Audio international AI-ST100X User manual

7300 Industry Drive, North Little Rock, AR 72117
Phone: [phone] Fax: [phone]
www.audiointl.com
Installation Manual
AI-ST100X
Stereo Power Amplifier
Document # 540048
a DeCrane Aircraft Company

Audio International, Inc. AI-ST100X Installation Manual
Document # 540048, Rev A, 03/2002 Page 1 of 12
Document Revision History
Rev. Level Date Description
IR 10/1998 Initial Release
A 03/2002 Update Format
Reference Documents
Document # Description
80-621 Rev B AI-ST100X Outline Drawing
Service Bulletin List
Service
Bulletin # Subject Manual Revision Revision Date
Table of Illustrations
Section # Description Page #
2.2 Block Diagram – Typical Application 4
2.3 Auxiliary Power 5
6.0 Reference Drawings 11-12
PROPRIETARY NOTICE: Despite any other copyright notice, this document and information
disclosed herein contains confidential, proprietary designs owned by Audio International, Inc.
Neither this document nor the data contained herein shall be reproduced, used, or disclosed to
anyone without the written authorization of Audio International, Inc.

Audio International, Inc. AI-ST100X Installation Manual
Document # 540048, Rev A, 03/2002 Page 2 of 12
Table of Contents
Section Description Page
1.0 General Information …………………………………………. 3
1.1 Introduction …………………………………………………….. 3
1.2 Purpose of the Equipment …………………………………… 3
1.3 Optional Equipment …………………………………………… 3
2.0 Application ……………………………………………………. 4
2.1 Introduction…………………………………………………….. 4
2.2 Block Diagram –Typical Application………………………… 4
2.3 Auxiliary Power………………………………………………… 5
3.0 Installation ……………………………………………………. 5
3.1 Prior to Installation ……………………………………………. 5
3.2 Unpacking and Inspection ……………………………………. 6
3.3
Cautions & Warnings …………………………………………. 6
3.4 Wiring Requirements …………………………………………. 7
3.5 Physical Characteristics………………………………………. 7
3.6 Electrical Characteristics……………………………………… 8
3.7 Mating Connector Information ……………..………………… 8
3.8 Pinout Assignment Descriptions …………………………….. 9
3.9 Post-Installation Test …………………………………………. 9
4.0 Troubleshooting……….……………………………………... 10
4.1 General Troubleshooting Procedures ………………………. 10
4.2 Troubleshooting Chart………………………………………… 10
5.0 Specifications ………………………………………………… 10
6.0 Reference Drawings ………………………………………… 11
6.1 Top View………………………………………………………... 11
6.2 Front View………………………………………………………. 12
6.3 Rear View………………………………………………………. 12

Audio International, Inc. AI-ST100X InstallationManual
Document # 540048, Rev A, 03/2002 Page 3 of 12
AI-ST100X
Stereo Power Amplifier
1.0 General Information
1.1 Introduction
This manual contains information for the proper installation of the Audio
International, Inc. (AI) Stereo Power Amplifier, Model No: AI-ST100X.
Also included are physical and electrical characteristics of the unit.
1.2 Purpose of the Equipment
1.2.1 The AI-ST100X is a two (2) channel, 100 WRMS (50 WRMS per
channel) professional stereo power amplifier that delivers high
performance, excellent frequency response, and clear sound
quality. A ‘soft’turn ON feature is incorporated into the unit to
eliminate unwanted noise.
1.2.2 The unit takes and amplifies low-level audio signals to properly
drive loudspeaker systems. Left and right-channel potentiometers
for audio input level (gain) adjustment are located on the rear of the
unit.
1.3 Optional Equipment
Audio International, Inc. offers a comprehensive family of Cabin Control
Modules. These modules provide convenient solutions for a variety of
frequently encountered interfacing needs or special requirements and are
an important part of AI’s “building block”system for configuring total cabin
management.
Contact your AI representative for details.

