AVCOMM Aviation Products

Installation Instructions: A C 6 P A In t er c om Page 1 of 4

Description: AVCOMM AC6PA is designed to provide the highest level of audio performance in a voice activated (VOX)
panel mount intercom. The rugged construction is built to withstand the extreme conditions common in open or closed
cockpit aircraft. The solid extruded aluminum framework dramatically reduces radio frequency interference (RFI) and will
fit virtually anywhere on the panel. Thermoplastic Elastomer gaskets seal out moisture and dust for trouble free performance.
Inside, a streamlined circuit board features ceramic hybrid IC chips for high reliability. The AC6PA is compatible with
either 12 or 24-volt electrical systems and is designed for use with up to six headsets so you can start with the pilot and co-
pilot positions and add passenger positions as needed.

Quick-install kit: This kit makes it a snap for almost anyone to install the AC6PA without the tedious time-consuming task of
soldering individual connectors. Preparation of the instrument panel is simplified with the transparent template included in
the kit. The pilot and co-pilot jacks are pre-wired with reinforced tensile copper wiring with spiral shielding and a
polyurethane cover. The harness and intercom feature a simple DB25 pin connection. Color coded wiring, molex connectors
and simple, straightforward instructions make it possible to be flying in two hours or less.

DXAC6PA Intercom with Quick-install Kit

1 PN#AC6PA - Aviation panel mount intercom
1 - Clear adhesive template
1 Standard hardware sets: 4 ea. (screws, washers, nuts)
3 Self-tapping hardware sets: 4 self-tapping screws
4 Molex connectors
AVCOMM International, Inc.
20 Crimp pins
1 PN# I0404 – Quick-install harness
2 PN# I0420 – Quick-install headset jack kit (5 ft.)
1 PN# I0412 – Quick-install radio wire
2 PN# I0411 – Quick-install PTT wire
1 PN# I0430 – Quick-iinstall audio panel

Optional Accessories
PN# I0410 – Quick-install solder less radio adapter
PN# I0421 – Quick-install headset jack kit (12 ft.)

DB25 Connector
(rear view of intercom)

DXAC6PA Quick-install kit

DXAC6PA General Specifications:

Electrical Control / Features Mechanical
Voltage range: Aircraft: 12 ~ 28V DC Voice activated (VOX) Number of positions: 2 – 6 places
Current consumption: 33 mA typical w/2 headsets Fail-safe pilot isolate Extruded aluminum construction
Max current consumption: < 90 mA Volume control Thermoplastic Elastomer gaskets
Audio output power: 250 mW Squelch control Pre-wired for optional passenger jacks
Mic source impedance: 680 ohms 2-stage LED with ‘stuck mic’ indicator Pre-wired for audio in–out panel
Mic source voltage: 8 ~ 9.6 V typical Pilot priority PTT Dimensions: 4.96” L x 2.69” W x 1.19” H
Headphone impedance: 150-1000  typical Stereo-IN with auto music mute Weight AC6PA intercom: 7.9 oz.
Audio distortion: <10% @ 85 mW into 150  load Record-OUT Weight DXAC6PA intercom & kit: 23.7 oz.
3 dB Mic frequency response: 300 Hz-3000 Hz

REV: 11-1-04 AVCOMM International, Inc.

4930 W. Cheyenne Ave. Ste. 190 Las Vegas, NV 89130
(800) 845-7541 (702) 655-0883 www.avcomm.com
 AVCOMM Aviation Products
Installation Instructions: A C 6 P A In t er c om Page 2 of 4

Communication features:
 Two stage LED displays green when power is on and amber during radio transmission making a ‘stuck mic’ easy to spot.
❖ Voice-activated squelch circuit (VOX) adjusts to a broad range of noise environments or can be set for a continuous open-
mic condition.
 Pilot isolate (ISO) provides exclusive pilot communications with the ATC, pilot priority PTT allows the pilot to override
co-pilot transmissions.
 ‘Fail-safe’ feature (ISO position) supplies a direct connection to the aircraft radio in case the power supply to the intercom
is disrupted.
 Music plugs in easily for in-flight entertainment with music automatically muting during intercom or radio activity.
 Audio-out jack allows you to document ATC transmissions or cockpit conversations, or use for video narrating.

