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PROCOM 4 AIRCRAFT INTERCOM I

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INSTALLATION AND OPERATION GUIDE

IMPORTANT!

a) If a BUILT-IN, YOKE-MOUNTED, COPILOT PTT SWITCH is wired in parallel with the pilot PTT switch, it
must bedisconnected and wired tothe ProCom4as shown in Figure3.The PILOTPTTSWITCH should be
left wired t o the aircraft radio, but should also be wired to the ProCom 4 as shown (see Figure 3).

i; b) PLUG-IN PORTABLE PTT SWITCHES (such as the Telex Model PT-300) typically have a plug for
connection to the aircraft transceiver and a jack to plug in the microphone. D O NOT PLUG THE
MICROPHONE INTO THIS TYPE OF PT'T SWiTCH,"BECAUSE THE SWITCH WILL HAVE TO BE
PRESSED TO TALK OVER THE INTERCOM! Plug the portable PTT switch into the existing hand
microphone jack, and plug the microphone into the jack wired to the ProCom 4 as shown i n Figure 3.
- ~~- ~~ -
-~pp--pp-p---. ~ ~~ ~ ~~ ~~~ ~~ ~ ~~~ --

TELEX,
TELEX COMMUNICATIONS, INC.
9600 Aldrich P.ve. So., Minneapolis, MN 55420 U.S.A.

@ Copyright Telex Communications, Inc. 1989

38109-183 Rev A
 INTRODUCTION
- GENERAL

The Telex Model ProCom 4 is a compact, panel-mounted aircraft intercom. It provides noise-free, voice-
activated communicationsfor a pilot, copilot, and up to three passengers. It has provisions for connections of 1
a music/auxiiiary source and a tape recorder to record all piiot/ATC communications.

FEATURES
!
IMPROVED SQUELCH (voice activation): The ProCom 4 is equipped with a master squelch control and
individual squelch circuits with trimmers for pilot, copiiot and passengers. Only the microphoneof the person
talking is "hot", resulting in less noise. In addition, using separate squelch trimmers solves squelch adjustment
problems caused by such things as different ambient noise levels at different microphones throughout the
cockpit, several types of microphones being used, and different user voice levels.

SEPARATE HEADPHONE VOLUME CONTROLS: Separate controls for pilot and copilot. Single controi for
passengers.
!
MODE SWITCH: Three operating modes (see Mode Switch Operation Table foroperational summary). I
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PTT SWITCHING: Pilot PTT access via existing yoke switch. Copilot access via single-pole, momentary
contact switch (Telex PT-300 or equivalent). Pilot has transmit priority over copiiot.

MOUNTING FLEXIBILITY: Reversible faceplate permits horizontal or vertical mounting in controi panel.
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FAIL-SAFE SWITCHING: In theevent of an intercom failure, the pilot can still usethe aircraft radio by turning
the intercom off.

INSTALLATION REQUIREMENTS

installation by a qualified avionics technician is recommended. Requires additional cabling and jacks for
installation. Cabling should beof atypeapproved forairframeand internal avionics. Power and ground wiring
- ... . --shouid-be~at-least-20-gauge.-All-other-wiring-shouid-be-at-least-22-gauge.P-ower-must-be-supplied-through-a~
separate breaker, orfuse (fuse and holder supplied, power cable is not). All connections to the intercom are
made using crimp-on terminals which are then inserted into a Molex connector housing on the rear panel of
the ProCom 4. The connector housing and terminals are provided with the ProCom 4.
0

SPECIFICATIONS
POWER REQUIREMENT: 12-28 volts dc, 125 miliiamps maximum with 28-volt dc aircraft supply.
/-
FUSE: 0.25 amp, 250-volt fast blow.

HEADPHONES:150-600ohm impedancegeneral aviation headphones (noiseattenuating types recommended

for best results). Separate outputs for pilot, copilot and up to three passengers. Power output: 120 miiiiwatts
into 150 ohms with 28-volt dc aircraft supply (800 mW total continuous).

MICROPHONES:Carbon, or carbon-equivalent amplified microphones (noisecanceiiing types recommended

but not required). Separate microphone inputs for piiot, copilot and up to three passengers.

MUSICIAUXILIARY PROGRAM:Accepts either monaural orstereo, high-level, low-impedanceinput (such as

headphone or speaker source). (ProCom 4 output is m~naural.)~Music
level is automatically reduced by
approximately 12 dB during voice communications.

CONTROLS:

Powerofflon switch. (In theoff position, the pilot microphoneand headphones areswitched directlyto the
radio for fail-safe operation.)

Separate piiot and copilot volume controls. Single passenger volume controi

Squelch control, with separate squelch trimmersfof pilot, copilot, passenger no. 1 and extra passenger, and
passenger no. 2.

Three-position mode switch.

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ii Music/auxiiiary input level trimmer.

Radio equalization trimmer: Equalizes headphone volume when switching between intercom and radio.