Audio International, Inc. AI-ST100X Installation Manual
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2.0 Application
2.1 Introduction
2.1.1 The AI-ST100X is a two (2) channel, 100 WRMS stereo amplifier
(50 WRMS per channel). The unit takes low-level audio signals and
amplifies them to properly drive loudspeaker systems. The unit
delivers high performance, excellent frequency response, and clear
sound quality.
2.1.2 An externally accessible 5-amp fuse protects the two (2) output
channels. The fuse ports are located on the rear of the unit.
Replace with Littelfuse, fast blow, part number F123-ND, or
equivalent AGC-5.
2.1.2 Left and right-channel gain potentiometers are located on the rear
of the unit for audio input level adjustment. Turn the potentiometer
in a clockwise direction to increase signal and counter-clockwise to
decrease.
2.2 Block Diagram –Typical Application

Audio International, Inc. AI-ST100X Installation Manual
Document # 540048, Rev A, 03/2002 Page 5 of 12
2.3 Auxiliary Power
The auxiliary power supply converts incoming +28 VDC to +12 VDC. A
1.5-amp fuse at the rear of the unit protects this auxiliary power supply.
The fuse provides over-current protection against unit failures.
3.0 Installation
3.1 During the design and layout of the aircraft cabin, careful consideration of
the location of this module is necessary. Some of the items to be
considered include:
• Space
• Available power supply
• Environmental conditions (temperature, humidity, etc.)
• Length of cable runs
• Proximity to other devices (i.e. source equipment)
• Convenience for user interface (if applicable)
• Access for service repair (if applicable)
• Location of other aircraft systems (i.e. oxygen delivery)
3.1.1 The AI-ST100X shall be installed to conform to the standards
designated by the customer, installing agency, and existing
conditions as to the unit location and type of installation.
3.1.2 Mounting screws are required to secure the unit. Refer to
Section 6.0, Reference Drawings, for mounting hole diameters and
configuration.
3.1.3 The unit must be located as close to source equipment as possible.
Long low-level runs may introduce noise into the audio signal.
3.1.4 Locate the unit to allow ease in adjustments. Master gain
potentiometers are located on the rear of the unit and must be
accessible for system adjustments and periodic maintenance.

Audio International, Inc. AI-ST100X Installation Manual
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3.1.5 The purpose of the audio amplifier is to compensate for low-level
audio signals and amplify the signal to a high level. The amplifier
adjustments will be most effective when the interior is thoroughly
furnished and all pieces of furniture are in place.
3.2 Unpacking and Inspection
3.2.1 Carefully open the packaging and remove the AI-ST100X. Verify
that all components have been included in the package per the
packing list. Inspect the unit for damage. Retain the packing
materials and packing list.
3.2.2 If damage has occurred during shipping, a claim must be filed with
AI within 24 hours and a Return Request Authorization Number
must be obtained from AI. Refer to the front cover of this manual
for address and telephone number of Audio International.
Repackage the unit in its original packaging materials and return it
to AI following instructions given by the AI representative. If no
return is necessary, retain the packing materials for storage or
reshipment if necessary.
3.3 Cautions and Warnings
3.3.1 It is important to do a pin-to-pin power and ground check on all
connectors. Ensure that power and ground are applied only where
specified. Damage to the unit may result if power or ground is
applied to the wrong points.
3.3.2 The unit generates considerable heat. Allow a MINIMUM 1-inch air
space around the amplifier due to the amount of generated heat.
3.3.3 DO NOT remove any factory-installed screws. Damage to the unit
may result and void any warranties.
3.3.4 NO scheduled maintenance is required to ensure continued
airworthiness.
3.3.5 ESD (Electro Static Discharge) guidelines shall be followed.

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3.4 Wiring Requirements
3.4.1 Introduction
The installing agency shall supply and fabricate all external cables
and mating connectors. The length and routing of external cables
should be carefully studied and planned before attempting
installation of the equipment. Allow adequate space for installation
of cable and connectors. Avoid sharp bends and placing cables
near aircraft control cables. Maintain a minimum clearance of three
(3) inches from any control cable. If wiring is run parallel to
combustible fluid or oxygen lines, maintain a separation of six (6)
inches between the lines.
3.4.2 Power Wires
The amplifier power and ground wires (P2-A, B) shall be 16 AWG,
MINIMUM shielded twisted pair with the shield properly bonded at
one end only. Power ground wires shall be bonded to electrically
FRQGXFWLYH FKDVVLV PRXQWLQJ SRLQW ZLWK   UHVLVWDQFH RU  
impedance. Additionally, ensure that the chassis grounding post is
bonded to aircraft frame ZLWK UHVLVWDQFHRU LPSHGDQFH
All wires shall be in accordance with the standard military
specification of MIL-W-22759 or equivalent. Protect power wires
with circuit breakers or fuses located close to the electrical power
source bus.
3.4.3 Audio Lines
All audio lines require 22 AWG, MINIMUM,twisted shielded cable
with the cable shields grounded at the source. Twisted, shielded
cable shall be in accordance with the standard military specification
of MIL-DTL-27500 or equivalent.
3.5 Physical Characteristics
3.5.1 Refer to Section 5.0 for unit dimensions.
3.5.2 Refer to Section 6.0 for attachment points.
3.5.3 When mounting the unit, allow sufficient space for mating
connectors.

