VAL Avionics AP 100 Setup guide

VAL AVIONICS LTD
AP 100 AUDIO PANEL
Audio Management System
Installation and Operator’s
Manual
Original Issue
October 06
P/N 0720100

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
Table of Contents Pg
1 SECTION I - GENERAL INFORMATION .............................................................. 1
1.1 INTRODUCTION .............................................................................................. 1
1.2 SCOPE................................................................................................................ 1
1.3 EQUIPMENT DESCRIPTION .......................................................................... 1
1.4 SPECIFICATIONS............................................................................................. 2
1.5 EQUIPMENT SUPPLIED.................................................................................. 3
1.6 EQUIPMENT REQUIRED BUT NOT SUPPLIED .......................................... 3
1.7 LICENSE REQUIREMENTS............................................................................ 3
2 SECTION II - INSTALLATION................................................................................ 4
2.1 GENERAL INFORMATION............................................................................. 4
2.1.1 Scope........................................................................................................... 4
2.2 UNPACKING AND INSPECTION................................................................... 4
2.3 EQUIPMENT INSTALLATION PROCEDURES ............................................ 4
2.3.1 Cooling Requirements ................................................................................ 4
2.3.2 Mounting Requirements.............................................................................. 5
2.3.3 Wire Harness Fabrication ........................................................................... 5
2.3.4 Audio Panel Installation.............................................................................. 5
2.4 POST INSTALLATION CHECK...................................................................... 6
2.4.1 Operational Check ...................................................................................... 6
2.4.2 Final Inspection........................................................................................... 6
2.5 LIMITATIONS................................................................................................... 7
3 SECTION III - OPERATION..................................................................................... 8
3.1 GENERAL INFORMATION............................................................................. 8
3.1.1 Scope........................................................................................................... 8
3.1.2 Transmit Selection...................................................................................... 8
3.1.3 Audio Selection........................................................................................... 8
4 SECTION IV - WARRANTY AND SERVICE....................................................... 10
4.1 WARRANTY ................................................................................................... 10
4.2 SERVICE.......................................................................................................... 11
5 Appendix A – INSTALLATION DRAWINGS AND CONNECTOR
LAYOUT.................................................................................................................. 12
6 Appendix B – WIRING DIAGRAMS...................................................................... 13
7 Appendix C – INSTRUCTIONS FOR CONTINUED AIRWORTHINESS ........... 15
7.1 MAINTENANCE INSTRUCTIONS ............................................................... 15
Table of Figures
Figure 1 Uint Controls....................................................................................................... 8
Figure 2 Unit Controls....................................................................................................... 9
Figure 3 Physical Dimensions ......................................................................................... 12
Figure 4 Panel Cut Out .................................................................................................... 12
P/N 0720100 i
Original Issue October 06

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
Table of Tables Pg
Table 1 Specifications......................................................................................................... 2
Table 2 Equipment Supplied.............................................................................................. 3
Table 3 Equipment Not Supplied....................................................................................... 3
Revision History
Rev. Date Description of change
IR September 2006 Initial Release
P/N 0720100 ii
Original Issue October 06

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
1 SECTION I - GENERAL INFORMATION
1.1 INTRODUCTION
Ease of installation and simple operation make the AP 100 Audio Management System
the communication solution for a wide variety of aircraft panels, from the Homebuilt
through heavy twins. The AP 100 satisfies the need for convenience of a fully
functioning quality Audio panel that can be counted on to provide years of reliable
service.
Before installing and /or using your new AP 100 Audio Panel please read this manual
completely. This will ensure proper installation and familiarize you with all of the
features your new audio panel has to offer.
1.2 SCOPE
This manual will provide detailed information about the installation and operation of the
AP 100 Audio Panel. It will also provide equipment limitation information and
instructions for continued airworthiness.
1.3 EQUIPMENT DESCRIPTION
The AP 100 has been designed for simplicity. It is straight forward to install and operate.
Using state of the art technology Val Avionics has created an Audio Panel that will
provide the pilot with simple unencumbered control of the various audio sources
commonly found in today’s civil aircraft.
