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Engineering Incorporated PAC45A Manual

Special mission audio controller system
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Special Mission Audio Controller System
with MultiTalker® and IntelliVox®
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
PAC45A
Document P/N 200-045-1000
Revision 18, December 2021
Audio Control System with Intercom
System Installation and Operation Manual
FAA - TSO C139a
Authorized PS Engineering dealer.
PS Engineering, Inc. 2021 ©
Copyright Notice

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Summary of Contents for Engineering Incorporated PAC45A

  • Page 1 9800 Martel Road Lenoir City, TN 37772 www.ps-engineering.com PAC45A Special Mission Audio Controller System with MultiTalker® and IntelliVox® Document P/N 200-045-1000 Revision 18, December 2021 Audio Control System with Intercom System Installation and Operation Manual FAA - TSO C139a Patented under one or more of the following;...

  • Page 2: Table Of Contents

    ECEIVE IGNAL NDICATOR 2.7.11 M ....................... 2-18 USIC UNCTIONS 2.7.12 S ....................2-18 PEAKER LERT UDIO 2.7.13 B ................... 2-18 ACKLIGHT IMMER OLTAGE 2.7.14 O ..................2-19 THER HARED UNCTIONS PAC45A P ..........................2-22 IN ASSIGNMENTS ............................2-23 IRING HECKOUT...
  • Page 3 ARRANTY .............................. 4-1 ACTORY ERVICE Appendix A – PAC45A Installation Drawings ............A Appendix B – Radio Interconnect Wiring ..............B Appendix C – Intercom Interconnect Wiring ............C Appendix D – Control Head Interconnect Wiring ............ D 8.1.1 EFIS I ........................
  • Page 4 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Revision History Date Change Jan. 2019 Initial Draft Manual January 2019 After Internal Review March 2019 Release for publication June 2019 Release after TSOA July 2019 Update Model Number August 2019 Add Music Mute control.

  • Page 5: Section I - General Information

    This device must accept any interference received, including interference that may cause undesired operation. SCOPE This manual provides installation and operation instructions for the PS Engineering PAC45A-series of Audio Selector Panel/Intercom Systems. This includes the following units: Model Number Description...

  • Page 6: Equipment Description

    Installation and Operator’s Manual EQUIPMENT DESCRIPTION The PAC45A is a state-of-the-art audio isolation amplifier and audio selector that contains an automatic voice activated (VOX) intercom system. It can switch up to eight transceivers (COM 1 to 8) and eight navigation receivers (AUX 1 to 8) that can be configured as desired.

  • Page 7: Equipment Supplied

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Alert Power <20 mA Lighting < 5mA Audio Selector Specifications 510  Audio selector panel input impedance: -60 dB (min.) Input Isolation: 16 (COM 1– COM 8, AUX 1- 8)
  • Page 8 EQUIPMENT REQUIRED BUT NOT SUPPLIED Circuit Breakers: 1 ea.; 5 amp PULL TYPE REQUIRED for HUB45aAR, 1 A for CTL45As Optional Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45A aural alerts, 1 ea. 1 A for failsafe power...

  • Page 9: Configuration

    PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Configuration The PAC45A System is comprised of a single PAC45A HUB (HUB45A) and up to four CTL45A Control Head “building blocks” to facilitate flexibility as well as simplicity. Bluetooth...

  • Page 10: License Requirements

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Telephone COM1-8 Cockpit NAV 1-2 Marker1-2 CVR P ADF1-2 CVR CP DME1-2 CVR O1 UNSW 1-5 CVR O2 RS422 RS422 RS422 RS422 EFIS INTERFACE EFIS INTERFACE Control Head...

  • Page 11: Section Ii - Installation

    2.3 Equipment Installation Procedures 2.3.1 Cooling Requirements Forced air-cooling of the PAC45A 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 12: Audio Controller Connector Assembly

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.3.3 Audio controller connector assembly The HUB45A 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 13: Power

    2.4.2 Power The PAC45A 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 14: Audio Controller Interface

    2.4.3 Audio controller interface The PAC45A is designed to interface with standard aircraft avionics and presents a 510  receiver imped- ance. For best results, a twisted-shielded cable is recommended from the avionics audio source to the audio controller, with the shield grounded at the audio controller end.

  • Page 15: Cockpit Voice Recorder

    2.4.6 Cockpit Voice Recorder The PAC45A audio controller contains independent Cockpit Voice Recorder outputs for the pilot, copilot and observer positions. The CVR output is consistent with RTCA DO-214A §1.5.7. Pilot CVR output is J452-60; Copilot CVR output is P452-61, Observer 1 CVR output P452-39, and Observer 2 P452-40, all with respect to any available audio low on J452.

