Audio international PA-480-01-x User manual

7300 Industry Drive, North Little Rock, AR 72117
Phone: [phone] Fax: [phone]
www.audiointl.com
Installation Manual
PA-480-01-x
Audio Amplifier
Document # 540241
a DeCrane Aircraft Company

Audio International, Inc. PA-480-01-x Installation Manual
Document # 540241, Rev IR, 04/2002 Page 2 of 15
Document Revision History
Rev. Level Date Description
IR 04/2002 Initial Release
Reference Documents
Document # Description
523506 Rev IR1 PA-480-01-x Outline Drawing
Service Bulletin List
Service
Bulletin # Subject Manual Revision
Revision
Date
Table of Illustrations
Section # Description Page #
2.2 Block Diagram 5
6.0 Reference Drawings 14-15
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. PA-480-01-x Installation Manual
Document # 540241, Rev IR, 04/2002 Page 3 of 15
Table of Contents
Section Audio Amplifier Page
1.0 General Information …………………………………………….. 4
1.1 Introduction ………………………………………………………… 4
1.2 Purpose of the Equipment ……………………………………….. 4
1.3 Optional Equipment ………………………………………………. 4
2.0 Application ………………………………………………………... 4
2.1 Introduction ………………………………………………………… 4
2.2 Block Diagram—Typical Application…………………………….. 5
2.3 Data Bus Control ………………………………………………….. 6
3.0 Installation ………………………………………………………… 6
3.1 Prior to Installation ………………………………………………… 6
3.2 Unpacking and Inspection ……………………………………….. 6
3.3
Cautions &Warnings ……………………………………………... 7
3.4 Wiring Requirements ……………………………………………... 8
3.5 Physical Characteristics ………………………………………….. 9
3.6 Electrical Characteristics …………………………………………. 9
3.7 Mating Connector Information …………………………………… 10
3.8 Pinout Assignments and Description …………………………… 11
3.9 Post-Installation Test ……………………………………………... 11
4.0 Troubleshooting …………………………………………………. 12
4.1 General Troubleshooting Procedures …………………………... 12
4.2 Troubleshooting Chart ……………………………………………. 13
5.0 Specifications …………………………………………………… 13
6.0 Reference Drawings …………………………………………….. 14

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PA-480-01-x
Audio Amplifier
1.0 General Information
1.1 Introduction
This manual contains information for the proper installation of the Audio
International, Inc. (AI) Audio Amplifier, Model No: PA-480-01-x. Also
included are physical and electrical characteristics of the unit.
1.2 Purpose of the Equipment
Audio International’s PA-480-01-x is a 4-channel audio amplifier
composed of two (2) separate amplifiers with two (2) channels each. It is
a 300 WRMS class D operation stereo/subwoofer power amplifier for
premium cabin audio systems and delivers high output, excellent
frequency response, and clear sound quality.
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.
2.0 Application
2.1 Introduction
2.1.2 The PA-480-01-x produces 4 x 75 WRMS output power. It can be
configured for up to four (4) full range speaker outputs or two (2)
high range and two (2) subwoofer speaker outputs. It produces
high fidelity stereo audio output for the entertainment system and
monaural audio output for PA/chime functions.

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2.1.3 The purpose of the audio amplifier is to accept low-level audio
signals and amplify them to a high level to drive entertainment
speakers. The amplifier will be most effective when the interior is
thoroughly furnished and all pieces of furniture are in place.
2.2 Block Diagram—Typical Application
2.2.1 Split Cabin Arrangement (No Subwoofers)
2.2.2 Single Cabin Configuration (with Subwoofers)

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2.3 Data Bus Control
2.3.1 The PA-480-01-x audio amplifier is designed to interface with Audio
International’s proprietary RS-485 data bus, allowing all
entertainment switch panels to operate the unit.
2.3.2 Components on the RS-485 data bus shall be connected in a “daisy
chain” configuration.
3.0 Installation
3.1 Prior to Installation
The PA-480-01-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 PA-480-01-x 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.
3.1.3 Mounting screws are required to secure the unit. Refer to
Section 6.0, Reference Drawings, for mounting hole diameters and
configuration.
3.1.4 The unit generates moderate heat. Allow a MINIMUM of 2 inches
of air space around the amplifier due to heat generation.
3.2 Unpacking and Inspection
3.2.1 Carefully open the packaging and remove the PA-480-01-x. Verify
that all components have been included in the package per the
packing list. Inspect the unit for shipping damage.

