Equipment Manual: Product Functional Specifications and Installation Manual
Equipment Manual: Product Functional Specifications and Installation Manual
Equipment Manual: Product Functional Specifications and Installation Manual
05
EQUIPMENT MANUAL
MODEL 438-[ ]
AND
2011.01.17
SEALED 13:05:17
-08'00'
IMPORTANT NOTICE
Chelton Avionics Inc. doing business as
Wulfsberg Electronics Inc. doing business
as Cobham Avionics will be responsible
for full distribution and revisions of ICA's
(Instructions for Continued Airworthiness).
CHANGE RECORD
DATE CHANGE CHECK APPROVAL
Revision A:
Added dB Systems reference paragraph and TSO
6-5-06 approved performance standards paragraph to SF AP
Section 1.0, Operating Instructions and Equipment
Limitation (paragraphs 1 & 2) (Type IV).
Revision B:
Corrected typos:
Revision 1.03:
Incorp ECR1 438-16:
10-23-08 SC AP
Updated Figure 1 to latest issue (includes 438—
007 and 438-008); Updated Figure 3 to latest
issue. Updated document format to NAT standard.
Revision 1.04:
6-26-09 Incorp ECR1 438-16-1: ZP AP
Added Detail Part Number Description table.
Zack
Revision 1.05: Pahl
man
SEE TITLE Incorp. ECR2 438-16. Updated Figure 1, outline, to Scot
Ford
2011.
01.17
2011.01.
TABLE OF CONTENTS
Page
Tables
Figures
EQUIPMENT MANUAL
MODEL 438-[ ]
The Model 438-[ ] Audio Control Amplifier is a remotely controlled, electronic unit which
operates upon command from switches and potentiometers in the cockpit. The Model 438-[ ]
is capable of switching and separately controlling the volume for up to 12 receiver inputs. It
also switches five sidetone inputs and an interphone line. In addition, two unswitches and
unmuted inputs are provided to accommodate an aural warning input and an auxiliary input.
Headphone and selected speaker outputs are isolated and a cockpit voice recorder (CVR)
output is provided from the headphone and interphone microphone audio. Microphone audio
can be recorded on the cockpit voice recorder at all times with the Model 438-[ ] (e.g., the
interphone microphone to CVR audio channel is unswitched and unmuted). A Pilot Select
COMM output (PSC) produces a summation of COMM1 through COMM 4, DME 1 and 2, and
the MKR 1 and 2 receiver inputs and is compatible with the Model 240, 250, or 251 PSC audio
input channel (or equivalent). PSC allows passengers to hear pilot selected audio if desired.
The speaker channel is powered through an internal fuse, separate from the headphone
channel so that a failure of the speaker channel will not disable the headphone channel.
Receiver and operating modes are electronically switched. Ground signals, applied by manual
switches in the cockpit, enable the electronic switches in the Model 438-[ ]. An electronic
attenuator is employed in each of the 12 receiver input channels. Every receiver input
attenuator has approximately 30 dB of range and is controlled by a volume control
potentiometer in the cockpit. Zero to 1K ohm linear taper pots are required for each volume
receiver control (maximum volume with maximum resistance).
Selective voice or code filtering is provided on four of the receiver audio inputs, intended for
ADF and NAV audio. The filter function is electronically controlled by ground signals from the
cockpit Voice-Off-Indent switch.
A Voice Activated switch is incorporated, in series with the microphone input, to reduce
interphone noise. This feature allows Hot Interphone operation without ambient noise being
coupled into the amplifier when the pilot is not talking. The threshold of voice activations may
be adjusted by an internal potentiometer screwdriver adjustment. It is factory set at 100
millivolts and adjustable from 15 to 350 millivolts. A 0 to 10K ohm external VOX threshold
potentiometer can be connected (maximum threshold with minimum resistance).
Operating modes of the Model 438-[ ] are listed in Table 1 and are established when a ground
signal is applied to the connector pin listed.
The conditions and tests required for TSO approval of this article are minimum performance
standards. It is the responsibility of those installing this article either on or within a specific type
or class of aircraft to determine that the aircraft installation conditions are within the TSO
standards. TSO articles must have separate approval for installation in an aircraft. The article
may be installed only if performed under 14 CFR part 43 or the applicable airworthiness
requirements.
