PS Engineering PAC45 System Installation And Operation Manual
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PS Engineering PAC45 System Installation And Operation Manual

Special mission audio controller system with multitalker and intellivox
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9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
PAC45
Special Mission Audio Controller System with
MultiTalker™ and IntelliVOX®
Document P/N 200-045-0000
Rev. 7, May 2019
Audio Control System with MultiTalker Technology
High-fidelity Stereo Intercom
System Installation and Operation Manual
FAA - TSO C139a
Patented under one or more of the following;
No. 4,941,187; 5,903,227; 6,160,496 and 6,493,450, 7,391,877
In certified aircraft, warranty is not valid unless this product is installed by an
Authorized PS Engineering dealer.
PS Engineering, Inc. 2019 ©
Copyright Notice
Any reproduction or retransmittal of this publication, or any portion thereof, without the expressed written permission of PS En-
gineering, Inc. is strictly prohibited. For further information, contact the Publications Manager at PS Engineering, Inc., 9800
Martel Road, Lenoir City, TN 37772. Phone (865) 988-9800, email contact@ps-engineering.com.

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  • Page 1 Any reproduction or retransmittal of this publication, or any portion thereof, without the expressed written permission of PS En- gineering, Inc. is strictly prohibited. For further information, contact the Publications Manager at PS Engineering, Inc., 9800 Martel Road, Lenoir City, TN 37772. Phone (865) 988-9800, email contact@ps-engineering.com.

  • Page 2: Table Of Contents

    2.5.1 U ....................2-7 NSWITCHED UDIO EVEL 2.5.2 A ........................2-8 DJUSTMENTS 2.5.3 L ......................2-8 OGIC WITCH PTIONS PAC45 P ..........................2-11 IN ASSIGNMENTS ............................2-13 IRING HECKOUT ..........................2-13 PERATIONAL HECKOUT 2.8.1 R ....................2-13 EQUIRED QUIPMENT 2.8.2 A .....................
  • Page 3 ARRANTY ..............................ACTORY ERVICE Appendix A – PAC45 Installation Drawings ............. A Appendix B – Radio Interconnect Wiring B Appendix C – Intercom Interconnect Wiring ............C Appendix D – Control Head Interconnect Wiring ............. D Appendix E, Unit Connector Wiring Reference ............E 10.1 J451 C...

  • Page 4: Section I - General Information

    Before installing and/or using this product, please read this manual completely. This will ensure that you will take full advantage of all the advanced features in the PAC45. 1.1.1 Limitations This article meets the minimum performance and quality control standards required by a tech- nical standard order (TSO).

  • Page 5: Equipment Description

    The individual volume controls select the receiver audio source provided to the headphones when selected to the “out” position. An eight-station voice activated (VOX) intercom is included in the PAC45. This system has PS En- gineering’s patented IntelliVOX® circuitry that eliminates manual adjustments. The intercom sys- tem incorporates pilot isolate, all and crew modes, a stereo music input with "SoftMute™".

  • Page 6: Specifications

    Up to 55,000 feet in a non-pressurized area of the cockpit. DIMENSIONS: Height: 1.9 in. (4.8 cm) Width: 5.75 in. (14.6 cm) Depth behind panel (PAC45): 7.38 in. (18.75 cm) in- cluding connectors UNIT WEIGHT PAC45 -001 2.0 lb. (0.90 kg) HUB45 1.0.

  • Page 7: Equipment Supplied

    050-045-6300* .*The part numbers shown are for “Standard” bezel label nomenclature. Custom bezel nomen- clature is available, using the custom configuration program at:http://www.ps- engineering.com/PAC45_custom_legend.shtml PAC45 Standard Installation Kit 250-945-0500 (37 & 50 Pin) Description PSE Part Number Qty. Manufacturer MFR Part...
  • Page 8 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual PAC45 Retrofit Installation Kit: 250-045-0100 Description PS E Quantity Manufacturer MFR Part Number Part Number D-Sub housing 9 pin female 425-009-7709 Amphenol L177-RR-E-09-S D-sub Pins Male 425-020-5089...
  • Page 9 Inc. EQUIPMENT REQUIRED BUT NOT SUPPLIED Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45, .05 A for CTL45s Optional Circuit Breaker: 0.5 ea.; 1 amp PULL TYPE REQUIRED for PAC45 aural alerts Headphone Jacks (Stereo, as Required) Microphone Jacks (as Required) Headphones, 150 ...

