PS Engineering PAC15 User Manual
9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
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Document P/N 200-015-0000
Revision 1, January 2014
Remote-Mounted Audio Controller with
High-fidelity Stereo Intercom
System Installation and Operation Manual
Patented under one or more of the following;
No. 4,941,187; 5,903,227; 6,160,496 and 6,493,450
PS Engineering, Inc. 2014 ©
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 contact@ps-engineering.com.
For use in Experimental/LSA/Non-certified aircraft ONLY
Not intended for installation in aircraft with standard airworthiness certification
The product warranty is not valid unless this product is installed by an
Authorized PS Eng
i
neering dealer.
Table of Contents
Section I – GENERAL INFORMATION1-1
1.1 INTRODUCTION...................................................................................................................... 1-1
1.2 SCOPE ....................................................................................................................................... 1-1
1.3 EQUIPMENT DESCRIPTION ................................................................................................. 1-1
1.4 APPROVAL BASIS — NONE................................................................................................... 1-1
1.5 SPECIFICATIONS.................................................................................................................... 1-2
1.6 EQUIPMENT SUPPLIED......................................................................................................... 1-2
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED.................................................................. 1-3
1.8 LICENSE REQUIREMENTS ................................................................................................... 1-3
Section II - INSTALLATION 2-1
2.1 GENERAL INFORMATION.................................................................................................... 2-1
2.1.1 SCOPE........................................................................................................................ 2-1
2.1.2 CERTIFICATION REQUIREMENTS................................................................................... 2-1
2.2 UNPACKING AND PRELIMINARY INSPECTION............................................................................... 2-1
2.3 EQUIPMENT INSTALLATION PROCEDURES ................................................................................... 2-1
2.3.1 COOLING REQUIREMENTS............................................................................................ 2-1
2.3.2 MOUNTING REQUIREMENTS......................................................................................... 2-1
2.3.3 AUDIO CONTROLLER MOUNTING RACK INSTALLATION................................................ 2-1
2.4 CABLE HARNESS WIRING ............................................................................................................ 2-3
2.4.1 NOISE.......................................................................................................................... 2-3
2.4.2 AUDIO CONTROLLER TRAY AND CONNECTOR ASSEMBLY............................................ 2-4
2.4.3 INPUT POWER .............................................................................................................. 2-4
2.4.4 AUDIO CONTROLLER INTERFACE.................................................................................. 2-4
2.4.5 "SWAP" MODE............................................................................................................. 2-4
2.4.6 UNSWITCHED INPUTS ................................................................................................... 2-4
2.5 INTERCOM WIRING ...................................................................................................................... 2-5
2.5.1 ENTERTAINMENT INPUTS............................................................................................. 2-5
2.5.2 ENTERTAINMENT MUTING............................................................................................ 2-5
2.6 ADJUSTMENTS ............................................................................................................................. 2-6
2.7 MICROPHONE GAIN REDUCTION .................................................................................................. 2-6
2.8 REASSEMBLY............................................................................................................................... 2-7
2.9 COMMUNICATIONS ANTENNA INSTALLATION NOTES .................................................................. 2-9
2.10 PAC15EX PIN ASSIGNMENTS .................................................................................................... 2-9
2.11 POST INSTALLATION CHECKOUT............................................................................................. 2-10
2.12 UNIT INSTALLATION................................................................................................................ 2-10
2.13 OPERATIONAL CHECKOUT ...................................................................................................... 2-10
2.14 FINAL INSPECTION................................................................................................................... 2-11
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page ii Rev. 1, Jan. 2014
Section III OPERATION 3-1
