PS Engineering PAC45T System Installation And Operation Manual

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PS Engineering PAC45T System Installation And Operation Manual | Manualzz

9800 Martel Road

Lenoir City, TN 37772 www.ps-engineering.com

PAC45T

Special Mission Audio Controller System with IntelliVox®

Document P/N 200-045-5100

Revision 2 January 2019

Audio Control System with 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 Engineering, 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 [email protected]

.

Table of Contents

Section I – GENERAL INFORMATION ................................................................ 1-1

1.1

INTRODUCTION ............................................................................................................................................. 1-1

1.1.1

L IMITATIONS ..................................................................................................................... 1-1

1.2

SCOPE ................................................................................................................................................................ 1-1

1.3

EQUIPMENT DESCRIPTION ........................................................................................................................ 1-1

1.4

APPROVAL BASIS FAA TSO ......................................................................................................................... 1-1

1.1.2

L IMITATIONS ..................................................................................................................... 1-1

1.5

SPECIFICATIONS ........................................................................................................................................... 1-2

1.6

EQUIPMENT SUPPLIED ................................................................................................................................ 1-2

1.8

C

ONFIGURATION

................................................................................................................................................. 1-5

1.9

LICENSE REQUIREMENTS .......................................................................................................................... 1-5

Section II - INSTALLATION 2-1

2.1

GENERAL INFORMATION ........................................................................................................................... 2-1

2.1.1

SCOPE .............................................................................................................................. 2-1

2.1.2

C ERTIFICATION R EQUIREMENTS ...................................................................................... 2-1

2.2

U NPACKING AND P RELIMINARY I NSPECTION ...................................................................................................... 2-1

2.3

E QUIPMENT I NSTALLATION P ROCEDURES .......................................................................................................... 2-1

2.3.1

C OOLING R EQUIREMENTS ................................................................................................ 2-1

2.3.2

M OUNTING R EQUIREMENTS ............................................................................................. 2-1

2.3.3

A UDIO CONTROLLER C ONNECTOR A SSEMBLY ................................................................. 2-2

2.4

C ABLE H ARNESS W IRING .................................................................................................................................... 2-3

2.4.1

E LECTRICAL N OISE ........................................................................................................... 2-3

2.4.2

P

OWER

.............................................................................................................................. 2-3

2.4.3

A UDIO CONTROLLER INTERFACE ...................................................................................... 2-4

2.4.4

B

ACKLIGHTING

................................................................................................................. 2-4

2.4.5

U NSWITCHED INPUTS ........................................................................................................ 2-4

2.4.6

C

OCKPIT

V

OICE

R

ECORDER

.............................................................................................. 2-4

2.4.7

A UDIO A LERTS ................................................................................................................. 2-5

2.5

U SER A DJUSTMENTS ............................................................................................................................................ 2-5

2.5.1

U NSWITCHED A UDIO L EVEL ............................................................................................ 2-5

2.5.2

A DJUSTMENTS .................................................................................................................. 2-5

2.5.3

L OGIC S WITCH O PTIONS ................................................................................................... 2-6

2.6

PAC45T P IN ASSIGNMENTS ................................................................................................................................ 2-9

2.7

W IRING C HECKOUT .......................................................................................................................................... 2-10

2.8

O

PERATIONAL

C

HECKOUT

................................................................................................................................ 2-11

2.8.1

R

EQUIRED

T

EST

E

QUIPMENT

.......................................................................................... 2-11

2.8.2

A UDIO CONTROLLER T EST .............................................................................................. 2-11

2.9

F INAL I NSPECTION ............................................................................................................................................ 2-12

Section III OPERATION L

3.1

SCOPE ................................................................................................................................................................... L

3.2

P OWER AND F AIL S AFE .......................................................................................................................................... B

3.3

C OMMUNICATIONS T RANSMIT (XMT) S ELECTION ............................................................................................... B

3.4

COM A UDIO S ELECTOR ........................................................................................................................................ B

3.5

N

AVAID

S

ELECTION

............................................................................................................................................... C

3.6

I NTERCOM O PERATION (8) .................................................................................................................................... C

3.6.1

I NTELLI V OX ® I NTERCOM VOX-S QUELCH ........................................................................... C

3.6.2

I NTERCOM V OLUME C ONTROL ............................................................................................ C

3.6.3

I NTERCOM M ODES ............................................................................................................... C

3.7

A LERT A UDIO ........................................................................................................................................................ D

Section IV – Warranty and Service A

4.1

W ARRANTY ........................................................................................................................................................... A

4.2

F ACTORY S ERVICE ................................................................................................................................................ A

Appendix A – PAC45T Installation Drawings .......................................................... A

Appendix B – Radio Interconnect Wiring ................................................................. A

Appendix C – Intercom Interconnect Wiring ........................................................... A

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix D – Control Head Interconnect Wiring..................................................... B

Appendix E, Unit Connector Wiring Reference ....................................................... A

9.1

P451 C ONNECTIONS .............................................................................................................................................. A

9.2

J452 C ONNECTIONS ................................................................................................................................................ B

9.3

P453 C ONNECTIONS .............................................................................................................................................. C

9.4

J454 C

ONNECTIONS

............................................................................................................................................... D

9.5

J455 C ONNECTIONS ............................................................................................................................................... D

Appendix F – Instructions for FAA Form 337 and continuing airworthiness ....... A

10.1

I NSTRUCTIONS FOR FAA F ORM 337, A UDIO CONTROLLERS ................................................................................. A

10.2

I NSTRUCTIONS FOR C ONTINUING A IRWORTHINESS , A UDIO S YSTEM .................................................................... A

Appendix G – RTCA DO160G Environmental Qualification Form....................... A

11.1

M ODEL N UMBER PAC45T A UDIO S ELECTOR P ANEL /I NTERCOM R EMOTE H UB ................................................. A

11.2

M

ODEL

N

UMBER

CTL45T, A

UDIO

S

ELECTOR

C

ONTROL

P

ANEL

.......................................................................... B

Rev Date

New June 2018

Change

Initial Draft Manual

1

2

December 2018

January 2019

Revised wiring diagrams changed orientation of CTL45T & label

Added lighting switch details, removed extraneous information.

200-045-5100 Page ii Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Section I – GENERAL INFORMATION

1.1 INTRODUCTION

The PAC45T Audio Control System represents a revolutionary step in cockpit audio control and intercommunications utility. Our patented IntelliVox® design, marks this panel as the next level of audio control.

The unit is designed for outstanding ergonomics and visually defined mode annunciation and selection.

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 PAC45T Audio System.

1.1.1 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.

The PAC45T has been designed to meet the objectives in Design Assurance Level C for Software and Complex Electronic Hardware.

Operation is subject to the following conditions:

This device may not cause harmful interference.

This device must accept any interference received, including interference that may cause undesired operation.

