Guide for Installing CEP900-I04 Interface into SPH Helmets

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" height=82 BGCOLOR="#99CC99" TEXT="#080000"> <div> <FONT SIZE="5" COLOR="#000000" FACE="Arial" ><B>Communications & Ear Protection, Inc.</B></FONT><B>     </B><B>|</B><B>     </B><A HREF="index.htm" TARGET="_top" TITLE="Communications Ear Protection, Inc."><U><B>home</B></U></A></div> <div> <A HREF="id35.htm" TARGET="_top" TITLE="CEP introduction"><U>CEP introduction</U></A>   |   <A HREF="id33.htm" TARGET="_top" TITLE="Test Data "><U>Test Data   </U></A>   |   <A HREF="id38.htm" TARGET="_top" TITLE="Product List "><U>Product List </U></A>   |   <A HREF="id40.htm" TARGET="_top" TITLE="Product Applications"><U>Product Applications</U></A>   |   <A HREF="id41.htm" TARGET="_top" TITLE="Navy Products"><U>Navy Products</U></A>   |   <A HREF="id28.htm" TARGET="_top" TITLE="Installation of CEP into HGU56/P and SPH"><U>Installation of CEP into HGU-56/P and SPH-4 helmets</U></A>   |   <B>Guide for Installing CEP900-I04 Interface into SPH Helmets</B>   |   <A HREF="id23.htm" TARGET="_top" TITLE="CEP fitting techniques"><U>CEP fitting techniques</U></A>   |   <A HREF="id39.htm" TARGET="_top" TITLE="Special applications"><U>Special applications</U></A>   |   <A HREF="id34.htm" TARGET="_top" TITLE="Air worthiness release"><U>Air worthiness release</U></A>   |   <A HREF="id18.htm" TARGET="_top" TITLE="Contact us"><U>Contact us</U></A>   |   <A HREF="id36.htm" TARGET="_top" TITLE="Links"><U>Links</U></A></div> <div> </div> </td> </tr><tr> <td valign="top" height=398 BGCOLOR="#FFFFCC" TEXT="#080000"> <div> <I>Guide for Installing CEP900-I04 Interface into SPH Helmets</I></div> <DIV ALIGN="LEFT"></DIV> <div> <A HREF="http://www.cep-usa.com/I04 E.jpg" TARGET="_top" TITLE="http://www.cep-usa.com/I04 E.jpg"><U><U><IMG SRC="15f5a3c0.jpg" border=0 width="90" height="60" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></U></U></A><A HREF="http://www.cep-usa.com/SPH4 with CEP.jpg" TARGET="_top" TITLE="http://www.cep-usa.com/SPH4 with CEP.jpg"><U><U><IMG SRC="19b5e3c0.jpg" border=0 width="94" height="60" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></U></U></A></div> <bR> <div> <U>STEP 1</U><I>     </I><B>CONNECTOR ASSEMBLY</B><FONT SIZE="4" COLOR="#111111" FACE="Arial" ><B>     </B></FONT></div> <bR> <div> Position helmet so that right side is facing up, visor housing towards you. </div> <bR> <div> The location of the hole to be drilled in the helmet shell is determined by drawing a line from the top edge of the visor housing to the center of the screw on the lower rear edge of the earcup dome. </div> <bR> <div> <IMG SRC="19ebd4e0.png" border=0 width="445" height="334" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></div> <div> Measure along the line to a point one-inch from the center of the screw and mark. </div> <bR> <div> Drill a 3/8" hole through the helmet shell at this location. Trim around the edge of the hole removing loose, excess fibers.</div> <bR> <div> Insert the interface, CEP900-I04, through the 3/8-inch hole, feeding the black and white wires through the hole first.  Seat the connector into the hole with the ABS spacer between the outer shell and the connector.</div> <bR> <div> On the inside of the helmet, pass the solder tab washer over the grommet and position on the inside of the shell over the connector threads.  </div> <bR> <div> Pass the connector nut over the grommet, may be a challenge the first time, and thread onto the connector threads.  </div> <bR> <div> Position the solder tab washer so the solder tab is directed toward the top of the helmet and tighten the connector nut.  The torque on the nut should be about 96-inch ounces.  </div> <bR> <div> Using long nose pliers, pull the solder tab washer at the solder hole up and away from the helmet shell about 1/2 inch.  Solder the black wire to the solder tab washer.  Bend the solder tab back to the surface of the helmet.  </div> <bR> <div> <U>STEP 2</U> <B>EARCUP ASSEMBLY</B></div> <div>  </div> <div> Position the helmet with the right earcup down, toward the table surface.</div> <bR> <div> Remove the earphone retaining foam, earphone receiver, and foam backing piece from the earcup.</div> <bR> <div> Disconnect the earphone receiver, using a jeweler's screwdriver.</div> <bR> <div> Carefully pull additional communication cable into the earcup to allow easier access to the metal tips. </div> <bR> <div> Rotate the earcup so the wire into the back of the earcup is positioned so the additional hole can be drilled through the earcup wall.</div> <bR> <div> Mark a location on the right earcup that is 3/8" to ½" adjacent to the existing grommet.</div> <bR> <div>                                                       <IMG SRC="15dee720.png" border=0 width="494" height="370" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"> </div> <bR> <div> Carefully drill a 1/4" hole at that location by positioning the drill bit 90 degrees to the surface of the earcup and drill through the earcup wall.  Be very careful to keep the wires inside the earcup away from the drill bit when drilling the hole.</div> <bR> <div> Insert the CEP interface-cable assembly, black wire and white wire, into the hole and seat the grommet. To make the solder connections easier, additional wire may be pulled through the grommet into the earcup.</div> <bR> <div> Grasp the metal tip with the pliers. A wide rubber band can be used to maintain pliers in a closed position.</div> <bR> <div> Position the pliers and tip for best access to unsolder the wire from the tip.</div> <bR> <div> With the wire removed, strip the wire insulation an additional 1/8". </div> <bR> <div> Replace the wire into the metal tip leaving 1/16" exposed wire at the base.</div> <bR> <div> With the long-nose pliers, bend the CEP interface-cable assembly wire into a hook and fit around the exposed wire at the metal tip base.</div> <bR> <div> Solder the metal tip and signal wires to form a single junction.</div> <bR> <div> Repeat this process for the other metal tip and CEP interface-cable assembly wire. </div> <bR> <div> Carefully pull the <U>excess</U> wire length from the communication signal wire and the CEP interface-cable assembly wire back through the grommet.</div> <bR> <div> Re-attach the earphone receiver.</div> <bR> <div> Replace the backing foam, earphone receiver, and the earphone retaining foam into the earcup.</div> <bR> <div> Position the earcup in the retaining harness at its original position for the user.</div> <bR> <bR> <div>  </div> <bR> <bR> <bR> <bR> </td> </tr></table></body>