Installation and Operation Manual: HSP-037-x, HSP-037C-x, HSP-045-x Headphone Switch Panel Document # 540083

Installation and Operation
Manual
HSP-037-x, HSP-037C-x, HSP-045-x
Headphone Switch Panel
Document # 540083
a DeCrane Aircraft Company
7300 Industry Drive, North Little Rock, AR 72117

Phone: 501-955-2929 Fax: 501-955-2988
www.audiointl.com
Audio International, Inc. HSP-037(045)(037C)-x Installation & Operation Manual
Document Revision History
Rev. Level Date Description

IR 04/1998 Initial Release
A 09/2001 Added HSP-037C-x
Reference Documents
Document # Description
523855 Rev IR Outline HSP-037C-x
521592 Rev IR HSP-045 Outline Drawing
520560 Rev !R HSP-037-1 Outline Drawing
520534 Rev IR HSP-037-2 Outline Drawing
Service Bulletin List
Service Manual Revision

Subject
Bulletin # Revision Date
Table of Illustrations
Section # Description Page #

2.3 Typical System Block Diagram 5
7.0 Reference Drawings 14-17
PROPRIETARY INFORMATION NOTICE: Despite any other copyright notice, this document and
information disclosed herein contains confidential, proprietary designs owned by Audio
International, Inc. Neither this document nor the data contained herein shall be reproduced, used,
or disclosed to anyone without the written authorization of Audio International, Inc.
Document #540083, Rev A, 09/2001 Page 2 of 18

Table of Contents
Section Description Page
1.0 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Purpose of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Typical System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Multiple Unit Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Cautions & Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.6 Electrical Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.7 Pinout Assignments and Descriptions. . . . . . . . . . . . . . . . . . . . 10
3.8 Post-Installation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Source Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.0 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 General Troubleshooting Procedures . . . . . . . . . . . .. . . . . . . . 12
5.2 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.0 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.0 Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

HSP-037-x, HSP-037C-x, and HSP-045-x
Headphone Switch Panels
1.0 General Information
1.1 Introduction
This manual contains information for the proper application, installation,

and operation of the Audio International, Inc. (AI), Headphone Switch
Panels, Model #s HSP-037-x, HSP-037C-x, and HSP-045-x. The “-x”
suffix in the model number designates the type of connector utilized. The
“C” suffix in the model number represents the availability of an optional
cover bezel. Also included are relative physical and electrical
characteristics of the unit.
1.2 Purpose of the Equipment
1.2.1 The Headphone Switch Panels are specifically designed for aircraft
use. They allow individual passenger control of audio selections
and volume. They are available in two types; the standard
headphone panel and a noise canceling headphone panel.
1.2.2 The HSP-037-x and HSP-037C-x allow individual passenger

headphone control of audio selections and volume level. These
switch panels are standard headphone panels pre-engineered for
easy configuration with cover bezel compatibility. They combine
volume up/down, source select, and a four (4) digit alphanumeric
digital display in one (1) self-contained unit and a 3.5mm (1/8")
headphone jack. They provide two (2) to five (5) source selections
with an internal library of 20 available source labels. These units
feature pushbutton programming and loop-through wiring. They
may be programmed or reprogrammed at any time.
1.2.3 The HSP-045-x is similar to the HSP-037 headphone panel, but

designed for a noise canceling headphone. These panels are
specifically designed for use with the Sennheiser HDC-45-16 noise
canceling headphone. A secondary 2.5mm jack provides 12 VDC
power to the headphone.

1.3 Operational Features
q Separate volume up/down

q Audio source selection control
q Standard 1/8" headphone jack (3.5mm)
q Pushbutton programming
q Loop-through (daisy chain) wiring
1.4 Optional Equipment
Audio International, Inc. offers a comprehensive family of Cabin Control

Modules for Passenger Control interface. These modules provide
convenient solutions for a variety of frequently encountered interfacing
needs or special requirements and are an important part of AI’s “building
block” system for configuring total cabin management.
Contact your AI representative for details.
2.0 Application
2.1 Introduction
The Headphone Switch Panel is part of a complete cabin audio

entertainment system. The application of the unit is specific to a particular
aircraft based upon the desires of the customer or designer.
2.2 Typical Application
The unit is a passenger headphone control panel for providing a digital

display volume control from such source equipment such as VCRs, CD
players, and DVD players. The unit may be connected in a “daisy-chain”
to incorporate up to 15 seat locations.

2.3 Typical System Block Diagram
*Note: It is recommended to employ one (1) HDM-3 for every one (1) source
when both speaker and headphone panels are utilized.
2.4 Multiple Unit Configurations
Audio International recommends the use of high quality headphones with

impedance value of 60 or greater when more than six (6) HSP-0xx are
used in line.