IN.DICATORS:-LED-transmission-i.ndicat.or-illum.inates-w.hen-either-pilotoccopilot-tcansmits.-.~------

WEIGHT: 0.61 ibs.

DIMENSIONS: See Figure 1.

ORDERING INFORMATION
ProCom 4 Aircraft Intercom ..................................................... Catalog No. 70650-000
With fuse and holder, Moiex connector kit, mounting template, and instructions
.;.
Jack Kit ....................... .............................................Catalog No. 70633-000
Includes four 0.206-inch dia microphone jacks, and four 0.250-Inch dia phone jacks with mounting hardware
Molex Connector Kit ........................................................... Catalog No. 70625-000
includes edge connector, polarizing key, terminals and mounting hardware
 DIMENSIONS

(88 MM)

1.406 IN.
ADDITIONAL ROOM 35.71 MM)
NEEDED FOR WIRING

6.125 IN.
(155.58 MM)*

(26.99)
- - - - - - ------- --
CONTROLS
INDIVIDUAL
SQUELCH
TRIMMERS

AND PILOT VOLUM

MODE TRANSMIT
SWITCH LED

MUSIC/AUX
LEVEL
TRIMMER
RADIO
EQUALIZATION
TRIMMER
- AIRCRAFT
INSTRUMENT
PANEL

NOTE c

SQUELCH TRIMMERS (1) PILOT, (2) COPILOT, (3) PASSENGER NO. 1

ADJUST LEVELS AS AND EXTRAPASSENGER.(4) PASSENGERNO. 2.
FOLLOWS: CLOCKWISE ROTATION DECREASESSQUELCH
ACTIVATION LEVEL.

Figure 1. ProCom 4 Intercom Reference Guide

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 OPTIONAL MODIFICATIONS
1. For proper operation, the aircraft radio should have sidetone during transmission. If it does not, the
ProCom 4 should be modified prior to installation to simulate sidetone as described below.

2. The ProCom 4 mutes music by approximately 12 dB during voice communication. T o obtain full muting,
the ProCom 4 may be modified prior to installation as described below.

Modification Procedure (See Figure 2)

1. Disassemble the unit as shown.

2. To simulate sidetone, remove CR9 (for pilot sidetone) and CR13 (for copilot sldetone) as shown.

3. For full muting of music, remove R113 as shown.

4. Carefully reassemble unit by reversing disassembly sequence.

TOP
DISASSEMBLY INSULATOR

@ REMOVE TWO SCREWS SECURING TOP

COVER.

@ REMOVETWO NUTS AND LOCKWASHERS

FROM CONTROL SHAFTS.

@) REMOVE SCREW, WASHER AND INSU-

LATOR, AND REMOVE DUAL CIRCUIT
BOARD ASSEMBLY FROM BOTTOM CASE.
REMOVE MYLAR INSULATOR.
DUAL CIRCUIT
- @ REMOVETHREE SCREWS, LOCKWASHERS BOARD ASSY
AND SPACERS TO SEPAR~TE CIRCUIT-~
BOARDS. REFER TO CIRCUIT BOARD
ILLUSTRATION BELOW AND REMOVE
COMPONENTS AS INDICATED. CASE

R113 (MUSIC MUTE)

CR13 (COPILOT SIDETONE) CR9 (PILOT SIDETONE)

Figure 2. Optional Modifications

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 INSTALLATION
lntercom Wiring (Figure 3)
i-"i
Before mounting the ProCom 4, make all required connections as indicated in Figure 3 using the supplied
connector and terminals. Secure connector to back of intercom using hardware supplied with connector.

NOTES:

1. The most ideal hook-up is when all grounds are connected to the ProCom 4 as shown to prevent ground
o
psi l and noise. The ProCom 4 has threeseparate ground pins. Pin 6is the aircraft power ground. Pin 7 is
the headphone ground. Pin 5 is the microphone ground. Ail similar groundsshould betied together at the
ProCom 4.

2. For proper intercom operation, theaircraft radio must havesidetone during transmission. If it does not,the
ProCom 4 must be modified to simulate sidetone. See Optional Modifications.

lntercom Location Selection and Preparation

CAUTION

When selecting a location for installation of the intercom, move all aircraft controls over their full range of
travel to make sure there will be no interference at the selected location.

1. Peel off backing and position template on aircraft panel at selected location.

2. Center punch each hole (ten total) at cross lines.

3. Drill li8-inch pilot holes at all locations.

4. Enlarge holes to dimensions indicated on the template.

5. Remove template.
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 4

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INTERCOM FUSE FUSED CABLE

14 OR 28V AIRCRAFT POWER (SEE WIRING NOTE 3)

AIRCRAFT POWER GROUND BUSS
TO TAPE RECORDER (OPTIONAL)

COPILOT PHONE
AIRCRAFT EXISTING JACKSISWITCHES
(NOT USED WITH PC 4. FOR
PASS. NO. 2 PHONE
EMERGENCY USE ONLY)

r---------
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1
PILOT
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I q I
'OK' I
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I I
I EXISTING I
"'P MIC I
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-- JACK
q- PHONE
JACK
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W
Y. I I
I I
COMM
I RADIO I