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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 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 DO NOT remove any factory-installed screws. Damage to the unit
may result and void any warranties.
3.3.3 DO NOT install near heat sources such as direct sunlight, warm air
exhausts, or heaters.
3.3.4 No scheduled maintenance is required to ensure continued
airworthiness.
3.3.5 The unit should be located as close to source equipment as
possible; long low-level runs may introduce noise into the audio
signal.
3.3.6 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
All power and ground wires 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 conductive chassis
mounting point with <1 Ωresistance or <50 Ωimpedance. Twisted
shielded cable shall be in accordance with MIL-W-27500 or
equivalent. Additionally, ensure that the chassis grounding post is
bonded to aircraft frame with <1 Ωresistance or <50 Ωimpedance.
Protect power wires with circuit breakers or fuses located close to
the electrical power source bus.
3.4.3 Audio Wires
All audio input cables should be 22 AWG, MINIMUM, shielded
twisted pair. All output cables should be 16 AWG, MINIMUM
shielded twisted pair. Twisted shielded cable shall be in accordance
with MIL-W-27500 or equivalent.
3.4.4 Data Bus Lines
3.4.4.1 All data bus connections require twisted shielded cable
with the cable shields properly grounded. Twisted shielded
cable must be in accordance with MIL-W-27500 or
equivalent. The wire size for the conductors in this cable is
to be 22 AWG MINIMUM. The shield is to be connected
wherever a shield pin is provided. Shield terminations are
to be made as close to the connector pin as possible. In
the event shield pins are not utilized, the data bus shield
must be terminated per AI’s RS-485 specification. AI’s
RS-485 serial data bus specification is available upon
request.

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3.4.4.2 All equipment on the RS-485 data bus shall be connected
in a “daisy-chain” configuration. AI’s RS-485 serial data
bus specification is available upon request.
3.5 Physical Characteristics
3.5.1 The PA-480-01-x shall 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 5.0 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 Characteristics
3.6.1 Electrical Specifications
Electrical Power 300 VA @ 115 VAC (nominal)
Frequency Range 47 to 440 Hz
Power Factor 0.99
Emergency Power 6A @ +28 VDC max
Audio Electronic Crossover Low Range: 135 to 20 kHz
High Range: 20 to 135 Hz
Output Power 4 channels x 75 WRMS
Inputs
2 Stereo Audio, 1 VRMS min,
2 VRMS optimum
PA/Chime, Range = 200 mV to
2 VRMS (adjustable)
Input Impedance 4.7 kΩ
Output Impedance 4 Ω

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3.6.2 Overview of all electrical connections
3.6.2.1 Signals interfaced through the P1 connector are two (2)
sets of entertainment audio inputs, page/chime audio
input and keyline, data ID, Weight-On-Wheels input, and
RS-485 data bus. When the PA key input is activated, all
entertainment audio is muted, and the page/chime (PA)
monaural input is directed out all speaker output
connections. When the PA key input is deactivated,
entertainment audio is again directed to all speaker
output connections accordingly.
3.6.2.2 Signals interfaced through the P2 connector of the unit
are two (2) sets of left/right speaker outputs, and a
+28 VDC emergency input. The emergency +28 VDC
power input is required for cabin PA and chime audio in
case of power failure.
3.6.2.3 Unit ID pins are provided to allow multiple PA-480-01-x
units to be connected simultaneously in the aircraft.
These binary ID pins identify each unit on the RS-485
data bus.
3.6.2.4 Signals interfaced through P3 is 115 VAC power for
Amps 1 and 2.
3.7 Mating Connector Information
All wiring harnesses to the unit shall be supplied and fabricated by the
installing agency.
PA-480-01-x
Connector Mating Connector
P1 (-01) RD25F10JVL0
P1 (-02) DBMA-25S
P2 MS3126F18-11S
P3 MS3126F10-6S