  • Page 10: Configurations

    The simplest, single audio controller system is a PAC45 where the audio hub is attached to the control head. HUB45 CTL45P Figure 1-1 Single panel configuration A second control head can be added, wired into the PAC45 either for a copilot (CTL45P) or as an observer instead of a copilot, CTL45M. HUB45 HUB45 CTL45P...

  • Page 11: License Requirements

    (not touching the ground). When any air- craft leaves the ground, all cellular telephones on board that aircraft must be turned off. PS Engineering, Inc. does not endorse using unapproved cellular telephone equipment in flight, and takes no responsibility for the user’s action.

  • Page 12: Section Ii - Installation

    2.3 Equipment Installation Procedures 2.3.1 Cooling Requirements Forced air-cooling of the PAC45 is not required. However, the units should be kept away from heat producing sources (i.e. defrost or heater ducts, dropping resistors, heat producing avionics) without adequate cooling air provided.

  • Page 13: Audio Controller Connector Assembly

    Installation and Operator’s Manual 2.3.3 Audio controller Connector Assembly The LRU connectors mate with one 50-pin, one 37-pin, and two 26-pin connectors in the PAC45. The connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from ta- ble below (or equiv.).

  • Page 14: Cable Harness Wiring

    This feature is usually transparent to the installer; however, it is important that the appro- priate music signal and ground connections are made directly to the dedicated music signal and ground inputs on the PAC45. The power for IFE and audio controller should be a common bus. 200-045-0000 Page 2-3 Rev.

  • Page 15: Power

    2.4.2 Power The PAC45 is compatible with 28 Volt DC systems. A one (1) Amp circuit breaker is required for all installations. Power and ground wires should be #22AWG connect power to P451 Pin 17.

  • Page 16: Transmit Interlock

    The PAC45 system can support six passenger intercom stations, in addition to the pilot and copi- lot. The input to the PAC45 P451 6, 23, 40 can be used as a hand mic, or as passenger 6, with transmit capability on the selected radio.

  • Page 17: Unswitched Inputs

    (or the remote ACK P454-9 grounded), or the input level reverts. When power is applied to the alerts and not the PAC45 audio controller, it will play the message three times or until the remote acknowledge is selected.

  • Page 18: Music Input

    All additional entertainment devices must be switched off for both takeoff and landing. 2.4.11 Receive Activity Indicator (-RXI) PAC45 systems (HUB45 Serial Number DH1069 and above) have a Receive Activity Indicator that flashes the selected receiver indicator when a signal is present on that receiver. This function is set at the factory at the installer’s request, and can only be changed at the factory.

  • Page 19: Adjustments

    Also, ACK can be pressed at any time to exit (if you want to adjust green but not white for example) 2.5.3 Logic Switch Options The PAC45 has several switches accessible through the side of the HUB45 to set specific func- tions 200-045-0000 Page 2-8 Rev.
  • Page 20 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Power must be cycled after selections are completed. 1-3: Alert polarity (ground or voltage trigger) 4-6: Alert type (edge or trigger) 7: Dimmer mode (5VDC or 28VDC) 8: Mic sensitivity (High noise applications) 9: Passenger HRTF enable (MultiTalker™...
  • Page 21 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.5.3.1 Alert Trigger Logic (1 – 3) Switches 1-3 set alert logic. DOWN for active high, UP for active low. 2.5.3.2 Alert Trigger Type (Switches 4 – 6) Switches 4-6 set alert type.

  • Page 22: Pac45 Pin Assignments

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.6 PAC45 Pin assignments P451 P452 FUNCTION FUNCTION COM2 KEY UNSWITCHED AUDIO 2 COM1 KEY COM 2 AUDIO HI COM3 KEY COM 1 AUDIO HI COM4 KEY...
  • Page 23 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual P453 P454 SERIAL TX2- PA KEY (S/N CHB0XXX and up) SERIAL TX2+ COPILOT CVR/Low Level SPR out (-0102 only) PAX 5 ICS PTT PAX 6 ICS PTT...

