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PS Engineering 

PAC45T Audio Selector Panel and Intercom System 

Installation and Operator’s Manual 

200-045-5100 

Appendix F 

  Rev. 2, Jan. 2019 

Appendix F – Instructions for FAA Form 337 and continuing airworthi-
ness 

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, Propel-

ler, 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 elec-
trical 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 instruc-
tions, 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 

Item 

Information 

Introduction 

Installation of audio control panel with intercommunications system, with inte-
grated audio alert system. 

Description 

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

Controls 

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

Servicing 

None Required 

Maintenance Instructions 

On Condition, no special instructions 

Troubleshooting 

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 un-
switched 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 and replacement infor-
mation 

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 se-
cure.  

Diagrams 

Not applicable 

Special Inspection Requirements 

Not Applicable 

10 

Protective Treatments 

Not Applicable 

11 

Structural Data 

Not Applicable 

12 

Special Tools 

None 

13 

Not Applicable 

Not Applicable 

14 

Recommended Overhaul Periods 

None 

15 

Airworthiness Limitations 

Not Applicable 

16 

Revision 

To be determined by installer 

Summary of Contents for PAC45T

Page 1: ...227 6 160 496 and 6 493 450 7 391 877 PS Engineering Inc 2019 Copyright Notice Any reproduction or retransmittal of this publication or any portion thereof without the expressed written permission of...

Page 2: ...ERFACE 2 4 2 4 4 BACKLIGHTING 2 4 2 4 5 UNSWITCHED INPUTS 2 4 2 4 6 COCKPIT VOICE RECORDER 2 4 2 4 7 AUDIO ALERTS 2 5 2 5 USER ADJUSTMENTS 2 5 2 5 1 UNSWITCHED AUDIO LEVEL 2 5 2 5 2 ADJUSTMENTS 2 5 2...

Page 3: ...ctions for FAA Form 337 and continuing airworthiness A 10 1 INSTRUCTIONS FOR FAA FORM 337 AUDIO CONTROLLERS A 10 2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS AUDIO SYSTEM A Appendix G RTCA DO160G Envir...

Page 4: ...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 uni...

Page 5: ...UB45R Height 1 9 Width 5 88 w mounting flanges Length 7 22 12 w all connectors See Figure 5 6 UNIT WEIGHT HUB45R CTL45T 2 0 905 kg 1 0 45 kg POWER REQUIREMENTS Voltage 18 to 33 VDC Maximum Current Typ...

Page 6: ...1 1 425 044 2043 Hi density Male Pins AMP 204370 2 88 475 045 3341 Thumbscrew Kit for DB Connector 3M 3341 7 4 Female Connector Kit 250 045 8277 J451 J453 Part Number Description MFR MFR PN Quantity 6...

Page 7: ...9 7709 Connector Female Shell DB9 Amphenol L177 RR E 09 S 1 425 020 5090 Standard density female pins Deutsch M39029 63 368 9 475 045 3341 Thumbscrew Kit for DB Connector 3M 3341 7 2 EQUIPMENT REQUIRE...

Page 8: ...B45R and up to four identical CTL45T Control Heads Hub Pilot VHF UHF Copilot 1 Control Head Control Head Ground RS422 RS422 RS422 RS422 Hand NAV 1 MKR 1 ADF1 NAV 2 MKR 2 TACAN DME1 2 UNSW1 4 CVR PA Pi...

Page 9: ...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 com ponents supplied with the list in 1 6...

Page 10: ...he 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...

Page 11: ...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 preve...

Page 12: ...ntroller 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 rad...

Page 13: ...dge 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...

Page 14: ...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 L...

Page 15: ...8 PAX 1 2 02 MICS UP 9 ALERT 3 TRIGGER EDGE UP LEVEL DN 9 PAX 3 4 OBSR 02 MICS DN 10 ALERT 3 POLARITY POS UP NEG DN 10 COM 7 COM 1 Sidetone DN 11 ALERT 4 TRIGGER EDGE UP LEVEL DN 11 PA SIDETONE DN 12...

Page 16: ...an 2019 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...

Page 17: ...31 No Connection 32 No Connection 32 No Connection 33 No Connection 33 COM1 Sidetone 34 No Connection 34 COM2 Sidetone 35 Pilot Headset 35 UNSW2 36 Copilot Headset 36 UNSW4 37 Observer 1 Headset 37 P...

Page 18: ...rver 1 14 Alert 5 Trigger 14 No Connection 15 Pilot O2 Mic 15 No Connection 16 Copilot O2 Mic 16 NoConnection 17 Observer 1 O2 Mic 17 No Connection 18 Observer 2 O2 Mic 18 No Connection 19 Alert 6 Tri...

Page 19: ...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...

Page 20: ...s 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 ai...

Page 21: ...le 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 indica...

Page 22: ...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 m...

Page 23: ...lect 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 interc...

Page 24: ...se 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 C...

Page 25: ...Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix A Rev 2 Jan 2019 Appendix A PAC45T Installation Drawings Figure 5 1 PAC45T Side View Figure 5 2 PAC45T CTL45...

Page 26: ...com System Installation and Operator s Manual 200 045 5100 Appendix A Rev 2 Jan 2019 CTL45T Top View Figure 5 3 HUB45R Top View P451 P453 J454 J452 1 21 22 43 62 42 1 21 22 43 62 42 1 9 19 26 10 18 19...

Page 27: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix A Rev 2 Jan 2019 J455 Figure 5 5 HUB45R Front View Figure 5 6 HUB45R Side Views...

Page 28: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix D August 2017 Appendix B Radio Interconnect Wiring...

Page 29: ...IO 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 36 57 15 37 58 16...

Page 30: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix C Rev 2 Jan 2019 Appendix D Control Head Interconnect Wiring...

Page 31: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix C Rev 2 Jan 2019 Appendix E Unit Connector Wiring Reference 9 1 P451 Connections...

Page 32: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix C Rev 2 Jan 2019 9 2 J452 Connections...

Page 33: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix C Rev 2 Jan 2019 9 3 P453 Connections...

Page 34: ...PS Engineering PAC45T Audio Selector Panel and Intercom System Installation and Operator s Manual 200 045 5100 Appendix C Rev 2 Jan 2019 9 4 J454 Connections 9 5 J455 Connections...

Page 35: ...udio System Sample ICA Checklist for PS Engineering PAC45T Audio System Section Item Information 1 Introduction Installation of audio control panel with intercommunications system with inte grated aud...

Page 36: ...tegory B Humidity 6 0 Equipment tested to Category A Shock 7 0 Equipment tested to Category B Standard opera tional shock and crash safety Vibration 8 0 Equipment tested to Category SM SB U2FF1 Hel ic...

Page 37: ...Equipment tested to Category B Severe Shock 7 0 Equipment tested to Category B Standard opera tional shock and crash safety Vibration 8 0 Equipment tested to SM SB U2FF1 Helicopter Random Explosion 9...

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