  • Page 16: Audio Alerts

    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 PAC45A audio controller, it will play the message continu- ously until the remote acknowledge is selected.

  • Page 17: Remote Alert Acknowledge And Alert Programming (P453-23)

    2.6 Wired Telephone/Satellite Communication input The PAC45A 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.
  • Page 18 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual CP/OBSVR Speaker & Satcom Volume Figure 2-2 Adjustment locations ( Config. ACJAB and below) Figure 2-3 Adjustment locations (Config. ACLAB and above) 200-045-1000 Page 2-8 Rev. 18, Dec. 2021...

  • Page 19: Logic Switch Options

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Unswitched input 5 volume (J452-57) Unswitched input 4 volume (J452-36) Unswitched input 3 volume(J452-56) Unswitched input 2 volume(J452-35) Unswitched input 1 volume (J452-55) Speaker Amplifier Volume (J452-41)
  • Page 20 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Switch functions and positions as shipped from the factory. The color coding denotes similar groups of functonality. 200-045-1000 Page 2-10 Rev. 18, Dec. 2021...
  • Page 21 PS Engineering PAC45A 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 22: Logic Switch Details

    PS Engineering PAC45A 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 23 PS Engineering PAC45A 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 24 PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.7.4.1 HUB45R Bottom Logic Switches In the PAC45A 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 25 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual J7 SWITCH FUNCTION NUMBER J452-57 IS UNSWITCHED J452-57 IS COPILOT UNSWITCHED #5 INPUT 5 HAND MIC INPUT* P452-58 IS OBS #1 TEL/MIC P451-58 IS WIRED TEL INPUT...

  • Page 26: Fail-Safe Audio And Reversionary Mode

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.7.5 Fail-Safe Audio and Reversionary Mode 2.7.5.1 Fail-Safe options When ON, Switch 1 allows the crew to have Audio Alerts in Fail-Safe, when the alert subsystem is powered.

  • Page 27: Microphone Settings

    Stuck PTT Mic Enable When Switch 30 is ON the PAC45A 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 28: Receive Signal Indicator

    Low Impedance (8Ω) 2.7.9.2 When Switch 40 is ON, the PAC45A audio output is optimized for a low-impedance headphone output of about 8Ω. When Switch 40 is OFF, the PAC45A audio output is optimized for a standard civil aviation headphone impedance headphone output of about 150-300Ω.

  • Page 29: Other Shared Functions

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 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.
  • Page 30 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Identify additional DIP switch bank Select options as needed. 49 50 51 52 53 54 55 56 57 58 59 60 200-045-1000 Page 2-20 Rev. 18, Dec. 2021...
  • Page 31 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual SWITCH FUNCTION ON (UP) OFF (DOWN) NUMBER BOLD IS FACTORY DEFAULT UP (ON) AUDIO ALERTS AUDIO ALERTS ALERTS ENABLE ENABLED DISABLED RECORD AUDIO ALERTS RECORD AUDIO NO AUDIO RECORDING...

  • Page 32: Pac45A Pin Assignments

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 2.8 PAC45A 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 33: Wiring Checkout

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual P453 J454 Description Description Ground TX- Pilot or Observer 2 Ground TX+ Pilot or Observer 2 Ground RX- Pilot or Observer 2 Ground RX+ Pilot or Observer 2...

  • Page 34: Operational Checkout

    2.10 Operational Checkout 2.10.1 Required Test Equipment In order to return an aircraft to service after installation of the PAC45A, 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 35: Bluetooth Checkout

    2.10.3.1 Bluetooth TEL Checkout Pair the PAC45A 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 36: Section Iii Operation

    The power controls all audio selector panel functions, and intercom. 3.3 Communications Transmit (XMT) Selection The PAC45A has a rotary control knob to select communications transceiver functions. To select a trans- ceiver for transmit; turn the knob to select the desired radio from the eight available.

  • Page 37: Com Audio Selector

    The radio is automatically selected to receive incoming radio calls when the XMT is selected. With a PAC45A, 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 38: Navaid Selection

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual The pilot controller can adjust the locations for the eight receive audio locations. Press and hold the HRTF button for > 1 second on the pilot’s panel until the HRTF button and all COM nomenclature start blink- ing green.

  • Page 39: Intercom Volume Control

    3.6.3.1 Intercom Operation with 4 CTL45A The PAC45A was designed for the special mission market (forestry, law enforcement, EMS, etc.) with the ability to allow controls heads to remove themselves and pull in other intercom stations during working/high communication special mission operations as needed. This was our goal and design purpose of the intercom states and is very practical to this environment.
  • Page 40 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual • Either pilot or copilot panel can select ALL and add everybody to the intercom. • The Observer 1 and Observer 2 panels can leave and return to ALL, unless a pilot or copilot has selected ISO or CREW.
  • Page 41 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual While the pilot & copilot are in either ISO or CRW mode then the OBS 1 and OBS 2 has the “cabin call” feature, either by pressing external CALL switch or pressing the ACK button on their control head.
  • Page 42 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 200-045-1000 Page 3-7 Rev. 18, Dec. 2021...