1.2 SCOPE

This manual provides detailed installation and operation instructions for the PS Engineering PAC45T-series of Audio Selector Panel/Intercom Systems. This includes the following units:

Model Number

HUB45R

Description

Remote-mounted Audio Hub for analog I/O and processing

CTL45T (qty. 4) Panel Mounted Control Head for Flight Crew

PS Engineering Part Number

050-045-5101

050-045-5201

1.3 EQUIPMENT DESCRIPTION

The PAC45T is a state-of-the-art audio isolation amplifier and audio selector that contains an automatic voice activated (VOX) intercom system. It can switch two transceivers (1 UHF and 1 VHF) and eight navigation receivers (Nav 1, Nav 2, ADF MKR 1, MKR 2, TACAN, DME 1 and DME 2).

There are four unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or radar altimeter warning.

In addition, nine alerts can be triggered by external sources to provide additional capability.

In addition to a radio master volume, 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 PAC45T. This system has PS Engineering’s patented IntelliVox® circuitry that eliminates manual adjustments.

1.4 APPROVAL BASIS FAA TSO [PENDING]

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.

200-045-5100 Page 1-1 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Refer to Advisory Circular 20-41A for information on TSO installation approval.

Operation is subject to the following conditions:

This device may not cause harmful interference.

This device must accept any interference received, including interference that may cause undesired operation.

1.5 SPECIFICATIONS

Audio Selector/Intercom

ENVIRONMENTAL Qualifications:

Temperature Range:

Operating:

Short Term Operating:

Survival:

Altitude :

DIMENSIONS:

UNIT WEIGHT

HUB45R

CTL45T

:

APPLICABLE DOCUMENTS:

Voltage :

Maximum Current :

Typical

Alert Power

Lighting Power

TSO COMPLIANCE

FAA TSO-C139A

RTCA/DO-214A

RTCA/DO-160G

RTCA/DO-178C

A1D1BABSXXXXXXZBABZATTMA3J33XXA

-20º C to +55ºC

-20°C to +70°C

-55º C to +85ºC Cold soak to –40˚C

Up to 55,000 feet in a non-pressurized area of the cockpit.

CTL45T: Height: 1.88 in. (4.78cm) Width: 4.90 in. (12.45 cm)

Depth behind panel: 2.35 in. (5.97)

HUB45R: Height: 1.9” Width: 5.88 w/mounting flanges, Length

7.22”, 12” w/ all connectors. See Figure 5-6

2.0. (.905 kg)

1.0. (.45 kg)

POWER REQUIREMENTS :

18 to 33 VDC

HUB45R 1.5 Amp (Externally protected by a 5 Amp circuit breaker.)

CTL45T 500 mA (Externally protected by a 1 Amp circuit breaker)

HUB45R only 750 mA +/-100mA

<20 mA

< 5mA

Audio Selector Specifications

Audio selector panel input impedance : 510

Input Isolation :

Switched Receiver Inputs :

Unswitched Inputs :

Transmitter Selections :

-60 dB (min.)

10 (UHF COM 1– VHF COM 2, NAV 1, NAV 2, Marker 1&

2, ADF, DME 1 & 2)

4

2 (UHF, VHF)

Receiver Selections

Headphone Impedance

Headphone Output :

Microphone Impedance

Speaker Output

PA

:

:

8 (NAV 1, NAV 2, TACAN, DME 1, DME 2, MKR 1, MKR

2, ADF)

8

200 mW into 8

headset, no clipping <.5% THD typical

150 - 600

1 ea. 10 W @ 28Vdc 4 Ω

10W @ 28Vdc 4 Ω

Intercom Positions :

Distortion:

Mic Freq. Response, 3 dB:

Intercom Specifications

Up to 8 places (with individual Intelli Vox® circuits)

<1% THD @ 200 mW into 8

300 Hz – 6000 Hz

1.6 EQUIPMENT SUPPLIED

The following units comprise the PAC45T System:

200-045-5100 Page 1-2 Rev. 2, Jan. 2019

Model

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Description Part Number

HUB45R

CTL45T

Remote-mounted Audio Hub for analog I/O and processing

Panel-mounted Control Head for Flight Crew, Jumpseat and Rear station (4 ea.)

050-045-5101

050-045-5201

PAC45T Installation Kit: 250-045-0801

Male Connector Kit 250-045-8177 (P452, P454)

Part Number Description

625-015-9215 Connector Backshell DB26 pin

625-037-9237 Connector Backshell DB62 pin

MFR

3M

3M

MFR PN

3357-9215

3357-9237

425-026-5601 Male Connector Shell DB26 pin

425-062-8177 Male Connector Shell DB62 pin

425-044-2043 Hi-density Male Pins

475-045-3341 Thumbscrew Kit for DB Connector

Harting

Harting

AMP

3M

9562005601

9564005601

204370-2

3341-7

Female Connector Kit 250-045-8277 J451, J453)

Part Number Description MFR MFR PN

625-015-9215 Connector Backshell DB26 pin

625-037-9237 Connector Backshell DB62pin

425-026-1800 Female Connector Shell DB26 pin

425-062-4701 Female Connector Shell DB62 pin

425-030-7354 Hi-density Female Pins

475-045-3341 Thumbscrew Kit for DB Connector

3M

3M

Norcomp

Harting

Amphenol

3M

3357-9215

3357-9237

180-026-273L000

99564004701

M39029/57-354

3341-7

9-Pin Connector Kit 250-045-0009 ( P455)

Part Number Description

625-009-9209 Connector Backshell DB9 pin

425-009-0777 Male Connector Shell DB9 pin

425-020-5089 Standard Density Male Pins

475-045-3341 Thumbscrew Kit for DB Connector

MFR

3M

Amphenol

Deutsch

3M

MFR PN

3357-9209

L777-RR-E-09-P

M39029/64-369

3341-7

Quantity

1

1

1

1

88

4

Quantity

1

1

1

1

88

4

Quantity

1

9

9

2

200-045-5100 Page 1-3 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

CTL45T 9-Pin Female Connector Kit 250-045-0009 ( J455)

Part Number Description MFR MFR PN

625-009-9209 (Modified) Connector Backshell DB9

425-009-7709 Connector Female Shell DB9

3M

Amphenol

3357-9209

L177-RR-E-09-S

Quantity

9

2

1

1

425-020-5090 Standard density female pins

475-045-3341 Thumbscrew Kit for DB Connector

Deutsch

3M

M39029/63-368

3341-7

EQUIPMENT REQUIRED BUT NOT SUPPLIED a.

Circuit Breakers: 1 ea.; 5 amp PULL TYPE REQUIRED for HUB45R, 1 amp for CTL45Ts b.

Circuit Breaker: 1 amp PULL TYPE REQUIRED for HUB45R aural alerts c.

Headphone Jacks (as Required) d.