001 Provides a higher SPKR, lower HDPH AW/AUX than the base model.
002 Provides different listening levels than the base model. Receiver and
sidetone audio output levels are 40 mW. Substitute (from base model)
3.00 VRMS SDTN to HDPH output, 2.30 VRMS COMM, MKR 1, 2, and DME
1, 2 to HDPH outputs.
003 Provides interphone operating levels for 8-station interphone system (37-
ohm interphone line). This unit provides more interphone audio to the
speaker and headphone than the base model, and increases the receiver
levels to compensate for increased load on the receivers by multistation
Model 438’s.
006 Provides a 2.7dB lower SPKR AW/AUX level than the base model.
007 Provides interphone operating levels for 4-station interphone system (75-
ohm interphone line). This unit provides more interphone audio to the
speaker and headphone than the base model, and increases the receiver
levels to compensate for increased load on the receivers by multistation
Model 438’s.
008 Provides interphone operating levels for 4-station interphone system (75-
ohm interphone line). This unit provides more interphone audio to the
speaker and headphone than the base model, and increases the receiver
levels to compensate for increased load on the receivers by multistation
Model 438’s.
Three separate electronic attenuators are employed in the Model 438-[ ] for audio master
volume control. One of them controls the level for both the headphone and speaker audio,
another controls the level for XMT and PA sidetone audio, and another controls the interphone
audio level. All three master attenuators have approximately 30 dB of range, controlled by
volume control potentiometers in the cockpit. Zero to 10,000 ohm linear taper pots are required
(maximum volume with maximum resistance).
All outputs (including the headphone and speaker outputs) of the Model 438-[ ] are open and
short circuit protected.
The speaker amplifier in the Model 438-[ ] is rated at 10 Watts into 4 ohms. This is a peak
rating intended for speech and music. The continuous rating of the amplifier is 1 Watt into 4
ohms for sine wave operation.
All internal screwdriver potentiometer adjustments of the Model 438-[ ] are set to factory
standards. If it is necessary to change a setting, refer to the calibration section of the
Acceptance Test Procedure, Document No. 438-4.
The amplifiers are adjusted for acceptable listening output levels into the proper loads with
receiver inputs of 7.75 volts RMS. This input level is realized when receivers are set for 100
milliwatts into 600 ohms. If 7.75 volts RMS is greatly exceeded at the inputs, the audio will
become distorted due to peak clipping and audio bleedthrough will be noticed. The amplifiers
will not be damaged however.
An important feature of the Model 438-[ ] is the Emergency Mode of Operation. The Model
438-[ ] automatically goes into this mode when the supply power to the unit is interrupted. In
the case of a critical electronic failure within the unit, the Emergency Mode of Operation can be
implemented by opening the switch (EMERGENCY switch) normally connecting pins P40-9 and
P40-3. In the Emergency Mode of Operation, the audio selected from COMM1 and 2, SDTN 1
and 2, and AURAL WARNING inputs is passed directly to the headphone output with 23 dB of
attenuation into 150 ohm headphone load.
2.0 SPECIFICATIONS
The Model 438-[ ] is intended for airplanes with two cockpit audio stations. Two Model
438-[ ] amplifiers are installed, one for each audio station. The receiver outputs are connected
to both Model 438-[ ] receiver inputs. The receiver input impedance of the Model 438-[ ] is
2,000 ohms so when the two specifications are installed, the receiver sees 1,000 ohms. Input
specifications are expressed in volts RMS, rather than milliwatts, to avoid any misunderstanding
INPUTS:
COMM: 4 dual audio inputs for receiver and sidetone. Receiver inputs level is 7.75 VRMS
and sidetone is 3.9 VRMS, both switched simultaneously.
PA SDTN: This is a switched audio input compatible with the PA sidetone output of Model
240, 250, 251 (or equivalent), which provides a 2.00 VRMS audio sidetone signal
produced from MIC (PA) to cabin paging.
RCVR: 4 signal, switched audio inputs for MKR, DME, etc. Input level is 7.75 VRMS.
