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PS Engineering PAC45D, System Installation And Operation Manual

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PS Engineering 

PAC45A Audio Selector Panel and Intercom System 

Installation and Operator’s Manual 

200-045-0100 

Page 3-1 

 January 2020 

Section III OPERATION 

3.1  SCOPE  

This section provides detailed operating instructions for the PS Engineering PAC45D Audio Selec-
tor 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 PAC45D systems. 
They are Communications Transceiver Selection, Audio Selector, Intercom, and special func-
tions, including the Bluetooth® functionality in the PAC45D. 
Note: The nomenclature may vary between user configurations. Pilot and copilot ides can be re-
versed.  

 

Figure 3-1 PAC45D Operating Controls 

3.2  Power and Fail Safe 

Unit power is controlled by push on/push off of the pilot side volume control knob.  In the 
"EMG" or off condition, the pilot headset is connected directly to COM 1 as well as alerts and 
unswitched input #1. This allows communication capability regardless of unit condition.  NAV1 
audio is also provided to the pilot in the other ear of a stereo headset.

 

Any time power is removed or turned off, the audio selector will revert to fail-safe mode. If fail-
safe audio is present in both ears of a stereo headset, or completely absent, verify that a stereo 
headset is used and is selected for stereo mode.  
The power controls all audio selector panel functions and intercom.  

PRELIMINARY

Summary of Contents for PAC45D

Page 1: ...941 187 5 903 227 6 160 496 and 6 493 450 7 391 877 PS Engineering Inc 2020 Copyright Notice Any reproduction or retransmittal of this publication or any portion thereof without the expressed written permission of PS En gineering Inc is strictly prohibited For further information contact the Publications Manager at PS Engineering Inc 9800 Martel Road Lenoir City TN 37772 Phone 865 988 9800 email c...

Page 2: ...4 3 AUDIO CONTROLLER INTERFACE 2 4 2 4 4 TRANSMIT INTERLOCK 2 5 2 4 5 BACKLIGHTING 2 5 2 4 6 UNSWITCHED INPUTS 2 7 2 4 7 COCKPIT VOICE RECORDER 2 7 2 4 8 AUDIO ALERTS 2 7 2 4 9 WIRED TELEPHONE SATELLITE COMMUNICATION INPUT 2 8 2 4 10 MUSIC INPUT 2 8 2 4 11 RECEIVE ACTIVITY INDICATOR RXI 2 8 2 4 12 COCKPIT SPEAKER OUTPUT PAC45D 050 045 0006 AND HUB45R 050 045 0103 ONLY 2 8 2 5 USER ADJUSTMENTS 2 8 ...

Page 3: ...HONE INPUT 3 7 3 8 ALERT AUDIO 3 7 Section IV Warranty and Service A 4 1 WARRANTY A 4 2 FACTORY SERVICE A Appendix A PAC45D Installation Drawings A Appendix B Radio Interconnect WiringA Appendix C Intercom Interconnect Wiring A Appendix D Control Head Interconnect Wiring A Appendix E Unit Connector Wiring Reference A 9 1 J451 CONNECTIONS A 9 2 J452 CONNECTIONS B 9 3 J453 CONNECTIONS C 9 4 J454 CON...

Page 4: ...val 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 PAC45D series of Audio Selector Panel Intercom Systems This includes the following units ...

Page 5: ...ggered by external sources to provide additional capability The individual volume controls select the receiver audio source provided to the headphones when selected An eight station voice activated VOX intercom is included in the PAC45D This system has PS Engineering s patented IntelliVOX circuitry that eliminates manual adjustments The intercom system incorporates pilot isolate all and crew modes...

Page 6: ...XXXZBABZATTMA3J33XXA Temperature Range Operating Short Term Operating Survival HUB45 45 C to 55 C 45 C to 71 C 55 C to 85 C CTL45 20 C to 55 C 40 C to 70 C 55 C to 85 C Altitude Up to 55 000 feet in a non pressurized area of the cockpit DIMENSIONS Height 1 9 in 4 8 cm Width 5 75 in 14 6 cm Depth behind panel PAC45D 7 38 in 18 75 cm in cluding connectors UNIT WEIGHT PAC45D 001 HUB45 CTL45 2 0 lb 0 ...

