Audio international AV-4595-0x-x User manual

7300 Industry Drive, North Little Rock, AR 72117
Phone: [phone] Fax: [phone]
www.audiointl.com
Installation & Operations
Manual
AV-4595-0x-x
Audio/Video Distribution Unit
Document # 540158
FINAL DRAFT DATE
June 23, 2000

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 2 of 18
Document Revision History
Rev. Level Date Description
IR 10/1999 Initial Release
Reference Documents
Document # Description
522229 AV-4595-0x-x Outline Drawing
Service Bulletin List
Service
Bulletin # Subject Manual Revision Revision Date
Table of Illustrations
Illustration # Description Page #
2.3 Block Diagram 5
3.6.2 Specifications 9
3.7 Mating Connector Information 9
3.8 Pin Out Assignments and Descriptions 10-13
5.3 Troubleshooting Chart 15
6.1 Unit Specifications 16
7.1 Dimensions 17
7.2 Connections 18
PROPRIETARY INFORMATION 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. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 3 of 18
Table of Contents
Section Description Page
1.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Purpose of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Functional Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Multiple Unit Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Data Bus Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Cautions & Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Physical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 8
3.6 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Mating Connector Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.8 Pin Out Assignments and Descriptions . . . . . . . . . . . . . . . . . . . . . . 10
3.9 Post Installation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Source Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 General Troubleshooting Procedures . . . . . . . . . . . .. . . . . . . . . . . . 15
5.3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1 Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.0 Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.1 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.2 Connections . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 18

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 4 of 18
AV-4595-0x-x
Audio/Video Distribution Unit
1.0 General Information
1.1 Introduction
This manual contains information for the proper application, installation, and operation of
the Audio International, Inc. (AI), Audio/Video Distribution Unit, Model # AV-4595-0x-x.
The -0x designates the configuration of the unit and the -x suffix designates the type of
connectors utilized. Also included are relative physical and electrical characteristics of
the unit.
1.2 Purpose of the Equipment
The Audio/Video Distribution Unit has been specifically designed to meet the special
requirements of aircraft use. The AV-4595-0x-x accepts audio and video inputs from the
entertainment source equipment. Using commands issued from switch panels, touch
screens or electro luminescent touch screens panels, the AV-4595-0x-x distributes the
audio/video to monitors, cabin speakers and headphones.
1.3 Functional Testing
Audio International has tested this product and has verified that the unit meets its design
specification requirements.
1.4 Features
q Allows multiple source audio/video inputs to be selected and routed independently to
multiple audio/video devices
q Up to 16 entertainment audio source inputs
q Up to 16 video source inputs
q Output to 16 audio stations for personal headphones and/or cabin speaker amplifiers
q 16 video stations for personal or cabin monitors
q Differential Video outputs over twisted pair wires
q Control, configuration, and interface with other components via Audio International’s
RS-485 serial data bus
q Three binary ID pin inputs identify each module on the data bus in a multi-unit
configuration
q A PA input mutes all entertainment audio when PA is activated
q A Video Briefer key input overrides all entertainment video when briefer is activated.
The source input for the briefer is configurable
q Power-up defaults can be configured for each output
q Lightweight, rugged aircraft design
2.0 Application

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 5 of 18
2.1 Introduction
The AV-4595-0x-x is part of a complete cabin audio and video entertainment system.
The application of the unit is specific to a particular aircraft based on the desires of the
customer or designer.
2.2 Typical Application
The unit provides a switching matrix for cabin entertainment systems utilizing multiple
source audio/video inputs and outputs. Since it resides on the RS-485 data bus, any
switch or control device can independently select from amongst the input sources.
Audio outputs are typically headphone stations and power amplifiers to drive cabin
speakers. Video outputs are typically passenger LCD screens or cabin monitors.
2.3 Block Diagram
2.4 Multiple Unit Configurations
AV-4595-0x-x
DVD
AIRSHOW
VideoIn
Chimes
Page
CD
VCP
/
AudioIn
VideoOut
Passenger
Headphones
Amplifier
AudioOut
Audio
MSM2915
MSM2917
Non-Differential
Video Compatible
LCD
Differential
Compatible
Monitors
Video
LCD’s
Compatible
Video
Differential

