Nk Cox-vox Operating instructions

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The Most Relied-Upon

Pocket Weather Instruments

in the World

Making Work & Play

Easier & Safer

COX-VOXTM SYSTEM

INSTALLATION, MAINTENANCE AND

TROUBLESHOOTING GUIDE

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COX-VOX OPERATION

On/Off

To use your Cox-Vox, simply place the unit in the cup bracket and plug it into the wiring harness.Be sure to

align the plug and receptacle properly! There is an arrow molded into the rubber for help visually aligning the

parts.The P5 can be damaged because of frequent improper alignment.

The large knob turns the unit on and off, and controls the volume.Twist the knob clockwise to turn the Cox-Vox

on. Find an appropriate volume so that everyone in the crew can hear the coxswain. Adjusting the speakers

slightly may help with this.Keep the volume as low as possible to prolong the battery life.

If any of these functions do not work properly, review each step of the installation, checking all

distances and alignments. Also review the“Troubleshooting” section for help pinpointing the

problem.

If you still are having problems, please contact our Repair Department on

02 6553 2473 or write to [email protected]

Airline Travel

With increased airport security, traveling with your Cox-Vox is trickier than ever. We recommend you

check the Cox-Vox in with your luggage.Include product literature that explains what the Cox-Vox is.

Brochures can be obtained from NK, or product literature can be printed from the website.

You certainly do not want to try to carry them onto an airplane. Cox-Voxes have been thrown into

bomb chutes, even before 9/11.

This new NK Gear Bag is a great replacement for your old black Cox-

Vox Carry Case.

It features multiple compartments with adjustable dividers that can

easily swallow up a Cox-Vox, mic, charger, SpeedCoach, Mainte-

nance Kit, tools and more.

Water-resistant construction and sturdy padding throughout will

keep all your gear protected, and a padded shoulder strap lets you

load the bag up and still carry everything hands-free.

Available NOW. Part #0117

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CARING FOR YOUR COX-VOX SYSTEM

Nielsen-Kellerman equipment is designed, built and tested to withstand the rigors of everyday use, but it is not

invincible and it can be damaged.The following information is intended to help you maintain your equipment

and prevent unnecessary repairs.

Charging

• Place the unit on charge whenever it is not in use, but do not leave the unit charging indeﬁnitely.The unit

should never be charged continuously for longer than 2 days.

• If the battery light comes on, be sure to charge the unit for at least 12 hours.

• Do not continue to use a unit with the low battery warning light illuminated.Repeated use with the low

battery light on may damage the batteries and unit.

• Under normal conditions, a fully charged battery should last at least 4 hours. If your unit is not providing

this much operational time, it may be time to return it to NK to have new batteries installed.We expect our

batteries to need replacement after three years of normal full-season use.

Care of Your Microphone

Your microphone is shipped attached to a headband and ready for use.The microphone is fully waterproof, and

may be fully immersed, but it will not ﬂoat on its own. Unless it is attached to a Cox-Vox, the microphone will

sink. Microphones should be treated with care.

• Do not attempt to bend the aluminum boom or twist the mouthpiece.

• Do not drop the microphone.

• Do not yank or pull on the microphone cable when

disconnecting from the Cox-Vox.

• Do not tighten the bayonet connector on the microphone to the

panel jack on the Cox-Vox. Just slip it into place.

• Do not carry the Cox-Vox by the microphone.

Often, when a customer attempts to replace a microphone BNC, the

replacement connector pin is of an incorrect diameter and damages

the center conductor of the Cox-Vox panel mount BNC.

NOTE: The NK warranty covers defects in materials and workmanship. It DOES NOT cover damage

caused by abuse, misuse, or attempts to repair the microphone on your own.

Additional Information

Never attempt to repair the Cox-Vox unit yourself.The units are specially sealed to make them watertight.

Breaking this seal often causes very expensive damage and will void the warranty.The only accessory

that we will repair is the microphone. We do encourage and will support experienced individuals to

repair and maintain wiring harnesses and speakers.