Page 7: ...PPLIED The following units comprise the PAC45D System Model Description Standard Part Number NVIS Compatible Part Number PAC45D Single Panel mounted System HUB45 and CTL45D 050 045 000X 050 045 600X Or HUB45R Remote mounted Audio Hub for analog I O and processing 050 045 010X N A CTL45D Panel mounted Control Head for Pilot and Copilot 050 045 0200 050 045 6200 CTL45M Panel mounted Control Head for...

Page 8: ...4 D Sub Latch slide clip 475 045 5206 4 Tyco Electronics 5206942 1 Backshell DB9 625 009 5750 1 Tyco Electronics 5750100 1 Backshell DB26 625 015 5206 2 Tyco Electronics 5206478 2 HUB45R Remote Hub Retrofit Installation Kit 250 045 0200 Description PS E Part Number Qty Manufacturer MFR Part Number D Sub housing 9 pin male 425 009 0777 1 Amphenol L777 RR E 09 P D sub Pins Male 425 020 5089 9 Deutsc...

Page 9: ...tch Counter Sunk 475 442 2001 12 Connector Backshell DB9 Plastic MODIFIED 625 009 1724 1 PS Engineering Connector Backshell DB9 Plastic NON MODIFIED 625 009 1724 Thumbscrew 475 002 0002 2 Lanpar Tech nologies Inc B71E014256 CTL45 Installation Kit 250 043 0100 Description PS E Part Number Qty Manufacturer MFR Part Number Modified Connector Plastic Back shell DB9 625 009 1724 1 PS Engineering Connec...

Page 10: ...NOTE Unauthorized use of unapproved cellular telephone devices in aircraft is subject to FCC enforce ment action which may include a 10 000 fine per incident FCC Regulation 47 CFR 22 925 Prohibition on airborne operation of cellular telephones Cellular telephones installed in or carried aboard airplanes balloons or any other type of aircraft must not be operated while such aircraft are airborne no...

Page 11: ...on 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 cor rect quantity of components supplied with the list in 1 6 If any claim is to be made save the shipping material and contact t...

Page 12: ...rs Refer to the connector pin maps to confirm compatibility The two 26 pin connectors are used to give the PAC45D systems added capability The PAC45D LRU Hub can be remote mounted and connections to control head s CTL45 Ensure that proper strain relief and chafing precautions are made during wiring and installation Manufacturer Crimping Tool Positioner Extraction tool AMP 601966 1 601966 6 91067 1...

Page 13: ...io equipment often found in today s aircraft there is a potential for both radiated and conducted noise interference The PAC45D 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 ...

Page 14: ...nnect power to P451 Pin 17 Connect airframe ground to P451 Pin 34 only Power consumption is as follows At 28V Hub Control Head 500 mA Control head Only 150 mA Hub Only 350 mA Alert audio power 10mA At minimum input voltage 18V Hub Control Head 750mA Control head Only 200mA Hub Only 500mA Lighting input 5mA CAUTION Do not connect or disconnect HOT SWAP any components with power applied this will da...

Page 15: ... for passenger 5 and 6 are paralleled from passenger 1 and passenger 2 NOTE Do not parallel headphones to passenger 3 or 4 2 4 3 4 Installation with Monaural Headsets Not recommended because the benefit of MultiTalker is lost However if desired the PAC45D can be installed monaurally by using the LEFT audio connections only left side contains Fail Safe audio Do NOT short left and right headphone ou...

Page 16: ... depending on configuration A long press 3 seconds of HRTF and ACK on pilot panel will cause the 2 potentiometer to ad just the green backlight level when in this mode the green LEDs will get brighter or dimmer Another simultaneous long press 3 seconds of HRTF and ACK on pilot control panel will adjust the white backlight level Another long press 3 seconds of HRTF and ACK to exit Also ACK can be p...

Page 17: ... CVR output is consistent with RTCA DO 214A 1 5 7 2 4 8 Audio Alerts The PAC45D contains an independent audio alerting system that will play up to three alert audio messages These messages are spoken words ALERT MASTER CAUTION and an audio chime The alert system has a power input P451 16 that will keep the systems operable if the PAC45D systems power source is removed Alert audio is provided in Fa...