Microphone Jacks (as Required) e.

Headphones, as required f.

Microphones, as required g.

Interconnect Wiring

200-045-5100 Page 1-4 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

1.8 Configuration

The PAC45T System is comprised of a single HUB45R and up to four identical CTL45T Control Heads.

VHF/UHF

NAV 1

MKR 1

ADF1

NAV 2

MKR 2

TACAN

Hub Amp

Pilot

Copilot

Amp Observer

Amp

Amp

DME1-2

UNSW1-4 CVR

RS422 RS422 RS422 RS422

Control Head Control Head Control Head Control Head

PA

PA

PA

Pilot Pilot

O2

Hand

Copilot 1 Copilot 1

O2

Observer Observer

O2

Rack Rack

O2

Ground

Figure 1-1 Four control head configurations

1.9 LICENSE REQUIREMENTS

None

200-045-5100 Page 1-5 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Section II - INSTALLATION

2.1 GENERAL INFORMATION

2.1.1 SCOPE

This section provides detailed installation and interconnection instructions for the PS Engineering PAC45T

Audio Selector Panel/Intercom system.

Please read this manual carefully before beginning any installation to prevent damage and post-installation problems.

Installation of this equipment requires special tools, test equipment (refer to §2.12.1) and installer knowledge as required by 14 CFR 65.81 (b).

2.1.2 Certification Requirements

NOTE

The PAC45T requires specialized knowledge and tools for an effective installation. An appropriately rated

Certified Aircraft Repair Station must install this equipment in accordance with applicable regulations. PS

Engineering, Incorporated warranty is not valid unless the equipment is installed by an authorized PS Engineering, Incorporated dealer.

Failure to follow any of the installation instructions, or installation by a non-certified individual or agency will void the warranty, and may result in an unairworthy installation.

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 AC 20-41A for information regarding Substitute TSO Aircraft Equipment.

2.2 Unpacking and Preliminary Inspection

Use care when unpacking the equipment. Inspect the units and parts supplied for visible signs of shipping damage. Examine the unit for loose or broken buttons, bent knobs, etc. Verify the correct quantity of components supplied with the list in §1.6. If any claim is to be made, save the shipping material and contact the freight carrier. Do NOT return units damaged in shipping to PS Engineering. If the unit or accessories show any sign of external shipping damage, contact PS Engineering to arrange for a replacement. Under no circumstances attempt to install a damaged unit in an aircraft. Equipment returned to PS Engineering for any other reason should be shipped in the original PS Engineering packaging, or other UPS approved packaging.

2.3 Equipment Installation Procedures

2.3.1 Cooling Requirements

Forced air-cooling of the PAC45T 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.

2.3.2 Mounting Requirements

The CTL45T Control Head must be rigidly mounted to the instrument panel of the aircraft structure, within view and reach of the pilot position(s). The CTL45T is designed for Dzus-rail mounting. Installation must comply with FAA Advisory Circular AC 43.13-2B, or other FAA-approved aircraft technical data. The unit may be mounted in any area where adequate clearance for the unit and associated wiring bundle exist.

The HUB45R is intended for mounting in the remote avionics rack.

To prevent noise, avoid installing the unit close to high current devices or systems with high-voltage pulse type outputs, such as DME or transponders. Avoid running the interconnecting bundles near any high current wires.

200-045-5100 Page 2-1 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

2.3.3 Audio controller Connector Assembly

The LRU connectors mate with two 62-pin, two 26-pin, and one 9-pin connectors in the HUB45R. The connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from table below (or equiv.).

62

42

21

1

22

43

P451

J452

43

22

21

1

42

62

26

18

P453

10

9

1

J454

19

19

10

1

9

18

26

Figure 2-1 - PAC45T Connector Layout

Figure 2-2 - Connector assembly

NOTE: Pass the wire bundle through the Cover Nut before inserting pins in the connector shell.

Insert the screw or thumbscrews through the top half of the shell (B), and apply the E-Ring to the unthreaded portion, and bend the E-ring holder back and forth to break it from the holder. Repeat for the other side.

Place the harness and connector in the bottom portion (A), and fold the retaining pars over the wires. Install the top shell (B) by inserting the screws the screws through the connector, and snapping the top over the bottom until the lances are in the cutouts. Be sure to align the lip of the shell over the connector edge before snapping in place. Slide the cover nut over the two haves and screw in place.

Ensure that proper strain relief and chafing precautions are made during wiring and installation.

200-045-5100 Page 2-2 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Manufacturer

AMP

Daniels

ITT-Cannon

Crimping Tool

601966-1

AFM8

995-0001-584

Positioner

601966-6

K42

995-0001-739

Extraction tool

91067-1

M24308-1

91067-1

Table 2-1 Connector Pin crimping tools

2.4 Cable Harness Wiring

Referring to the appropriate Appendix, assemble a wiring harness as required for the installation. All wires must be MIL-SPEC in accordance with current regulations. Two- and three-conductor shielded wire must be used where indicated, and be MIL-C-27500 or equivalent specification. Proper stripping, shielding and soldering technique must be used at all times. It is imperative that correct wire be used.

Refer to FAA Advisory Circular 43.13-2B for more information. Failure to use correct techniques may result in improper operation, electrical noise or unit failure. Damage caused by improper installation will void the

PS Engineering warranty.

See Appendix C and D for intercom connection configurations. It is critical to the proper operation of this system to have this connector wiring made in accordance with these diagrams. Use 2- and 3-conductor, MILspec cable as shown. Connect the shields at the audio controller end only, and tie to the audio low inputs as shown.

2.4.1 Electrical Noise

Due to the variety and the high power of radio equipment often found in today's aircraft, there is a potential for both radiated and conducted noise interference.

The HUB45R power supply is specifically designed to reduce conducted electrical noise on the aircraft power bus by at least 50dB. Although this is a large amount of attenuation, it may not eliminate all noise, particularly if the amplitude of noise is very high. Shielding can reduce or prevent radiated noise (i.e., beacon, electric gyros, switching power supplies, etc.) However, installation combinations can occur where interference is possible. The HUB45R was designed in a RFI hardened chassis and has internal Electromagnetic Interference (EMI) filters on all inputs and outputs.

Ground loop noise occurs when there are two or more ground paths for the same signal (i.e., airframe and ground return wire). Large cyclic loads such as strobes, inverters, etc., can inject noise signals onto the airframe that are detected by the audio system. Follow the wiring diagram very carefully to help ensure a minimum of ground loop potential. Use only Mil Spec shielded wires (MIL-C-275000, or better). Under no circumstances combine a microphone and headphone wiring into the same shielded bundle. Always use a 2- or 3-conductor, shield wire as shown on the installation-wiring diagram.

The shields can be daisy-chained together, and then connected to the ground.