The COM 1 / COM 2 XMT SEL switches make it easy to select a transceiver for
transmitting and receiving radio communications. The selected transceiver is indicated by
an illuminated LED. This LED flashes while the transmit key is depressed. Received
audio from the selected transceiver is automatically switched to the headphones.
Received audio from both COM 1 and COM 2 can be routed to the headphones as desired
by activating the BOTH switch. When both audios are selected an LED annunciation will
illuminate.
NAV 1 and NAV 2 audios can be switched to the headphone using the NAV 1 and NAV
2 selector switching. These selections are also indicated by LED annunciation. All of the
selected audios can be switched to the cabin speaker with the SPKR select switch. An
LED annunciation will indicate this selection.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
Muting for the external marker beacon receiver audio is provided by the MKR switch. A
steady LED annunciator for the MKR switch indicates that marker beacon received
audio, if present, will be heard in the headphones and over the cabin speaker if the SPKR
switch is selected. The pilot may mute the marker audio by depressing the MKR select
switch. Doing so will mute the incoming marker audio for approximately 20 seconds.
While the marker audio is muted the MKR LED annunciator will flash.
Four un-switched audio inputs are provided at the rear connector for such audio inputs as
DME, ADF, Auto Pilot alerts or any other audio source which would commonly be
routed to the aircraft headphone and cabin speaker systems.
A Fail-safe feature has been incorporated into the design of the AP 100 that will
automatically connect the pilot’s headphones and microphone to the aircrafts COM 1
radio in the event that power is removed from the audio Panel or if the unit is powered
down.
1.4 SPECIFICATIONS
Table 1 Specifications
DIMENSIONS
Hight 1.0 in. (2.54 cm)
Width 6.34 in (16.10 cm)
Depth 5.83 in (14.81 cm) behind the panel
WEIGHT 16 oz
ELECTRICAL
Voltage input range 12.5-18 Vdc
Current 500 mA max
Audio input impedance 600 ohms
Input isolation Better than 80db
AUDIO OUTPUT
Headphones 50 mW Continuous RMS power into 150
ohms
Cabin speaker 2.5 W Continuous RMS power into 4 ohms
AUDIO INPUTS
Switched COM 1, COM 2, NAV 1, NAV 2, MKR
Un-switched 4 (examples ADF, DME, Autopilot Alerts)
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
1.5 EQUIPMENT SUPPLIED
Table 2 Equipment Supplied
QTY DESCRIPTION PART NUMBER
1 AP 100 AUDIO PANEL 0800100
1 MOUNTING TRAY 0511002
1 INSTALLATION KIT 0650100
1.6 EQUIPMENT REQUIRED BUT NOT SUPPLIED
Table 3 Equipment Not Supplied
QTY DESCRIPTION PART NUMBER
1 Interconnect Wire Harness VPN 0751005 or field
fabricated
1 Microphone Jacks Switchcraft P/N S12B (Ref
VPN 550018)
1 Headphone Jacks Switchcraft P/N 11 (Ref
VPN 550017)
1 Circuit Breaker 2 amp Potter & Brumsfield W58-2
(Ref VPN 0331005)
1 Aircraft Cabin Speaker Ref aircraft parts manual for
specific part number
1 Contact Crimping Tool w/
Positioning Tool AMP P/N 601966-1 AMP P/N 601699-5
1.7 LICENSE REQUIREMENTS
None
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
2 SECTION II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 Scope
This section of the manual will provide the needed information to successfully complete
the installation of your new AP 100 Audio Panel. Please read this section completely
before proceeding with the installation process. Although the AP 100 installation
procedures are designed with the do-it-yourselfer in mind, we at Val Avionics strongly
suggest that you seek the advice of a qualified avionics installation facility before
beginning this or any other installation project. Qualified Avionics installation
technicians can offer good advice as to time-tested installation practices and techniques
that can save you many hours of time and frustration.
