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PS Engineering PAC45L Manual

Retrofit audio controller system with multitalker and intellivox
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Retrofit Audio Controller System
with MultiTalker® and IntelliVox®
System Installation and Operation Manual
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
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.
9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
PAC45L
Document P/N 200-045-3000
April 2021
Audio Control System with Intercom
FAA - TSO C139a
Authorized PS Engineering dealer.
PS Engineering, Inc. 2021 ©
Copyright Notice

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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

    ECEIVE IGNAL NDICATOR 2.7.11 M ....................... 2-17 USIC UNCTIONS 2.7.12 S ....................2-18 PEAKER LERT UDIO 2.7.13 B ................... 2-18 ACKLIGHT IMMER OLTAGE 2.7.14 O ..................2-18 THER HARED UNCTIONS PAC45L P ..........................2-19 IN ASSIGNMENTS ............................2-20 IRING HECKOUT...
  • Page 3 ARRANTY .............................. 4-1 ACTORY ERVICE Appendix A – PAC45L 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 J451 C ..............................

  • Page 4: Section I - General Information

    Section I – GENERAL INFORMATION INTRODUCTION The PAC45L represents an evolution in the well-received PAC45 Series of audio controllers for legacy jet aircraft. MultiTalker®, using licensed U.S. Air Force patented technology, provides True Dimensional Sound, helping pilots to more easily discern from simultaneous radio receptions.

  • Page 5: Specifications

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 1.1.2 Limitations This article meets the minimum performance and quality control standards required by a technical standard order (TSO). Installation of this article requires separate approval. Refer to Advisory Circular 20-41A for information on TSO installation approval.

  • Page 6: Equipment Supplied

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual EQUIPMENT SUPPLIED The following units comprise the PAC45L System: Model Description Part Number HUB45AR Remote-mounted Audio Hub for analog I/O and processing 050-045-1001 Control Head for pilot or copilot positions – Black...
  • Page 7 EQUIPMENT REQUIRED BUT NOT SUPPLIED Circuit Breakers: 1 ea.; 5 amp PULL TYPE REQUIRED for HUB45aAR, 1 A for CTL45Ls Optional Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45L aural alerts, 1 ea. 1 A for failsafe power...

  • Page 8: Configuration

    PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Configuration The PAC45L System is comprised of a single PAC45L HUB (HUB45AR) and up to four CTL45L Control Head “building blocks” to facilitate flexibility as well as simplicity. SAT/...
  • Page 9 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 200-045-3000 Page 1-6 April 2021...

  • Page 10: Section Ii - Installation

    2.3 Equipment Installation Procedures 2.3.1 Cooling Requirements Forced air-cooling of the PAC45L is not required. However, the units should be kept away from heat pro- ducing sources (i.e., defrost or heater ducts, dropping resistors, heat producing avionics) without adequate cooling air provided.

  • Page 11: Audio Controller Connector Assembly

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.3.3 Audio controller connector assembly The HUB45AR LRU connectors mate with two 62-pin, and two 26-pin connectors. One of each gender. The connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from table below (or equiv.).

  • Page 12: Power

    2.4.2 Power The PAC45L is compatible with 28 Volt DC systems. A five (5) Amp circuit breaker is required for all installations. Power and ground wires should be #22AWG connect power to P451 Pin 42. Connect airframe ground to P451 Pin 20 and 21 only.

  • Page 13: Backlighting

    2.4.3.1.1 Navaid Ident Filter (front panel VOC) The PAC45L Systems is equipped with an identifier filter that will enhance the 1030 Hz Morse Code identi- fier (ID Mode), or reduce the Morse Code identifier for clearer reception of voice transmissions or VOR (VOC).

  • Page 14: Cockpit Voice Recorder

    2.4.8 Audio Alerts The PAC45L contains an independent audio alerting system that will play up to 9 messages that can be stored by the user (see §3.11.1). Factory stored default audio is shown below. The alert system has a power input (P451-41) that will keep the systems operable if the PAC45L systems power source is removed.

  • Page 15: Ctl45L Wiring

    Alerts with level trigger will play continuously until the Acknowledge button (ACK) is pressed (remote ACK P454-23 grounded), or the input level reverts. When power is applied to the alerts and not the PAC45L audio controller, it will play the message continu- ously until the remote acknowledge is selected.

  • Page 16: Wired Telephone/Satellite Communication Input

    2.6 Wired Telephone/Satellite Communication input The PAC45L can accommodate a wired cell phone interface on J452 Pins 58, 59, and 38. Both Bluetooth and wired Telephone and be accommodated, however, only ONE can be active at a time. Low impedance satellite phones might require a tactical radio adapter, PS Engineering P/N 12100 Visit website (https://www.ps-engineering.com/assets/docs/radio_adapter.pdf)

  • Page 17: Unswitched Audio Level

    PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.7.1 Unswitched Audio Level Unswitched inputs one through five are installation adjustable through the side of the PAC45L unit. 2.7.2 Adjustments On the side of the PAC45L/HUB45AR are 15 adjustment potentiometers. These are ALL 30-turn pots.