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REGULAR MAINTENANCE SCHEDULE AND TIPS

Daily Maintenance

1. If you row on salt water, rinse the Cox-Vox off with fresh water and dry

it after every use.

2. Charge the unit whenever it is not in use, but do not leave the unit on

charge indeﬁnitely.The unit should not be charged for longer than 2

days straight.

3. Slip the metal microphone bayonet on the Cox-Vox panel jack

without twisting to lock it. Do not tighten it fully.

4. Inspect the toggle-switch seal for integrity.This is especially

important if you row in salt water and wash your unit regularly.

Once a Month

This maintenance is easy to perform with a Cox-Vox Maintenance Kit,

available from NK.

1.Wash the Cox-Vox display panel with warm water and mild soap. Rinse well and dry.

2. Use the drill bit from the Cox-Vox Maintenance kit to clean out the metal sockets inside the rubber plug on

the unit. Rotate the bit inside the sockets to dislodge any dirt or debris.

3. Check the inside of the rubber plug on the wiring harness for any dirt. Inspect the wires leading to the plug

for any nicks or cuts. If these exist, contact NK about repairing them.

4. Apply silicone grease to the outside of the rubber plug on the Cox-Vox.This helps to minimize the damage

done by repeatedly removing the unit from the boat.Try not to get silicone into the plug itself.

5. Microphone BNC and Panel BNC Connector:You can greatly reduce microphone static with regular

maintenance of these connectors.Use the provided small screwdriver to gently spread the contact ﬁns in

the center of the mic BNC.The Socket Maintenance kit includes instructions and photos of this step. Use

the syringe to run a generous bead of Nyogel on the inside diameter of the BNC connector on the Cox-Vox

panel.This grease will transfer to the mic BNC when it is next connected.

6. Inject a small amount of electrical contact grease (Nyogel) into the sockets on the rubber Cox-Vox plug.

Connect the unit to the harness.This will coat the pins with Nyogel and push some Nyogel deeper into the

sockets, protecting them as well.

End of the Season

1. Inspect the toggle switch seal.Perform this step before washing the unit.

2.Wash the Cox-Vox with fresh water and dry it carefully.

3. Repeat the cleaning and lubricating steps under “Once a Month” maintenance.

4. Fully charge the Cox-Vox then unplug it and store it in a cool, dry place.

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Battery Life

The life of your battery depends upon many things: the age of the battery pack, the volume and used by the coxswain

and the extent of charge. Here are some performance guidelines that should help you plan your Cox-Vox use.

• A fully charged battery will power a Cox-Vox with NO audio (volume turned all the way down) for 16 hours.

• With the volume turned all the way up, the battery can supply power for 50 minutes of continuous talk.

• Therefore, with an average volume setting and a coxswain talking less than half the time, a fully charged Cox-Vox

will provide at least two to three hours of power, and usually more.

• Having the Coxswain turn the volume down as low as possible will help prolong the battery life.

• A fully drained Cox-Vox battery requires 12 hours on charge to attain maximum capacity.

• It is not necessary to try to discharge the Cox-Vox batteries fully between charging— there is virtually no memory

effect in modern nickel cadmium batteries.

• If your Cox-Vox unit is more than three years old, the battery performance will decrease. Simply return the unit to

NK for a new battery replacement. If you would like to determine the age and/or repair history of a unit, please

send an e-mail to [email protected]om.au

Avoid overcharging your Cox-Vox. NK chargers are current-limiting and help prevent battery damage from

overcharging. However, leaving the unit plugged in for many days or weeks (past full charge) may still cause damage.

Please be sure to unplug and store your units during your off season breaks.

A note about your CV BATTERY TEST FUNCTION.

Very early CoxVox units have a battery light test function.This test function has been deleted on later models.This

may create some confusion amongst users as they believe that their battery is ﬂat.

How it works.

With your CoxVox switched ON, if you switch it OFF, then switch it back ON quickly (within 10 seconds),The“BATT“

lamp will ﬂash.This is just a BATT lamp test, your battery is NOT discharged.