Page 18: ...ndesired interference with other aircraft systems Before takeoff operate the entertainment devices to determine if there is any adverse effect within the aircraft systems If any unusual operation is noted in flight immediately switch off the entertainment devices All additional entertainment devices must be switched off for both takeoff and landing 2 4 11 Receive Activity Indicator RXI PAC45D syst...

Page 19: ...he dim mer input to full bright The pot permits adjustment from 0V to nominal dimmer voltage 28V or 5V depending on configuration Long press 3 seconds of TEL and ACK on pilot panel will cause the 2 potenti ometer to adjust the green level when in this mode the green LEDs will get brighter or dimmer Another long press 3 seconds of TEL and ACK on pilot panel will adjust the white level Another long ...

Page 20: ...WN for high noise environment As shown High noise 2 5 3 5 Passenger Head Related Transfer Function HRTF Disable Switch 9 Switch 9 enables HRTF mode for passengers UP disabled DOWN enabled Disable only if headsets are monaural 2 5 3 6 Offside com audio active during transmit Switch 10 When this switch is in the UP position the receive audio on other radios is not muted when one crew member transmit...

Page 21: ...ring PAC45 Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 0100 Page 2 11 January 2020 As shown Observer Control Head in System 12 11 10 9 8 7 6 5 4 3 2 1 P R E L I M I N A R Y ...

Page 22: ... MIC AUD 18 PILOT PHONES L HI 19 COM1 MIC AUD 19 28 V LIGHTS 20 COM3 MIC AUD 20 UNSWITCHED AUDIO 2 LO 21 COM4 MIC AUD 21 COM 2 AUDIO LO 22 COM5 MIC AUD 22 COM 1 AUDIO LO 23 PAX 6 HAND MIC AUD 23 COM 3 AUDIO LO 24 PILOT MIC AUD IN 24 COM 4 AUDIO LO 25 COPILOT MIC AUD IN 25 COM 5 AUDIO LO 26 PASS1 MIC AUD 26 NAV 1 AUDIO LO 27 PASS2 MIC AUD 27 NAV 2 AUDIO LO 28 PAX 3 MIC AUDIO 28 ADF 1 AUDIO LO 29 PA...

Page 23: ...3 UNSW 4 AUD IN 14 PAX 2 HP RT 14 UNSW 3 AUD IN 15 PAX 3 HP RT 15 NC 16 PAX 4 HP RT 16 PAX 5 MIC AUD 17 NC 17 TEL AUD IN 18 NC 18 REMOTE ISO 19 SERIAL TX3 19 COPILOT HP LOW 20 SERIAL RX3 20 PILOT HP LOW 21 SERIAL RX3 21 CVR LOW 22 SERIAL 2 LOW 22 UNSW 4 AUD LOW 23 PAX HP LOW 23 UNSW 3 LOW 24 SERIAL 2 LOW 24 NC 25 PAX HP LOW 25 PAX 5 MIC AUD LOW 26 NC 26 TEL AUD LOW Table 2 3 PAC45D Pin Assignments...

Page 24: ...ion COM 1 5 Check intercom operation 6 Verify that the COM 1 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 7 Verify proper transmit and receive operation from the cop...

Page 25: ... 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...

Page 26: ... Note The nomenclature may vary between user configurations Pilot and copilot ides can be re versed Figure 3 1 PAC45D Operating Controls 3 2 Power and Fail Safe Unit power is controlled by push on push off of the pilot side volume control knob In the EMG or off condition the pilot headset is connected directly to COM 1 as well as alerts and unswitched input 1 This allows communication capability r...

Page 27: ...ive au dio all the way off The volume of all receivers is adjusted by rotating the RAD inner knob for pilot or copilot PS Engineering recommends a higher volume at the radio and lower audio panel setting to mini mize noise 3 4 1 MultiTalker Head Related Transfer Function HRTF Communication receiver audio signals are presented to the DSP and processed to appear in a different location to the crew M...

Page 28: ...r to spot an active radio even if the volume is turned down This function is set at the factory at the installer s request and can be changed only at the factory 3 4 5 Monitor Mode With the toggle switch in the down position the PAC45D is in Monitor Mode In this mode the audio from the COM radio that is selected for transmit will mute the other COM audio when it is active For example if COM 1 is s...