  • Page 18: Logic Switch Options

    Installation and Operator’s Manual 2.7.3 Logic Switch Options The PAC45L has switches accessible through the side of the HUB45AR to set specific functions Switch functions and positions as shipped from the factory. The color coding denotes similar groups of functonality.
  • Page 19 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual TOP ROW BOTTOM ROW SWITCH FUNCTION POSITION* SWITCH FUNCTION POSITION* FAILSAFE ALERTS TO COPILOT CONTROL CREW HEAD INSTALLED FAILSAFE ALERTS TO OBSVR 1 CONTROL OBSERVERS HEAD INSTALLED...

  • Page 20: Logic Switch Details

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.7.4 Logic Switch Details SWITCH FUNCTION NUMBER NO ALERT AUDIO IN FAILSAFE ALERTS TO PILOT AND COPILOT HEAR FAILSAFE (RADIOS CREW ALERTS IN FAILSAFE MODE ONLY) FAILSAFE ALERTS TO...
  • Page 21 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual SWITCH FUNCTION NUMBER J452-33 IS COM 7 COM 7 & COM 8 AUDIO J452-33 IS COM 1 SIDETONE AUDIO INPUT OR COM 1 & COM 2 INPUT...
  • Page 22 PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.7.4.1 HUB45R Bottom Logic Switches In the PAC45L System, the DIP switches located on the bottom of the HUB45 is configured from the fac- tory: Position Switch If it is necessary to check or set these switches, remove the foil covers.
  • Page 23 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Figure 2-4 LOGIC SWITCH LOCATIONS HUB45A After any necessary adjustments are complete, apply the gold foil covers, rectangular (575-998-0100) and round (575-998-0050). Spare covers are included in the installation kit.
  • Page 24 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual J7 SWITCH FUNCTION NUMBER J452-57 IS UNSWITCHED J452-57 IS HAND MIC UNSWITCHED #5 INPUT 5 INPUT P451-58 IS OBS #1 TEL/MIC P451-58 IS WIRED TEL INPUT HAND MIC...

  • Page 25: Fail-Safe Audio And Reversionary Mode

    Stuck Mic Enable When Switch 30 is ON the PAC45L will ignore any push-to-talk input that is held low for more than 35 seconds. This function resets if the PTT ground is released. If Switch 30 is OFF, a PTT will key the selected radio indefinitely, and rely on the radio’s internal stuck mic protection.

  • Page 26: Unswitched Audio

    Low Impedance (8Ω headphones) 2.7.9.2 When Switch 40 is ON, the PAC45L audio output is optimized for a low-impedance headphone output of about 8Ω. When Switch 40 is OFF, the PAC45L audio output is optimized for a standard civil aviation headphone impedance headphone output of about 150-300Ω.

  • Page 27: Speaker Alert Audio

    For 14 VDC backlighting, Switch 47 is OFF and 48 is ON. For 5 VDC backlighting, both Switches 47 and 48 are OFF 2.7.14 Other Shared Functions Some functions are set by switches not easily accessible to the installer. Contact PS Engineering for detailed information. These include: •...

  • Page 28: Pac45L Pin Assignments

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.8 PAC45L Pin assignments P451 J452 Description Description Ground Lighting Common Ground Music Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground Ground...

  • Page 29: Wiring Checkout

    After wiring is complete, verify power is ONLY on pins 41, 42 & 62 of J451 and airframe ground on pins 20 & 21. Failure to do so will cause serious internal damage and void PS Engineering's warranty. CAUTION: Do not connect or disconnect (...

  • Page 30: Operational Checkout

    2.10 Operational Checkout 2.10.1 Required Test Equipment In order to return an aircraft to service after installation of the PAC45L, 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 31: Bluetooth Checkout

    2.10.3.1 Bluetooth TEL Checkout Pair the PAC45L with a Bluetooth telephone device. Verify that the pilot headset is connected to the cellular telephone system (if installed). The telephone function will allow any person heard by the pilot on the inter- com, also heard on the telephone.

  • Page 32: Section Iii Operation

    The radio is automatically selected to receive incoming radio calls when the XMT is selected. With a PAC45L, 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 33 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual volumes. The RAD volume control is to allow an easy way to reduce all radio volumes temporarily to assist in intercommunications (intercom). You will always hear the audio from the selected transceiver; even if the selected com audio is turned all the way down on the audio controller because it cannot turn off the selected receive audio all the way.

  • Page 34: Navaid Selection

    ADF 2 will be heard if ADF is selected. 3.5.1 Ident Filter The PAC45L System is equipped with an identifier filter that will enhance the 1030 Hz Morse Code identifier (ID Mode), or reduce the Morse Code identifier for clearer reception of voice transmissions or VOR (VOC).

