XLR5 to GA headset adapter

[yonygg]

Hi ya all
I fly ATR aircraft which has a XLR 5 headset connector (aka airbus adapter) and I want to use my own headset while flying. Problem is my headset has a GA-type plugs (PJ-55 for the phone - 0.25"/6.35 mm - aka M642/4-1, and PJ-068 - 0.206"/5.25 mm for the mic aka M642/5-1)
I know there are tons of commercially available adopters out there but I want to build an adapter myself.
I already have all the parts and tools BUT I have one thing missing - the ATR/AIRBUS XLR5 and the General Aviation type headset connectors-pinout / wiring diagram.

I wasn't able to find it online even after a prolonged search.

Any lead would be appreciated.
:ok:

[GarageYears]

XLR-5 pinout:
Pin1 - Ear+
Pin2 - Ear-
Pin3 - Mic +
Pin4 - Mic -
Pin5 - No connect

GA
0.25" 2-pin jack (earphones)
Tip - Ear+
Sleeve - Ear-

0.206" 3-pin jack (mic)
Tip - No connect
Ring - Mic+
Sleeve - Mic-

[yonygg]

So that means that the tip of the 0.25" plug should be connected to pin 1 of the XLR and the sleeve of the 0.25" plug is connected to pin 2 of the XLR.

I have a connector which is wired the opposite way: 0.25" tip to XLR pin 2 (EAR -) and 0.25" sleeve to CLR pin 1 (EAR +).

What will happen in this case?

Will it not work?

[GarageYears]

For the earphones the polarity is not significant, so reversing the connections within the adapter will not matter, but strictly tip of 0.25" connector should connect to pin1 of the XLR.

Consider a sine wave - the signal moves positive then negative to complete the sine wave cycle. All that happens with the reversed wiring case is instead of having the cone of the speaker move outwards initially, it will move inwards - the phase is reversed. This will not affect what you hear to any degree since humans are not phase sensitive.

Phase really only matters when you have multiple speakers driving into a single 'space' - for example if you wire one speaker in-phase and one out-of-phase then you will suffer cancellation, which will be more pronounced at the lower frequencies, perhaps to the point of no bass at all!

[yonygg]

For the earphones the polarity is not significant, so reversing the connections within the adapter will not matter, but strictly tip of 0.25" connector should connect to pin1 of the XLR.

I got confused. I thought the 0.25" connector IS the earphones plug and on one end you say that reversing the polarity doesn't matter and on the other hand you say I MUST connect the tip of the 0.25" connector (which is the earphones connector) to the XLR pin 1.

Maybe I was not clear myself so I will re-explain the situation: I have a GA-type headset (with 2 plugs - one for audio [the 0.25" plug] and one for mic [the 0.206" plug]) which I want to connect to an Airbus/ATR plane (which uses the XLR 5 connection), and I also have an adapter for this purpose.
I reverse engineered the adapter to check which part of my GA headset would connect to which XLR pin on the plane, and I found out that my adapter will connect the TIP of my headset's audio plug (which is the 0.25" plug) to the plane's XLR pin #2 (which is in opposed to what you wrote that it must be connected to the XLR pin #1) and the SLEEVE of my headset's audio plug (still 0.25") to the plane's XLR pin # 1.

I'm attaching a picture of the diagram I drew while reverse engineering it to make my current situation more clear. On the picture there are 2 different mic (0.206") plugs, it's because I have 2 headsets which have a slightly different mic plugs. Disregard it.

https://www.dropbox.com/s/mfyor49n97g6zxl/Photo%20Nov%2016%2C%2023%2009%2004.jpg
(https://www.dropbox.com/s/mfyor49n97g6zxl/Photo%20Nov%2016%2C%2023%2009%2004.jpg)

[EEngr]

www.sennheiser-aviation.com/downloads_other_2112261

Might be of interest.

[yonygg]

Hi EEngr

That is an extremely precious document to have. Thank you.

