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PS Engineering 

PAC24 Series Audio Selector Panel and Intercom System 

Installation and Operator’s Manual 

200-240-0010 

Page ii 

Rev. 29, Sept. 2021 

2.9

 

P

OST 

I

NSTALLATION 

C

HECKOUT

.................................................................................... 2-16

 

2.10

 

U

NIT 

I

NSTALLATION

 ...................................................................................................... 2-16

 

2.10.1

 

O

PERATIONAL 

C

HECKOUT

 ............................................................................................ 2-16

 

2.11

 

F

INAL 

I

NSPECTION

 ......................................................................................................... 2-17

 

 

SECTION III OPERATION ................................................................................................ 3-1

 

3.1

 

SCOPE ................................................................................................................................ 3-1

 

3.2

 

 

PAC24

 

C

ONTROLS

 ............................................................................................................ 3-1

 

3.3

 

P

OWER 

S

WITCH 

(3)

 

(EMG-F

AIL 

S

AFE 

O

PERATION

) ....................................................... 3-1

 

3.3.1

 

S

INGLE 

P

ANEL 

F

AIL 

S

AFE 

O

PERATION

 ............................................................................. 3-1

 

3.3.2

 

D

UAL 

P

ANEL 

F

AIL 

S

AFE 

O

PERATION

 ............................................................................... 3-1

 

3.4

 

C

OMMUNICATIONS 

S

ELECTION 

(2) ................................................................................... 3-2

 

3.4.1

 

T

ELEPHONE 

O

PERATION 

(S5

 

S

WITCH 

4

 SELECTED 

ON) ................................................... 3-2

 

3.4.2

 

S

TUCK 

M

ICROPHONE 

P

ROTECTION

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

 

3.4.3

 

S

WAP 

M

ODE 

(R

EMOTE TRANSFER OF COM TRANSCEIVERS

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

 

3.4.4

 

O

BSERVER TRANSMIT SELECTION 

(

PART NUMBER 

–0400

 SERIES

). .................................. 3-3

 

3.5

 

R

ECEIVE 

A

UDIO 

S

ELECTOR 

(1) ......................................................................................... 3-3

 

3.5.1

 

S

PEAKER 

A

MPLIFIER 

(4) ................................................................................................... 3-3

 

3.5.2

 

K

EY 

“C

LICK

” .................................................................................................................... 3-3

 

3.6

 

S

PLIT 

M

ODE

 ....................................................................................................................... 3-3

 

3.6.1

 

S

PLIT 

M

ODE

,

 

S

INGLE PANEL

 ............................................................................................. 3-3

 

3.6.2

 

S

PLIT 

M

ODE

,

 

D

UAL 

P

ANEL

 ............................................................................................... 3-4

 

3.6.3

 

S

PLIT 

M

ODE

,

 

O

BSERVER 

P

ANEL 

(-04XX) ........................................................................ 3-4

 

3.7

 

I

NTERCOM 

O

PERATION

 ..................................................................................................... 3-4

 

3.7.1

 

I

NTELLI

V

OX

®

 

VOX-S

QUELCH

 .......................................................................................... 3-4

 

3.7.2

 

V

OLUME 

C

ONTROL 

(3) ..................................................................................................... 3-5

 

3.7.3

 

I

NTERCOM 

M

ODES 

(5) ...................................................................................................... 3-5

 

3.7.4

 

E

NTERTAINMENT 

I

NPUT

 ................................................................................................... 3-6

 

3.8

 

T

ELEPHONE 

M

ODE

............................................................................................................. 3-6

 

 

SECTION IV- WARRANTY AND SERVICE................................................................... 4-1

 

4.1

 

W

ARRANTY

 ......................................................................................................................... 4-1

 

4.2

 

F

ACTORY 

S

ERVICE

 ............................................................................................................. 4-1

 

 

APPENDIX A – INSTALLATION DRAWING ................................................................... A

 

 

APPENDIX B SINGLE UNIT INTERCONNECT WIRING (DOES NOT APPLY TO 

050-240-0400, DUAL OBSERVER) ............................................................................................. A

 

 