2.2 UNPACKING AND INSPECTION
Use care when unpacking the equipment. Inspect the unit and supplied parts for visual
signs of damage during shipment. Examine the unit for loose screws, dents, broken
buttons and other signs of damage that may have occurred during shipment. Verify the
contents of the container with the list in section 1.5. If any damaged or missing parts are
discovered during the inspection save the shipping material and contact the freight carrier
to file a claim. If it is suspected that parts were omitted from the container please feel free
to contact Val Avionics to acquire the missing items.
2.3 EQUIPMENT INSTALLATION PROCEDURES
2.3.1 Cooling Requirements
Forced air cooling is not required for the AP 100 audio Panel. However, when planning
the location for mounting ensure adequate spacing from heat producing sources such as
heating or defrosting ducts.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
2.3.2 Mounting Requirements
The AP 100 Mounting Tray (VPN 0511002) should be rigidly mounted in the avionics
stack using the hardware provided in the installation kit. Ensure that the mounting
location will provide easy access and a clear view of the equipment’s front panel from the
pilot’s position. Ensure that the mounting position will provide adequate clearance
between the unit and the associated wire harness and the aircraft controls. Bracing at the
rear of the unit should be installed to ensure rigidity in the panel. Consult FAA Advisory
Circular AC 43.13-2A for acceptable practices and techniques.
2.3.3 Wire Harness Fabrication
Val Avionics recommends that a factory fabricated wire harness (VPN 0751005) be used
for the installation of the AP 100 Audio Panel. Use of the factory fabricated wire harness
will ensure proper operation of the Audio Panel, reduction in the occurrence of
interfering audio signals and ground loops, greatly reduced installation time, and provide
prolonged trouble-free performance of your new equipment. Contact Val Avionics or
your local avionics distribution center for AP 100 Wire Harness ordering information.
Although strongly recommended, it is not required to use the factory fabricated wire
harness when installing the AP 100 Audio Panel. A wiring harness can be fabricated in
the field. Refer to appendix B of this manual for a complete wiring diagram. All wires
must be 22 AWG MIL-SPEC, unless otherwise noted in accordance with current
regulations. Two and three conductor shielded MIL-C-27500 or equivalent wire must be
used where indicated. Use AMP Contact Crimping Tool (AMP P/N 601966-1) with
Positioning Tool (AMP P/N 601699-5) or equivalent to ensure good quality contacts.
Refer to FAA Advisory Circular AC 43.13-2A for acceptable practices and techniques.
2.3.4 Audio Panel Installation
Carefully insert the Audio Panel into the mounting tray. The unit should slide into the
tray freely without binding. Approximately 3/8” before complete insertion into the tray
check for alignment of the DB25 connector on the unit and the mating DB25 connector at
the back of the tray. Using a 7/64” allen wrench access the locking pawl screw located at
the top center access hole on the face of the unit. Rotate the screw clockwise to draw the
Audio Panel fully into the mounting tray. There will be a .020” gap between the back
surface of the unit’s faceplate and the front edge of the mounting tray when the unit is
fully seated.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
2.4 POST INSTALLATION CHECK
2.4.1 Operational Check
•Switch on Aircraft Master and Avionics Master as appropriate.
•Power on the unit by pressing the ‘PWR’ switch. The blue LED should
illuminate.
•Plug headset into jackset
•Select COM 1 by pressing the ‘COM 1’ XMT SEL’ switch. The green LED will
illuminate. If the LED is flashing, stop testing and troubleshoot the microphone
PTT installation. A flashing indicator in the COM select button indicates that the
key line is grounded.
•Verify proper transmit and receive operation on the NO. 1 COM. Note that the
LED flashes during the transmit function.
•Select COM 2 by pressing the ‘COM 2’ XMT SEL’ switch. The green LED will
illuminate. Note that the LED flashes during the transmit function.
•Press the ‘BOTH’ button and verify that COM 1 and COM 2 receive audios can
be heard. Note that the button stays in and the LED illuminates.
•Verify proper operation of the NAV 1 and NAV 2 receiver sources by selection
them using the ‘NAV 1’ and ‘NAV 2’ buttons. Note that the button for the
receiver source stays in and the LED illuminates to show which source is in use.