MIC: The microphone input, used for interphone mode, supplies bias and is
compatible with carbon and amplified dynamic microphones. Voice activated
within 1.5 milliseconds by a circuit which provides 30dB minimum attenuation
within 2 seconds after speech (15 to 350 millivolt threshold range). Microphone
audio from this input is channeled directly to the CVR output amplifier. If
interface to low impedance microphones is desired, use Model 213 or Model
263 microphone amplifier.
FLTR: 4 single, switched audio inputs for NAV, ADF, etc. 7.75 VRMS inputs have
selected filtering, switched by the Voice-Off-Ident switch.
AW: This is an unswitched and unmuted input compatible with the aural
warning output of Model 630 (or equivalent), which provides aural
warning tones.
MASTER VOLUME: Controls level of all 12 receiver audio inputs to the speaker,
headphone, and cockpit voice recorder outputs. Volume control
range is 30 dB (minimum) controlled by a 10,000 ohm 1/2 Watt,
linear taper pot. Maximum volume is with maximum resistance.
SIDETONE VOLUME: Controls level of all 5 sidetone audio inputs to the speaker,
headphone, and cockpit voice recorder outputs. Range and control
same as MASTER VOLUME specification.
INTERPHONE VOLUME: Controls level of interphone audio input to the speaker, headphone,
and cockpit voice recorder outputs. Range and control same as
MASTER VOLUME specification.
RECEIVER VOLUME: (One electronic attenuator per receiver input). Controls level of the
respective receiver audio input before subject to control of the
MASTER VOLUME electronic attentuator. Volume control range is
25 dB (minimum) controlled by a 1K ohm (500 ohm for two Model
438-[ ] amplifiers connected in parallel), 1/2 Watt, linear taper pot.
Maximum volume is with maximum resistance.
OUTPUTS:
SPEAKER: The speaker amplifier is designed for speech signals and has both
a Rated Power and a Continuous Power specification. The
continuous rating is the power the amplifier can continuously deliver
with a sine wave. The Rated Power is the peak power it can deliver
COCKPIT VOICE
RECORDER: The CVR will deliver 1.7 milliwatts into 600 ohms continuously.
Rated and continuous power ratings are the same.
PILOT COMM: This Pilot Select COMM output will deliver 1.7 milliwatts into 600
ohms continuously. Rated and continuous power ratings are the
same.
INTERPHONE: The INPH output will deliver 1.5 milliwatts into 430 ohms
continuously. Rated and continuous power are the same.
FREQUENCY
RESPONSE: Flat within 3 dB from 350 Hz to 6,000 Hz.
HARMONIC
DISTORTION: Less than 3 percent distortion, all outputs
ISOLATION BETWEEN
CHANNELS: 60 dB
OPERATING
TEMPERATURE: From –55 to +70 degrees C.
2.1 Physical
Installation dimensions are shown on the Model 438-[ ] outline drawing (Figure 1). The
amplifier enclosure is designed for installation in a King rack assembly no. 071-4004-00. The
unit and rack assembly can be mounted in any position compatible with the rack assembly
because the unit fits into the rack assembly in only one position. No shock or vibration isolators
are required.
The Model 438-[ ] and the rack assembly can be mounted to a metal or plastic surface, but is
necessary to ground the case to the metal aircraft structure. When mounting to a plastic
surface, use a grounding strap. The case is finished with an electrically conductive film so it is
not necessary to remove the film for electrical bonding.
2.2 Electrical
Connections to the Model 438-[ ] are made through two “D” subminiature connectors. Each
mating connector manufactured by Positronic Industries, Inc. has part numbers for the
complete connector assembly. The part numbers are listed below.
Numeric pin identification and wiring diagrams are shown in Section 3.0. Shielded wire must be
used where indicated on the diagrams. AWG 24-26 size wire should be used for all
connections except those to the input power, power ground, and speaker amplifier output where
AWG 20-22 size should be used at pins 8, 10, 35, and 37 of P40.
The control switches shown will switch low current loads and should have a DC rating of 28
VDC. Typical switches for this application include Alco MTA series.
The 12 receiver volume control pots required (one each for both Model 438-[ ] amplifiers) are
linear taper, zero to 1,000 ohms (500 ohms when two 438’s are connected in parallel), 1/2 Watt
or greater. The Master, Sidetone, and Interphone volume control pots required are linear taper,
zero to 10,000 ohms, 1/2 Watt or greater. Electrically, the pots are wired to provide maximum
resistance to the Model 438-[ ] for full volume (fully clockwise rotation).