APPENDIX C DUAL INTERCONNECT RADIO WIRING (ALL VERSIONS) ............. B

 

7.1

 

D

UAL 

PAC24

 

C

REW 

A

UDIO 

W

IRING

,

 

S

TANDARD 

(-0100,

 

-0500,

 

-0503)

 

U

NITS

 ................ C

 

7.2

 

D

UAL 

PAC24

INTERCOM AUDIO WIRING WITH 

O

BSERVER 

C

ONFIGURATION 

U

NITS 

(050-

240-0400

 

ONLY) ............................................................................................................................ D

 

7.3

 

D

UAL 

PAC24

INTERCOM AUDIO WIRING WITH 

O

BSERVER 

C

ONFIGURATION 

(050-240-

0400

 ONLY

)

 AND EXPANSION UNITS

 ............................................................................................... E

 

 

APPENDIX D- INSTRUCTIONS FOR FAA FORM 337 AND CONTINUING 

AIRWORTHINESS ...................................................................................................................... A

 

8.1

 

I

NSTRUCTIONS FOR 

FAA

 

F

ORM 

337,

 

A

UDIO 

P

ANELS

 ......................................................... A

 

8.2

 

I

NSTRUCTIONS FOR 

C

ONTINUING 

A

IRWORTHINESS

,

 

A

UDIO 

P

ANELS

 ............................... A

 

 

APPENDIX E – RTCA DO160D (EUROCAE ED-14) ENVIRONMENTAL 

QUALIFICATION FORM ........................................................................................................... A

 

Summary of Contents for PAC24

Page 1: ...1 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 info ps engineering com In certified aircraft warranty is not valid unless t...

Page 2: ...ROSS REFERENCE 2 6 2 3 EQUIPMENT INSTALLATION PROCEDURES 2 8 2 3 1 MOUNTING REQUIREMENTS 2 8 2 3 2 COOLING REQUIREMENTS 2 9 2 3 3 MOUNTING RACK INSTALLATION 2 9 2 3 4 TRAY AND CONNECTOR ASSEMBLY 2 9 2 4 CABLE HARNESS WIRING 2 9 2 4 1 NOISE 2 9 2 4 2 EXISTING KMA 24H INSTALLATION 2 10 2 4 3 POWER 2 10 2 4 4 COMMUNICATIONS PUSH TO TALK SINGLE PANEL INSTALLATION 2 10 2 4 5 AUDIO PANEL INTERFACE 2 10 ...

Page 3: ...INGLE PANEL 3 3 3 6 2 SPLIT MODE DUAL PANEL 3 4 3 6 3 SPLIT MODE OBSERVER PANEL 04XX 3 4 3 7 INTERCOM OPERATION 3 4 3 7 1 INTELLIVOX VOX SQUELCH 3 4 3 7 2 VOLUME CONTROL 3 3 5 3 7 3 INTERCOM MODES 5 3 5 3 7 4 ENTERTAINMENT INPUT 3 6 3 8 TELEPHONE MODE 3 6 SECTION IV WARRANTY AND SERVICE 4 1 4 1 WARRANTY 4 1 4 2 FACTORY SERVICE 4 1 APPENDIX A INSTALLATION DRAWING A APPENDIX B SINGLE UNIT INTERCONNE...

Page 4: ... 2 4 3 POWER 2 10 2 4 4 COMMUNICATIONS PUSH TO TALK SINGLE PANEL INSTALLATION 2 10 2 4 5 AUDIO PANEL INTERFACE 2 10 2 4 6 TRANSMIT INTERLOCK 2 10 2 4 7 SWAP MODE 2 11 2 4 8 BACKLIGHTING 2 11 2 4 9 UNSWITCHED INPUTS 2 11 2 4 10 PA MUTE J3 PIN 8 2 11 2 4 11 PUBLIC ADDRESS J3 PIN B 2 11 2 4 12 INTERCOM WIRING 2 11 2 4 13 ENTERTAINMENT INPUT J3 PIN 7 2 12 2 4 14 INTERCOM EXPANSION P N 11606 OR 11606R ...