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 6 of 18
There is ONLY 16 audio or video sources possible. If more than 16 audio or video
stations are needed, multiple-unit configurations are possible on the RS-485 data bus.
This allows selection of any Audio/Video sources from any station. The number of
possible units in a system is dependent on other modules used within the cabin audio
system – up to eight (8) can be used on the same RS-485 line, yielding a potential of
128 audio and video stations.
2.5 Data Bus Control
2.5.1 There are no controls on the distribution module. Switching control of the unit is
handled by commands via the RS-485 serial data bus.
2.5.2 Programmable Features
A software program, using an external PC (typically a laptop) and a MSM2912,
designed by Audio International specifically for this task sets the following
configurations:
• Power-up state for each audio and video station
• Video Briefer source unit
• Trim levels for each audio input source
3.0 Installation
3.1 Prior to Installation
The AV-4595-0x-x is a simple module to install. Prior to installation the following items
should be considered:
3.1.1 During the design and layout of the aircraft cabin, careful consideration of the
location of this and all other audio/video modules is necessary. Some of the
items to consider include:
• Space
• Proximity to other devices (i.e. source equipment)
• Available power supply
• Length of cable runs
• Environmental conditions (temperature, humidity, etc.)
• Location of other aircraft systems (i.e. oxygen delivery)
• Access for service repair (if applicable)
• Convenience for user interface (if applicable)
3.1.2 The module shall be installed to conform to the standards designated by the
customer, installing agency, or other specified requirements.
3.1.3 Prior to installation, select a mounting location for the AV-4595-0x-x. User
access is NOT a consideration when placing unit into the suitable mounting
location. Refer to Section 7.0 for dimensions and attachment points. The unit
shall be bonded to the aircraft frame.
3.2 Unpacking and Inspection

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 7 of 18
3.2.1 Carefully open the packaging and remove the AV-4595-0x-x. Verify that all
components have been included in the package per the packing list. Inspect the
unit for shipping damage.
3.2.2 If damage has occurred during shipping, a claim should be filed with Audio
International WITHIN 24 hours and a Return Request Authorization Number
shall be obtained from AI. Refer to the front cover of this manual for address
and telephone number of Audio International, Inc. 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 list and the
packing materials for storage.
3.3 Cautions & Warnings
3.3.1 All audio output lines from the Audio/Video Distribution Unit shall be shielded
and properly grounded. Audio input lines shall be shielded and grounded at the
source, unless indicated otherwise. Avoid placing cables near high power wires.
3.3.2 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 can result if power or ground is applied to the wrong points.
3.3.3 DO NOT connect or disconnect the unit while power is applied.
3.3.4 DO NOT connect or disconnect any inputs or outputs when power is applied to
the unit.
3.3.5 DO NOT remove any factory-installed screws. Damage to the unit can result
and void any warranties.
3.4 Wiring Requirements
The installing agency shall supply and fabricate all external cables and 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.
3.4.1 Audio and Video Input/Output Lines
All audio and video lines shall be 22 AWG (MINIMUM) twisted, shielded cable
with the shields grounded at the source.
3.4.2 Power Wires
All power and ground wires shall be 20 AWG, MINIMUM. Power ground wires
shall be grounded within twelve (12) inches of the unit. Protect power wires with
circuit breakers or fuses located close to the electrical power source bus.
3.4.3 RS-485 Data Bus
The AV-4595-0x-x is designed to interface with other Audio International
equipment via AI’s proprietary RS-485 serial data bus. The data bus shall be

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 8 of 18
implemented using a twisted shielded pair cable in accordance with MIL-W-
27500 or equivalent. The wire size for the conductors in this cable shall be 22
AWG, MINIMUM. The shield shall be connected everywhere a shield pin is
provided. Shield terminations shall be made as close to the connector pin as
possible.
3.4.4 All modules on the RS-485 data bus shall be connected in a daisy-chain
configuration.
3.4.5 All wires shall be in accordance with MIL-W-22759 or equivalent. Twisted,
shielded cable shall be in accordance with MIL-W-27500 or equivalent.
3.4.6 When running cables, 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.
3.5 Physical Requirements
3.5.1 The Audio/Video Distribution Unit should be located away from heat sources,
magnetic fields, direct sunlight, and areas with excessive dust. The unit shall
NOT be mounted to the skin of the aircraft.
3.5.2 Refer to Section 7.0 for unit dimensions and mounting hole sizes.
3.5.3 The unit shall be rigidly mounted to its location using the appropriate fastening
hardware supplied by the installing agency.
3.5.4 When mounting the unit to the aircraft’s frame, allow sufficient space for mating
connectors.
3.6 Electrical Requirements
3.6.1 The AV-4595-0x-x utilizes eight (8) Positronic or D-SUB connectors, each with
multiple wires: two 50-pin (P4, P7), three 37-pin (P1, P2, P5), and three 15-pin
(P3, P6, P8). Refer to section 3.7 for mating connector information, section 3.8
for pin out designations and descriptions.
3.6.2 Specifications:
Electrical Power +28 VDC nominal
Operating Range +18 to +32 VDC