Operating instructions:
 Plug all headsets into the appropriate jacks and turn on the radio
and intercom. The green PWR/TX light should illuminate.
❖ Turn the volume control on the headsets to the highest point.
Position the mic boom at the corner of your mouth 1/8” from your
lips. Speak into the mic and adjust the volume control on the
intercom to a comfortable listening level.
 Additional operating instructions – see chart below. AVCOMM International, Inc.

Intercom front panel

ON-OFF/Volume Radio Squelch Power/TX

VOL: The volume control Radio switch: two positions Squelch control: Voice PWR/TX: 2-stage LED
turns the intercom on and off activated circuit with manual indicates system power and
and adjusts the volume of the
 ISO: Pilot’s headphone adjustment. radio transmission:
and mic are connected
intercom.
directly to the radio. Co-  Initial setting: Start at the
 Power switch: To turn pilot and passenger will not full clockwise position, turn the Green: Intercom power is ON.
the intercom on, rotate the hear pilot’s transmissions. knob counter-clockwise until
volume control clockwise This position bypasses the background noise is just silenced. Amber: Indicates the push-to-talk
until the green PWR/TX intercom and connects is depressed and you are
❖ Adjustments during flight:
light illuminates. directly to the radio, ‘fail- transmitting on the radio. If the
Re-adjust as needed for changes
❖ Volume: safe’ feature. amber light is illuminated and the
in noise levels.
❖ ALL: All positions can push-to-talk is not activated, a
• Increase intercom volume • If setting is too high, counter- ‘stuck mic’ condition may have
by turning the volume communicate through the
intercom. clockwise, your voice will be cut occurred. Diagnosis problem or
control clockwise. out unless you speak very loudly. see a radio shop for repair.
• Decrease intercom • If setting is too low, clockwise,
volume by turning volume background noise will be heard
knob counter-clockwise. occasionally.
• The volume control  “Continuous open-mic”:
adjusts only the volume of rotate knob clockwise until it
the intercom. Use the stops.
volume control on the radio
or other music source to
adjust the audio level.

REV: 11-1-04 AVCOMM International, Inc.

4930 W. Cheyenne Ave. Ste. 190 Las Vegas, NV 89130
(800) 845-7541 (702) 655-0883 www.avcomm.com
 AVCOMM Aviation Products
Installation Instructions: A C 6 P A In t er c om Page 3 of 4

IMPORTANT NOTE 1. Panel space required: minimum 89 mm (3.5”) x 41 mm (1.6”)

Please be sure to read the complete Depth required behind panel for DB25 connector: minimum 178 mm (7”)
instructions before beginning the
installation. 2. Select front panel location: Test site by moving the aircraft flight controls
through the entire range of motion to make sure there is no interference.
3. Panel preparation: Use the clear adhesive template provided as a
pattern and position it over the selected area of the instrument Drill 4 holes (4.2 mm dia.) and cut a square
panel. Cut the square opening following the template. Mark the opening using the template provided.

position for the mounting screw holes, center punch the cross
lines, and drill the four 4.2 mm diameter holes (Fig. 1). Slide the
intercom in place. Check fit and position of the drilled mounting
holes, modifying aircraft panel if needed. Remove intercom. Aircraft
Panel
4. Mount the pilot/co-pilot headset jacks: Select a location that has
good support and is easily accessible to the user. Test all flight
instruments or controls adjacent to the proposed site by moving
each through the entire range of motion to make sure there is no
AC6PA
interference. Before mounting the jacks, check wire length to
make sure it is sufficient to connect to the intercom. If needed,
adjust jack location or re-route the wire. Mount the jacks using the
4 self-tapping screws or the 4 screws, washers and nuts provided.
Drill 2.3 mm diameter holes for self-tapping screws or 3.10 mm
diameter holes for screws and nuts. Fig. 1: Panel preparation/intercom mounting