Page 5: ...NTINUING AIRWORTHINESS AUDIO PANELS C APPENDIX D RTCA DO160D EUROCAE ED 14 ENVIRONMENTAL QUALIFICATION FORM D Rev Date Change 9 March 2005 Clarified Expansion Grounding also pin out diagram on 2 11 10 March 2006 Added cross reference tables for DIP switch settings 2 3 2 11 January 2007 Added Vertical Orientation Units 12 May 2007 Clarified DIP switches Section 2 3 13 September 2007 Added Appendix ...

Page 6: ...single or dual installation 050 240 0100 PAC24 Observer 3rd Transmit Seat Qty 2 PAC24s 050 240 0400 PAC24 Standard same as 0100 with Vertical Orientation 050 240 0500 PAC24 Special Mission Application Units Vertical 050 240 0503 PAC24 Standard PAC24 but with NVG Compatibility 050 240 8100 PAC24 Observer 3rd Transmit Seat Qty 2 PAC24s with NVG Compatibility 050 240 8400 PAC24 Standard NVG same as 8...

Page 7: ...nd copilot passengers outer knob Inter com squelch is automatic The PAC24 is form fit and function compatible with the King Radio KMA24H part number 066 1055 71 and may be compatible with 066 1055 70 depending on application 1 4 APPROVAL BASIS FAA TSO Approval The PAC24 Audio Selector Panels are FAA approved under TSO C50c Audio Amplifiers In addition the PAC24 is JAA JTSO approved under LBA N O 1...

Page 8: ... with 10 THD into 150 Microphone Impedance 150 600 Intercom Specifications Intercom Positions Minimum of 5 places with individual IntelliVox cir cuits Music Input 1 Monaural Music Muting 30 dB Soft Mute when Com or intercom active Distortion 1 THD 38 mW into 150 10 THD 120mW into 150 Mic Freq Response 3 dB 300 Hz 6000 Hz Music Freq Response 3 dB 100 Hz 18kHz 1 6 EQUIPMENT SUPPLIED 1 ea of the foll...

Page 9: ...40 0007 Grounding bar 1 430 007 0001 6 32 X 3 4 pan head Phillips screw 2 475 632 0038 6 32 Nut Flat 2 475 632 0003 6 32 Lock Nut 2 475 632 0004 Cable Clamp 1 625 001 0002 6 32 x Flat head Phillips screw 6 475 632 0012 6 32 Clip Nut 6 475 630 0002 Parts identification sheet 1 002 250 0240 1 7 EQUIPMENT REQUIRED BUT NOT SUPPLIED a Circuit Breaker 1 ea 3 amp b Cockpit Speaker 4 recommended c Cabin o...

Page 10: ...ade save the shipping material and contact the freight carrier Do NOT return units damaged in shipping to PS Engineering If the unit or ac cessories shows any sign of external shipping damage contact PS Engineering to arrange for a replace ment 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 ...

Page 11: ...eries Audio Selector Panel and Intercom System Installation and Operator s Manual 200 240 0010 Page 2 2 Rev 29 Sept 2021 Figure 2 1 Cover Screw Locations Figure 2 2 Locations DIP Switches Remove 2 top screws Circuit Jumpers ...

Page 12: ...nfiguration jumpers J4 J5 Single System or Pilot Audio Panel Copilot Audio Panel J4 ON installed J4 OFF Removed J5 Jumper Pins 1 2 J5 Jumper Pins 2 3 Figure 2 3 Circuit Jumper Configurations Pilot Audio Panel left Copilot audio panel right C H A S S I S J4 J5 Pilot Audio Panel J4 Installed J5 Pins 1 2 C H A S S I S J4 J5 Copilot Audio Panel J4 Removed J5 Pins 2 3 ...

Page 13: ...Dual Installation ON Copilot unit Dual Installation 3 OFF OFF ON Table 2 1 Pilot Copilot Dual Panel Selection Switch S5 2 2 4 Passenger and Expansion DIP Switch Configurations 2 2 4 1 Pass 3 Expansion P N 11606 J3 pin a configuration S2 As shipped the PAC24 is 5 place intercom and the ability to convert the system from a 5 place intercom to use an expansion unit that will allow up to 8 places on t...