Radiated signals can be a factor when low level microphone signals are "bundled" with current carrying power wires. Keep these cables physically separated. It is very important that you use insulated washers to isolate the ground return path from the airframe to all headphone and microphone jacks.

2.4.2 Power

The PAC45T is compatible with 28 Volt DC systems. A five (5) Amp circuit breaker is required for the

HUB45R installations. Power and ground wires should be #22AWG connect power to P451 Pin 42. Connect airframe ground to P451 Pin 20 and 21 only.

Power consumption is as follows:

At 28V:

Control head Only: 400 mA

Hub Only: 750 mA

Alert audio power: 20mA

200-045-5100 Page 2-3 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

At minimum input voltage (20V):

Control head: 600mA

Hub Only: 950mA

Lighting input: <5mA

CAUTION: Do not connect or disconnect ( HOT SWAP ) any components with power applied, this will damage the units

2.4.2.1 Alert power, P451 Pin 41,

The PAC45T has an independent alert system with the ability to play alerts even when the audio controller is powered off. To take full advantage of this isolation a separate one (1) Amp circuit breaker is required.

Power should be #22AWG connect power to P451 Pin 41.

When power to P451-41 is present, the message will play three times or until the remote acknowledge is selected.

2.4.2.2 Failsafe Power P451 Pin 62 and O

2

Enable P453 Pin 26

When connected to the aircraft bus, it allows for the use of Oxygen microphones in failsafe, when the O

2 microphone discrete, J453 Pin 26 is grounded.

2.4.3 Audio controller interface

The PAC45T is designed to interface with standard aircraft avionics, and presents a 510

receiver impedance. 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.

Some avionics do not provide a separate audio low, and may introduce additional electrical noise into the system. For best results, connect the audio low from the audio controller to the radio ground, using one conductor of the twisted-shielded cable.

2.4.4 Backlighting

Control of the unit backlighting is through the aircraft avionics dimmer, each control head is independent.

Connect P455 Pin 6 to the aircraft dimmer bus. The ratio of white to green indicator intensity is adjustable,

see §2.5.2

.

The dimmer voltage can be configured in the field. See § 2.5.4.1 for details .

2.4.5 Unswitched inputs

These inputs are presented to the pilot and copilot regardless of the audio configuration, and will always mute the crew entertainment inputs. These 510 Ω inputs can be used for altimeter DH audio, TAWS audio, TCAS audio, or any other critical audio signal.

Unswitched #1 is always presented to the crew headphones, and is available to the pilot in fail-safe (off) mode.

Unswitched

Input

Input Pins Pilot Hear in

Fail Safe

Hear in

Crew Headset

1

2

3

4

P452 - 55

P452 - 35

P452 - 56

P452 - 36

WRT

WRT

WRT

WRT

15

16

17

18

Yes

No

No

No

Yes

Yes

Yes

Yes

Table 2-2 Unswitched inputs

2.4.6 Cockpit Voice Recorder

The PAC45T audio controller contains a Cockpit Voice Recorder output for the pilot and copilot.

Pilot CVR output is P454-62; Copilot CVR output is P454-61 both with respect to CVR low, P454 19

The CVR output is consistent with RTCA DO-214A §1.5.7,

200-045-5100 Page 2-4 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

2.4.7 Audio Alerts

The PAC45T contains an independent audio alerting systems that will play nine alert audio tones.

The alert system has a power input (P451-42) that will keep the systems operable if the PAC45T systems power source is removed. Alert audio is provided in Fail-safe when power is on P451-23.

Alert Input

1

2

3

4

5

6

7

8

9

Alert Power

Remote

Acknowledge

Function

Altitude Alert

Autopilot Disconnect

Gear Warning

Stall Warning

Overspeed Warning

Decision Height

Seat Belt Tone

Fire Bell

Pitch Trim Warning

Input Pins

P453 – 10

P453 – 11

P453 – 12

P453 - 13

P453 - 14

P453 - 19

P453 - 20

P453 - 21

P453 - 22

P451 - 42

P453 – 23

The alert triggers can be configured to be Active High (>4.5 VDC) or Active Low (<0.5 VDC), and trigger

at the leading edge transition or by the voltage level. See § 2.5.3

for configuration options.

Alerts with edge triggers will play three times or until the remote Acknowledge button (ACK) ( P454-9 grounded).

Alerts with level trigger will play three times or until the Acknowledge button (ACK) is pressed (P453-23-9 grounded), or the input level reverts.

As configured from the factory for the HUB45R, P/N 050-045-5101, all alerts are level triggered except for

Alert 7, the Seat belt Chime, which is edge triggered.

When power is applied to the alerts and not the PAC45T audio controller, it will play the message three times or until the remote acknowledge is selected.

Audio alerts are inhibited for the first 30 seconds after power up to reduce nuisance triggers.

2.5 User Adjustments

The PAC45T is factory set for typical installation. However, several installation adjustments are available.

2.5.1 Unswitched Audio Level

Unswitched inputs one through four are installation adjustable through the side of the PAC45T unit.

2.5.2 Adjustments

On the side of the HUB45R are 15 adjustment potentiometers.

200-045-5100 Page 2-5 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

HUB45R Potentiometers

Line Level Volume

CVR Volume

External PA Sidetone

External Com 1 (UHF) Sidetone

External Com 2 (VHF) Sidetone

Alert Volume

Green Brightness

White Brightness

RESERVED

UNSW4 Volume

UNSW3 Volume

UNSW2 Volume

UNSW1 Volume

Speaker Amplifier Volume PA Amplifier Volume

1.

Reserved

2.

Unswitched input 4 volume

3.

Unswitched input 3 volume

4.

Unswitched input 2 volume

5.

Unswitched input 1 volume

6.

Speaker Amplifier Volume

7.

PA Amplifier Volume

8.

Line Level volume out

9.

Cockpit Voice Recorder Volume

10.

External PA Sidetone

11.

External UHF Sidetone

12.

External VHF Sidetone

13.

Alert volume (adjusts the level of the internal audio alerts and annunciations generated by the PAC45T)

14.

Green backlight level

15.