But does anyone knows what would happen if a plugs adapter is wired wrong? (headset"s AUDIO HI connected to plane's AUDIO LO, and headset's AUDIO LO connected to plane's AUDIO HI) ???

[EEngr]

But does anyone knows what would happen if a plugs adapter is wired wrong?Reversing the polarity on the headphones should have no effect*. The same (probably) goes for the microphone outputs, as most amplifiers are AC coupled. Reversing the external DC supply could be problematic. As in the headset electronics won't work and might be damaged.

*Reversing the headphone polarity at some point inside a noise canceling system (not at the GA or XLR interface) could render that system non-functional.
:8

[yonygg]

Roger that.
Next week I will get to try this "reverse-wired" headset adapter and I will report the results.

Thank you,
Cheers!

[yonygg]

Hi
So I tried it and it works the way I had it wired up!
Thanks to everyone who replied and in case someone else reads this thread, looking for the same answers as I did - please don't hesitate to post here and I'll be glad to help according to my knowledge.

Cheers!

[VinceTheBeast]

Hi all. I would also like to make my own adapter (for my Bose X G/A plugs to XLR5 plug).
Would anybody happen to know where I can buy a jack/female plug for the microphone (PJ-068 or M642/5-1) please?

Google didn't help me much sadly...

Many thanks in advance!

[wingwalker123]

I just made my own adapter cable to convert my Bose a21 XLR (XLR to GA) as some of our Airbusses actually use GA plugs :ugh:

Anyway, I also had some difficulty to find the 5,23mm jack, as it is used only in the military/aviation. My local electronics shop had even never heared of it. I found it at Conrad electronics. As you are from the UK this should be the correct link: Neutrik NP3CM-B,STEREO NP 3 CM-B Jack Plug 5.23 MM Straight, MIL-Type Number of pins=3/stereo Content: 1 pc(s) from Conrad Electronic UK (http://www.conrad-electronic.co.uk/ce/en/product/734004/Neutrik-NP3CM-BSTEREO-NP-3-CM-B-Jack-Plug-523-MM-Straight-MIL-Type-Number-of-pins3stereo-Content-1-pcs?ref=searchDetail)


Enjoy!

[VinceTheBeast]

Thanks for the link wingwalker123.

The thing is, I was after a jack (so a 'female') not a plug ('male') as I'm converting from GA to XLR5 (not XLR5 to GA). Thanks anyway.

I have now found one in the US and have soldered a converter plug and it works a treat (on a Boeing 737-800NG).:D

If anybody is looking for the same thing, please contact me.

[a320skipper]

Can you please send me the wiring ?
im converting a uflymike from GA to XLR5
So I need to know how you wired the female plus to accept the GA pins in them , and how you wired the XLR5 as well.
let me know what type of cable you used and if it is possible to uncsre the caps and take pic of all 3 of the connectors..
Best if I see pictures ,,,I would really appreciate it...
I hate to have to cut the GA plugs from the mike to fit an XLR plug, but im not having any luck finding a diagram..

many thanks

[Pointer]

Hi guy's, I have a slightly different problem..

My single plug 5.23mm/.206" of my Plantronics ms50/t30-1 has been broken by a careless individual. I want to convert it to a XLR 5 pin. Now I only have 3 wires.. and can't find anyone to tell me which wire go's were..

Red/green/ground in this order as well on the picture.

https://www.dropbox.com/s/0jtb06sfh6y2snt/pj-068-wiring-diagram-schematic.jpg?dl=0

so headphone and mic are shared over one plug. how to connect now on the XLR 5-pin?

Thanks for the help! :ok:

[LeadSled]

Folks,
Please be aware of the potential criminal liability you are creating for yourself and liability for your employer by using uncertified/home made devices operationally on the flight deck in any air transport operation.
Indeed, in many countries it would be illegal even for a private day/VFR operation, to use such equipment.

[Pointer]

duly noted sled.. and yes I know its more for my benefit than it is yours.. (Sigh)

Lets hope someone has actually something useful to contribute.. I'm still non the wiser.. (except for some unsolicited legal advice :{ )

[EEngr]

The wiring given in post #2 is pretty much correct*.