Page 14: ... Recorder audio output connector pin 2 Switch S2 1 ON CVR Output OFF OPEN 2 OFF ON 2 2 4 5 14 Volt Backlighting Swap J3 pin 18 configuration S4 The installer has the option of implementing PS Engineering s patented Swap function which allows the pilot to switch between Com 1 and Com 2 with an external switch The Swap command is controlled through the unused backlight input and selected by the inte...

Page 15: ...re used Part Number 050 240 0400 the cockpit unit is configured as Crew and the Observer station is configured as Observer Switch S5 2 ON Crew unit Observer Installa tion ON Observer unit Installation 3 OFF ON Switch S3 1 OFF P N 11606 Expansion In enabled 2 ON 3 OFF P N 11606 Expansion Out enabled 4 ON Switch S2 3 ON Pass Input 4 OFF In an observer unit jumpers J4 and J5 should be configured like...

Page 16: ... OFF See notes 4 ON ON OFF See notes J4 On J5 Pins 1 2 J4 Off J5 Pins 2 3 Table 2 4 Dual Audio Panel DIP Switch Settings with expansion Dual PAC24 Observer 0400 CREW Panel 28 Volt Aircraft Dual PAC24 Observer 0400 Observer Panel 28 Volt Aircraft SW2 SW3 SW4 SW5 SW2 SW3 SW4 SW5 1 ON OFF OFF OFF 1 ON OFF OFF OFF 2 OFF ON ON ON 2 OFF ON ON ON 3 ON OFF ON OFF 3 ON OFF ON ON 4 OFF ON OFF See notes 4 OF...

Page 17: ...et it to OFF For 14V aircraft change SW4 1 4 to ON OFF OFF ON For CVR output change SW2 1 2 to ON OFF NOTE IRS cannot be used 2 3 Equipment Installation Procedures 2 3 1 Mounting Requirements The PAC24 must be rigidly mounted to the instrument panel of the aircraft structure and within view and reach of the pilot position s Installation must comply with FAA Advisory Circular AC 43 13 2A The unit m...

Page 18: ...correct techniques may result in improper operation electrical noise or unit failure Damage caused by improper installation will void the PS Engineering warranty 2 4 1 Noise Due to the variety and the high power of radio equipment often found in today s general aviation aircraft there is a potential for both radiated and conducted noise interference The PAC24 power supply is specifically designed ...

Page 19: ... breaker is re quired Power and ground wires must be a 18 AWG pair Connect airframe power ground to J3 Pin 25 only No dropping resistors are required 2 4 4 Communications Push to Talk single panel installation Unless the system is in split mode only the person who presses their transmit PTT switch will be heard over the radio If the pilot and copilot both use the PTT only the pilot position has ac...

Page 20: ...io signal NOTE In installations where an expansion unit is NOT used the passenger and copilot audio output is paralleled J1 pin b Therefore unswitched audio will be heard by the passenger s Use an expansion unit P N 11606 or 11606R remote to isolate passenger audio from unswitched alert audio 2 4 10 PA Mute J3 Pin 8 Pin 18 of J3 is a TTL logic output that is pulled low during PTT operation This se...

Page 21: ...ere is the possibil ity of power ripple entering the system The Music input can be deactivated from the front panel by press ing the NAV 1 and AUX ADF in 0500 buttons for at least 3 seconds The audio panel will then ignore any signal on this input until the Music Off mode is toggled again 2 4 14 Intercom expansion P N 11606 or 11606R The PAC24 contains a five place intercom pilot copilot and up to...

Page 22: ...mmodate the typical requirements for most aircraft configurations There are two adjustments however that will allow the installer to tailor the speaker volume controls to suit specific functions The PA volume adjusts the level of pilot and copilot mic audio in Public Address mode The Master Volume adjusts the level of all audio presented to the cockpit speaker Figure 2 6 PAC24 Adjustments 2 6 Comm...