  • Page 24: Wiring Checkout

    2.8 Operational Checkout 2.8.1 Required Test Equipment In order to return an aircraft to service after installation of the PAC45, the installer must have access to headset(s), and be able to establish 2-way communications on appropriate radios. Equivalent test equipment is acceptable as long as the testing requirements can be met.

  • Page 25: Final Inspection

    To make or receive a phone call, you must press the TEL switch in the OUT position on the audio controller panel and verify the volume is turned to an acceptable volume. The PAC45 has the ability to turn the telephone audio completely off by turning the TEL volume knob all the way CCW.

  • Page 26: Section Iii Operation

    The radio is automatically selected to receive incoming radio calls when the XMT is selected. With a PAC45, you will never transmit on a radio that you are not receiving. The selected audio is indicated by both knob position and the green text.

  • Page 27: Com Audio Selector

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 3.4 COM Audio Selector The communications receiver audio sources are controlled by a combination push on-push-off switch/volume control. Communication audio from another radio, not selected for transmit, can be heard by pressing the associated RCV switch, which will place it in the OUT position.

  • Page 28: Navaid Selection

    Installation and Operator’s Manual 3.4.4 Receiver Activity Indication (-RXI) PAC45 systems (HUB45 Serial Number DH1069 and above) have a Receive Activity Indicator that flashes the selected receiver indicator when a signal is present on that receiver. This allows the user to spot an active radio, even if the volume is turned down. This function is set at the factory at the installer’s request, and can be changed only at the factory.

  • Page 29: Push To Talk Intercom (Ptt Ics)

    Some passenger headsets are connected in parallel. Therefore, if a monaural headset is plugged in to a PAC45 Stereo installation, one channel may be shorted. Although no damage to the unit will occur, all passengers with stereo headsets will not hear one channel, unless they switch to the “MONO”...

  • Page 30: Intercom Modes

    3.7.1 Pairing and unpairing Bluetooth devices The PAC45 can be paired with up to eight individual devices, but will only connect to one at a time. When that number is exceeded, the PAC45 will drop a device to allow the new device to be added.

  • Page 31: Wired Satcom/Cell Phone Input

    In CREW mode, the pilot and copilot are connected to the telephone. In ISO intercom mode, when the PAC45 is in the TEL mode, the pilot position is in the "Phone Booth." Only the pilot will hear the telephone, and only he will be heard.

  • Page 32: Observer/Mission Control Panel Operation

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Figure 3-4 Copilot Audio controller, Dual Configuration CTL45P 3.9.1.1 Intercom Operation, Two (Pilot, Copilot) Control Heads If two control heads are used, the following rules apply: •...

  • Page 33: Alert Audio

    3.11.1 Storing Alert Audio The PAC45 systems can store three audio alerts. You must record all three when the unit is in au- dio program mode. You cannot change only one at a time. If you wish to replace just one mes- sage, we recommend you write down all the messages before starting the procedure.
  • Page 34 NOTE: If ACK is not pressed to indicate end of recording, it will record for five seconds, and then advance to next alert. After all three time slots are timed out, the PAC45 will exit the alert re- cording mode.

  • Page 35: Intercom Operation Block Diagrams

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 3.12 Intercom Operation Block Diagrams These block diagrams illustrate the audio distribution for intercom and radios in four different configurations, single panel, dual panel pilot/copilot, dual panel pilot-copilot/observer, and three control head.

  • Page 36: Dual Control Head, Pilot Ctl45P And Copilot Ctl45P

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 3.12.2 Dual Control Head, Pilot CTL45P and Copilot CTL45P DUAL CONTROL HEAD INTERCOM MODES ALL - ALL MODE PILOT ISOLATE MODE ISO-ISO MODE Selected Radios Selected Radios...

  • Page 37: Dual Control Head Pilot & Copilot Ctl45P Plus Observer Ctl45M

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 3.12.3 Dual Control Head Pilot & Copilot CTL45P plus Observer CTL45M 200-045-0000 Page 3-3 Rev. 7, May 2019...