3.0 Installation
3.1 Prior to Installation
The Headphone Switch Panels are simple modules to install. Prior to

installation, the following items should be considered:
3.1.1 During the design and layout of the aircraft cabin, careful
consideration of the location of this and all other audio modules is
necessary. Some of the items to consider include:
• Space
• Proximity to other devices (i.e. source equipment)
• Available power supply
• Length of cable runs
• Environmental conditions (temperature, humidity, etc.)
• Location of other aircraft systems (i.e. oxygen delivery)
• Access for service repair (if applicable)
3.1.2 The modules shall be installed to conform to the standards

designated by the customer, installing agency, or other specified
requirements.
3.1.3 Select a mounting location for the Headphone Switch Panels prior
to installation. Refer to Section 7.0 for dimensions and attachment
points. The units shall be bonded to the aircraft frame with a
bonding resistance of less than 0.001 .
3.2 Unpacking and Inspection

3.2.1 Carefully open the packaging and remove the Headphone Switch
Panel. Verify that all components have been included in the
package per the packing list. Inspect the unit for shipping damage.
3.2.2 If damage has occurred during shipping, a claim should be filed

with Audio International within 24 hours and a Return Request
Authorization Number shall be obtained from AI. Refer to the
front cover of this manual for address and telephone number of
Audio International, Inc. Repackage the unit in its original
packaging materials and return it to AI following instructions given
by the AI representative. If no return is necessary, retain the
packing list and the packing materials for storage.

3.3 Cautions & Warnings
3.3.1 All analog audio output lines from the HDM-3 to HSP-0xx units
shall be shielded and properly grounded. Analog audio input lines
shall be shielded and grounded at the source, unless indicated
otherwise. Avoid placing cables near high power wires.
3.3.2 It is important to do a pin-to-pin power and ground check on all

connectors. Ensure that power and ground are applied only where
specified. Damage to the unit can result if power or ground is
applied to the wrong points.
3.3.3 DO NOT connect or disconnect the unit while power is applied.
3.3.4 DO NOT connect or disconnect any inputs or outputs when power

is applied to the unit.
3.3.5 NO scheduled maintenance is required to ensure continued

airworthiness.
3.3.6 DO NOT remove any factory-installed screws. Damage to the unit

can result and void any warranties.
3.4 Wiring Requirements
3.4.1 The installing agency shall supply and fabricate all external cables
and connectors. The length and routing of external cables should
be carefully studied and planned before attempting installation of
the equipment. Allow adequate space for installation of cable and
connectors.

3.4.2 All signal wires shall be 24 AWG minimum, except for pins 1 and 2,
which shall be 20 AWG. All audio lines require twisted, shielded
cable with the cable shields grounded at the source. Power and
ground wires should be 20 AWG minimum. All wires shall be in
accordance with the standard military specification of MIL-W-22759
or equivalent. Twisted, shielded cable must be in accordance with
the standard military specification of MIL-DTL-27500 or equivalent.
3.4.3 Clearance and Separation Requirements
When running cables, avoid sharp bends and placing cables near
aircraft control cables. Maintain a MINIMUM clearance of three (3)
inches from any control cable. If wiring is run parallel to
combustible fluid or oxygen lines, maintain a separation of six (6)
inches between the lines.
3.5 Physical Characteristics
3.5.1 The Headphone Switch Panel should be located away from heat
sources, magnetic fields, direct sunlight, and areas with excessive
dust and/or moisture. The unit shall NOT be mounted to the skin of
the aircraft.
3.5.2 Refer to Section 7.0 for unit dimensions and mounting hole sizes.
3.5.3 The unit shall be rigidly mounted to its location using the
appropriate fastening hardware supplied by the installing agency.
3.5.4 When mounting the unit to the aircraft’s frame, allow sufficient
space for mating connectors.
3.6 Electrical Characteristics
3.6.1 Electrical Specifications typical for all HSP-xx:
Electrical Power 100 mA @ +28 VDC, max.