•Push in the ‘SPKR’ button to activate the cabin speaker and verify that the
selected audio source can be heard over the cabin speaker. Verify that the speaker
is muted when a transmitter is keyed.
•Press the ‘MKR MUTE’ button and verify that the marker audio is muted and that
the LED indicator flashes for approximately 20 seconds. The LED indicator will
then go steady again and the marker audio can be heard.
•Verify that the AP 100 Audio Panel does not adversely affect any other aircraft
system by systematically switching the unit on and off while monitoring the other
avionics and electrical equipment on the aircraft.
2.4.2 Final Inspection
Verify that the wiring is bundled away from all controls and that no part of the
installation interferes with the movement of the aircraft controls. Move all of the aircraft
controls through their full range of movement while visually verifying that the
installation does not mechanically interfere with the control movement. Verify that the
wiring harnesses are properly secured to the aircraft structure in accordance with
accepted practices as described in AC 43.13 and that adequate strain relief and service
loops have been provided. Ensure that there are no kinks or sharp bends in the wire
harnesses. Verify that the wire bundles are not exposed to any sharp or abrasive surfaces.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
Complete log book entries, FAA form 337, weight and balance computations and other
documentations as required.
2.5 LIMITATIONS
There are no known limitations to the operation of the AP 100 Audio Panel. Instructions
for Continued Airworthiness and Return to Service Instructions can be found in
Appendix C.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
3 SECTION III - OPERATION
3.1 GENERAL INFORMATION
3.1.1 Scope
This section will provide detailed operating instructions for your new AP 100 Audio
Panel. Please read this section completely to become familiar with all of the features of
the audio management system.
Figure 1 Unit Controls
3.1.2 Transmit Selection
With the unit turned on, the pilot can select to transmit on COM 1 or COM 2 by
depressing the corresponding selector button. The selected transceiver is indicated by an
illuminated LED. Received audio from the selected transceiver is automatically switched
to the headphones. While the transmit key is depressed the LED indicator will flash
alerting the pilot that the selected transmitter is active. Only one transmitter can be
selected at any time. With the unit turned off the pilot’s microphone and head set are
automatically connected to COM 1.
3.1.3 Audio Selection
Received audio from both COM 1 and COM 2 can be routed to the headphones as desired
by activating the BOTH switch. When both audios are selected an LED annunciation will
illuminate. NAV 1 and NAV 2 audios can be switched to the headphone using the NAV 1
and NAV 2 selector switching. These selections are also indicated by LED annunciation.
All of the selected audios can be switched to the cabin speaker with the SPKR select
switch. An LED annunciation will indicate this selection.
If the audio from an external marker beacon receiver is connected to the AP 100 the
received audio will be routed to the headphones without any action required by the flight
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
crew. Muting for the external marker beacon receiver audio is provided by the MKR
switch. A steady LED annunciator for the MKR switch indicates that marker beacon
received audio, if present, will be heard in the headphones and over the cabin speaker if
the SPKR switch is selected. The pilot may mute the marker audio by depressing the
MKR select switch. Doing so will mute the incoming marker audio for approximately 20
seconds. While the marker audio is muted the MKR LED annunciator will flash.
Four un-switched audio inputs are provided at the rear connector for such audio inputs as
DME, ADF, Auto Pilot alerts or any other audio source which would commonly be
routed to the aircraft headphone and cabin speaker systems. These audios are not
controlled by any of the selector switches on the AP 100, therefore audio levels for these
devices will be controlled on each respective unit.
Figure 2 Unit Controls
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Original Issue December 06

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
4 SECTION IV - WARRANTYAND SERVICE
4.1 WARRANTY
The equipment delivered with this Standard Factory Warranty is manufactured by Val
Avionics, Ltd. and is guaranteed against defective materials and workmanship for one
year from date of original retail purchase. Any unit found to be defective due to material
and workmanship during the warranty period will be repaired or replaced at the sole
discretion of Val Avionics.