  • Page 38: Three Control Head, Pilot Ctl45, Copilot Ctl45P And Mission Observer Ctl45M

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 3.12.4 Three Control Head, Pilot CTL45, Copilot CTL45P and Mission Observer CTL45M 200-045-0000 Page 3-4 Rev. 7, May 2019...

  • Page 39: Section Iv - Warranty And Service

    All domestic transportation charges for returning the exchange or repaired unit to the purchaser will be borne by PS Engineering, Inc. The risk of loss or damage to the product is borne by the party making the shipment, unless the purchaser requests a specific method of shipment.

  • Page 40: Appendix A - Pac45 Installation Drawings

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix A – PAC45 Installation Drawings Figure 5-1 – PAC45 Rear/Connector View (not to scale) J451: 50-PIN FEMALE ON HARNESS J452: 37-PIN FEMALE ON HARNESS Figure 5-2 – PAC45 Side View...
  • Page 41 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual PAC45 Overall 200-045-0000 Appendix A Rev. 7, May 2019...
  • Page 42 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual CTL45 Top View 200-045-0000 Appendix A Rev. 7, May 2019...
  • Page 43 PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual HUB45R Top View Figure 5-4 - HUB45R Side View 200-045-0000 Appendix A Rev. 7, May 2019...

  • Page 44: Appendix B - Radio Interconnect Wiring B

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix B – Radio Interconnect Wiring 200-045-0000 Appendix A Rev. 7, May 2019...

  • Page 45: Appendix C - Intercom Interconnect Wiring

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix C – Intercom Interconnect Wiring P453 P451 P452 P454 Pilot Mi c Aud io H i Pilot Mi c L o Pilot Mi c PTT PIL PH N (R )

  • Page 46: Appendix D - Control Head Interconnect Wiring

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix D – Control Head Interconnect Wiring PAC45 COPILOT HUB LRU P 45 5 P455 J4 55 J4 53 R X- R S422 TX - R X- R S422 TX -...

  • Page 47: Appendix E, Unit Connector Wiring Reference

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix E, Unit Connector Wiring Reference 9.1 J451 Connections P451 PAC45 Connec tors , J451 C om 1 M ic A ud io H i Commu n ication s...

  • Page 48: J452 Connections

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.2 J452 Connections P452 PAC45 Connector, J452 Com 1 Audio Hi Communications Receiver #1 Com 1 Lo Communications Com 2 Audio Hi Receiver #2 Com 2 Audio Low...

  • Page 49: J453 Connections

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.3 J453 Connections P A C 45 C o nnec to rs, J45 3 P453 Com 6 Mic A udio Hi C ommun ica tio ns Tran smitter...

  • Page 50: J454 Connections

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.4 J454 Connections Com 6 A udi o Hi C o mmu n ic at io ns Com 6 A udi o Low R ec ei v er # 6...

  • Page 51: Appendix F - Instructions For Faa Form 337 And Continuing Airworthiness

    Aircraft equipment list, weights and balance amended. Compass compensation checked. A copy of the operation in- structions, contained in PS Engineering document 202-045-( ), revision ( ), dated ( ), is placed in the aircraft records. All work accomplished listed on Work Order 10.2 Instructions for Continuing Airworthiness, Audio System...

  • Page 52: Appendix G - Rtca Do160G Environmental Qualification Form

    PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix G – RTCA DO160G Environmental Qualification Form 11.1 Model Number PAC45 Audio Selector Panel/Intercom Remote Hub Part Number: 050-045-( ) FAA TSO Number: C139a, Manufacturer: PS Engineering Incorporated...

  • Page 53: Model Number Ctl45, Audio Selector Control Panel

    PS Engineering PAC45 Audio Selector Panel and Intercom System Installation and Operator’s Manual 11.2 Model Number CTL45, Audio Selector Control Panel Part Number: 050-045-(02XX, -03XX, -62XX, -63XX ) FAA TSO Number: C139a Manufacturer: PS Engineering Incorporated 9800 Martel Road Lenoir City TN 37772...

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