  • Page 43: Speaker Operation

    Pairing and unpairing Bluetooth devices The PAC45A can be paired with up to eight individual devices but will only connect to one at a time. When that number is exceeded, the PAC45A will drop a device to allow the new device to be added.

  • Page 44: Bluetooth® Telephone Mode

    In CREW mode, the pilot and copilot are connected to the telephone. In ISO intercom mode, when the PAC45A 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 45: Storing Alert Audio

    3.10.1 Storing Alert Audio The PAC45A systems can store nine audio alerts. You must record all nine when the unit is in audio pro- gram 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 46: Section Iv - Warranty And Service

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Section IV – Warranty and Service 4.1 Warranty In order for the factory warranty to be valid, the installations in a certified aircraft must be accomplished by an FAA- (or other ICAO agency) certified avionics shop and authorized PS Engineering dealer.

  • Page 47: Appendix A - Pac45A Installation Drawings

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix A – PAC45A Installation Drawings Figure 5-1 - CTL45A Front View Figure 5-2 CTL45A Top View 200-045-1000 Appendix A Rev. 18, Dec. 2021...
  • Page 48 PS Engineering PAC45A 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 49 PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual BLUETOOTH ANT CONN J455 Figure 5-5 HUB4A5R Front View Figure 5-6 - HUB45A Side Views 200-045-1000 Appendix A Rev. 18, Dec. 2021...

  • Page 50: Appendix B - Radio Interconnect Wiring

    Com 8 Mic Key Com 8 Mic Low Because of the labeling flexibility on the PAC45A System, the nomenclature on the CTL45 may not match the wiring diagram. Shown here are the switch positions for each of the available inputs.

  • Page 51: Appendix C - Intercom Interconnect Wiring

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix C – Intercom Interconnect Wiring J451 P ilot M ic Audio Hi P ilot M ic Lo P ilot M ic PTT P454 Copil ot Mic Audio Hi...

  • Page 52: Appendix D - Control Head Interconnect Wiring

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix D – Control Head Interconnect Wiring PAC45 HUB45R LRU RX- RS422 TX - RX+ RS422 TX + RS422 RX - RS422 RX + PILOT CTL45A HEAD...

  • Page 53: Efis Interface

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 8.1.1 EFIS Interface PAC45 HUB LRU RX- RS422 TX - PILOT RX+ RS422 TX + EFIS RS422 RX - INTERFACE RS422 RX + J455 P455 P454 RX- RS422 TX -...

  • Page 54: Appendix E, Unit Connector Wiring Reference

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix E, Unit Connector Wiring Reference 9.1 J451 Connections J451 COM 1 C OM 1 MIC AU D IO H I C OM 1 MIC KEY S WIT CH...

  • Page 55: J452 Connections

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.2 J452 Connections Com 1 Audio Hi COM 1 Com 1 Lo HUB45A CONNECTOR P452 MALE ON HARNESS Com 2 Audio Hi COM 2 Com 2 Audio Low...

  • Page 56: J453 Connections

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.3 J453 Connections J453 FEMALE ON HARNESS GROUND GROUND GROUND GROUND GROUND ALERT 1 ALERT 2 ALERT 3 ALERT 4 ALERT 5 ALERT 6 ALERT 7 ALERT 8 ALERT 9 ALERT PGM &...

  • Page 57: Efis Interface

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 9.4.1 EFIS Interface P 45 4 M A LE O N H A R N E S S P ILO T E FIS S E R IA L...

  • Page 58: Appendix F - Instructions For Faa Form 337 And Continuing Airworthiness

    One method of airworthiness approval is through an FAA Form 337, Major Repair and Alteration (Airframe, Powerplant, Propel- ler, or Appliance) In the case of the PAC45A, you may use the following text as a guide. Installed audio selector and 6-place intercom, PS Engineering PAC45A, part number 050-045-(XXXX) in ( location ) at station .

  • Page 59: Appendix G - Rtca Do160G Environmental Qualification Form

    PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual Appendix G – RTCA DO160G Environmental Qualification Form 11.1 Model Number PAC45A Audio Selector Panel/Intercom Remote Hub Part Number: 050-045-( ) FAA TSO Number: C139a, Manufacturer: PS Engineering Incorporated 9800 Martel Road...

  • Page 60: Model Number Ctl45A, Audio Selector Control Panel

    PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator’s Manual 11.2 Model Number CTL45A, 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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