Sigtronics Sport 200S User manual

Sigtronics Sport 200S Installation Instructions
Specialists in “SOUND” Management
178 East Arrow Highway, San Dimas, CA 91773 ( 909 ) 305-9399
INTRODUCTION
ATTENTION INSTALLER: To assure a trouble free installation,
please read the entire instructions through once before
beginning.
Sport 200S SYSTEM SPECIFICATIONS
CONFIGURATION – The Sport 200S Intercom system is specically
designed for permanent, panel mounted installation in aircraft. The Sport
200S provides voice activated (VOX) intercom and music input for two
headset positions in a small single chassis unit.
STEREO MUSIC INPUT – Music input accepts standard portable music
headphone or line level outputs. Automobile
Speaker level outputs can be adapted for use with Sport 200S systems.
COMPATIBILITY – Sport 200S intercoms have been designed to operate
with all standard general aviation aircraft radios and headsets.
SIZE: Panel – 1” x 2½”. Chassis – 1” high x 2½” wide x 4” deep.
Can be mounted either horizontally or vertically in the aircraft panel.
WEIGHT: 5.5 ounces (Sport 200S intercom unit with panel and knobs).
Jacks and wiring harness weigh 6.0 ounces
INPUT POWER: 11 VDC through 32 VDC. Maximum current drain 0.11 Amps
DISTORTION: Less than 1% total harmonic distortion.
WARRANTY: Sport 200S intercoms are constructed of high quality
components and carry a ve year parts and labor warranty.
HARDWARE SUPPLIED
Besides the intercom unit and instructions, each Sport 200S system
comes with the following hardware:
Headphone Output Jacks - Accept standard 0.250” aircraft
stereo headphone plugs. ......................................................................................... 2
Microphone Input Jacks - Accept standard 0.206” aircraft
microphone plugs. (U93 plug compatible jacks can be used in
place of the jacks provided – monaural installations only). ....................... 2
Mic Jack Insulating Washers, Flat .......................................................................... 2
Mic Jack Insulating Washers, Shoulder ............................................................... 2
Intercom Panel - lettered on both sides. ........................................................... 1
Intercom Control Knobs ........................................................................................... 2
Mounting Screws 4-40 x 1/2 ................................................................................... 2
Drill Template - Adhesive backed hole size pattern for
drilling aircraft panel. ................................................................................................ 1
Intercom / Aircraft Interface Cable (4 feet long) ............................................. 1
Headphone / Music Interface Cable (4 feet long) .......................................... 1
Stereo music input jack 3.5mm ............................................................................. 1
MUSIC MUTE OPTIONS
FACTORY DEFAULT - PARTIAL MUSIC MUTE DURING ICS - When
listening to music and someone speaks on the intercom the default
factory operation is to partially mute the music so you can hear the
conversation. The Sport 200S intercoms have one additional option
that can be enabled if desired. This option is enabled with the intercom
removed from the aircraft.
FULL MUSIC MUTE DURING ICS OPTION - The music can be completely
muted during intercom conversations. To enable this option, small jumper
wires are installed on the solder side of the circuit board.
CHASSIS INSTALLATION
Unit Placement
The Sport 200S unit has been designed to mount either horizontally or
vertically in your aircraft panel. The location selected for the unit requires
a minimum front panel area of 2½” by 1”. Depth required behind panel is
4” plus cable access.
CAUTION: Move the aircraft ight controls through the limits of travel
while observing the selected area and making sure that the rear of the
intercom and cable will not interfere with any aircraft control components.
Panel Preparation
1. Position the adhesive drill template on the aircraft panel in the selected
area.
2. Center punch each hole at the cross lines. (Five holes are in a straight
line and equally spaced 0.4” apart)
3. Drill ¹⁄₈” pilot holes in all ve places.
4. Enlarge holes to ¼” and ³⁄₈” per the template.
WARNING: This product can expose you to chemicals including
Polyvinyl Chloride, which is known to the State of California to
cause cancer, and Lead, which is known to the State of California
to cause birth defects or other reproductive harm. For more
information go to www.P65Warnings.ca.gov.