  • Page 35: Speaker Operation

    Pairing and unpairing Bluetooth devices The PAC45L can be paired with up to eight individual devices but will only connect to one at a time. When that number is exceeded, the PAC45L will drop a device to allow the new device to be added.

  • Page 36: Music Muting Control

    3.11.1 Storing Alert Audio The PAC45L systems can store nine audio alerts. You must record all nine when the unit is in audio program mode. You cannot change only one at a time. If you wish to replace just one message, we recommend you write down all the messages before starting the procedure.
  • Page 37 NOTE: If the acknowledge button is not pressed to indicate end of recording, it will record for five seconds, and then advance to next alert. After all time slots are timed out, the PAC45L will exit the alert recording mode.

  • Page 38: Section Iv - Warranty And Service

    (2) years from the date of sale. During the first twelve (12) months of the two-year warranty period, PS Engineering, Inc., at its option, will send a replacement unit at our expense if the unit should be determined to be defective after consultation with a factory technician.

  • Page 39: Appendix A - Pac45L Installation Drawings

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix A – PAC45L Installation Drawings Figure 5-1 - CTL45L Front View Figure 5-2 CTL45L Top View Figure 5-3 CTL45L Side View 200-045-3000 Appendix A , April 2021...
  • Page 40 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual P455 9--PIN MALE 425-009-0777 625-009-9034 P451 (TOP) 62-PIN MALE 425-062-8177 625-037-3703 P453 (BOTTOM) 62-PIN FEMALE 425-062-4701 625-037-3703 P453 26-PIN MALE (TOP) 425-026-5601 625-015-1503 P454 26-PIN FEMALE (BOTTOM)
  • Page 41 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual BLUETOOTH ANT CONN J455 Figure 5-6 HUB4A5R Front View Figure 5-7 - HUB45AR Side Views 200-045-3000 Appendix A , April 2021...

  • Page 42: Appendix B - Radio Interconnect Wiring

    Unswitched Audio Lo Figure 6-1 Switch Positions Because of the labeling flexibility on the PAC45L System, the nomenclature on the CTL45 may not match the wiring diagram. Shown here are the switch positions for each of the available inputs. 200-045-3000...

  • Page 43: Appendix C - Intercom Interconnect Wiring

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix C – Intercom Interconnect Wiring J451 Pilot Mic Audio Hi Pilot Mic Lo Pilot Mic PTT Copilot Mic Audio Hi Copilot Mic Lo COPILOT MIC PTT...

  • Page 44: Appendix D - Control Head Interconnect Wiring

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix D – Control Head Interconnect Wiring PAC45L HUB45AR LRU RX- RS422 TX - RX+ RS422 TX + TX- RS422 RX - TX+ RS422 RX + PILOT...

  • Page 45: Appendix E, Unit Connector Wiring Reference

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix E, Unit Connector Wiring Reference 9.1 J451 Connections J451 COM 1 COM 1 MIC AUDIO HI COM 1 MIC KEY SWITCH COM 1 MIC AUDIO LO...

  • Page 46: J452 Connections

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.2 J452 Connections COM 1 Audio Hi PAC45L CONNECTOR P452 COM 1 COM 1 Lo MALE ON HARNESS COM 2 Audio Hi COM 2 Audio Lo COM 2...

  • Page 47: J453 Connections

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.3 J453 Connections J 453 FEMALE ON HARNESS GROUND GROUND GROUND GROUND GROUND ALERT 1 ALERT 2 ALERT 3 ALERT 4 ALERT 5 ALERT 6 ALERT 7...

  • Page 48: 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 instruc- tions, contained in PS Engineering document 202-045-(XXXX), revision ( ), dated ( ), is placed in the aircraft records. All work accomplished listed on Work Order...

  • Page 49: Appendix G - Rtca Do160G Environmental Qualification Form

    PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix G – RTCA DO160G Environmental Qualification Form 11.1 Model Number PAC45L Audio Selector Panel/Intercom Remote Hub Part Number: 050-045-( ) FAA TSO Number: C139a, Manufacturer: PS Engineering Incorporated 9800 Martel Road...
  • Page 50 PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 11.2 Instructions for Continuing Airworthiness, Audio System Sample ICA Checklist for PS Engineering PAC45L Audio System: Section Item Information Introduction Installation of audio control panel with intercommunications system, with inte- grated audio alert system.

  • Page 51: Model Number Ctl45L, Audio Selector Control Panel

    PS Engineering PAC45L Audio Selector Panel and Intercom System Installation and Operator’s Manual 11.3 Model Number CTL45L, Audio Selector Control Panel Part Number: 050-045-(20, -40XX) FAA TSO Number: C139a Manufacturer: PS Engineering Incorporated 9800 Martel Road Lenoir City TN 37772...

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