Page 23: ...output the PTT for Com 5 is inactive and audio from Com 5 is presented to the headset This allows a telephone like audio interface The COM 5 input and output is compatible with aviation radios In a DUAL Audio Panel installation the telephone mic audio input should be connected to the both audio panels COM 5 Mic output J3 pin only PS Engineering makes no expressed or implied warranty that the equip...

Page 24: ...ckpit Spkr Out Com 5Mic Audio Pilot Headphones Com 3Mic Audio SCL 1 A 2 B 3 C 4 D 5 E 6 F 7 H 8 J 9 K 10 L 11 M 12 N 13 P 14 R 15 S 16 T 17 U 18 V 19 W 20 X 21 Y 22 Z J3Connector PAX out ICS Cross Tie2 Com 1Mic Aud Pilot ICS PTT CVROutput 28 V lights Hi 23 24 25 a b c DME Audio Unswitched Audio In 2 Pass 3 Mic AudioHi PAX IN ICS X tie 1 11 33 Aircraft Power Com 2Mic Audio Com 5Mic Key ADF Audio Na...

Page 25: ...s proper transmission on the selected transceiver Verify that the Com 1 Xmt button blinks when transmitting 9 Verify that pushing the COM 2 button causes the button to illuminate and the Com 2 receiver to be heard Verify operation on Com 1 from the pilot position 10 Repeat for other transceivers and standard Com 5 if installed 11 Press and hold the Com 1 Xmt button While holding the Com 1 button p...

Page 26: ...xists Verify that the cables are secured to the aircraft structure in accord ance 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 logbook entry FAA Form 337 weight and balance comp...

Page 27: ...ols 1 Receiver Source Selection 2 Transmitter Selection 3 Volume Power Controls 4 Speaker Selector 5 Intercom Mode Selector 3 3 Power Switch 3 EMG Fail Safe Operation Unit power is turned on and off by pushing the center pilot volume knob The power switch controls the audio selector panel functions and intercom 3 3 1 Single Panel Fail Safe Operation In the OFF or EMG position the pilot is connecte...

Page 28: ...he pilot audio panel will ONLY receive audio selected by the pilot Do not use the expansion Mono input for radio 11606 Pin 22 3 4 1 Telephone Operation S5 Switch 4 selected ON In a single installation the intercom mode select switch determines who is on the phone ISO pilot CREW pilot and copilot passengers if IntelliPAX expansion NOT present ALL pilot copilot passengers In a standard dual installa...

Page 29: ...e labeled C1 through C5 NAV is N1 N2 3 5 1 Speaker Amplifier 4 The 3 position SPR switch controls the distribution of the audio in the cockpit or external public ad dress speakers In the up SPR position all selected audio is presented to the cockpit speaker Unswitched audio autopilot disconnect altimeter warning etc will come through the speaker regardless of the speak er button position In PA the...

Page 30: ...e press COM1 and COM2 for COM1 2 mode The observer s panel will split as in a conventional dual panel installation 3 7 Intercom Operation 3 7 1 IntelliVox VOX Squelch No adjustment of the IntelliVox squelch control is necessary There is no field adjustment Through individual signal processors the ambient noise appearing in all six microphones is con stantly being sampled Non voice signals are bloc...

Page 31: ... 3 position mode switch that allows the crew to tai lor the intercom function to best meet the current cockpit situation 3 7 3 1 Single Installation Intercom Modes ISO Up Position The pilot connected to the PAC24 is isolated from the intercom and is connected only to the aircraft radio system He will hear the selected aircraft radio reception and sidetone during radio transmissions The copilot wil...

Page 32: ...nytime a person speaks on the intercom or there is radio traffic the music will be muted It will return gradually through the use of SoftMute circuitry The SoftMute can be defeated for a Karaoke Mode music does not mute by pressing the NAV1 and NAV2 buttons simultaneously for at least 3 seconds Pressing the buttons again will reactivate SoftMute While in the ISO Isolate mode the non isolated crewm...

Page 33: ...cannot put the passengers on the phone and the passengers can only get on the phone when the pilot is on the phone In an observer dual installation the crew box works like a single installation The observer is treated like a passenger so he would be on the phone line when COM5 Xmt is selected and the intercom switch is in ALL mode The observer cannot select telephone mode independently The observe...