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 9 of 18
Current Draw 4 A max
1 A nom @ +28 VDC
Audio 16 Inputs 1 to 5 VRMS @ 4.7 kΩ
impedance
16 Outputs 350 mW RMS @ 50 Ω
PA Audio Input 1 to 5 V p-p @ 1.0 kΩ
2 V p-p optimum
Headphone
Impedance 50 Ωminimum to
1 KΩmaximum
Video 16 Inputs 75 Ω, 1 to 4 V p-p Composite
16 Outputs 75 Ω, Gain = 1, Composite
3.7 Mating Connector Information: A/V-4595-0x-x
AV-4595-0x-1 MATING CONNECTOR CHART
Connector # Part Number Description
P1 RD37F10JVL0 Female Plug (Positronic)
P2 RD37M10JVL0 Male Plug (Positronic)
P3 RD15M10JVL0 Male Plug (Positronic)
P4 RD50F10JVL0 Female Plug (Positronic)
P5 RD37M10JVL0 Male Plug (Positronic)
P6 RD15F10JVL0 Female Plug (Positronic)
P7 RD50F10JVL0 Female Plug (Positronic)
P8 RD15M10JVL0 Male Plug (Positronic)
ALL POSITRONIC CONNECTORS TO HAVE LOCK TAB SETS
AV-4595-0x-2 MATING CONNECTOR CHART
Connector # Part Number Description
P1 DBMA-37S Female Plug (D-SUB)
P2 DBMA-37P Male Plug (D-SUB)
P3 DAMA-15P Male Plug (D-SUB)
P4 DAMA-15S Female Plug (D-SUB)
P5 DBMA-37P Male Plug (D-SUB)
P6 DAMA-15S Female Plug (D-SUB)
P7 DDMA-50S Female Plug (D-SUB)
P8 DAMA-15P Male Plug (D-SUB)
ALL D-SUB CONNECTORS TO HAVE SCREW LOCK SETS

Audio International, Inc. AV-4595-0x-x Installation & Operation
Document #540158, Rev IR, 10/1999 Page 10 of 18
3.8 Pin Out Assignments and Descriptions
P1
PIN # PIN #
1 Video High Input CH 0 20 Video Low Input CH 1
2 Video High Input CH 1 21 Video Low Input CH 2
3 Video High Input CH 2 22 Video Low Input CH 3
4 Video High Input CH 3 23 Video Low Input CH 4
5 Video High Input CH 4 24 Video Low Input CH 5
6 Video High Input CH 5 25 Video Low Input CH 6
7 Video High Input CH 6 26 Video Low Input CH 7
8 Video High Input CH 7 27 Video Low Input CH 8
9 Video High Input CH 8 28 Video Low Input CH 9
10 Video High Input CH 9 29 Video Low Input CH A
11 Video High Input CH A 30 Video Low Input CH B
12 Video High Input CH B 31 Video Low Input CH C
13 Video High Input CH C 32 Video Low Input CH D
14 Video High Input CH D 33 Video Low Input CH E
15 Video High Input CH E 34 Video Low Input CH F
16 Video High Input CH F 35 Reserved
17 Reserved 36 Reserved
18 Reserved 37 Reserved
19 Video Low Input CH 0
P2
1 Video High Output CH 0 20 Video Low Output CH 0
2 Video Shield CH 0 21 Video Shield CH 1
3 Video High Output CH 1 22 Video Low Output CH 1
4 Video High Output CH 2 23 Video Low Output CH 2
5 Video Shield CH 2 24 Video Shield CH 3
6 Video High Output CH 3 25 Video Low Output CH 3
7 Video High Output CH 4 26 Video Low Output CH 4
8 Video Shield CH 4 27 Video Shield CH 5
9 Video High Output CH 5 28 Video Low Output CH 5
10 Video High Output CH 6 29 Video Low Output CH 6
11 Video Shield CH 6 30 Video Shield CH 7
12 Video High Output CH 7 31 Video Low Output CH 7
13 Video High Output CH 8 32 Video Low Output CH 8
14 Video Shield CH 8 33 Video Shield CH 9
15 Video High Output CH 9 34 Video Low Output CH 9
16 Video High Output CH A 35 Video Low Output CH A
17 Video Shield CH A 36 Video Shield CH B
18 Video High Output CH B 37 Video Low Output CH B
19 Reserved