Backlighting Green
Wire Bundle 12" ± 1"

3.6.2 Headphone Switch Panel Mating Connectors
HSP-037-1
P1 Connector Description P2 Connector Description

RD15M10JV30 Connector RD15M10JV30 Connector
RD15F10JVL0 Mating Connector RD15F10JVL0 Mating Connector
HSP-037-2

DBMA-15P Connector DBMA-15S Connector
DBMA-15S Mating Connector DBMA-15P Mating Connector
DB24659 Backshell DB24659 Backshell
D20418-2 Female Screw Lock D20419-18 Male Screw Lock
HSP-045-1

DBMA-9P Connector DBMA-25S Connector
DBMA-9S Mating Connector DBMA-25P Mating Connector
DE24657 Backshell DB24659 Backshell
D20418-2 Female Screw Lock D20418-2 Female Screw Lock

3.7 Pinout Assignments and Descriptions typical for all HSP-xx.
P1 Pinout Chart P2 Pinout Chart

Pin # Description Pin # Description
1 +28 VDC Power Input 1 +28 VDC Power Output
2 Ground 2 Ground
3 R+ Source 1 Input 3 R+ Source 1 Output
4 L+ Source 1 Input 4 L+ Source 1 Output
13 Audio Common 13 Audio Common
14 Reserved 14 Reserved
15 Reserved 15 Reserved
3.8 Post Installation Test
3.8.1 With the aircraft power “ON”, select an audio source unit and
operate that unit to create audio signal to the Headphone Switch
Panel. Verify that an audio output is present at one (1) of the audio
output locations. Repeat this test for each audio source unit in the
system. Repeat this test for each audio output location in the
system.
3.8.2 Repeat the above tests using all control units in the aircraft (switch
panels, IR Remotes, LCD touch-screen monitors, etc.)
3.8.3 Activate and speak into a microphone to verify that the PA audio
overrides the entertainment audio.
3.8.4 All aircraft audio functions should be tested for proper operation. If
all audio functions are operational, the Headphone Switch Panel
has been properly installed. Refer to Section 5.0, Troubleshooting,
if problems are encountered.
4.0 Operation
4.1 Power Up
Power to the unit is initiated when the aircraft power is turned on and
remains on at all times.

4.2 General Audio and Volume Control
The headphone switch panels allow the passenger to control his/her

seating requirements.
4.2.1 Audio selection is displayed via the four digit alphanumeric display.
Up to twenty labels are available for display. By pressing audio
select, the sources are sequentially selected. The labels available
for programming include: CD, CD1, CD2, CD3, VCR, VCR1, VCR2,
VCR3, VCP, TAPE, COMM, CASS, ST, VHF, OFF, VDP, AUX,
VID, DISC, DAT, and DVD. If no button is pressed, audio selected
is the default setting (last-state device).
4.2.2 Volume control is accomplished via the volume up and volume

down buttons. When selected, a percentage value will indicate
current level. Volume resolution is 16 steps from 0% to 100%. The
indications are 0%, 10%, 20%, 30%, 40%, 50%, 55%, 60%, 65%,
70%, 75%, 80%, 85%, 90%, 95%, and 100%. If no volume is
pressed, audio mode is the default (volume setting is last-state
memory).
4.3 Programming
4.3.1 Selection of number of sources
The HSP-037-x, HSP-037C-x, and HSP-045 will select from 2 – 5

sources. The number of sources is determined by proceeding
through the following steps. Once the number of sources has been
selected, it will be stored into permanent memory.
4.3.1.1 Press “AUDIO SELECT” and “VOLUME DOWN” together

for approximately four (4) seconds. The display will show
“PGM”, “#SOU”, (number of sources). The number
shown will be what is currently shown in memory.
4.3.1.2 Pressing “AUDIO SELECT” will cycle through the options:

2, 3, 4, and 5. When the correct value is show, press
“VOLUME DOWN”. The selection will be stored into
permanent memory and you will exit the programming
mode.

4.3.2 Selection of source labels
There are twenty labels to choose from when assigning labels to

sources. Labels are assigned to each source by proceeding
through the following steps. Once the labels have been assigned,
they will be stored into permanent memory.
4.3.2.1 Press “AUDIO SELECT” and “VOLUME UP” together for

approximately four (4) seconds. The display will show
“PGM”, #S1#, (source label). The label shown will be
what is currently in memory. You will be ready to assign a
label to source #1.
4.3.2.2 Pressing “AUDIO SELECT” will cycle through the options

as listed in 3.1.1. When the desired label is shown, press
“VOLUME UP”. The label will be assigned to source 1
and stored into permanent memory. The display will now
show “PGM”, “#S2#, (source label) and you will be ready
to assign a label to source #2.
4.3.2.3 Pressing “AUDIO SELECT” will again cycle through the

options as listed in 3.1.1. When the desired label is
shown, press “VOLUME UP”. The label will be assigned
to source 2 and stored into permanent memory. The
display will now show “PGM”, “#S3#”, (source label) and
you will be ready to assign a label to source #3.
4.3.2.4 Continue as above until all sources have been assigned

labels. When all labels have been assigned, press
“VOLUME DOWN” to exit the programming mode. The
“VOLUME DOWN” button may be pressed at any time to
exit the programming mode.
5.0 Troubleshooting
5.1 General Troubleshooting Procedures
Many problems can be isolated with the following general techniques:
• To verify power to the unit, recheck +28 VDC power is applied to

the proper pins on the unit. Use a voltmeter to verify correct level.
• To reset, remove power from the unit for at least one (1) minute
and reapply power to verify that the problem still exists.