5. Wiring general instructions: Wrap a small piece of electrical tape around the connector pins at the end of the cables
to keep them straight and prevent damage to the pins during installation. Route the wires through the aircraft frame
carefully so that the connectors and wire insulation are not damaged by sharp or rough surfaces. After routing all wires,
carefully remove the tape from the pins.
6. Molex connector instructions: Before proceeding, check the Quick-install harness diagram Fig. 2 for the location of
each wired pin. Following the instructions below, work carefully and make sure the wired pins are accurately inserted
into the correct location. When complete, the molex connectors are plugged into the mating connector on the wiring
harness. In case an extraction tool is needed, one can be purchased from Radio Shack (PN# 274-223).
6.1 Molex connector A (red)
Quick-install pilot/co-pilot headset jacks: Follow general instruction steps 5 and 6, install the crimp pins into the molex
connector A (Fig. 3).
Permanent PTT connection: To wire the yoke PTT, use the PTT wire supplied in the Quick-install kit. Solder the end
of the wire without the crimp pins to the wire of the yoke PTT. Following the pin assignment in Fig. 4-1, install the
crimp pins into the molex connector A. Molex connector A is now complete and may be plugged into the harness
(Fig. 2)
Portable PTT connection (option): An easy option to the permanent PTT connection is to simply purchase an
AVCOMM Deluxe Push-to-talk switch (PN# P2-001) and connect as shown in Fig. 4-2.
6.2 Molex connector B (yellow) Note: the intercom is pre-wired for pilot, co-pilot and 4 passenger positions
Optional Quick-install headset jacks – passenger 1 & 2: For each passenger position, purchase a pre-wired Quick-
install headset jack kit – 12 ft. (PN# ACI0421). Installation procedure is the same as the pilot/co-pilot headset jacks
installation Follow the instructions in step 4 – 6, install crimp pins into molex connector B (Fig. 5-1). Plug into the
harness (Fig. 2).
6.3 Molex connector C (blue)
Optional Quick-install headset jacks - passenger 3 & 4: Preparation is the same as passenger 1 & 2. Install crimp pins
into the molex connector C (Fig. 5-2).
Quick-install audio panel – audio OUT: The pre-wired audio panel comes with 36” of wire with crimp pins installed.
Simply mount the unit in the desired location, follow the pin assignment in Fig 6 (C5, C10) and install the crimp pins into
the molex connector. Molex connector C is now complete and may be plugged into the harness (Fig. 2).
6.4 Molex connector D (white)
Optional Quick-install audio panel – Audio IN: Follow the pin assignment in Fig. 6 (D1, D2, D6) and install crimp pins
into the molex connector.
7. Radio connection - Intercom wired directly to radio: Contact an avionics shop for your radio connection. The
existing pilot headset jacks can be used as a convenient tie-in point for the radio connections or as a standby radio

REV: 11-1-04 AVCOMM International, Inc.

4930 W. Cheyenne Ave. Ste. 190 Las Vegas, NV 89130
(800) 845-7541 (702) 655-0883 www.avcomm.com
 AVCOMM Aviation Products
Installation Instructions: A C 6 P A In t er c om Page 4 of 4

connection if the intercom is removed for servicing. See Fig. 7, #1 before beginning the radio installation. Use the
radio wire supplied in the Quick-install kit and solder the ends of the wires without the crimp pins to the existing mic,
PTT, phone and shield terminals. CAUTION: DO NOT solder the phone wire to the radio external speaker output; solder
only to the radio headphone output. Following the pin assignment, install the crimp pins into molex connector. Molex
connector D is now complete and may be plugged into the harness (Fig. 2).
Radio connection - Optional Quick-install solder less radio adapter: An easy option for the radio connection is to
purchase a Quick-install solder less radio adapter (PN# ACI0410). Follow the pin assignment in Fig. 7, #2. Install the
crimp pins into the molex connector D. Connect the Quick-install radio adapter mic and phone plugs into the existing
aircraft radio headset jacks. The microphone jack must be wired for PTT to key the radio (most aircraft jacks are wired in this
configuration).
8. Intercom power connection: The intercom is designed for 12 or 24-volt D.C. systems. Connect the red and black
power wires to the aircraft power source: the black wire to the negative, the red wire to the positive (Fig. 2). Voltage range
for the intercom is 12 to 28 volts D.C.