Before slicing off the XLR5 connector, open it up (if its not a molded connector) and note which wires go to which pins. If it's a molded connector, leaving enough cable to go back (if necessary) strip back the outer cable jacket. Then, one at a time, cut each inner wire and use a continuity tester to see which wire goes to which pin. Make sure you can uniquely identify each wire.

Use the continuity tester on the GA plugs as well. Getting the correct functions (mic+, mic-, etc.) connected to the correct GA plug positions is more important than color codes.

*On some headsets, DC is supplied to noise canceling electronics. The DC+ is connected to the XLR5 pin 5 (otherwise not connected). On the GA mic plug, the plug tip is DC+ (otherwise not connected).

[Francoisk1979]

Hi, I bought a bose A20 with U384 plug, and I buy from nexus u384/u to xlr5, but I set the xlr5 pin configuration
XLR-5 pinout:
Pin1 - Ear+
Pin2 - Ear-
Pin3 - Mic +
Pin4 - Mic -
Pin5 - No connect
With this configuration works only the mic, but earphones eater one not working, I use for the U384 this configuration
U-385/U jack.

Wiring Configuration:

Civilian Stereo:
Microphone High to Pin 1
Microphone Low to Pin 2
Earphone Left High to Pin 3
Earphone Right High to Pin 4
Earphones Low to Pin 5
Please help me what I'm doing wrong, thanks.

[kalhimeo]

Hi,

This topic is very interesting. I have one question for avionics experts, is the power supplied to the GA 0.206" mic pin tip the same standard (voltage, amps) than the power supplied to the XLR pin 5 ?

If yes, is there any adapter from XLR5 (headset) to GA (aircraft) with such power capability ?

My A/C has the GA type connector with power supplied through mic pin, and I would love to use my XLR5 ANC headset without batteries thanks to the right adapter.

Thank you very much in advance !

[EEngr]

I don't know what the ANC headset acceptable supply voltage range is. And I'd be careful with the 'power' seen on the GA microphone tip. Some of the GA mics use the tip for a PTT (push to talk) signal. It might appear to have a voltage on it, but this is through a sensing circuit that looks for it to be pulled to ground when the PTT is pressed. Connect that to an ANC headset power pin and 1) you won't get much power and 2) the GA radio system will see that as a continuous PTT signal. Not good.

The safest bet is to leave the mic/noise cancelling supply alone and use batteries. And to leave the GA mic tip not connected.

There was a Sennheiser document referenced earlier in this thread that had some better information on pin functions. But it appears to be gone. Perhaps wisely, as too much home brewing can be a bad thing. I have seen some adapters for sale on line for not many dollars. The certification of which should be verified prior to use.

[W8HSR]

Hey!

After about 40min of searching google this is the closest discussion I can find to hopefully get the answers I need for my problem... I've just started learning to fly only 25 hours in so go easy on me!

I have purchased on eBay a (condition new) Bose A20 Non-Bluetooth Headset that has a XLR 5 Pin female plug, I also purchased from Amazon a Male XLR 5pin to Duel Male G/A Plugs adaptor. The headset arrived yesterday, (also came with the same adaptor. Looks just like the Amazon one I ordered, so don't think its a Bose Accessory.) Got in the P28-161 I was flying the same day. Plugged the headset in to find it wouldn't work. Both with or without the batteries in. My instructor plugged in his Sennheiser headset to find that my Bose was causing a issue, he descried it as causing a static noise in his headset and also thought it was causing the radio to transmit constantly. So we ceased using the Bose immediately. I flew using a club headset an we didn't mess around trying to get it to work any more.

Reading lots of posts about pin outs and what pin goes to what, I am thinking and hoping the issue is with the adaptor and maybe re-soldering the configuration will fix it? Something todo with the DC+?

Any help would be greatly appreciated! I am finding it hard to see a XLR to GA Duel Plugs wiring diagram.