Audio International, Inc. AI-ST100X Installation Manual
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3.6 Electrical Characteristics
3.6.1 Electrical Specifications:
Electrical Power 5 amp MAXIMUM at +28 VDC,
continuous power output
Operating Voltage
Range +18 to +32 VDC +28 VDC, NOMINAL
Current
Consumption 2 to 3 amps, NOMINAL
Power Output 50 WRMS per channel
into 4
Audio Input
Level +200 mV to +2 VDC (adjustable)
Audio Input
Impedance 10 k
Speaker Load 4 , MINIMUM
Remote Turn ‘ON’
Input +28 VDC for amplifier operation
Outputs +12 VDC, 1 amp each
(Do not exceed total combined
current rating of 3 amps)
3.6.2 P1 provides left and right audio input, remote turn on input,
+28 VDC input for +12 VDC supply, and +12 VDC output.
3.6.3 P2 provides +28 VDC power input, ground, and left / right stereo
speaker output.
3.6.4 The auxiliary power supply converts incoming +28 VDC to
+12 VDC. A 1.5-amp fuse is provided for this auxiliary power
supply. This fuse is located on the rear of the unit. This fuse
provides over-current protection against unit failure.
3.7 Mating Connector Information
All wiring harnesses to the unit shall be supplied and fabricated by the
installing agency.
Connector Mating Connector
P1 DAMA-15S
P2 MS3126F18-11S

Audio International, Inc. AI-ST100X Installation Manual
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3.8 Pinout Assignment Descriptions
Pinout assignment for the AI-ST100X is as follows:
3.9 Post-Installation Test
3.9.1 Verify +28 VDC power has been properly connected to the unit.
3.9.2 Load the audio source with selected material. With the aircraft and
audio power ‘ON’, apply power to the unit.
3.9.3 Verify that the selected material may be heard through the
headphone and/or speaker system.
3.9.4 Audio level adjustments are accomplished via the gain
potentiometers on the rear of the unit. To increase amplification,
rotate the potentiometers in a clockwise direction; to decrease
amplification, rotate in a counter-clockwise direction.
P1 P2
Pin # Description Pin # Description
1 R+ Audio Input A +28 VDC Power Input (Amp)
2 R- Audio Input B Ground
3 L+ Audio Input C R+ Stereo Speaker Output
4 L- Audio Input D R- Stereo Speaker Output
5 Remote Turn On Input (+28 VDC active) E L+ Stereo Speaker Output
6 +28 VDC Input for +12 VDC supply F L- Stereo Speaker Output
7 +12 VDC Output (1 amp) G Reserved
8 +12 VDC Output (1 amp) H Reserved
9 +12 VDC Output (1 amp) J Reserved
10 Reserved K Reserved
11 Reserved
12 Reserved
13 Reserved
14 Reserved
15 Reserved

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4.0 Troubleshooting
4.1 General Troubleshooting Procedures
Many problems can be isolated with the following general techniques:
• To verify power to the unit, recheck +28 VDC power is applied to the
proper pins on the unit. Use a voltmeter to verify correct level.
• Reset by removing power from the unit for at least one (1) minute and
then reapply power.
• Recheck all connections to the unit for security. Check all harness
runs for possible pinching. Recheck all pinouts for application
accuracy.
• Verify the on/off selection is properly applied.
4.2 Troubleshooting Chart
Problem Possible Cause Solution
No sound ½ Unit improperly
installed
½ No audio material in
source unit
½ Fuse blown
• Verify +28 VDC power
and audio input is
present
• Insert audio material in
source unit
• Replace fuse
• Contact AI Product
Support
Poor audio
quality ½ Audio controls are not adjusted properly • Adjust gain
potentiometers
• Contact AI Product
Support
5.0 Specifications
Physical Specifications
Housing Aluminum
Weight 1.9 lb / 0.86 kg
Dimensions
(l x w x h) 4.5" x 4.75" x 3.1" 11.4 cm x 12.0 cm x 7.9 cm

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6.0 Reference Drawings
The following diagrams show the unit dimensions, mounting locations, and
connector locations for the AI-ST100X.
6.1 Top View

Audio International, Inc. AI-ST100X Installation Manual
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6.2 Front View
6.3 Rear View