NOTES:
1. THE ENCLOSURE IS FABRICATED FROM 0.062 THK
ALUMINUM ALLOY CHROMATE CONVERSION
TREATED TO PREVENT CORROSION AND
PROVIDE ELECTRICAL BONDING.
8. REFERENCE DRAWINGS:
438-8 QUAL TEST REPORT
438-16 EQUIPMENT MANUAL
NOTES:
AURAL WARNING. 1. P50-XX REPRESENTS PIN NUMBERS OF THE 50 PIN
FROM 611 OR 630 AW GENERATOR P50-35 28VDC CHASSIS GND. D SUBMINIATURE CONNECTOR.
AUX INPUT P50-34 CW 2. P40-XX REPRESENTS PIN NUMBERS OF THE 37 PIN
AW INPH VOL.
P50-22 AUX PWR.GND. D SUBMINIATURE CONNECTOR.
P50-41 10K,LIN.
PA SDTN CW 3. P50-25 IS AUDIO COMMON FOR ALL RECEIVER
P50-1 FET SDTN VOICE MASTER NORM EMERG.
FROM 240, 250 OR 251 PA AMP INPUTS. COMMON TIE POINT SHOULD BE LOCATED
VOL. OFF VOL. AS NEAR AS POSSIBLE TO THE 438 AMPLIFIERS.
CW
COMM1 SDTN 10K, IDENT
10K,LIN.
SDTN HI P50-19 FET LIN.
XMT SDTN 4. ALL UNSHIELDED WIRES EXCEPT P40-3,8,9,10 & 19
ATTN MAY BE ENCLOSED IN A SINGLE CABLE.
RCVR HI COMM2 SDTN (30 AWG. MINIMUM)
P40-10
P40-19
P40-21
P40-20
P40-11
P40-12
P50-4 FET
P40-8
P40-9
P40-3
LO 5. REPRESENTS INTERNAL SCREWDRIVER
COMM3 SDTN P50-20 FET POTENTIOMETER ADJUSTMENT.
TYPICAL
XCVR COMM4 SDTN P50-21 FET
CONNECTION EMERG.
28VDC P40-13 SPARE
NAV1 P50-32 FET ATTN POWER 2KOHM
SUPPLY P40-15 SPARE
P50-27 COMM1
P50-45
FILTER COMM1 SDTN P40-17 SPARE
AND
NAV2 P50-31 FET ATTN REGULATOR COMM2
P50-11 COMM2 SDTN
P50-44 AW
ADF1 P50-14 FET ATTN SHOWN
P50-10 DE-ENERGIZED
P50-48 (EMERG. MODE)
VOICE/ FLTR
ADF2 P50-15 FET ATTN IDENT MASTER HDPH
FILTER 150-600 OHMS (NO MOD TO MOD C)
P50-9 ATTN AMPL. 8-600 OHMS (MOD D AND ABOVE)
P50-49
HDPH HEADPHONE
P50-18 FET ATTN
P50-6
P50-40 AUDIO CONTROL AMPLIFIER P40-4
CW
H 24 AWG (MIN)
P50-25 AUDIO COMMON VOICE
I
COMM1 (SEE NOTE 3) ACT.SW.
E 2
L 3
D 4
PA MIC P40-2 THLD
MIC
A TO 240, 250 OR 251 PA AMP P40-22
P40-27
P40-28
P40-29
P40-30
P40-31
P40-32
P40-33
P40-34
L
P40-25
P40-14
P40-18
P40-1
P40-6
L 1 P40-16
2 EXTERNAL JUMPER
3 THRESHOLD FOR INPH INPH SPKR
4 10K, LIN. INTERNAL HOT TO SW AUDIO LO's
P50-42
P50-43
P50-26
PTT
P50-8
PA KEY SPKR
TO 240, 250 OR 251 PA AMP SWITCH CW HOT
TO INTERFACE LOW
MIC SELECT IMPEDANCE MIC'S USE AUDIO LO's
FOR AUX, AW, ETC.