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3.8 Pinout Assignment and Descriptions
P1
Pin Description Pin Description
1 Left Audio Input #1 High 14 Unit ID3
2 Left Audio Input #1 Low 15 ID Common
3 Right Audio Input #1 High 16 RS-485 Data Bus A (Hi)
4 Right Audio Input #1 Low 17 RS-485 Data Bus B (Lo)
5 Left Audio Input #2 High 18 RS-485 Data Bus Shield
6 Left Audio Input #2 Low 19 Weight-On-Wheels Input (Gnd Active)
7 Right Audio Input #2 High 20 Reserved
8 Right Audio Input #2 Low 21 Reserved
9 PA Audio Input High 22 Reserved
10 PA Audio Input Low 23 Reserved
11 PA Key Input (Gnd Active) 24 Reserved
12 Unit ID1 25 Reserved
13 Unit ID2
P2 P3
Pin Description Pin Description
A Reserved A 115 VAC H 400 Hz Amp #1
B Emergency Input DC Ground B 115 VAC N 400 Hz Amp #1
C Right Speaker Output #1 High C AC Ground #1
D Right Speaker Output #1 Low D 115 VAC H 400 Hz Amp #2
E Left Speaker Output #1High E 115 VAC N 400 Hz Amp #2
F Left Speaker Output #1 Low F AC Ground #2
G Right Speaker Output #2High
H Right Speaker Output #2 Low
I Left Speaker Output #2 High
J Left Speaker Output #2 Low
K +28 VDC Emergency Input
3.9 Post-Installation Test
3.9.1 With the aircraft power ON, test the audio amplifier. Any unit
properly connected to the RS-485 data bus may be used to test
operation.
3.9.2 While an entertainment audio unit is sending audio signals through
the amplifier, key and speak into a microphone to ensure that the
page / chime overrides the entertainment audio. Ensure all
microphones are tested. Verify briefer audio can be heard through
the speakers.
3.9.3 Remove power from the amplifier and verify the +28 VDC
emergency power is supplied to the amplifier. Verify that the
subwoofers are disabled while emergency power is applied.
Ensure that PA audio can be heard in the speaker system from all
respective microphones.

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4.0 Troubleshooting Guide
4.1 General Troubleshooting Procedures
Many problems can be isolated with the following general techniques:
• To verify power to the unit, recheck 115 VAC and +28 VDC power is
applied to the proper pins on the unit. Use a voltmeter to verify correct
level.
• Remove 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.
• To check data bus integrity, utilizing a voltmeter, oscilloscope, or other
instrument, verify proper input voltage on the data bus pins. Typical
measurements with no device(s) on bus transmitting are as follows:
A-to-Ground : 4.0 to 4.5 VDC
B-to-Ground : 0.1 to 1.0 VDC
If any device is transmitting (i.e., holding bus active), then these typical
measurements would be reversed for the A-to-Ground and B-to-
Ground measurements. This troubleshooting tool can help indicate a
data bus lockup.
• The RS-485 data bus is a bi-directional bus that does not have a ‘bus
controller’. The bus uses a differential digital signal that will transmit
only when commands are entered via switch selection or other system
synchronizing commands. The “A” leg of the bus is HI and the “B” leg
LOW when no devices are transmitting data on the bus.

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4.2 Troubleshooting Chart
Problem Possible Cause Solution
No Sound Ø Improperly installed
Ø Power not applied
Ø No audio material in
selected source
equipment
• Recheck all connections
• Verify 115 VAC and
+28 VDC power are applied
to the proper pins on the
unit
• Insert audio equipment in
source unit
Noise introduced
in audio signal
Ø Long low-level runs
Ø Interference from
outside source
• Relocate unit closer to
source equipment
• Reposition wires away from
sources of interference
5.0 Specifications
Unit Specifications
Physical Specifications
Housing Anodized Aluminum
Weight 6.5 lb / 2.95 kg
Dimensions
(l x w x h)
9.1" x 9.8" x 3.0"
23.11cm x 24.89cm x 7.62cm

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6.0 Reference Drawings
The following diagrams show the unit dimensions, mounting locations, and
connector locations for the PA-480-01-x.

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