Setcom System 1600 Installation and Operation Instructions
Page #8
5.0. INSTALLATION
5.1. BEFORE STARTING
Prior to installing hardware, be sure you have an overall understanding of the system you are installing. Compare the
number of stations, headset style, model of radios to the System Drawing prepared for your order and insure they
agree with the hardware you have received. The MS-1600 unit is set at the factory to correctly modulate the radio
models identified at the time of purchase. The MS-1600 will interface with these radios without need of any internal
adjustments. If the radio model is changed before installation, a different radio interface device (MAC or Radio Cable)
and a different setting on one or more of the internal gain setting may be required to allow the MS-1600 to correctly
modulate a new radio. You will need to call our toll free service line 1-800-966-1034 to determine the correct radio
interface device and the gain setting required for the new radio. If you wish to exchange components, now is the time
to contact the factory. After you have determined that all components, including cable lengths, are correct you are
ready to start.
5.2. NEGATIVE GROUND
The Setcom MS-1600 is designed for 12-volt negative ground electrical system. A common grounding point is
provided on the MS-1600 Master and each of the RS-1600 Remote Stations. A common ground wire should connect
these component grounds to chassis ground. If vehicle has a positive ground, a DC converter must be used.
5.3. PRE-EXISTING CONDITIONS
Due to the fact the headset will reduce background noise by over 90%, any alternator whine or other objectionable
noise will become more noticeable. Presence of such noise can be detected prior to intercom installation by placing
your ear directly against the radio speaker with a normal volume setting on your radio, and with the vehicle engine
running. Check both with a modulated carrier being received and with the radio in the standby mode. In some
instances it may be necessary to connect a set of headphones across the speaker if it is not possible to listen directly
to the speaker itself. If a problem exists and you have a Motorola or GE radio with a remote control head, first check
the power leads. These radios will normally have two leads for power. The orange wire (Motorola) is connected to
the ignition switch; the green lead is connected to a continuously hot 12-volt power source. The green wire typically
powers the audio speaker amplifier. Connecting a suitable filter in line with the green lead will usually reduce
alternator whine to an acceptable level. Filters such as Radio Shack Part Number 270-051 can be used and are
inexpensive. If there is detectable whine in the transmitted signal, a similar filter should be installed in series with the
orange lead.
5.4. SECURING STATION HARDWARE
Take into consideration the radio cable routing, station orientation, and drilling location to determine the installation
position. When location has been determined insure that pilot holes will not damage hidden vehicle components such
as radiators, electrical wiring, etc. Mark hole locations with pencil. Using a #25 drill bit, drill pilot holes. Number 6
sheet metal screws, supplied in the PN-21-8003 Installation Kit if purchased, are recommended. Using the number 6
sheet metal screw, screw down the station until it is held snugly. When mounting enclosures to steel backing panels
greater than 1/16” thick or aluminum panels greater than 1/8” thick, it is advisable to use self tapping machine screws
or to drill and tap for the mounting screws. This precaution will eliminate the possibility of shearing off the screw
heads during installation. Pass through holes for the interconnecting cabling connectors should be 3/4". Split ring
grommets as provided in the installation kit should be installed in pass through holes to protect system cabling.
Double-sided tape may only be used to mount the MS-1600 Master Station.
5.5. MS-1600 MASTER STATION
It is best to first locate and mount the MS-1600 Intercom/mixer station and the microphone adapter cables and any
radio cables followed by the remote stations. Select a mounting point convenient to the radio and centrally located for
the routing of the radio interface cabling and the remote to master station cabling. The location should be chosen as
to not interfere with normal operations of the crew and need not be accessable as there are no user operated controls
on the master.