TO CPLT 438
MODEL 213 OR 263
Calibration procedures are included in documents 438-4 and 438-4-1 (for ITAR controlled
models), Acceptance Test Procedure.
Schematics, PCB assembly drawings, and parts lists, are contained within document 438-16
and 438-16-2 (for ITAR controlled models) for purposes of troubleshooting and repair by the
factory.
DO-160B
Conditions Section/ Description of Conducted Tests
Paragraph
Temperature and altitude 4.0 Equipment meets requirements of Category F2
similarity to the Model 418 amplifier.
.
Altitude 4.6.1
Temperature variation 5.0 Equipment meets requirements of Category B by
similarity to the Model 438 amplifier.
Humidity 6.0 Equipment meets requirements of Category A by
similarity to the Model 418 amplifier.
Operational shocks and 7.0
Crash safety Equipment meets requirements of DO-160B,
paragraphs 7.2.1, 7.3.1, 7.3.2, and 7.3.2.2 by
Operational shocks 7.2 similarity to the Model 418 amplifier.
Crash safety 7.3
Vibration 8.0 Equipment meets requirements (without shock
mounts) of Categories J, L, and O (DO-160B,
table 8-1) by similarity to the Model 418 amplifier.
Explosion proofness 9.0 Equipment identified as Category X, no test
required.
Waterproofness 10.0 Equipment identified as Category X, no test
required.
Fluids susceptibility 11.0 Equipment identified as Category X, no test
required.
Sand and dust 12.0 Equipment identified as Category X, no test
required.
Fungus resistance 13.0 Equipment identified as Category X, no test
required.
Salt spray 14.0 Equipment identified as Category X, no test
required.
DO-160B
Conditions Section/ Description of Conducted Tests
Paragraph
Magnetic effect 15.0 Equipment identifed as “X”, no test required.
Power input 16.0 Equipment qualified to Categories B and Z by
similarity to the Model 418.
Voltage spike 17.0 Equipment meets requirements of Category A
by similarity to the Model 418.
Audio frequency conducted 18.0 Equipment meets requirements of Category A
susceptibility by similarity to the Model 418.
Induced signal susceptibility 19.0 Equipment meets requirements of Category A
by similarity to the Model 418.
Radio frequency susceptibility 20.0 Equipment meets requirements of Category A
by similarity to the Model 418.
Emission of radio frequency energy 21.0 Equipment meets requirements of Category A
by similarity to the Model 418.
Lightning induced transient 22.0 Equipment meets requirements of Category L
susceptibility by similarity to the Model 418.
Lightning direct effects 23.0 Equipment identified as Category X, no test
required.
Icing 24.0 Equipment identified as Category X, no test
required.
Other Tests:
Acceptance Tests according to dB Systems Procedure 438-4 and performance tests in accordance with RTCA
Document DO-170, Appendix D were conducted to verify complete and proper operation of the Model 438
qualification test unit S/N 101. The Model 438-[ ] MOD D was tested to RTCA DO-214 and dB Systems
Procedure 438-4 to verify complete and proper operation of the Model 438 qualification test unit S/N 3069.
Remarks:
• Tests of DO-160B, Sections 4.0 (paragraphs 4.5.1 and 4.5.3), 5.0, 16.0, and 18.0 were conducted on the
Model 418 amplifier at dB Systems, Inc. in Redmond, Washington
• Tests of DO160B, Sections 4.0 (paragraph 4.6.1), 6.0, 7.0, 8.0, 17.0, 19.0, 20.0, and 21.0 were conducted on
the Model 418 amplifier at Sundstrand Data Control, Inc. in Redmond, Washington.
• Tests of D0-160B, Section 22.0 were conducted on the Model 418 amplifier at Beech Aircraft Corporation in
Wichita, Kansas.
• The Model 438-[ ] MOD D redesign was qualified by similarity to the Model 456-[ ] Audio Control Amplifier.
All tests conducted on the Model 456-[ ] are summarized in dB Systems Document No. 438-8 Appendix B.
• The Model 438-[ ] MOD D was retested to RTCA DO-160C sections 7.0 and 8.0 at Primex Aerospace in
Redmond, Washington. Section 8.0 category L was extended from 150Hz to 2000Hz. Section 7.2 was tested
to a level of 20g in 6 directions while operating.