To reset the test, turn the CoxVox OFF for longer than approx 15 seconds.

When you now turn it ON, the BATT lamp should be off.

If the battery lamp is ON, them indeed, your battery is discharged.

TROUBLESHOOTING

A Cox-Vox system consists of four major components: the Cox-Vox unit, the microphone, the wiring and the speakers.

All of these components must function for your system to work properly. If you are having a problem with your

system, the best diagnostic tool is to swap out each component, one at a time, with a working component.When the

problem disappears, you know you have pinpointed the trouble area.

Cox-Vox Will Not Take or Hold a Charge

—Is the Cox-Vox being charged correctly?

Review the“Charging” section under Maintenance above and conﬁrm that proper procedures are being observed

when charging the Cox-Vox.

—Is the correct charger being used?

Our chargers are rated 12VDC and 300mA and are sent to the user with a special plug attached. We recommend

that all chargers be purchased from NK, and that you do not modify a charger purchased elsewhere for use with a

Cox-Vox.

—Is the charger working?

• Is the red LED illuminated when the charger is plugged in?

• Is the charger warm? A normal charger will be very warm after less than one hour’s operation. If the charger is

not warm then it is not operating correctly. However, chargers can be warm, but not work properly.

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• Does the unit charge with a different charger? If so, then the ﬁrst charger

is bad.If you suspect that your charger is not working correctly you can

perform the following test:

Obtain a multimeter—almost any type will do.Turn the multimeter

on and set it at 20 VDC. After plugging the charger in (be VERY

careful, the charger is ON!), place the positive lead from the

multimeter on the plus pin, and the negative lead from the

multimeter onto the ground pin.The multimeter should read

between 13.5V -15V. Any deviation from this range indicates that

the charger is not working.If you do not get any voltage reading on

the multi-meter, the internal transformer is damaged the charger

must be replaced.

—Have the batteries exceeded their lifespan?

A Cox-Vox Battery is expected to provide 3 years of normal use (daily practices for approximately six to nine

months of the year). If you know your unit’s batteries are older than three years, we recommend that the unit be

returned to NK for new batteries and servicing. We can often check our records to determine the age of your unit’s

batteries.

ground plus

plus

NOTE: NK NO LONGER REPAIRS CHARGERS!

If you wish to repair a charger plug, you may obtain pins and instructions from NK. However, for most

people, the most cost- and time-effective approach is simply replacement.

No Audio/Intermittent Audio/Static

—Is the wiring clean of cuts or nicks?

Cuts or nicks in the wiring are the most frequent causes of audio problems. Be sure that all of the connectors

(pins, sockets, plugs, receptacles) are not damaged and are positioned properly.

—Is the microphone working properly?

The microphone may be the cause of failure.Test the system with a microphone you know is good. Note: A

damaged microphone often causes static.

—Are the connectors (pins, sockets, plugs, receptacles) properly positioned?

See installation.

—Are the speakers working properly?

Be sure all of the speakers are plugged in properly and are in working order (replace one at a time with a

known good speaker to test). If you are getting a loud squealing noise, try pointing the speakers away from

the coxswain to minimize feedback.

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LAY OUT THE PARTS OF YOUR SYSTEM

Uncoil the wiring harness and lay it out in the shell. If you are installing your COX Vox in a sectional

shell, the harness should be equipped with a plug/receptacle pair which should be within a foot of

the sectional bulkheads.

INSTALLING YOUR SYSTEM

PLEASE, read through ALL of the installation instructions

before beginning to install your system!

Check that you received everything required. If you purchased a complete CoxVox system you

should have received the following items:

Carrying bag .......................................................................................................(1)

CoxVox control unit .........................................................................................(1)

microphone.........................................................................................................(1)

charger..................................................................................................................(1)

speakers............................................................................... (as ordered 2 or 3)

mounting cup ....................................................................................................(1)

harness..................................................................................................................(1)

“Do’s & Don’ts” card ..........................................................................................(1)

hardware pack with magnet ........................................................................(1)

NOTE: The double-sided “VHB” tape provided for mounting is epoxy based and requires 12 hours of

cure time. Do not get this tape wet while curing for best results.

