such as an inverter, motor or blower, or significant
audio interference will result.
2.3.2 Cautions
In all installations, use shielded cable exactly as shown, and ground only as indicated. Significant
problems may result from not following these guidelines.
All audio installations can be seriously degraded by incorrect wiring and shielding, which may result in
abnormal cross-talk, hum and ground-loop noise. Be particularly careful with all microphone wiring and
tie line wiring, as these lines carry the lowest level signals in the aircraft.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-2
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
2.3.3 Cabling and Wiring
All unshielded wire shall be selected in accordance with AC43.13-1B Change 1, Paragraphs 11-76
through 11-78. Wire types should be 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 wiring diagrams in Section 2.6 as required.
Allow 3 inches from the end of the wire to the shield termination to allow the hood to be easily installed.
Note that the hood is a ‘clamshell’ hood, and is installed after the wiring is complete. Aircraft harnessing
should permit the unit to be lowered from the panel for easy access to all side adjustments. Do NOT
mount the unit until all adjustments have been carried out.
All wiring should be at least 22 AWG, except power and ground lines, which should be at least 20 AWG.
Ensure that all ground connections are clean and well secured, and that the unit shares no path with any
electrically noisy aircraft accessories such as blowers, turn and bank instruments or similar loads. Power
to this unit must be supplied from a separate breaker (1 A) and not attached to any other existing breaker
without additional protection.
2.3.4 Adjustments
The unit ships 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 as follows:
2.3.4.1 Right Side Panel Adjustments
The ICS GAIN LEVEL trimpot adjusts the internal gain of the intercom.
The MIC LEVEL trimpot is used to adjust the audio level of the pilot microphone.
2.3.4.2 Left Side panel adjustments
The trimpots on the left side panel are used to adjust the levels of audio in the user’s headphones. Rotating the
trimpots clockwise (cw) increases the level, and counterclockwise (ccw) reduces it.
The DIR AUD LEVEL trimpot is used to adjust the level for the Direct Audio signal.
The S/T LEVEL trimpot adjusts the internal gain of the sidetone of the selected transceiver (from the front
panel).
DIR AUD
LEVEL
S / T
LEVEL
VOX
LEVEL
ICS GAIN
LEVEL
MIC
LEVEL

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SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-3
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
The VOX LEVEL trimpot sets the sensitivity level for the front panel VOX control (the level of audio
required to activate microphones).
2.3.5 Mechanical Mounting
The AA95-766 may be mounted vertically or horizontally in standard Dzus rails.
Before the unit is mounted, make all functional tests and trimpot adjustments. Be sure the harness has
enough clearance to permit the unit to be pulled out for re-adjustment, if needed later. Make sure unit is
securely fastened to the Dzus rail, and that the connector locks are tightened before any flight is
attempted.
2.3.6 Post-Installation Checks
If any preset requires adjustment, be sure this is carried out before the aircraft leaves, and that the unit
and its mating connector are secured before departure.
2.3.6.1 Voltage/Resistance Checks
Do not attach the AA9x series until the following conditions are met.
Check the following:
a) P101 pin <17> for +28 Vdc relative to ground.
b) P101 pin <34> for continuity to ground (less than 0.5 :).
c) P101 pins <7> <8> <9> and <10> for continuity to ground (less than 0.5 :) when the relevant
switches are keyed.
d) P102 pin <19> for lights bus voltage (+28 Vdc) relative to ground.
e) Check all Mic, phone, music and key lines for shorts to ground or adjacent pins.
2.3.6.2 Power On Checks
Power up the aircraft's system with the unit installed, and turn on the radios and accessories required for
the system. Refer to Section 3 for operation and set-up information.
Start with only the pilot's headset installed (lo-z mic, hi-z phones). Check for correct ICS, radio, and
transmit 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 AA95-766 in Pilot ISO mode, then adjust the AA95-766 front panel RX master volume control
level in NORMAL mode.
Unusual buzzes, hums or other background audio are symptomatic of multiple grounds or noisy external
systems sharing the same wire bundle. Note that incorrect jack wiring is a common fault, especially for
passenger stations, and may cause loss of audio, a tone on the headset lines, or other problems. Failure
to key or correctly modulate a transceiver may be caused by missing grounds on the radio or audio
controller.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-4
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
Plug in the hand mic (if installed) and test for correct operation. (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.
Plug in the remaining headsets (hi-z mic, hi-z phones) and check for proper 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 2.3.7 below.
Note: Different headsets may have significantly different mic characteristics, which will affect VOX
squelch settings.
Check levels and operation of all functions in flight to ensure proper adjustments and settings have been
made.
Upon satisfactory completion of all performance checks, make the required log entries and
complete the necessary Regulatory Agency paperwork before releasing the aircraft for service.
2.3.7 In-line PTT Cordsets
2.3.7.1 General
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, ICS and TX keylines are needed to properly activate
the associated PTT circuitry inside the AA95-766. For headsets connected to the PASSENGER
inputs/outputs of the AA95-766, 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.
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 AA95-766, AEM 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 (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 the drawing below for details.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-5
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
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.
2.3.7.2 Cautions
Although in-line PTT cordsets can be used conveniently to 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 AA95-766 is floating, which will lead to incorrect keying
of the intercom and radio systems if this type of cordset is used.
In-line PTT cordsets can be a very real 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.

AA95-766 Single Channel Audio Controller
SM95-766 Installation and Operation Manual
June 20, 2012 Rev: 3.00 Page 2-6
ENG-FORM: 805-0100.DOTX
CONFIDENTIAL AND PROPRIETARY TO ANODYNE ELECTRONICS MANUFACTURING CORP.
2.4 Continued Airworthiness
Maintenance of the AA95-766 Single Channel Audio Controller is ‘on condition’ only. Periodic
maintenance of this product is not required.
2.5 Accessories Required But Not Supplied
Installation kit AA90-IKC (AEM Part # D50S37SL-IKC) is required to complete the installation. It consists
of one 50-Pin D-min Female Crimp Kit (D50SL-IKC) and one 37-Pin D-min Female Crimp Kit (D37SL-
IKC)
AEM Part #: D50SL-IKC
Quantity Description AEM Part #
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
AEM Part #: D37SL-IKC
Quantity Description AEM Part #
1 D-min 37 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.
2.6 Installation Drawings
DRAWING
REV.
DESCRIPTION
TYPE
AA95\766\403-0
1.03
Audio Controller
Interconnect
AA95\766\403-1
1.03
Audio Controller
Interconnect
AA95\766\403-2
1.03
Audio Controller
Interconnect
AA95\766\405-0
1.02
Audio Controller
Connector Map
AA95\766\905-0
1.10
Audio Controller (sheet 1 of 2)
Faceplate
AA95\766\922-0
1.00
Audio Controller
Mechanical Installation
Section 2.0 ends following above documents

2
TX
1
NORMAL
-766
AA95 43
LIVE
1
RX-ON
RX VOL
ICS VOL
5PA
NAV1
NAV2
ADF
MKR
KEY
ICS
VOX
2
TX
1
NORMAL
-766
AA95 43
LIVE
1
RX-ON
RX VOL
ICS VOL
5PA
NAV1
NAV2
ADF
MKR
KEY
ICS
VOX
ISOISO EMREMR
//
VOXVOX
Confidential and Proprietary to NAT