SHOULDER
WASHER
FLAT
INSULATED
WASHER
FLAT
METAL
WASHER
NUT
AIRCRAFT
PANEL
RING
BARREL
TIP
Figure 5
TIP
(RIGHT)
RING
(LEFT)
BARREL
(COMMON)
AIRCRAFT PANEL
NUT
Figure 3
Microphone Jack
RIGHT
LEFT
STEREO
+
-
+
-
+-
+-
RC
RC
C – 220 MFD, 25 VOLT CAPACITOR
R – 100 OHM, 5 WATT RESISTOR
NO CONNECTION
J2 (6) WHITE / VIOLET
J2 (4) WHITE / BROWN
J2 (5) BLACK
To Sport 200S
Figure 6
Figure 2
4–40 SCREWS SWITCH
NUT
KNOB
KNOB
AIRCRAFT PANEL
INTERCOM PANEL
DO NOT
REMOVE
THESE
NUTS
INTERCOM CHASSIS
MOD. ADJ.
MOUNTING CHASSIS (See Figure 2)
1. Remove the knobs from the Volume and Squelch controls using a 0.050”
Allen wrench. Remove the nut from the ON/OFF switch. NOTE: DO NOT
REMOVE the nuts from the Volume and Squelch controls.
2. Insert the Sport 200S unit from the rear of the aircraft panel with the
appropriate UP arrow for horizontal or vertical installation.
3. Install the printed Sport 200S panel and lightly thread the two 4-40 screws
through the holes in intercom panel. The nuts on the Volume and Squelch
controls will t inside the ³⁄₈” diameter holes.
4. Tighten the two screws and switch nut.
5. Install the knobs on the Volume (VOL) and Squelch (SQ) control shafts
and tighten the Allen screws.
MOUNTING HEADPHONE AND MICROPHONE JACKS (See Figure 3)
1. Locate the mounting areas. (One mic and one headphone jack required
for each headset). Again, make sure that the jacks will not interfere with
any aircraft control components. (Note that the jack contacts will expand
when a plug is inserted into the jack and must have clearance to prevent
shorting.)
2. Drill ³⁄₈” diameter holes for headphone jacks and install.
3. Drill ½” diameter holes for the mic jacks and install with the insulating
washers supplied. (See Figure 3).
Note: If the aircraft already has pilot headset jacks, the location can be used
for intercom with the following changes. The mic jack must be re-wired as
follows:
1. Remove any existing wires from the tip, ring, and barrel connections.
2. Connect the intercom white/black wire to the ring terminal.
3. Connect one end of a ground wire to the barrel terminal of the mic jack
and connect the other end to Intercom Central ground Point “A”.
4. Install insulating washers as necessary if the barrel of the mic jack is
mounted in metal. For the headphone jack, replace the mono headphone
jack with the stereo headphone jack. Connect the green wire (P2 pin 1)
to the tip connection. Connect the white/green wire (P2 pin 2) to the
ring connection.
WIRING INSTRUCTIONS
Connections should be made as shown in Figure 4 and indicated in Tables
1 and 2. Read also the referenced notes below. If longer wire lengths are
required, use a good quality multi stranded hook-up wire - 22 gauge or
larger. Although not necessary, shielded audio wire can be used if desired.
1. The blue wire from Pin 3 must be connected to the aircraft radio headphone
output - NOT the speaker output. NOTE – If aircraft radio volume heard
in the headsets changes signicantly when switching the ON/OFF switch
a minor adjustment to the radio receive potentiometer will x this. See
“INSTALLATION CHECK-OUT AND ADJUSTMENTS” section on page 3.