INSTALL THE LOUDSPEAKERS

The NK loudspeakers are factory assembled and waterproofed using silicone-based protective

coatings. Rain, fresh water, and salt water should not harm the speakers, but we strongly

recommend that you install and angle the speakers so that any water which gets in can run out

again.The plug-in feature of NK speakers makes replacement very easy.

1. Install the speakers using #6 x 1/2” panhead screws and the metal bracket (attached

to the speaker). We have supplied SIX screws; you will not use all of them unless you

are installing a three speaker system. Remember, it is best if the speakers are angled

downward to let water run out.

2. Connect the speakers to the wiring harness. Use the remaining six cable clips to secure

the wiring harness.We suggest you use the #6 x ½” brass screws supplied to fully secure

these clips.

INSTALL THE MOUNTING CUP

Decide where you want to secure the cup and mark off the surface using the cup as a template.

Drill two pilot holes for the #8 x ½” panhead screws and secure the cup. Do NOT over tighten the

screws!

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Cox-Vox Maintenance

If you row, cox or coach a coxed boat, you know the CoxVox is an important part of every practice or race. Though designed to perform

in conditions that would destroy most electronics in minutes, there are a few things you can do to help your CoxVox last longer and

perform better. For every waterproof electronic product, the connections are the potential trouble spots. NK sells a complete Cox-Vox

Maintenance Kit with everything needed to make it easy to maintain the connections on your equipment. Follow these steps to keep

your Cox-Vox, Cox-Vox, Microphones & Wiring static-free and reliable for years.

Cox-Vox Panel Connectors -

MONTHLYWASH the Cox-Vox panel with warm water and mild soap. RINSE well. DRY thoroughly

ROTATE DRILL BIT

inside metal sockets of

rubber P5 connector

to dislodge dirt and

corrosion and lift debris

out of sockets.

APPLY ELECTRICAL

CONTACT GREASE

from syringe inside

metal sockets. Avoid

over filling sockets or

getting into rubber.

APPLY GREASE from

syringe inside metal

BNC connector in a

small bead between

white conductor and

metal can.

USE FOAM SWAB to

apply SILICONE from

small plastic tub to...

OUTSIDE OF P5

until a visible film

of SILICONE covers

surface. (Keep foam

swab in provided bag

for future use.)

INSPECT rubber boot

around toggle switch

for tears or damage.

RETURN to NK if any

visible damage.

Tips to Help You Get the Most From Your Cox-Vox

· Make sure that the CoxVox is carried by the handle, and NEVER by the microphone. After use, detach the microphone, and do not store the

unit with the mic attached. When attaching the mic to the CoxVox unit, avoid twisting the BNC connection down until it locks. Instead, connect

the mic, and twist the socket just enough to keep it attached.

· Keep your CoxVox clean by rinsing it off after use, ESPECIALLY if you row in salt water.

· Store your CoxVox in a cool, dry place. Avoid leaving it in severe heat or cold (such as the dashboard of a car or an unheated boathouse in

the winter) which can greatly shorten the life of the rechargeable battery pack.

CHARGING

· Recharging: Recharge a regularly-used CoxVox whenever possible to ensure that it will have enough power for the next practice. A fully

drained CoxVox battery pack requires 12 hours on charge to attain maximum capacity. At the end of the season, charge the unit for 12

hours, disconnect the microphone and charger, and store in a cool dry place until ready to use next season.

· Memory Effect: It is not necessary to try to discharge the CoxVox batteries fully between charging - there is virtually no memory effect in

modern nickel cadmium batteries.

· Avoid Overcharging: NK chargers are current-limiting and help prevent battery damage from overcharging. However, leaving the unit

plugged in for many days or weeks (past full charge) may still cause damage. So PLEASE be sure to unplug and store your units during your off

season breaks.

BATTERY LIFE

The life of your battery depends upon many things: the age of the battery pack, the volume and talkativeness of the coxswain, and the extent

of charge. Here are some performance guidelines that should help you plan your CoxVox use.