MUSICIAUX SOURCE
(STEREO OR MONO)

SEE WIRING NOTE1

CONNECTOR
VIEW

~ - .
.. -~ -

POLARIZER KEY
BETWEEN SLOTS 0 AN0 9

WIRING NOTES:

1. SOME TRANSCE~VERSDO NOT ISOLATE THEIR TRANSMIT RELAY FROM THE TRANSMIT KEY LINE
WlTH A DIODE. IFTHISTYPEOFTRANSCEIVER LOSES POWER OR ISTURNED OFF. ITWILL PULLTHE
TRANSMIT KEY LINE LOW, CAUSING THE PROCOM 4 T 0 MUTETHE PILOT HEADPHONES. (COPILOT
AN0 PASSENGER POSITIONS REMAIN FULLY FUNCTIONAL.) TO PREVENT THIS. CONNECTA DIODE
(IN4001 OR EQUIVALENT RECOMMENDED) IN SERIES WlTH THE TRANSMIT KEY AS SHOWN.

2. IF DESIRED. THE HEADPHONE HOT TERMINALS ON ALL PASSENGER PHONE JACKS MAY BE TIED
TOGETHER AND RETURNED TO INTERCOM CONNECTOR PIN 2, B OR C.

3. THE INTERCOM MAY BE POWERED USING THE SUPPLIED FUSE AND FUSE HOLDER, OR OPTIONALLY
VIA A SEPARATE 1-AMP CIRCUIT BREAKER (NOT SUPPLIED).

Figure 3. intercom Wiring Diagram

 intercom and Jack Mounting (Figure 4)

1. insert ProCom 4 through aircraft panel from rear, and install faceplate and two mounting screws.
r.
/'
j/ 2. Install control knobs on shafts, and secure using a hexagon wrench. (Hexagon wrench size is 0.050forthe
small knob and 0.062 (1/16) for the large knob.) Check knobs for smooth rotation. if friction or rubbing is
noted, loosen knobs and increase spacing.

3. Install pilot, copilot and passenger microphone and headset jacks.

I .

REVERSIBLE
FACE PLATE
INTERCOM
44-40 SCREWS (2)

INSTRUMENT
PANEL
-- -- -- - - - -- - - -- -
INSULATED
SHOULDER
TIP WASHER

BARRE

/
I

MICROPHONE JACK AIRCRAFT

INTRUMENT
PANEL

Figure 4. Intercom and Jack Mounting

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 SYSTEM CHECKOUT AND OPERATION
-. 1. Turn on the ProCom 4, aircraft radio and music source. Adjust the volume of the aircraft radio and music
source to the'desired listening levei when using the cabin speaker.
i
V
,
2. Plug in pilot, copilot and passenger headsets and check for proper intercom operation in the three mode
switch positions as summarized in the following table.

Mode Switch Operatlon

MODE SWITCH TALK ON AIRCRAFT RADIO MUSICIAUX

POSITION INTERCOM LISTEN TRANSMIT SOURCE
(See Note 1)
Radio Copilot Pilot Pilot Copilot
(Pilot isolate) Passengers Passengers

See Note 2

Ail Pilot Pilot Pilot Pilot

Copilot Copilot Copilot Copilot
Passengers Passengers Passengers

See Note 3

Crew Pilot &Copilot Pilot Pilot Passengers

on one channel Copilot Copilot Only

Passengers on See Note 2

a separate
channel

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NOTES:
1. Fully muted music is obtained by removal of R113 from ProCom 4.
(See Optional Modifications.)
2. Music is partially muted by talk.
3. Music is partially muted by aircraft radio audio or talk.

3. If necessary, adjustthe intercom's radio equalization trimmer sothatthe pilot's headphonevolume level is
the same when switching between the intercom and the radio.
' 4. Ifdnecessary, adjust the music level trimmer for the desired listening levei.
 SYSTEM CHECKOUT AND OPERATION (Continued)
5. Set the squeich ievei as follows:

a. Turn control clockwise untii sound is heard in the headphones. Now slowly rotate control
counterciockwise until the headphone sound just stops. Rotate the control slightly farther counter-
clockwise. The sound should come back on if someone talks into a microphone.

b. Occasionally squelch adjustment problems may be caused by such things as different ambient noise
leveisat different microphones throughout the cockpit, several typesof microphones being used, and
different user voice levels. Use the squeich adjustment trimmers to compensate for these variations.
For example: if the squeich seems to be activated too easily at one microphone position, adjust the
squelch trimmer for that position to a higher squelch ievei (counterciockwise).

6. i f a tape recorder is being used to record ATCIpiiot communications, check that it is operating
correctly.
"*..*,.-'
7. if an intercom failure occurs, or it is desired to use the radio but not the intercom, turn the intercom
off.

8. Unused headsets plugged into the ProCom 4 may cause feedback (whistling) in the intercom. To prevent
this, turn down the volume controls for these headsets or unplug them.