White backlight level

2.5.3 Logic Switch Options

The PAC45T has switches accessible through the side of the HUB45R to set specific functions

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PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

11

12

13

14

7

8

9

10

SWITCH

1

2

5

6

3

4

19

20

21

22

15

16

17

18

23

24

TOP ROW

FUNCTION

FAILSAFE ALERTS TO CREW

FAILSAFE ALERTS TO OBSERVERS

ALERTS TO CREW

ALERTS TO OBSERVERS

ALERT 1 TRIGGER

ALERT 1 POLARITY

ALERT 2 TRIGGER

ALERT 2 POLARITY

ALERT 3 TRIGGER

ALERT 3 POLARITY

ALERT 4 TRIGGER

ALERT 4 POLARITY

ALERT 5 TRIGGER

ALERT 5 POLARITY

ALERT 6 TRIGGER

ALERT 6 POLARITY

ALERT 7 TRIGGER

ALERT 7 POLARITY

ALERT 8 TRIGGER

ALERT 8 POLARITY

ALERT 9 TRIGGER

ALERT 9 POLARITY

RESERVED

RESERVED

POSITION

UP

UP

UP

UP

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

EDGE UP, LEVEL DN

POS UP, NEG DN

DN

DN

11

12

13

14

7

8

9

10

SWITCH

1

2

5

6

3

4

19

20

21

22

15

16

17

18

23

24

BOTTOM ROW

FUNCTION

COPILOT CONTROL HEAD INSTALLED

OBSVR 1 CONTROL HEAD INSTALLED

OBSVR 2 CONTROL HEAD INSTALLED

REVERSIONARY MODE

TRANSMIT MUTE

STUCK MIC ENABLE

HIGH MIC SENS

PAX 1 & 2 = 0

2

MICS

PAX 3 & 4 = OBSR 0

2

MICS

COM 7 COM 1 Sidetone

PA SIDETONE

UNSW 1 & 2 SPLIT

UNSW OBSVR

STEREO OBSVR

8-OHM HEADSETS

RESERVED

RESERVED

RESERVED

RESERVED

RESERVED

RESERVED

ALERTS ON SPEAKER

DIMMER 28V

DIMMER 28V

DN

UP

UP

UP

DN

UP

DN

DN

POSITION

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

UP

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PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

2.5.4 CTL45T Configuration Switches

The configuration switches are located on the TOP of the CTL45T

2.5.4.1 Dimmer Voltage

As shipped, the backlight dimmer is set for 28VDC

Set Pilot/Copilot J7 switches to: on/on/on/off/off/off for 5 VDC Lighting

Set Observer/Lav J7 switches to: off/off/on/off/off/off for 28 VDC Lighting

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PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Pin

1

48

49

50

51

52

53

54

55

56

57

58

41

42

43

44

45

46

47

34

35

36

37

38

39

40

30

31

32

33

25

26

27

28

29

18

19

20

21

22

23

24

14

15

16

17

9

10

11

12

13

6

7

8

2

3

4

5

2.6 PAC45T Pin assignments

P451

Description

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Aircraft Ground

Aircraft Ground

Pilot Hand Mic

Pilot Mic

Copilot Mic

Observer 1 Mic

Observer 2 Mic

COM1 Mic

COM2 Mic

No Connection

No Connection

No Connection

No Connection

No Connection

No Connection

Pilot Headset

Copilot Headset

Observer 1 Headset

Observer 2 Headset

Passenger 2,3 Headset

Passenger 4,5 Headset

Alert Power

Aircraft Power

Pilot Hand TX PTT

Pilot TX PTT

Copilot TX PTT

Observer 1 TX PTT

Observer 2 TX PTT

COM1 Key

COM2 Key

No Connection

No Connection

No Connection

No Connection

No Connection

No Connection

Pilot Right Headset (connect to 451-35)

Copilot Right Headset (connect to 451-36)

Observer 1 Right Headset (connect to 451-37)

59

60

61

62

Observer 2 Right Headset (connect to 451-38)

Passenger 2,3 Right Headset (connect to 451-39)

Passenger 4,5 Right Headset (connect to 451-40)

No Connection

58

59

60

61

62

J452

Pin Description

1 Lighting Common

48

49

50

51

52

53

54

55

56

57

41

42

43

44

45

46

47

34

35

36

37

38

39

40

30

31

32

33

25

26

27

28

29

18

19

20

21

22

23

24

14

15

16

17

9

10

11

12

13

6

7

8

2

3

4

5

COM2 Sidetone

UNSW2

UNSW4

PA Sidetone

No Connection

Speaker out OBSVR 1

Speaker out COPILOT

Speaker Pilot

PA Out

No Connection

Radio Mute

No Connection

Call

NAV1

NAV2

TACAN

DME 1

DME 2

MKR 1

MKR 2

ADF

UNSW1

UNSW3

Copilot Hand Mic

No Connection

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Ground

Speaker Ground

PA Ground

Lighting In

No Connection

No Connection

No Connection

Passenger 5 Mic Audio

COM1 Audio Hi

COM2 Audio Hi

No Connection

No Connection

No Connection

No Connection

COM1 Sidetone

Observer 1 Hand Mic

No Connection

No Connection

No Connection

PA Key

200-045-5100 Page 2-9 Rev. 2, Jan. 2019

Pin Description

1 Ground

2 Ground

3 Ground

P453

4 Ground

5 Ground

6 Ground

7 Ground

8 Ground

9 Ground

10 Alert 1 Trigger

11 Alert 2 Trigger

12 Alert 3 Trigger

13 Alert 4 Trigger

14 Alert 5 Trigger

15 Pilot O

2

Mic

16 Copilot O

2

Mic

17 Observer 1 O

2

Mic

18 Observer 2 O

2

Mic

19 Alert 6 Trigger

20 Alert 7 Trigger

21 Alert 8 Trigger

22 Alert 9 Trigger

23 Alert Ack

24 Copilot Hand Mic PTT

25 OBSVR Hand Mic PTT

26 Oxygen Mask Enable

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

P454

Pin Description

1 TX- Observer 2

2 TX+ Observer 2

3 RX- Observer 2

4 RX+ Observer 2

5 Ground

6 Ground

7 Ground

8 Ground

9 Ground

10 TX- Observer 1

11 TX+ Observer 1

12 RX- Observer 1

13 RX+ Observer 1

14 No Connection

15 No Connection

16 No Connection

17 No Connection

18 No Connection

19 TX- Copilot

20 TX+ Copilot

21 RX- Copilot

22 RX+ Copilot

23 No Connection

24 No Connection

25 No Connection

26 No Connection

Table 2-3: PAC45T Pin Assignments

2.7 Wiring Checkout

After wiring is complete, verify power is ONLY on pin 41 & 42 of J451and airframe ground on pin 20 & 21.

Failure to do so will cause serious internal damage and void PS Engineering's warranty.

200-045-5100 Page 2-10 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

2.8 Operational Checkout

2.8.1 Required Test Equipment

In order to return an aircraft to service after installation of the PAC45T, 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.

2.8.2 Audio controller Test

NOTE

The IntelliVOX ® is designed for ambient noise levels of 80 dB or above. Therefore some clipping may occur in a quiet cabin, such as without the engine running, in a hangar. This is normal .

1.

Apply power to the aircraft and avionics.

2.

Verify fail-safe operation by receiving and transmitting on UHF from the pilot position, with the audio controller power off /EMG mode (XMT Selector fully CW).

3.

Switch on the unit by turning the XMT select knob to the UHF position

4.

