Active Noise Reduction ModulerM lnstallation and

Active Noise Reduction ModulerM lnstallation and

Shownwnh opl ona equrpmenl
Active NoiseReductionModulerM
lnstallation and Operatinglnstructions
For installation into GentexHelmet Model:
SPH-3
SPH-4
HGU-33
HGU-55
INDEX
I
PartsList & ToolsRequired...................................
I. Removeoriginalspeakers.
.....................................2
tr. Removeoriginalcrossover
cable..,........................4
m. Solderingthewiringharness..................................6
Prefened
methodfor soldersplice.........................7
TV. Aboutsoldering
...........................8
8
V. Soldering
thewires.................................................
VI. Solder
wiresto modules.........................................9
Insertmodulesinto earcups
Install new siliconegel earseals
..........
.................
...............10
vm.OperatingInstructions
Caution
Read theseinstructions completely before beginning the installation. The
anr modules are finely tuned & requirc that installation be performed
strictly in accordancewith this manual. Deviations from the instructions
contained herein will result in a systemrnalfunction. Purchaser assumes
all risks arising frorn an improper installation.
This product is intended for'sself installation into your helmet
and requires reasonableskill in the use of a soldering tool but a minimal
unilerstanding of electronics.ff you question your ability to perforrn the
installation, you are adviseil to take this unit & your helnet to the nearest electronic technician, or ship them to HEADSETS, INC. for a factory
installation. Any radio/tv technician or avionicstechnician should be able
to install the modulesin approximately 3 hours.
PartsList
Checkto seeyou havereceivedall materials
L pair modules (2 modules)- markedR & L. Eachmodulecontainsan
anr speaker,audiospeaker,microphoneandcircuit board
pair
1
siliconegel earseals- designedspecificallyfor helmettypeearcups
in orderto optimizeanrperformanceandcomfort.
I battery case- Sliding door permitseasyaccessto the 9v battery.
1 power cable - 60 inch, 2 conductor(red= 9v+ black or white =
ground-).
1 crossovercable - a 4 conductorcable, 33" length.
1 zipJoc bag of installation materials: solder,28gawire, shrink-wrap,
tie-wraps,strips of double sidedadhesivetape,2 fabic pads(black/
white oval), 4 piecesof temperfoaminsulation(4 pink crescentshaped
pieces).
Tools Nceded
1. Finetip solderingtool (20 wattor less)
2. Powerdrill and5/16"bit
3. Smallwire cutters
4. Small screwdriverset
5. Damp sponge- to cleansoldertip
6. Butanelighter - to heatshrink wrap
7. ContinuityTester(optional)- very helpful to confirm & identify wire leads
InstallationOveryiew
Earcupswith earsealsarerequiredfor installationinto aviationhelmets.Includedwith this kit is one pair of siliconegel type earsealsthat
will fit most helmetearcups.Earcupsare availablefor purchaseif your
helmetis not aheadyso equipped.
l. R€mov€original audio spcakcls
Removethe earsealfrom eachearcupandsetaside.Reachinto each
earcupand pull out the foam insulation and audio speaker.Disconnect
both wires from eachspeaker.
Confirmtheidentity of thesetwo wireson eachside. In mostGentex
helmetsaudio(+) is white andaudio(-) is black.Usinga continuitytester,
refer to Figure 1 at right andconfirm the color codingfor (+) and C).
Figure1
Originalwiringharness
afterspeakerremoval
white1= audio(+)
black2- audio(-)
Cut hereand remove
nalcrossovercable
originalcrossovercable
to boom
mic
audio(-)
MilitaryPlug
audio(+)
mic(+
GivilianPlugs
3
ll. Removeoriginal crosgovercable
Cut the original crossovercableat the placeshownin Figure l.
Removethe original crossovercablefrom the right earcupandsetaside.
Withdraw the main audio cablefrom the left earcupand partially withdraw
this cableftom the main grommet.
Enlargethe hole in the left earcupto 5/16 inch diameter.
Insert the 9v power cable (togetherwith the main audio cable) throughthe
main grommetandinto the left earcupasshownin Figure3.
Insertthenewcrossovercableinto the left earcupasshownin Figure3. Insert
the otherend of the crossovercableinto the right earcup.
The installationshouldnow look like Fieure3.