2. Connect all intercom mic jack grounds to a single aircraft chassis ground
point - Intercom Central ground Point “A” - as shown in Figure 4. (Use the
black washers supplied to insulate the intercom mic jacks from aircraft
chassis ground). Note this intercom central grounding point is used to
eliminate any unwanted electrical noises, such as alternator whine or
strobe noise, from being induced into the intercom system through the
grounds. All intercom mic jack barrels must be insulated from ground
where they are mounted and connected back to Intercom Central Ground
Point “A” on their own individual ground wire. Similarly, both intercom
ground wires (J1 pin 4) and the push-to-transmit switch grounds must
also be connected back to Intercom Central Ground Point “A”. It is not
necessary, however, to connect the headphone jack barrels to Intercom
Central Ground Point “A”. They can either be grounded where they are
mounted or some place nearby.
3. The red wire may be connected to either 12V (14V) or 24V (28V) power
source. No switching or adjustments are required to operate from either
source.
4. The Sport 200S system provides
a stereo music input. This music
input accepts portable music
Headphone or Line level music
sources. The wiring diagram shows
how to wire the Sport 200S for
use with a portable stereo music
source. A small stereo input jack is
supplied for this purpose. Connect
the White/Brown, White/Violet, and
Black wires to one jack as shown in Figure 4. Identify the jack terminals
using Figure 5. Drill a ¼” hole for the jack and mount on the aircraft panel.
To use, connect an adapter cable between the music input jack and the
output of the portable stereo. Suitable cables are available at your local
Stereo or electronics store as well as from Sigtronics. Speaker level output
car stereo music sources can also be used with the Sport 200S system. A
Floating Ground Adapter or a four wire to three wire converter will have
to be used between the Stereo and the Sport 200S music input. Figure 6
shows such an adapter and how it is wired into the Sport 200S.
5. The Sigtronics Sport 200S system can be installed as shown for use with
Stereo headsets. Alternatively, monaural general aviation type headsets
can be used. To use monaural headsets follow the installation instructions
as normal except for the wiring of the stereo headphone jacks. Use the
Page 2 SigtronicS Sport 200S Panel Mount intercoMS www.SigtronicS.coM

TO AIRCRAFT
POWER BUSS
12/28 VDC CENTRAL
GROUND
POINT) AIRCRAFT
HEADPHONE
JACK
POINT
AIRCRAFT / INTERCOM
INTERFACE AREA
(INTERCOM MIC AUDIO
HEADPHONE AUDIO
TIP
TIPRING
AIRCRAFT
HAND MIC
JACK
RADIO MIC KEY
J1 (2) WHITE/RED
J1 (1) WHITE/BLACK
J1 (11) WHITE/ORANGE
J1 (3) BLUE
J1 (6) BROWN
J1 (10) WHITE/BLUE
J1 (5) WHITE
J1 (4) BLACK J1 (7) RED
J2 (1) GREEN J2 (2) WHITE/GREEN
HEADPHONE
JACK
BARREL
TIP RING
MIC JACK
TO
BARREL
TIP
BARREL
HEADPHONE
JACK
TIP
MIC JACK
RING
BARREL
TIP
TO
CO-PILOTPILOT
RING
RING
J2 (4) WHITE/BROWN
J2 (5) BLACK
J2 (6) WHITE/VIOLET
A A
A
INTERCOM
CIRCUIT
BREAKER
(1 AMP)
MUSIC SOURCE
MUSIC
INPUT JACK
TO
A
TO
A
PILOT
PTT SWITCH
CO-PILOT
PTT SWITCH
TO
TO A
A
BARREL
TIP
RING
P2
J2 P1
J1
Optional Push-To-Intercom Switches
( 1 Per Headset )
J1 (12) VIOLET
Sport 200 S
INTERCOM
INTERCOM
Sport 200S
SQ ON VOL
12345
AIRCRAFT RADIO
AIRCRAFT CHASSIS GROUND.
2.)
NOTES
1.) IF PILOT PTT SWITCH IS CONNECTED TO THE AIRCRAFT HAND MIC JACK,
IT MUST BE DISCONNECTED AND CONNECTED TO THE WHITE / RED
CONNECTED TO THE WHITE / RED WIRE AS SHOWN.