Verify that the UHF legend in both the XMT and RCV change to green. Verify that transmit indicator is not flashing green . . . If the LED is flashing green, stop testing and troubleshoot the microphone PTT installation. If for any reason the transmit PTTs are stuck then they will disconnect after 35 seconds.

5.

Verify proper transmit and receive operation from the pilot position, noting that the copilot PTT switch allows proper transmission on the selected transceiver. Verify that the Selected XMIT legend flashes green when transmitting.

6.

Rotate the XMT knob to the VHF transceiver position and verify the indicators change to track the selection, and VHF receiver is heard.

7.

Rotate the master volume knob (inner knob) and verify the VHF receiver volume varies.

8.

Verify proper operation of all receiver sources (NAV 1, NAV 2, ADF, MKR 1, MKR 2, TACAN, DME

1, and DME 2) by selecting them by pulling the appropriate knob to the out position. Turn the knob and verify that the audio level changes.

9.

With several sources selected, verify that the volume level of the radios in the headset is controlled by the outer concentric knob.

10.

Pull out the SPR knob and verify that the legend turns green, and selected radio audio is present in the speaker. Turning this knob also controls the volume of the speaker.

11.

Verify the proper operation of the Ident/Voice function : a) Select a navigation aid (Nav 1 for example), that can receive an active station. b) Push the ID/VOC button, and see that the green ID illuminates. The 1020 Hz audio identifier

Morse code should become audible. c) Press the button again, and the VOC will light green, and the Morse code tones will become lower in volume – any voice on the station will be heard.

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PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

12.

Select the OXY button; verify that all microphone audio source is their respective Oxygen Mask.

13.

Verify proper monaural Intercom system operation in the A LL , I SO and C REW modes.

14.

With the intercom in ISO mode, activate a CALL request from observer stations by pressing external switch, and observe that the CALL light illuminates, and a chime is heard in the headsets.

Verify that switching the intercom into ALL mode will cancel the CALL function.

15.

Verify that the volume level of the intercom is controlled by the outer concentric volume knob.

16.

Verify that the audio selector panel system does not adversely affect any other aircraft system by systematically switching the unit on and off, while monitoring the other avionics and electrical equipment on the aircraft.

17.

Repeat for the other aircraft crew stations.

2.9 Final Inspection

Verify that the wiring is bundled away from all controls and no part of the installation interferes with aircraft control operation. Move all controls through their full range while examining the installation to see that no mechanical interference exists. Verify that the cables are secured to the aircraft structure in accordance with good practices, with adequate strain relief. Ensure that there are no kinks or sharp bends in the cables and coaxial cables. Verify that the cables are not exposed to any sharp edges or rough surfaces, and that all contact points are protected from abrasion.

Complete documentation that may be required, such as a logbook entry, weight and balance computation and

FAA Form 337. Sample text for FAA Form 337, and instructions for continuing airworthiness can be found in Appendix F. Return completed warranty registration application to PS Engineering, or complete online at www.ps-engineering.com.

Section III OPERATION

3.1 SCOPE

This section provides detailed operating instructions for the PS Engineering PAC45T, Audio Selector

Panel/Intercom Systems. Please read it carefully before using the equipment so that you can take full advantage of its capabilities.

This section is divided into sections covering the basic operating areas of the PAC45T systems. They are

Communications Transceiver Selection, Audio Selector, Intercom, and special functions.

200-045-5100 Page 3-12 Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Figure 3-1 PAC45T Operating Controls

3.2 Power and Fail Safe

Unit power is controlled by the transmitter (XMT) selector knob, top right. In the " EMG " or OFF (fully clockwise) position, the pilot headset is connected directly to UHF as well as alerts and unswitched input #1.

This allows communication capability regardless of unit condition.

The power controls all audio selector panel functions, and intercom.

3.3 Communications Transmit (XMT) Selection

The PAC45T has a rotary control knob to select communications transceiver functions. To select a transceiver for transmit; turn the knob to select the desired radio from the two available.

The radio is automatically selected to receive incoming radio calls when the XMT is selected. With a PAC45T, 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.

3.4 COM Audio Selector

The communications receiver audio sources are controlled by a combination Pull- onpush-off switch/volume control. Communication audio from another radio, not selected for transmit, can be heard by pulling the associated RCV switch, which will place it in the OUT position. The selected audio is indicated by both knob position and the green nomenclature text.

You will always hear the audio from the selected transceiver, even if the selected comm audio is turned all the way down on the audio controller because it cannot turn the selected receive audio all the way off.

The volume of the received source is adjusted by rotating the knob.

If audio is not heard, verify master radio volume is turned up.

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

3.5 Navaid Selection

Navigation receivers are selected in the same manner as the communication receiver, pull-on/push off the knob associated with the desired navigational aid, and rotate to adjust the receiver volume.

3.5.1 Navaid Ident Function

The ID/VOC button controls a notch filter to either reject1020 Hz (VOICE) ident tone on ADF and navigation audio inputs, or enabling the band-pass filter to emphasize

1020 Hz ident tone (IDENT). To listen to the Morse identifiers, push the ID/VOC button until ID is green. To listen to any voice messages on the navaid, select VOC.

3.6 Oxygen Microphone Selector

When the OXY button is pushed, all microphone inputs to the system will be transferred from the headset to the oxygen microphone input. The button “OXY” will illuminate green when the mode is selected.

3.7 Intercom Operation (8)

3.7.1 IntelliVox® Intercom VOX-Squelch

No adjustment of the IntelliVox ® squelch control is necessary. Through individual signal processors, the ambient noise appearing in all microphones is constantly being sampled. Non-voice signals are blocked.

When someone speaks, only their microphone circuit opens, placing their voice on the intercom.

The system is designed to block continuous tones; therefore people humming or whistling in monotone may be blocked after a few moments.

For consistent performance, any headset microphone must be placed within ¼-inch of your lips, preferably against them. (ref: RTCA/DO-214, 1.3.1.1 (a )).

NOTE

It is also a good idea to keep the microphone out of a direct wind path. Moving your head through a vent air stream may cause the IntelliVox ® to open momentarily. This is normal.

The IntelliVox ® is designed to work with normal aircraft cabin noise levels (70 dB and above). It loves airplane noise! Therefore, it may not recognize speech and clip syllables in a quiet cabin, such as in the hangar, or without the engine running. This is normal.

3.7.2 Intercom Volume Control

The outer concentric volume control knob adjusts the loudness of the intercom for the intercom stations(s) connected to the audio controller panel. It has no effect on selected radio levels, or music input levels. The audio outputs are monaural.

3.7.3 Intercom Modes

The “ ICS ” pushbutton switch on the panel provides the selection of the intercom modes

The intercom mode defaults to “ALL” at power up. Then the button cycles through the intercom modes, from top to bottom, then bottom to top as: ISO, CRW, ALL. A green indicator shows which mode is currently active.