Val Avionics, LTD’s liability under this warranty is limited to servicing, repairing or
adjusting any equipment returned prepaid to the Val Avionics’ factory by express written
or verbal authorization for that purpose and to repair or replace defective parts thereof.
If, upon examination, it is determined that a malfunction has been caused by misuse of
the equipment, installation or operation not in accordance with factory instructions,
accident or negligent damage, alterations of any manner, and repair by other than the
factory, the repairs will not be covered under the warranty. In such cases, an estimate will
be submitted for approval before repair is initiated. In most cases, Val avionics, Ltd. will
provide 72-hour turn around on its warranty and repair service. We recommend that
contact be made with the FACTORY CUSTOMER SERVICE DEPARTMENT prior to
any unit return and obtain RETURN AUTHORIZATION AND INSTRUCTIONS. This
will provide proper control and expedite service.
Val Avionics, Ltd. reserves the right of continuous product development without
obligation to install changes in previously manufactured products.
Installation of Val Avionics, Ltd. products must conform to methods acceptable by the
Federal Aviation Administration as described in the appropriate Federal Aviation
Regulations (FAR’s) and Advisory Circulars (AC’s).
To ensure proper warranty registration, type or print clearly the application information
on the enclosed PRODUCTS WARRANTY REGISTRATION FORM and return to Val
Avionics, Ltd.
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
4.2 SERVICE
Repair service for the AP 100 Audio Panel is available at our manufacturing facility.
Units in need of servicing should be returned prepaid to Val Avionics Ltd at the
following addresses.
If you are shipping by the US Postal Service address To:
Val Avionics
P.O. Box 13025
Salem, OR 97309
If you are shipping by Fedex, UPS or other shipping company, address To:
Val Avionics
3280 25th ST SE
Salem, OR 97302
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
5 Appendix A – INSTALLATION DRAWINGS AND
CONNECTOR LAYOUT
.54
.36
5.83 6.80
6.34
1.00
Figure 3 Physical Dimensions
Figure 4 Panel Cut Out
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Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
6 Appendix B – WIRING DIAGRAMS
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Original Issue December 06
Aircraft Phone
Aircraft Mic
Mic Audio
Mic Key
Audio GND
COM 1
Mic GND
Com 1 Phone Audio In
Com 1 Mic Audio Out
Com 1 Mic Key Out
Mic Audio
Mic Key
COM 2
Audio GND
Mic GND
Cabin Speaker
Cabin Speaker Out
Aircraft Mic Return
Aircraft Mic Audio In
Aircraft Mic Key In
Com 1 Phone Return
Aircraft Phone Return
Aircraft Phone Out
Com 2 Mic Key Out
Com 2 Mic Audio Out
Com 2 Phone Return
Com 2 Phone Audio In
Phone Audio Out
Phone Audio Out
To Intercom System
Avionics Bus (B+)
Avionics Bus (B+)
Aircraft Ground
Aircraft Ground
2 A
Avionics Bus
J1
[NOTE 1]
[NOTE 3]
[NOTE 2]
[NOTE 4]

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
Audio Out
Audio Gnd
MARKER REC
Audio Out
NAV 2
Audio Gnd
Audio Out
NAV 1
Audio Gnd
Audio Out
Audio Gnd
AUTO PILOT
Audio Out
Audio Gnd
Audio Out
DME
Audio Gnd
Audio Gnd
Audio Out
Unswitched Audio 4
Unswitched Audio 1
Unswitched Audio 3
Unswitched Audio 2
Marker Audio
Nav 2 Audio
[NOTE 6]
Nav 1 Audio
J1
TAS
ADF
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Original Issue December 06

Val Avionics Ltd
AP 100 Audio Panel
Installation and Operator’s Manual
7 Appendix C – INSTRUCTIONS FOR CONTINUED
AIRWORTHINESS
7.1 MAINTENANCE INSTRUCTIONS
Maintenance of the AP 100 is on condition only. No periodic maintenance is required. If
unit is removed for service, upon re-installation perform Post Installation check as
described in section 2.4 of this manual.
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Original Issue December 06