· A fully charged battery will power a CoxVox with NO audio (volume turned all the way down) for 16 hours.

· With the volume turned all the way up, the battery can supply power for 50 minutes of continuous talk.

· Therefore, with an average volume setting and a coxswain talking less than half the time, a fully-charged CoxVox will provide at least two to

three hours of power, and usually more.

· Having the Coxswain turn the volume down as low as possible will help prolong the battery life.

· If your CoxVox unit is more than three years old, the battery performance will decrease. Simply return the unit to NK for a new battery

replacement. If you're not sure how old your unit is, give the Service Department at NK a call and they can research your unit's serial number to

tell you when it was last serviced.

Visit www.nk.com.au for more maintenance and troubleshooting tips, or contact NK email support on [email protected]

Microphone - MONTHLY or As Needed

GENTLY SPREAD GROUND CONDUCTOR "FINS" of the microphone BNC away from the center white insulator using the

small screwdriver. A slight gap between the fins and insulators should remain. Slip the BNC onto the greased Cox-Vox

panel BNC to transfer grease into the body of the microphone BNC. INSPECT cable for intact heat shrink and connection

to BNC. Return to NK for repair if there is visible damage.

REMEMBER! DO NOT lock the BNC ring when plugging in to the Cox-Vox. DO NOT carry the Cox-Vox by the microphone.

DO NOT bend the microphone boom, twist the mouthpiece or twist or yank the cable.

Speaker/Harness Connectors - TWICE A YEAR (End of Season)

ROTATE DRILL BIT

inside metal sockets of

rubber P2 connectors

to dislodge dirt and

corrosion and lift

debris out of sockets.

APPLY ELECTRICAL

CONTACT GREASE

from syringe inside P2

metal sockets. Avoid

over filling sockets or

getting onto rubber.

USE FOAM SWAB to apply

SILICONE to outside of P2

connectors. Reconnect all

P2/R2 connectors firmly.

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New from Nielsen-Kellerman: the Coxswain’s Kit.

Everything the prepared coxswain needs for practice. Kit

Includes: Custom Pack with pouch and external CoxVox

holder, one adjustable wrench, one 7/16” wrench, one 10mm

wrench, athletic tape, electrical tape, Blister Medic first aid kit,

2 Carabineers, a tube of waterproof sun block and lip balm. NK

PART 4050

With the growing use of licence free, 2-way radios, NK have

made available a special connector that allows a 2-way radio

system to be used through an existing NK Cox-Vox or Cox-Vox

system.The radio to microphone ‘T’ piece connector fits on

the BNC microphone input of the amp unit. One end connects

to a 2-way radio, the other is used to connect the existing

microphone.The coach (with another 2-way radio) can then

communicate to the crew discreetly. With multi-channels

available, it is possible for the coach to speak to a number of

crews at once or by switching channels, to just one crew individually.

Charge your Cox-Vox from any car or truck cigarette lighter. Great when

traveling to regattas! CAR CHARGER – NK PART 0234 –

SILICONE GREASE – NK PART 0241 –Silicone is the proper grease for lubricating

all rubber plugs and receptacles in your Cox-Vox system.This grease will ensure

that the plugs will connect and disconnect easily and will not swell or crack.

Note: please do NOT use petroleum jelly or other lubricants that may cause the

rubber to wear prematurely.

SOCKET MAINTENANCE KIT – NK PART 0242 –

NK developed this kit to make it easy for you to care for

the metal connectors inside your Cox-Vox P5 connector

as well as the P2 connectors on the NK speakers.The kit

includes a specially sized drill bit for cleaning corrosion

and dirt from inside the sockets, as well as a syringe loaded with Nyogel for injecting into the sockets.

Regular use of these tools will ensure long life and reliable performance of the connectors. One kit will

allow you to maintain numerous Cox-Voxes for at least a season.

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Wiring built as tough

as your workouts.

Nielsen-Kellerman’s

All New Modular Harness System

You want to spend your time on rowing, not repairs.