RADIO RECEIVE
ADJUST
Figure 4
stereo headphone jacks supplied with the Sigtronics Sport 200S but leave
the “RING” connections open. Instead connect both headphone wires to
the “TIP” of the respective jacks. Connect both the WHITE/GREEN and
GREEN on to the TIP of the headphone jack.
6. The Violet wire (J1 pin 12) is provided on Sport 200S models only for
an optional Push-to-intercom function. For wiring and additional
instructions see the “Sport 200S PUSH-TO-INTERCOM INSTRUCTIONS”
section on page 4. Make sure any unused wires are properly insulated
and kept from shorting to any other wires or aircraft ground. Skip to the
“INSTALLATION CHECK OUT AND ADJUSTMENT” section below.
INSTALLATION CHECK-OUT AND ADJUSTMENTS
After the unit is installed, again check that the Sport 200S unit chassis, jacks,
and wiring harness are clear of all aircraft operating controls and cause no
interference with them. Next, to check out the Sport 200S unit installation,
plug in all the headset mic and phone plugs into the respective intercom
jacks. Put on the pilot’s headset and position the boom mic close to the
mouth. Voice clarity is best when the mic is at one side of the mouth and
¼” from the lips.
To assure that the aircraft radios, pilot’s headset, and PTT switch are
connected and functioning properly, switch the Sport 200S ON/OFF switch
to the “o” position. If applicable, set the aircraft audio panel to “Headphone”
position. Then turn on the aircraft radio(s) as usual, and verify that the pilot
can hear the radios and can transmit using his push-to-transmit switch and
headset. Aircraft radio(s) and audio panel should operate exactly as they did
before the Sport 200S system was installed. Aircraft radio reception should
also be heard in the co-pilot headset. There should be no intercom between
headsets with the Sport 200S unit “o”. Next turn the Sport 200S unit “on”.
Set the Sport 200S volume control to mid-position. Set Sport 200S squelch
control fully clockwise. Verify that the Pilot and co-pilot can operate the
aircraft radio(s). As before, all headsets on the intercom will hear the aircraft
radio(s). Check that both headset positions can intercom.
TABLE 1 - P1/J1 - See Wiring Instructions
PIN WIRE COLOR FUNCTION CONNECT TO
1White/Black Pilot Mic Input Ring Terminal of Pilot Mic Jack
2White/Red Pilot Transmit Switch
Input
Pilot Transmit Switch (PTT) (Switch
to Ground to Transmit)
3Blue *1 Radio Headphone Input Radio Headphone Output
4Black *2 Intercom Central
Grounding Point“A” Aircraft Chassis Ground
5White Radio Transmit Key
Output
Tip Terminal of Aircraft Hand Mic
Jack, or Key Input of Aircraft Radio
or Audio Panel
6Brown Transmit Mic Audio
Output
Ring Terminal of Aircraft Hand Mic
Jack or Mic Input of Aircraft Radio
or Audio Panel
7Red *3 12 through 28 VDC Power
Input Intercom Circuit Breaker
8— None No Connection
9— None No Connection
10 White/Blue Co-Pilot Transmit Switch
Input
Co-Pilot Transmit Switch (PTT)
(Switch to Ground to Transmit)
11 White/Orange Co-Pilot Mic Input Ring Terminal of Co-Pilot Mic Jack
12 Violet *7 ICS PTT ICS PTT Switches
TABLE 2 - P2/J2 - See Wiring Instructions
PIN WIRE COLOR FUNCTION CONNECT TO
1Green *6 Intercom Right
Headphone Output Tip Terminal of Headphone Jack
2White/Green *6 Intercom Left
Headphone Output Ring Terminal of Headphone Jack
3NC None No Connection
4White/Brown *2 Music Input Left Channel Left Music Source Headphone or
Line output
5Black *5 Music Input Common Music Source Common Headphone
or Line Output
6White/Violet *5 Music Input Right Channel Right Music Source Headphone or
Line Output
www.SigtronicS.coM SigtronicS Sport 200S Panel Mount intercoMS Page 3

Figure 7
Sigtronics Corporation
178 East Arrow Highway
San Dimas, CA 91773
909) 305-9399
www.sigtronics.com
HOW TO SELECT MUSIC OPTION
To select full music mute during intercom, the unit must be removed from
the aircraft. This is done by rst removing the volume and squelch control
knobs with a 0.05 inch Allen wrench. Then remove the two mounting screws
and switch nut that holds the unit in the panel. The unit is now free for
removal from the aircraft after disconnecting the cables at the plugs.