Page 29: ...utput is OFF only alerts and unswitched inputs will be present 3 5 Intercom Operation 8 3 5 1 IntelliVOX Intercom VOX Squelch No adjustment of the IntelliVOX squelch control is necessary Through individual signal proces sors the ambient noise appearing in all microphones is constantly being sampled Non voice sig nals are blocked When someone speaks only their microphone circuit opens placing their...

Page 30: ...n AIR3000 90015 90010 Table 3 1 Mic Muff Part Numbers 3 5 2 Push to talk intercom PTT ICS Pressing the copilot s intercom volume knob ICS VOL will place the system all headsets into the Push to talk PTT for Intercom use mode This will disable the voice activation VOX and require that the external push to talk intercom buttons for each position be used to speak on the intercom Push the knob again a...

Page 31: ...volume automatically decreases The music volume increases gradu ally back to the original level after communications have been completed CRAW Pilot and copilot are connected on one intercom channel and have exclusive access to the aircraft radios 3 5 4 1 Remote ICS Mode Control P454 connector pin 18 An optional external switch can act as a remote intercom mode selector Pressing the switch will inc...

Page 32: ...uetooth module clearing out the connected devices press TEL and ICS for more than three seconds Then Forget the PAC45 on your mobile device and pair agan from the be ginning 3 6 3 Music Muting Control The PAC45D incorporates PS Engineering s trademark SoftMute The SoftMute circuit will mute the music whenever there is conversation on the radio or the intercom When that con versation stops the musi...

Page 33: ...ser 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 war ranty is void if there is...

Page 34: ...ation and Operator s Manual 200 045 0100 Appendix A January 2020 Appendix A PAC45D Installation Drawings Figure 5 1 PAC45D Rear Connector View not to scale Figure 5 2 PAC45D Side View Figure 5 3 PAC45D CTL45D Front View J451 50 PIN FEMALE ON HARNESS P R E L I M I N A R Y ...

Page 35: ...PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 0100 Appendix A January 2020 PAC45D Overall Top View P R E L I M I N A R Y ...

Page 36: ...PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 0100 Appendix A January 2020 CTL45D Top View P R E L I M I N A R Y ...

Page 37: ...PS Engineering PAC45A Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 0100 Appendix A January 2020 HUB45R Top View Figure 5 4 HUB45R Side View P R E L I M I N A R Y ...

Page 38: ...om 4 Audi o Low 21 4 38 Com 4 Mic Audio Hi 5 24 Com 4 Mic Low Com 5 Audi o Hi Com 5 Mic Key Com 5 Audi o Low 22 5 39 Com 5 Mic Audio Hi 6 25 Com 5 Mic Low TEL Audi o Hi TEL Audi o Low SAT COM Transceiver TEL Mic Audi o Hi 17 26 7 P454 12 21 Pil ot CVR OUT CVR LOW ADF 1 Audi o Hi ADF 1 Audi o Lo ADF1 9 28 12 31 MKR Audi o Hi MKR Audi o Lo MKR 13 32 UNSW 1 Unswi tched Input 1 Hi Unswi tched Audi o L...

Page 39: ... Low PAX2Phones Jack 31 48 14 PAX2PHN L PAX2PHN R PAX2PHN Low PAX3Phones Jack 32 49 15 PAX3PHN L PAX3PHN R PAX3PHN Low PAX4Phones Jack 33 50 16 PAX4PHN L PAX4PHN R PAX4PHN Low Mic AudioHi Add l Mic PTT Mic Lo 23 6 40 P451 P453 P454 PAX1ICS PTT PAX4ICS PTT PAX2ICS PTT PAX3ICS PTT 4 5 6 7 PAX5ICS PTT 3 Swap 8 PAX5Mic AudioHi PAX5Mic Lo 16 25 RemoteISO 18 Pilot Mic PTT 8 7 17 34 28V ACRFT POWER POWER...