• Recheck all connections to the unit for security. Check all harness
runs for possible pinching. Recheck all pin outs for application
accuracy.
5.2 Troubleshooting Chart
Problem Possible Cause Solution

Increase headphone amplifier
Audio level too low ½ Low amplifier setting
settings
½ Less than 60 headphone
Use 60 or higher impedance
used
headphone
Too many sources ½ Programming incorrect Change programming

Change programming, if needed
Incorrect source label ½ Programming incorrect
label is not available, contact AI
Only one (1) source ½ Minimum selection is two (2) Label one (1) source “OFF” during
needed sources programming
6.0 Specifications
Physical Specifications
Housing Black Anodized Aluminum

Weight 0.34 lb / 0.15 kg
Dimensions
2.8" x 1.75" x 1.3"
(HSP-037 and HSP-037C)
(l x w x h)
7.1 cm x 4.4 cm x 3.3 cm
Dimensions
2.8" x 2.08" x 1.3"
(HSP-045)
(l x w x h) 7.1 cm x 5.28 cm x 3.3 cm

7.0 Reference Drawings
The following diagrams show the unit dimensions, mounting locations, and
connector locations for the HSP-037 and HSP-037-1.

connector locations for the HSP-037-2.

connector locations for the HSP-037C-x.

connector locations for the HSP-045-x.

Installation and Operation Manual: HSP-037-x, HSP-037C-x, HSP-045-x Headphone Switch Panel Document # 540083

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Installation and Operation

a DeCrane Aircraft Company

7300 Industry Drive, North Little Rock, AR 72117

Document Revision History

Rev. Level Date Description

Service Bulletin List

Service Manual Revision

Section # Description Page #

Document #540083, Rev A, 09/2001 Page 2 of 18

7.0 Reference Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Document #540083, Rev A, 09/2001 Page 3 of 18

HSP-037-x, HSP-037C-x, and HSP-045-x

Headphone Switch Panels

1.0 General Information

This manual contains information for the proper application, installation,

1.2 Purpose of the Equipment

1.2.2 The HSP-037-x and HSP-037C-x allow individual passenger

1.2.3 The HSP-045-x is similar to the HSP-037 headphone panel, but

Document #540083, Rev A, 09/2001 Page 4 of 18

1.3 Operational Features

q Separate volume up/down

1.4 Optional Equipment

Audio International, Inc. offers a comprehensive family of Cabin Control

Contact your AI representative for details.

The Headphone Switch Panel is part of a complete cabin audio

2.2 Typical Application

The unit is a passenger headphone control panel for providing a digital

Document #540083, Rev A, 09/2001 Page 5 of 18

2.3 Typical System Block Diagram

2.4 Multiple Unit Configurations

Audio International recommends the use of high quality headphones with

Document #540083, Rev A, 09/2001 Page 6 of 18

3.1 Prior to Installation

The Headphone Switch Panels are simple modules to install. Prior to

3.1.2 The modules shall be installed to conform to the standards

3.2 Unpacking and Inspection

3.2.2 If damage has occurred during shipping, a claim should be filed

Document #540083, Rev A, 09/2001 Page 7 of 18

3.3 Cautions & Warnings

3.3.2 It is important to do a pin-to-pin power and ground check on all

3.3.3 DO NOT connect or disconnect the unit while power is applied.

3.3.4 DO NOT connect or disconnect any inputs or outputs when power

3.3.5 NO scheduled maintenance is required to ensure continued

3.3.6 DO NOT remove any factory-installed screws. Damage to the unit

3.4 Wiring Requirements

Document #540083, Rev A, 09/2001 Page 8 of 18

3.4.3 Clearance and Separation Requirements

3.5 Physical Characteristics

3.6 Electrical Characteristics

3.6.1 Electrical Specifications typical for all HSP-xx:

Electrical Power 100 mA @ +28 VDC, max.

Document #540083, Rev A, 09/2001 Page 9 of 18

3.6.2 Headphone Switch Panel Mating Connectors

P1 Connector Description P2 Connector Description

P1 Connector Description P2 Connector Description

P1 Connector Description P2 Connector Description

Document #540083, Rev A, 09/2001 Page 10 of 18

3.7 Pinout Assignments and Descriptions typical for all HSP-xx.

P1 Pinout Chart P2 Pinout Chart

3.8 Post Installation Test

Document #540083, Rev A, 09/2001 Page 11 of 18

4.2 General Audio and Volume Control

The headphone switch panels allow the passenger to control his/her