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

I SO : The pilot is isolated from the intercom and is connected only to the aircraft radio system. He will hear the aircraft radio reception (and sidetone during radio transmissions). Copilot will have radios, and .

Observers will have intercom.

C REW : Pilot and copilot are connected on one intercom channel and have exclusive access to the aircraft radios.

A LL : All parties will hear the aircraft radio, intercom.

3.7.3.1 Intercom Operation

The following rules apply:

System defaults to ALL at power up.

Any panel can select ISO, and be removed from the intercom.

Either pilot or copilot panel can select CRW, and place all panels in Crew mode. Pilot and copilot are on one intercom, while the observer stations are on another.

Either pilot or copilot panel can select ALL and add everybody to the intercom.

The Observer and Rack panels can select ISO, and then select ALL, unless a pilot or copilot has selected ISO or CREW.

The observer/mission personnel can isolate their audio feed from the crew by pressing the ICS button. When the CTL45T is in CRW mode, the observer/passengers will have intercom among themselves, and be able to use the selected radios.

3.8 Alert Audio

The PAC45T incorporates an independent alert audio system which plays when triggered by an external source.

The following alert tones are incorporated into the HUB45R, shown in order of priority:

1. Fire Bell

2. Stall Warning

3. Overspeed Warning

4. Gear Warning

5. Pitch Trim Warning

6. Autopilot Disconnect

7. Decision Height

8. Altitude Alert

9. Seat Belt Chime

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T 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. If the unit is being installed by a non-certified individual in an experimental aircraft, a factory-made intercom harness must be used for the warranty to be valid.

PS Engineering, Inc. warrants this product to be free from defect in material and workmanship for a period of two (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. For the remaining twelve (12) months of the twoyear warranty period, PS Engineering, Inc., at its option, will send a similar replacement unit at the customers’ expense if the unit should be determined to be defective after consultation with an authorized PS Engineering dealer.

All transportation charges for returning the defective units are the responsibility of the purchaser. 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. In this case, the purchaser assumes the risk of loss.

This warranty is not transferable. Any implied warranties expire at the expiration date of this warranty. PS

Engineering SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty does not cover a defect that has resulted from improper handling, storage or preservation, or unreasonable use or maintenance as determined by us. This warranty is void if there is any attempt to disassemble this product without factory authorization. This warranty gives you specific legal rights, and you may also have other rights, which may vary from state to state. Some states do not allow the exclusion of limitation of incidental or consequential damages, so the above limitation or exclusions may not apply to you.

All items repaired or replaced under this warranty are warranted for the remainder of the original warranty period. PS Engineering, Inc. reserves the rights to make modifications or improvements to the product without obligation to perform like modifications or improvements to previously manufactured products.

4.2 Factory Service

The units are covered by a two-year limited warranty. See warranty information. Call PS Engineering, Inc. at (865) 988-9800 before you return any unit. This will allow the service technician to provide any other suggestions for identifying the problem and recommend possible solutions.

After discussing the problem with the technician and you obtain a Return Authorization Number, ship product to:

PS Engineering, Inc.

Attn: Service Department

9800 Martel Rd

Lenoir City, TN 37772

(865) 988-9800 FAX (865) 988-6619

Email: [email protected]

Units that arrive without an RMA number, or telephone number for a responsible contact, will be returned un-repaired. PS Engineering is not responsible for items sent via US Mail.

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix A – PAC45T Installation Drawings

Figure 5-1 – PAC45T Side View

Figure 5-2 - PAC45T/CTL45T Front View

PAC45T Overall

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

CTL45T Top View

Figure 5-3 - HUB45R Top View

P451

62

42

21

1

22

43

J452

Figure 5-4 - HUB45R Rear Connector View

43

22

21

1

42

62

26

18

9

10

1

P453

J454

19

19

10

1

9

18

26

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

J455

Figure 5-5 HUB45R Front View

Figure 5-6 - HUB45R Side Views

200-045-5100 Appendix A Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix B – Radio Interconnect Wiring

200-045-5100 Appendix D August 2017

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix C – Intercom Interconnect Wiring

J451

CONNECTS TO

MALE P451 ON HUB

PILOT MIC AUDIO HI 23

P452

CONNECTS TO

FEMALE J452 ON HUB

57

COPILOT HAND MIC AUDIO HI

2

PILOT MIC LO 16 COPILOT HAND MIC LO

PILOT MIC PTT

COPILOT MIC AUDIO HI

COPILOT MIC LO

COPILOT MIC PTT

44

24

3

45

58

17

OBS 1 HAND MIC AUDIO HI

OBS 1 HAND MIC AUDIO LO

J453

CONNECTS TO

MALE P453 ON HUB

24

COPILOT HAND MIC PTT

OBS 1 MIC AUDIO HI

OBS 1 MIC PTT

OBS 1 MIC LO

OBS 2 MIC AUDIO HI

OBS 2 MIC PTT

OBS 2 MIC LO

PILOT HAND MIC AUDIO HI

PILOT HAND MIC PTT

PILOT HAND MIC LO

26

47

5

22

43

1

25

46

4 25 OBS 1 HAND MIC PTT

TO HEAR ALERTS IN

FAILSAFE MUST WIRE

PILOT, COPILOT, OBS 1 and OBS 2 PHONE

AUDIO HI TO 56,57,58,59

J453

CONNECTS TO

MALE P453 ON HUB

PILOT O2 MIC HI

15

PILOT O2 MIC LO

COPILOT O2 MIC HI

COPILOT O2 MIC LO

OBS 1 O2 MIC HI

6

16

7

17

OBS 1 O2 MIC LO

OBS 2 O2 MIC HI

OBS 2 O2 MIC LO

8

18

9 18

40

19

37

58

16

38

59

17

39

35

56

14

36

57

15

PILOT PHONE AUDIO HI

PILOT PHONE AUDIO LO

COPILOT PHONE AUDIO HI

COPILOT PHONE AUDIO LO

OBS 1 PHONE AUDIO HI

OBS 1 PHONE AUDIO LO

OBS 2 PHONE AUDIO HI

OBS 2 PHONE AUDIO LO

PAX 2 & 3 PHONE AUDIO HI

PAX 2 & 3 PHONE AUDIO LO

PAX 4 & 5 PHONE AUDIO HI

PAX 4 & 5 PHONE AUDIO LO

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix D – Control Head Interconnect Wiring

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix E, Unit Connector Wiring Reference

9.1 P451 Connections

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

9.2 J452 Connections

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

9.3 P453 Connections

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

9.4 J454 Connections

9.5 J455 Connections

200-045-5100 Appendix C Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix F – Instructions for FAA Form 337 and continuing airworthiness

10.1 Instructions for FAA Form 337, Audio controllers

One method of airworthiness approval is through an FAA Form 337, Major Repair and Alteration (Airframe, Powerplant, Propeller, or Appliance) In the case of the PAC45T, you may use the following text as a guide.