To enable this option, modication to the bottom of the units’ circuit
board is required. CAUTION – a qualied technician should perform this
modication. First remove the three screws securing the bottom cover to
the case and carefully lift and remove the cover. Note that the circuit board
does not have to be removed from its case to complete the modications.
To select full mute during intercom solder the two small-insulated jumper
wires at the locations specied in Figure 7.
Replace the cover and secure it with the three screws as before. Install the
unit back into the panel and plug in the two cables.
Sport 200S PUSH-TO-INTERCOM INSTRUCTIONS
Install a separate momentary switch at each headset position. Connect per
Figure 4. To use the push-to-intercom feature, turn the squelch control on
the intercom fully counter-clockwise. Then to activate, press the push-to-
intercom switch(s). Alternately, to use the intercom in voice activated (VOX)
mode set the intercom squelch as normal. See the separate Sport 200S
OPERATING INSTRUCTIONS sheet.
Mic Output Adjust
It may be necessary at this time to adjust the Sport 200S unit mic output
to the aircraft radios. A small adjustable potentiometer is provided inside
the unit for this purpose. It is accessible through a hole in the side of the
Sport 200S chassis. It is marked “Mod. Adj.”, and can be adjusted with a small
blade screwdriver (see Figure 2). In the event of over-modulation (garbled)
or reports of weak transmissions over the aircraft radio, an appropriate
adjustment can be made. Clockwise rotation increases the output level
to the aircraft radio mic input. Counter-clockwise rotation decreases
modulation level. This adjustment sometimes needs to be made after the
initial installation of the intercom or if a new radio is installed. (The output
is set for unity gain at Sigtronics).
Radio Receive Adjust
It may also be necessary to adjust the unit radio receive input from the
aircraft radio. A small adjustable potentiometer is provided inside the unit
for this purpose. It is accessible under a sticker on top of the chassis box
(see Figure 4), and can be adjusted with a small blade screwdriver. In the
event of low aircraft radio volume in the “ON” mode relative to “OFF” mode,
an appropriate adjustment can be made. Clockwise rotation increases the
input level to the Sport 200S radio receive input. Counter-clockwise rotation
decreases input level. This adjustment sometimes needs to be made after
the initial installation of the intercom or if a new radio is installed that has a
low output impedance or low output power. The adjustment is best made
with all headsets plugged in. (The input is set full CCW which is unity gain for
500Ω radios). Note: Be sure to replace the sticker when you have completed
the adjustment.
You are now ready to check for proper wiring of the music source. First, make
sure squelch is o (full counter clockwise) and intercom is ON. Turn on the
music source and listen for music through pilot and co-pilot headsets, and
passenger headsets. There should be music.
If everything checks out, refer to the Sport 200S OPERATING INSTRUCTIONS
sheet for proper use and other operating modes of the Sigtronics Sport
200Sintercom system. If something does not work as described, carefully
go over the intercom wiring again. If something is still not right or you have
any questions regarding the installation and operation of the Sigtronics
Sport 200Sintercom or any other Sigtronics product feel free to contact
us directly or E-mail us at [e-mail]. Technicians are available
Monday though Friday 8 am to 4:30 PM Pacic time.
See the separate Sport 200S OPERATING INSTRUCTIONS sheet for complete
operation information.
Sport_200S_REV-F_Installation.pdf 8-22-2023 PN 700115
Page 4 SigtronicS Sport 200S Panel Mount intercoMS www.SigtronicS.coM