3.1 SCOPE ....................................................................................................................................... 3-1
3.2 POWER AND FAIL SAFE (1)........................................................................................................... 3-1
3.3 COMMUNICATIONS TRANSMIT (XMT) SELECTION (2) ................................................................ 3-1
3.4 COM AUDIO SELECTOR (3) ........................................................................................................ 3-2
3.5 NAVAID AUDIO SELECTION (4)..................................................................................................... 3-2
3.6 INTERCOM OPERATION (8) .......................................................................................................... 3-2
3.6.1 INTELLIVOX® VOX-SQUELCH...................................................................................... 3-2
3.6.2 INTERCOM VOLUME CONTROL (7) ............................................................................... 3-3
3.6.3 INTERCOM MODES (8) ................................................................................................. 3-3
3.7 MUSIC MUTING (9)...................................................................................................................... 3-3
3.7.1 MUSIC 2 MUTE CONTROL............................................................................................ 3-4
Section IV – Warranty and Service 4-1
4.1 WARRANTY ................................................................................................................................. 4-1
4.2 FACTORY SERVICE ...................................................................................................................... 4-1
Appendix B – PAC15EX Installation Drawings .......................................................... A
5.1 REMOTE MOUNTING ......................................................................................................................B
Appendix C – J1 Connector Interconnect A
Appendix D – J2 Connector Interconnect A
Rev Date Change
New October 2012 First Release
1 January 2014 Removed erroneous references
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 1-1 Rev. 1, Jan. 2014
Section I – GENERAL INFORMATION
1.1 INTRODUCTION
The PAC15EX represents another evolutionary step in cockpit audio control and intercommunications
utility. Using our patented IntelliVox® design and pilot programmable configurations, this marks the next
level of audio control. This unit is designed specifically to be used as remote-mounted audio selector/intercom, controlled by specific integrated avionics suites for experimental aircraft.
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 PAC15EX.
1.2 SCOPE
This manual provides detailed installation and operation instructions for the PS Engineering PAC15EXseries of Audio Selector Panel/Intercom Systems. This includes the following unit:
Model Description PS Engineering
Part Number
PAC15EX Remote-mounted Audio Selector Panel with stereo intercom. 050-015-0100
1.3 EQUIPMENT DESCRIPTION
The PAC15EX is a state-of-the-art audio isolation amplifier and audio selector that contains an automatic
voice activated (VOX) intercom system and serial data control by a integrated avioncs controller, such as
an MFD. It can switch two transceivers (Com 1, Com 2) and two receivers (Nav 1, Nav 2).
There are four unswitched inputs, available for traffic or EGPWS, autopilot disconnect tones, and/or radar
altimeter warning.
Remote MFD control can select the communication transceivers for the pilot and copilot position, and
allows radio transmission. In "Split Mode" the PAC15EX has the ability to allow the pilot to transmit on
Com 1 while the copilot can transmit on Com 2. A fail-safe mode connects the pilot headphone and microphone to COM 1 if power is removed for any reason, or if the power switch is placed in the Off (Failsafe) position. Unswitched input #1 is also provided to the pilot headphone in fail-safe
A four-station voice activated (VOX) intercom is included in the PAC15EX. This system has PS Engineering’s patented IntelliVox® circuitry that eliminates manual adjustments. The intercom system incorporates pilot isolate, all and crew modes, two independent stereo music inputs with "SoftMute™".
1.4 APPROVAL BASIS — NONE
The PAC15EX is not intended, or approved for installation on US Registered Civilian Aircraft with
normal airworthiness certificates.
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 1-2 Rev. 1, Jan. 2014
1.5 SPECIFICATIONS
DIMENSIONS: Height: 1.3 in. (3.3 cm) Width: 6.25 in. (16.9 cm)
Depth behind panel 7.15 in. (18.16 cm)
WEIGHT
PAC15EX Unit
Rack with connectors
1.34 lb. (0.61 kg)
0.51 lb. (0.24 kg)
AUDIO CONTROLLER POWER REQUIREMENTS (Including Internal Lighting):
Voltage: 11-33 VDC
Maximum Current: 2.5 Amp (Externally protected by a 3A pull-type
breaker)
Audio Controller Specifications
Audio selector panel input impedance:
510
Input Isolation: -60 dB (min.)
Receiver Inputs: 4 (Com 1, Com 2, Aux 1, Aux 2)
Unswitched Inputs: 4
Transmitter Selections: 3 (Com 1, Com 2,
Com1/2)
Headphone Impedance:
150 – 1000
Headphone Output: 38 mW each headset, no clipping <1% THD typi-
cal into 150
Microphone Impedance:
150 - 600
Intercom Specifications
Intercom Positions: 4 places (with individual IntelliVox® circuits)
Music Inputs:
2, (Independent, Stereo)
Music Muting:
>-30 dB "Soft Mute" when Com or intercom active.