Figure2
Removeoriginalcrossovercableandpartially
withdrawmainaudiocabls
fromh€lmet.
enlargethishole
to 5/16inch
(leftearcuponly)
marn
grommer
MilitaryPlug
originalcrossover
cable
audio.C)
audio(+)
mic(+
CivilianPlugs
9 volt(+)
I voltC)
to boom
mic
I voltpowercable
lll. Solderingthe wifng harness
Aflel installationof all cables,your headsetshouldlook like Figure 3. Review
Figure 3 and Figure5, but belbre soldering,srudySectionIV "About Soldering"and
Figure 4 "Plefered method for soldersolice".
white 1
black2
green3
red 4
black5
red 6
otacK I
Figure3
Mainwiringharnessbeforesplicing
= audio(+)
= audio(-)
= audio(+)
= 9v(+)
= commonground(-)
= 9v(+)
= 9vC)
.,
6
*Disregard
this white wire from
new crossovercable as it is not
usedin thisapplication.
newcrossover
ca0le
original
crossover
MilitaryPlug
audio.(-)
caDte
to boom
mtc
a u d i o( + )
mrc(+
Audio+
CivilianPlugs
I volt (+)
I volt (-)
Usc thetie wrapsprovidcdto
tie thenewpowcrcableto the
originalaudio cable.Do not
over tighten or wircs inside-----".\
cablenlay break.
9 volt powercable
Figure4
A-F
Preferredmelhod for
solder splice
A
B
c
D
E
F
Stripabout1/4inchinsulation
fromeachwireend.
Twistwirestrands.
Tineachwireendby meltingsolderintotwistedwireends.
Holdwireendstogetherandmeltintoone(fuse).
Slideshrinkwrapoverspliceandheatwithflamefor 1-2seconds.
Heatonlytheshrinkwrap- avoidburninginsulation.
Finishedspiceshouldlooklikethis.
7
lV.About soldering
If you are not experiencedwith a fine tip solderingtool, a few
minutes of practice will greatly improve your proficiency. Spend
enoughtime andcarcto insurethatsolderjointsandsplicesarecleanly
done.
Useonly the 28 ga. wire providedwhenconstructingthe wiring
hamessandattachingto thep.c.board. Do not useheaviergagewire
or the final installationwill bemoredifficult (i.e.,tuckingwires& closing unit). Using theflexible 28ga.wire (andremoving excesslengths
of original wire) will resultin a moreprofessionalinstallation.
ReviewFigure5 for wiring sequence,
butbeforesolderingreview
Figure4, "Preferredmethodfor soldersplice".
V. Solderingthe wires
Solder/splicewire #6 to wiule#4. Auacha 3 inch pieceof 28 ga.
red wire. Coverwith shrink wrap.
Solder/splicewtre #7 to wire #2 and#5 (it may be necessaryto
lengthenwire #2 first, by usingshortlengthof black 28 ga.wire). Attach a 3 inch pieceof 28 ga.black wire. Coverwith shrink wrap.
to lengthen
Solder/splicewire #l to wire #3 (it maybe necessary
wire #1 first, by using shortlengthof green28 ga.wire). Attach a 3
inch pieceof 28 ga.greenwire. Coverwith shrink wrap.
Your wiring harnessshouldnow look like Fieure5.
w h i t e1
black2
green3
red4
black5
red 6
black7
=audio(+)
=audioC)
=audio(+)
= 9v(+)
= commonground(-)
= 9v(+)
= 9vG)
Figure5
Mainwiringharness
layout
* Typicalsoldersplicelocation
9v(+)
commonground(-)
Vl.
Solderwiresto modules
Insertmodulesinto earcups
lnstall newsiliconegel earseals
Melt a small spotof solderon to eachof the threeattachpoints
locatedon thecomerof eachmodule'scircuit board.Carefullysolder
the threewires to eachcircuit boardaccordingto Figure6.
Apply the 2 sidedadhesivetapeas shownin Figure 6, leaving
the exposedbacking paperin place until the foam insulationis in
place.Tirck the cablesaway andinsertthe pink temperfoaminsulation in the earcups.Compressthe temperfoamunderthe edgeofthe
earcupsandfit the modulesin place.ff modulesfit properly(flush),
pull eachmoduleout just enoughto removeadhesivebackingpaper
and pressmoduleinto place.Insertone black/whiteoval fabric pad
into eachmodule.Thesepadsareyery important. They functionto
acousticallydampenthe modulesand rnust remain in place.If the
padsbecomelost or soiled,call for a free setof replacements.
Install the gel earsealsby carefully sferching them aroundthe
flangeof the earcups.
green= audio(+)
red= 9v(+)
black= commont)
Figure6
Wiringto modules
If it is necessaryto remove a module after final installation, take care not to
damage module during removal. Carefully pry module from earcup. Removal is
accomplishedby insertingknife bladebetweenmoduleflangeand earcup.This will
deform the tape, separatingearcup and module without damage. This adhesivetape
is semi-permanentand may need to be replaced if module is removed from earcup.
We can provide additionaltapefree of charge.
Vll. Operatinginstructions
1. The silicone gel earsealsprovided with this product are required for
proper operation of this unit.