Page 34: ...ring 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 do...

Page 35: ...A Rev 29 Sept 2021 5 Appendix A Installation Drawing OFTHEUNIT L C 6 298 6 165 1 248 1 312 6 485 INSIDE OUTSIDE INSIDE OUTSIDE 0 320 5 570 6 450 6 690 Key between 17 and 18 c b a 25 24 23 J1 Z Y X W V U T S R P N M L K J H F E D C B 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 A 1 Rear Connector Viewed from front J3 ...

Page 36: ...AC24 Series Audio Selector Panel and Intercom System Installation and Operator s Manual 200 240 0010 Appendix C Rev 29 Sept 2021 6 Appendix B Single Unit Interconnect Wiring does not apply to 050 240 0400 dual observer ...

Page 37: ... AudioHi Nav 2 Audio Lo Nav 2 Audio Hi NAV 1 Audio Lo Nav 1 Audio Hi Com 1 Lo Com 1 Mic Key Com 1 Audio Hi Com 4 Mic Key Com 4 Lo Com 4 Mic Audio Hi Com 4 Audio Hi Com 5 Mic Key Com 5 Lo Com 5 Mic Audio Hi Com 5 Audio Hi ADF Audio Lo ADF Audio Hi Mkr Audio In Lo Mkr Audio In Hi Com 3 Mic Key Com 3 Lo Com 3 Mic Audio Hi Com 3 Audio Hi Com 2 Mic Audio Hi Com 2 Lo Com 2 Mic Key Com 2 Audio Hi Com 1 M...

Page 38: ...as s 2 Mic Hi Pas s 3 Mic Lo Pas s 3 Mic Hi 22 23 a 25 25 CopilotPhones Lo CopilotPhones D Speak er Lo Coc kpitSpeak er Hi Y Y SDA 18 14 V dimmer Swap Note 17 U 28 V dimmer Swap Note 17 8 PA Mute Note 8 Pil ot ICS key Note 7 Expansion Input Expansion Output Expansion Power Out Note 5 CVR OUT 4 1 Expansion Input Expansion Output Expansion Power Out Note 5 24 U 28 V dimmer Swap Note 17 8 PA M ute No...

Page 39: ...s 11 33 VDC c Audi o Low Airframe Ground A 2A Music Low Music In 7 2 22 23 25 25 Observer Phones Lo Observer Phones D Speaker Lo Local Speaker Hi Y Y SDA 18 14 V dimmer Swap Note 17 U 28 V dimmer Swap Note 17 8 PA Mute Note 8 Pilot ICS key Observer CVR 4 1 Pilot Copilot 24 19 Z Observer Mic Lo Observer Mic PTT Observer Mic Audio Hi 17 Backlight Lo Copilot Mic PTT Copilot Mic Audio Hi Copilot PTT S...

Page 40: ...n 2 4 12 1 8 PA M ute is TTL Level logic l ow when transmit PTT is active 9 For music distribution information see Secti on 2 4 13 10 All wiring must be 24 AWG or larger unl ess otherwise noted 11 Power and Ground to be 18 AW G or l arger For best results power and ground wires shoul d be twisted together for greater noi se immunity 12 See Secti on 2 3 2 for detail s on dual mode pins selected thr...

Page 41: ...ds All work accomplished listed on Work Order 8 2 Instructions for Continuing Airworthiness Audio Panels Sample ICA Checklist for PS Engineering Audio Panels Section Item Information 1 Introduction Installation of audio control panel with integrated marker beacon receiver and intercommunications system 2 Description Installation as described in manufacturer s installation manual referenced on FAA ...

Page 42: ...Humidity 6 0 Equipment tested to Category A Operational Shock and Crash Safety 7 0 Equipment tested Category B Vibration 8 0 Equipment tested to Category G M Explosion 9 0 Category X not tested Waterproofness 10 0 Category X not tested Fluids Susceptibility 11 0 Category X not tested Sand and Dust 12 0 Category X not tested Fungus 13 0 Category X not tested Salt Spray 14 0 Category X not tested Ma...

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