Distortion:
<1% THD @ 38 mW into 150
Mic Freq. Response, 3 dB:
300 Hz - 6000 Hz
Music Freq. Response, 3 dB:
10 Hz – 26 kHz
1.6 EQUIPMENT SUPPLIED
1 ea. of the following items:
Model Description Part Number
PAC15EX PAC15EX Remote-mounted Audio Controller with intercom 050-015-0100
Installation Kit: 250-015-0000, containing:
Description Quantity Part Number
PAC15EX installation rack assembly 1 430-890-0040
PAC15EX Rack back plate 1 430-890-0050
44-pin connector kit 2 120-891-2045
Backshell, connector 2 625-025-2465
Backshell Retainer 2 431-891-0100
4 40 X 7/16 screw w/nylon patch 4 475-440-0007
4 40 X 3/8 screw w/lock washer 4 475-440-1038
4 40 X 1/8 screw w/lock washer 2 475-440-0001
Solder Lug 2 475-009-0001
Cable Clamp 1 625-001-0002
#6-32 x ½” Flat head Philips screw 6 475-632-0012
#6-32 Clip Nut 6 475-630-0002
PAC15EX Horizontal Mounting Flange 2 430-200-0042
PAC15EX Vertical Mounting Bracket 1 430-200-0070
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 1-3 Rev. 1, Jan. 2014
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED
a. Circuit Breaker: 1 ea; 3 amp PULL TYPE REQUIRED for PAC15EX
b. Headphone Jacks (up to 4 Stereo, as Required)
c. Microphone Jacks (up to 4 as Required)
d. Headphones, 150 (Stereo), up to 4 as required
e. Microphones, up to 4 as required
f. Interconnect Wiring, coaxial cable
1.8 LICENSE REQUIREMENTS
None.
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 2-1 Rev. 1, Jan. 2014
Section II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnection instructions for the PS Engineering
PAC15EX Audio Controller with Intercom.
Please read this manual carefully before beginning any installation to prevent damage and postinstallation problems. Installation of this equipment requires special tools and knowledge.
2.1.2 Certification Requirements
NOTE
The PAC15EX is not approved for installation in aircraft with a standard airworthiness certificate.
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 Section 1.6 (B). 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 PAC15EX 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 PAC15EX must be rigidly mounted to the aircraft structure, The unit may be mounted in any area
where adequate clearance for the unit and associated wiring bundle exist.
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.
2.3.3 Audio Controller Mounting Rack Installation
Remove the unit from the mounting tray by unscrewing the 3/32" hex-head screw that is in the center of
the unit. Carefully slide the unit free of the tray. Set the unit aside in a safe location until needed.
The unit can be installed horizontally, with two mounting flanges (430-200-0042), six #6-32 clip nuts
(475-630-0002), and six FHP 6-32 x ½" screws (475-632-0012). to attach the tray to the flanges with the
screw head on the inside of the tray.
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 2-2 Rev. 1, Jan. 2014
Figure 2-1 Horizontal Mounting Flanges
Figure 2-2 Vertical Mounting Bracket
430-200-0042 (x2)
475-630-0002 (x6)
Unit & Tray
430-200-0070
475-630-0002 (x3)
PS Engineering Inc. ®
PAC15EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-015-0000 Page 2-3 Rev. 1, Jan. 2014
The flanges can then be attached to the aircraft structure as appropriate. Refer to FAA AC 43.13-2B,
Chapter 1 and 2 for more information.
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.
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 PAC15EX 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. There must be at least 13.8 VDC present at the connector, J2 pins 8 & 9, of the PAC15EX for the power supply to work in its designed regulation. Otherwise, it
cannot adequately attenuate power line noise. 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 PAC15EX 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 lugs mounted on the center
of the back plate.
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.
430-200-0070
Vertical Mounting Bracket
PAC15EX Unit
430-890-0040
Tray &
430-890-0050
Back Plate
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