2. A standardaircraft radio is all that is requiredto power the audioportion of
for theactivenoisereducthe anrmodules.However,anaudiosignalis not necessary
tion circuit to operate.Supplying9v to themoduleswill activatethenoisecancelling
is "scratchy",checkfor tarnishedbrass
system.If audioreceptionor transmission
tips on audioor mic plug.Polishif necessary.
3. In cold conditions(below32f OAI) removethehelmetfrom theaircraftafter
eachflight.If helmetbecomescoldsoakedit is moresubjectto moisturecondensawill not damngg616sgradethe unit,
tion. Although summertimecabintemperatures
the batterycasecan warpif left in direct sunlight.
f cabintemp)canresult
4. Operationundercoldconditions(below40 degrees
insidetheearcups,
causingtemporarymalfunction.Allow
in moisturecondensation
unit to warm& dry beforeresuminguse.
5. Testthe activenoisesystemon the rampprior to eachuse.If thereis any
malfunction (squealing,humming,or oscillation),the power shouldbe tumed off
and the helmetusedconventionally.Minor hummingor oscillation can usually be
stoppedby applyinglight pressureto the earcup.
6. Life of a high quality9V batteryshouldbe approximately15-20hours.To
guardagainstaccidentallyleaving power on, unplug the power cablefrom battery
casewhenunit is not in use.An optionalautoshut-offbatterycaseis availablewhich
will automaticallyturn the poweroff after4 minutesof inactivity.
7. The active noisereductionmodules require a very stable power supply.
powersupplysystemswill causemalUse of cheap9v batteriesor nonapproved
functions, possiblydamagingthe circuitry. WerecommendDura-Cell , Energizer,
or Ray-O-Vac.
10
8. Do not attempt to power the anr modules directly from your aircraft
electricalsystemwithout usingour panelmountpowerunit. The voltagespikesand
backgroundstaticfrom mostaircraftwill soondamagethevery sensitiveintegrated
circuitsin themodules.Our panelmountpowerunit hasa .25ampfuse,dualvoltage
regulators,andis isolatedwith a DC/DC converter.
9. A continuity testeris very helpful, andis usuallyrequiredto tracea shortor
brokenwire.Theyareavailablefor undergl5.
10. Do not insert any material into the modules,suchas the original cloth
insertsor earcovers,foam rubber,etc.,exceptfor the black and white oval fabric
piecesprovided.
IMPORTANT: 2 blacklwhiteovalpiecesoffabric areprovidedwith eachset.
This material is intendedto keepdirt & debris out of the speakerelementsand to
acousticallydampentheanr modules,Oneshouldbeplaced insideeachanr module, coveringthe speakergrill holes & the microphones.tlse of thelabric pads is
mandatory.Failure to usethesemeyresultin feedback(squealing).IJ thepads are
lost or becomesoiled,call for a lree setof replacements.
For free technicalassistance
call 806-358-6336
weekdaysfrom 9:00A.M. to 5:00 P.M. (Central Time).
11
LimitedWarranty
This productis warrantedto be free from defectsin materialsor
workmanshipfor one(1) yearfrom the dateof purchase.Within this
period,IIEADSETS, INC. will at its soleoption,repairor replaceany
components
whichfails in normaluse. Suchrepairsor replacement
will be madeat no chargeto the customerfor partsandlabor; provided, however,that the customershallbe responsiblefor any transportation cost. This warrantydoesnot coverfailure dueto abuse,misuse,
accidentor unauthorizedalterationor repairs. HEADSETS,INC. assumesno responsibilityfor special,incidental,punitiveor consequential damages,
or lossof use.
TI{E WARRANTIESAND REMEDIESCONIAINED HEREIN
ARE EXCLUSryE, AND IN LIEU OF ALL OT}IER WARRANTIES
AND REMEDIESEXPRESSEDOR IMPLIED, INCLUDING ANY
LIABILITY ARISING I.INDERWARRANTY OF MERCHANTABILITY OR FITNESSFORA PARTICULARPURPOSE,STATUTORY OR OTTIERWISE.THIS WARRANTY GTVESSPECIFIC
LEGALRIGHTSWHICH MAYVARYFROM STAIETO STAIE.
To obtail warrantyservice,retum the unit alongwith a brief note
indicatingthe natureof the problem. Includeyour full name,address,
anddaytimephonenumber.Placethe unit in a box only (no padded
envelopes).The unit shouldbe insuredandsentfreight prepaidto
HEADSETS,INC., 2320LakeviewDrive.Amarillo.Texas79109
12
@Jteadsets
e-mail: orders@headsetsinc.com
Phone:806-358-6336. Fax: 806-358-6449
2320LakeviewDrive . Amarillo, TX 79I 09