The unique engineering of NK’s modular harness

ensures improved durability and flexibility. • Fully molded and sealed

design to stand up to the

harsh demands of rowing

and environmental exposure.

• Build EVERY harness you

need from three simple

pieces. Even add on pieces as

your budget allows.

• Affordable modules

eliminate the need for

repairs - simply plug in a new

section if needed.

• Plug-in rate sensor for

instant repairs and

trouble-shooting.

• NK proprietary gold-plated

pins and sockets

resist corrosion.

• Lighter than the HD harness

system

(24oz/680g for

8-3 harness).

• Fully compatible with all NK

speakers and Cox-Box systems.

• Full 3-year warranty:

Date coded with month

and

year.

MODULARHARNESS

COMPONENTS

(SEE BACK FOR TYPICAL CONFIGURATIONS)

1. A+ (AUDIO & RATE SENSOR)

2. R (RATE SENSOR)

3. A (AUDIO)

4. M (MULTI-SPEAKER)

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WARRANTY

Warranty Issues - NK products are carefully manufactured with high quality materials and thoroughly tested before

shipping. We do not believe in “disposable electronics”. Accordingly, all of our products are covered by a conditional

warranty* for the first two years and a “customer care” policy thereafter.

- During the first two years, products with a warranty issue will be repaired or replaced at no charge (including

return shipping within Australia) to the customer.

- During the third year & subsequent years, we will replace a failed unit with a unit at the“customer care price”

shown on the chart below, plus shipping OR, if possible, we will repair the unit. We reserve the right to restrict this

offer.

CUSTOMER CARE

NK wants you to be a customer for life, so we take care of you even beyond the terms of your product’s warranty.

We offer you a quick & economical service for the repair of your NK rowing equipment.

COX Vox overhaul: $195.00 inc GST

COX VOX overhaul: $165.00 inc GST

This is not just a simple repair, it is a major overhaul of your unit.Typically, this unit will function perfectly for the

next 5 to 8 years (provided you follow our guidelines for care of the unit). Replaced items include: ALL seals, battery,

panel rubber connector, all GOLD pins on connector, panel BNC, upgrade charge circuit, upgrade LCD lamp, supply

silicone lubricant. Any further items that require repair are subject to the Customer Care Pricing chart. All repairs

have a ONE YEAR warranty. Optionally, we can replace the can with a STAINLESS STEEL one for increased durability

($50.00 inc GST). Should your Aluminium can be excessively dented, then we must replace it with a stainless steel

unit as above. We can also repair your crackling microphone ($38.50 inc GST). Should your unit not be economical

repair, then we can offer you a NEW unit, with a TWO YEAR warranty at our customer care price. That is, you send

us your old unit & we sell you a new unit at a discounted price (call us for exact prices). No ifs, no butts, that is a

brand new unit.We do ask that the unit that you are sending to us has a valid serial number and must not have

been repaired or attempted to be repaired by anyone other than us. This offer excludes products that have been

physically abused. Customer must pay freight to have the unit delivered.

Customer Care Pricing Chart (all prices include GST)

Please visit our web site or call us for latest pricing.

* Customer Care policy is valid only for components listed above for as long as we manufacture them and does not cover product upgrades. All other parts

and accessories are covered under warranty up to one year from date of purchase.

HD harness has a 3 year warranty.

Units purchased prior to 1st January 2004 are covered by a one year warranty.

Warranty covers defects in materials & workmanship. Excludes damage due to improper use or neglect (including corrosion), modifications or attempted

repairs by someone other than NK, impact damage, failed batteries & normal wear & tear.

Units must have been purchased in Australia from an authorised Nielsen Kellerman agent.

Except as otherwise provided herein, no other warranties, expressed or implied, are made with respect to these products, including, but not limited to, any

implied warranty of merchantability or fitness for a particular purpose. NK assumes no liability for any damages, losses or expenses resulting directly or

indirectly from product use.

All prices & services offered are subject to change.

Details are correct as at 1st APRIL 2009