Installed audio selector and 6-place intercom, PS Engineering PAC45T, part number 050-045-(XXXX) in ( locations ) at station . Installed per AC43.13-2, Chapter 2, paragraph 23 (Instrument Panel Mounting). Installed per PS Engineering

Installation Operators Manual p/n 200-045-(XXXX), revision (), dated ( ).

These units are FAA-Approved under TSO C139A for audio amplifiers, and meets environmental qualifications outlined in RTCA DO-160G as appropriate or this aircraft.

Interface to existing aircraft radios in accordance with installation manual and in compliance with practices listed in

AC43.13-2 , Chapter 2. All wires are Mil-Spec 22759 or 27500. Connection to aircraft dimmer bus is

____________________. Power is supplied to the unit through a 5A circuit breaker (type and part number), and total electrical load does not exceed % of the electrical system capacity with the PAC45T added.

Aircraft equipment list, weights and balance amended. Compass compensation checked. A copy of the operation instructions, 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

Sample ICA Checklist for PS Engineering PAC45T Audio System:

Section

1

2

7

8

9

10

11

12

13

14

15

16

3

4

5

6

Introduction

Description

Item

Controls

Servicing

Maintenance Instructions

Troubleshooting

Removal and replacement information

Diagrams

Special Inspection Requirements

Protective Treatments

Structural Data

Special Tools

Not Applicable

Recommended Overhaul Periods

Airworthiness Limitations

Revision

Information

Installation of audio control panel with intercommunications system, with integrated audio alert system.

Installation as described in manufacturer’s installation manual referenced on installation documentation (FAA Form 337, etc.), including interface with other avionics audio as required.

See installation and operator’s guide referenced on installation documentation.

None Required

On Condition, no special instructions

In the event of a unit problem, place the unit into “off,” “fail-safe” and/or

“emergency” mode. This allows pilot communications using UHF, and unswitched audio for critical alerts, copilot communications on VHF. Follow checkout instructions in the installation manual referenced on the FAA Form

337. For a specific unit fault, contact the manufacturer at (865) 988-9800 for special instructions.

Removal: The CTL45T is attached to the aircraft using ¼-turn Dzus fasteners.

To release, insert a slotted screwdriver into the head and turn counterclockwise.

Release the wiring connectors by sliding the latches from the retaining standoff.

The HUB45R is attached to the aircraft using four #6 screws on the flanges.

Installation: Reverse the connector installation process. Place the unit against the Dzus rail and with the slotted screwdriver push gently and turn ¼-turn to secure.

Not applicable

Not Applicable

Not Applicable

Not Applicable

None

Not Applicable

None

Not Applicable

To be determined by installer

200-045-5100 Appendix F Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

Appendix G – RTCA DO160G Environmental Qualification Form

11.1 Model Number PAC45T Audio Selector Panel/Intercom Remote Hub

Part Number: 050-045-( )

FAA TSO Number: C139a,

Manufacturer: PS Engineering Incorporated 9800 Martel Road Lenoir City TN 37772

Conditions

Temperature and Altitude

Low Temperature

High Temperature

In-flight Loss of Cooling

Altitude

Decompression

Overpressure

Temperature variation

Humidity

Shock

Vibration

Explosion

Waterproofness

Fluids Susceptibility

Sand and Dust

Fungus

Salt Spray

Magnetic Effect

Power input

Voltage Spike

Audio Frequency Susceptibility

Induced Frequency Susceptibility

Radio Frequency Susceptibility

Radio Frequency Emission

Lightning Induced Transient Susceptibility

Lightning Direct Effects

Icing

ESD

Section

4.0

4.5.1

4.5.2

4.5.4

4.6.1

4.6.2

4.6.3

5.2

6.0

7.0

8.0

17.0

18.0

19.0

20.0

21.0

22.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

23.0

24.0

25.0

Conducted Tests

Equipment tested to CAT D2

-45°C Low Operating

-55° C Survival,

-45°C Low Short Term Operating

+85°C Survival,

+55°C High Operating

+70°C High Short Time Operating

Not Applicable, no cooling required

50,000’ unpressurized (D2)

Not Applicable

Not Applicable

Equipment tested to Category B

Equipment tested to Category A

Equipment tested to Category B Standard operational shock and crash safety

Equipment tested to Category SM, SB, U2FF1, Helicopter Random

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Equipment tested to Category Z

Equipment tested to Category Z (28V)

Equipment tested to Category A (600V)

Equipment tested to Category Z

Equipment tested to Category ZC

Equipment tested to Category T

Equipment tested to Category B

Equipment tested to Category A3J33

Category X, not tested

Category X, not tested

Category A

200-045-5100 Appendix E Rev. 2, Jan. 2019

PS Engineering

PAC45T Audio Selector Panel and Intercom System

Installation and Operator’s Manual

11.2 Model Number CTL45T, Audio Selector Control Panel

Part Number: 050-045-(02XX, -03XX, -62XX, -63XX )

FAA TSO Number: C139a

Manufacturer: PS Engineering Incorporated 9800 Martel Road

Conditions

Temperature and Altitude

Low Temperature

High Temperature

In-flight Loss of Cooling

Altitude

Decompression

Overpressure

Section

4.0

4.5.1

4.5.2

4.5.4

4.6.1

4.6.2

4.6.3

Temperature variation

Humidity

Shock

Vibration

Explosion

Waterproofness

Fluids Susceptibility

Sand and Dust

Fungus

Salt Spray

Magnetic Effect

Power input

Voltage Spike

Audio Frequency Susceptibility

Induced Frequency Susceptibility

Radio Frequency Susceptibility

Radio Frequency Emission

Lightning Induced Transient Susceptibility

Lightning Direct Effects

Icing

ESD

5.2

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

Lenoir City TN 37772

Category X, not tested

Category X, not tested

Category A

Conducted Tests

Equipment tested to CAT D1

-20°C Low Operating

-55° C Survival,

-40°C Low Short Term Operating

+85°C Survival,

+55°C High Operating

+70°C High Short Time Operating

Not Applicable, no cooling required

50,000’ unpressurized (D2)

Not Applicable

Not Applicable

Equipment tested to Category B

Equipment tested to Category B (Severe)

Equipment tested to Category B Standard operational shock and crash safety

Equipment tested to SM, SB, U2FF1, Helicopter

Random

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Category X, not tested

Equipment tested to Category Z

Equipment tested to Category Z (28V)

Equipment tested to Category A (600V)

Equipment tested to Category Z

Equipment tested to Category ZC

Equipment tested to Category T

Equipment tested to Category B

Equipment tested to Category A3J33

200-045-5100 Appendix E Rev. 2, Jan. 2019

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