Page 40: ...AD PAC45 HUB LRU R X R S422 TX R X R S422 TX TX R S422 R X TX R S422 R X GND N O C ON N EC TION POW ER AIR C R AFTGN D N O C ON N EC TION 1 2 3 4 5 6 7 8 9 J4 53 PAC45 HUB LRU R X R S422 TX R X R S422 TX TX RS422 R X TX RS422 R X GND N O C ON N EC TION AIR C R AFTPOWER AIR C R AFTGN D N O C ON N EC TION 1 2 3 4 5 6 7 8 9 OBSR P455 OBSERVER CTL45M HEAD J4 51 17 34 20 21 10 19 24 28V ACRFT POWER 0 5...

Page 41: ... Copilot Mic Lo 25 42 PAX OBS 1 Mic Audio Hi PAX OBS 1 Mic Lo 26 43 PAX 2 Mic Audio Hi PAX 2 Mic Lo 27 44 PAX 3 Mic Audio Hi PAX 3 Mic Lo 28 45 PAX 4 Mic Audio Hi PAX 4 Mic Lo 29 46 23 6 40 P451 Pilot Mic PTT 8 7 11 12 13 16 ALERT 1 ALERT 2 ALERT 3 ALERT PWR 17 34 Pilot ICS PTT 9 Copilot ICS PTT 10 14 15 PA MIC AUD OUT PA AUD LOW Public Addess PAX 1Phones Jack 30 47 PAX 1 PHN L PAX 1 PHN Low PAX 2...

Page 42: ...Audio Low 2 21 Com 3 Audio Hi Com 3 Audio Low 4 23 Com 4 Audio Hi Com 4 Audio Low 5 24 Com 5 Audio Hi Com 5 Audio Low 6 25 12 31 MKR Audio Hi MKR Audio Lo MKR 13 32 UNSW 1 Unswitched Input 1 Hi Unswitched Audio Lo 1 20 UNSW 2 Unswitched Input 2 Hi Unswitched Audio Lo 28VDC Dimmer Music Left Music Right Music Lo 14 15 34 Music Source 19 Pilot Phones Jack 18 37 PIL PHN L PIL PHN Low Copilot Phones J...

Page 43: ...nes Jack 13 24 PAX OBS 1 PHN R PAX OBS 1 PHN Low PAX 2 Phones Jack 14 PAX 2 PHN R PAX 2 PHN Low PAX 3 Phones Jack 15 25 PAX 3 PHN R PAX 3 PHN Low PAX 4 Phones Jack 16 PAX 4 PHN R PAX 4 PHN Low CTL45 Obsver Serial TX Serial TX Serial TX Serial RX Ground ACFT Power PAX 1 Radi o PTT 9 PAX 5 Phones Jack PAX 5 PHN R PAX 5 PHN Low PAX 6 Phones Jack PAX 6 PHN R PAX 6 PHN Low C O N N E C TTOA IR C R A FTP...

Page 44: ...mote ACK PA Key Output 1 PA System 3 PAX6 ICSPTT SAT COM CVR Low COPILOT CVR OUT PILOT CVR OUT NOTE COPILOT CVROUTPUT ON 050 045 0005 HUB45 050 045 0101 PIN 2 IS COCKPIT SPEAKER ON 050 045 0006 HUB45 050 045 0103 J454 Connections with Single CVR and Speaker Output 050 045 0006 and 050 045 0103 TEL Audio Hi TEL Audio Low TEL Mic Audio Hi 17 26 7 14 23 PAX 5 Mic Audio Hi PAX 5 Mic Lo 16 25 Remote IS...

Page 45: ...ineering PAC45D Audio System Section Item Information 1 Introduction Installation of audio control panel with intercommunications system with inte grated audio alert system 2 Description Installation as described in manufacturer s installation manual referenced on installation documentation FAA Form 337 etc including interface with other avionics audio as required 3 Controls See installation and o...

Page 46: ...Humidity 6 0 Equipment tested to Category A Shock 7 0 Equipment tested to Category B Standard op erational shock and crash safety Vibration 8 0 Equipment tested to Category SM SB U2FF1 Helicopter Random 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 te...

Page 47: ...ested to Category B Severe Shock 7 0 Equipment tested to Category B Standard op erational shock and crash safety Vibration 8 0 Equipment tested to SM SB U2FF1 Helicopter Random 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 Categ...

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