Final Checkout and Adjustment INSTALLATION CHECKLIST

✓ Prepare installation site
Final-checkout: Checkout should be made before intercom is permanently mounted in ✓ Complete harness and wiring
the instrument panel. First secure the DB25 connector to the rear panel of the intercom connections
with the two thumbscrews on the connector. Make sure the wires are not kinked, caught, ✓ Install optional accessories
or squeezed by any equipment on the instrument panel. ✓ Test intercom functions before
permanent mounting
1. Preset controls as follows: Set squelch to full clockwise position; ISO/ALL ✓ Make adjustments if needed
switch to ALL; volume to the OFF, full counter-clockwise position. Make sure a 2- ✓ Finish permanent installation
amp fuse is in the inline fuse holder and the power to the instrument panel is on.
✓ Re-test all intercom functions
Turn the radio on first and then turn on the power to the intercom by rotating the
✓ Have installation signed off by
volume knob to ¾ rotation clockwise, the PWR/TX indicator should show a green light. licensed A&P mechanic
2. Test headset function: Plug the headset mic and phone plugs into the respective
intercom jacks. Put on the pilot’s headset. The intercom should be operating with the squelch in the open mic mode, at fully
clockwise position. As you speak you should be able to hear your voice in the headset as side tone. Repeat procedure for co-pilot, and
passenger jacks if they have been installed.
3. Test squelch: Use the pilot jack, adjust the squelch knob counter-clockwise until the sound just disappears, then speak into the
microphone. This should break the squelch and your voice then can be heard through the headset.
4. Test radio connection: Aircraft radio reception should be heard in all headsets regardless of the squelch setting. The volume of
radio reception should be adjusted at the radio. Starting with the pilot headset, test the radio transmission by pressing the yoke PTT
and performing a radio check. Repeat this test for the co-pilot headset. Please note the pilot always has priority when transmitting.
5. Test intercom fail-safe (ISO) operation: Turn the intercom OFF, set the intercom toggle switch to ISO position, plug a headset
into the pilot jacks, turn the radio ON and test the unit (you should be able hear the radio and transmit using the headset and push-
to-talk switch even though the intercom power is off). There should be no communication between the pilot and all other headsets in
ISO mode.
6. Test Audio Panel function: (1) Audio In – Use a mono-stereo 3.5 mm phone plug adapter cord (not supplied) and plug into the
stereo source (CD, MP3, or tape player). With headset on, turn on the intercom and the music source. Adjust the volume on the
music source (volume is controlled by the music source not the intercom). When you speak through the headset, the music will
automatically mute. Repeat steps 3 and 4. Make sure the music mutes when the squelch is broken by your voice or when you receive
a transmission from the ATC through the intercom. (2) Audio Out – Using a mono-stereo 3.5 mm phone plug adaptor cord, plug into
the microphone input jack on the recording devise (tape recorder, video camera etc). Turn recorder on and repeat step 2. Rewind the
recorder and play back. Both sides of the conversation with the pilot, co-pilot, passengers and ATC will be recorded.
7. Final connections: Remove the DB25 connector from the intercom. Route the completed wire harness into the instrument panel
to the location of the back of the intercom. Make sure the wires are not kinked, caught, or squeezed by any other equipment behind
the instrument panel. To prevent wire movement and vibration, secure the wire bundles with nylon wire ties (not supplied in kit). Slide the
intercom in place and install the intercom mounting screws (Fig. 1). Connect the DB25 connector to the back of the intercom.
8. Post-installation check:
 Check intercom jacks and wiring harness to make sure they are clear of all aircraft operating controls.
 Repeat Final Checkout steps 1–5 to make sure all intercom functions are working.
 Consult a licensed A&P mechanic to have your installation checked and signed off [FAR part 43 requirement].

REV: 11-1-04 AVCOMM International, Inc.

4930 W. Cheyenne Ave. Ste. 190 Las Vegas, NV 89130
(800) 845-7541 (702) 655-0883 www.avcomm.com