Page 1
9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
PAC45
Special Mission Audio Controller System with
MultiTalker™ and IntelliVOX®
Document P/N 200-045-0000
Rev. 7, May 2019
Audio Control System with MultiTalker Technology
High-fidelity Stereo 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
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 contact@ps-engineering.com.
In certified aircraft, warranty is not valid unless this product is installed by an
Authorized PS Engineering dealer.
Page 2
Table of Contents
Section I – GENERAL INFORMATION .................................. 1-1
1.1 INTRODUCTION ............................................................................................................................................ 1-1
1.1.1 LIMITATIONS ........................................................................................................................ 1-1
1.2 SCOPE .......................................................................................................................................................... 1-1
1.3 EQUIPMENT DESCRIPTION ........................................................................................................................... 1-2
1.4 APPROVAL BASIS –PENDING- ........................................................................................................................... 1-2
1.1.2 LIMITATIONS ........................................................................................................................ 1-2
1.5 SPECIFICATIONS ........................................................................................................................................... 1-3
1.6 EQUIPMENT SUPPLIED ................................................................................................................................. 1-4
1.8 CONFIGURATIONS .............................................................................................................................................. 1-7
1.9 LICENSE REQUIREMENTS .............................................................................................................................. 1-8
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 CONNECTOR ASSEMBLY ............................................................................. 2-2
2.4 CABLE HARNESS WIRING ..................................................................................................................................... 2-3
2.4.1 ELECTRICAL NOISE ................................................................................................................. 2-3
2.4.2 POWER ............................................................................................................................... 2-4
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 ............................................................................................................. 2-6
2.4.7 COCKPIT VOICE RECORDER ..................................................................................................... 2-6
2.4.8 AUDIO ALERTS ...................................................................................................................... 2-6
2.4.9 WIRED TELEPHONE/SATELLITE COMMUNICATION INPUT ............................................................. 2-6
2.4.10 MUSIC INPUT ..................................................................................................................... 2-7
2.5 USER ADJUSTMENTS .......................................................................................................................................... 2-7
2.5.1 UNSWITCHED AUDIO LEVEL .................................................................................................... 2-7
2.5.2 ADJUSTMENTS ...................................................................................................................... 2-8
2.5.3 LOGIC SWITCH OPTIONS ......................................................................................................... 2-8
2.6 PAC45 PIN ASSIGNMENTS ................................................................................................................................ 2-11
2.7 WIRING CHECKOUT ......................................................................................................................................... 2-13
2.8 OPERATIONAL CHECKOUT .................................................................................................................................. 2-13
2.8.1 REQUIRED TEST EQUIPMENT ................................................................................................. 2-13
2.8.2 AUDIO CONTROLLER TEST ..................................................................................................... 2-13
2.8.3 BLUETOOTH CHECKOUT ....................................................................................................... 2-13
2.9 FINAL INSPECTION ........................................................................................................................................... 2-14
Section III OPERATION ............................................ 3-1
3.1 SCOPE .......................................................................................................................................................... 3-1
3.2 POWER AND FAIL SAFE ....................................................................................................................................... 3-1
3.3 COMMUNICATIONS TRANSMIT (XMT) SELECTION ..................................................................................................... 3-1
3.4 COM AUDIO SELECTOR ...................................................................................................................................... 3-2
3.4.1 MULTITALKER™ HEAD RELATED TRANSFER FUNCTION (HRTF) .................................................... 3-2
3.4.2 HRTF ON /OFF .................................................................................................................... 3-2
3.4.3 AUDIO LOCATION .................................................................................................................. 3-2
3.5 NAVAID SELECTION ............................................................................................................................................ 3-3
3.5.1 TELEPHONE CONTROL ............................................................................................................ 3-3
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page ii Rev. 7, May 2019
3.6 INTERCOM OPERATION (8) .................................................................................................................................. 3-3
3.6.1 INTELLIVOX® INTERCOM VOX-SQUELCH ................................................................................... 3-3
3.6.2 PUSH TO TALK INTERCOM (PTT ICS) ........................................................................................ 3-4
3.6.3 INTERCOM VOLUME CONTROL ................................................................................................ 3-4
3.6.4 INTERCOM MODES ................................................................................................................ 3-5
3.7 BLUETOOTH® CONNECTION .................................................................................................................................. 3-5
3.7.1 PAIRING AND UNPAIRING BLUETOOTH DEVICES .......................................................................... 3-5
3.7.2 BLUETOOTH® TELEPHONE MODE ............................................................................................ 3-5
3.8 WIRED SATCOM/CELL PHONE INPUT ...................................................................................................................... 3-6
3.9 DUAL CONTROL PANEL OPERATION/PILOT & COPILOT................................................................................................ 3-6
3.10 OBSERVER/MISSION CONTROL PANEL OPERATION .................................................................................................... 3-7
3.11 ALERT AUDIO ................................................................................................................................................... 3-8
3.11.1 STORING ALERT AUDIO ........................................................................................................ 3-8
3.12 INTERCOM OPERATION BLOCK DIAGRAMS ............................................................................................................... 3-1
3.12.1 SINGLE CONTROL PANEL ...................................................................................................... 3-1
3.12.2 DUAL CONTROL HEAD, PILOT CTL45P AND COPILOT CTL45P ................................................... 3-2
3.12.3 DUAL CONTROL HEAD PILOT & COPILOT CTL45P PLUS OBSERVER CTL45M ............................... 3-3
3.12.4 THREE CONTROL HEAD, PILOT CTL45, COPILOT CTL45P AND MISSION OBSERVER CTL45M ......... 3-4
Section IV – Warranty and Service .......................................
4.1 WARRANTY ..........................................................................................................................................................
4.2 FACTORY SERVICE ...................................................................................................................................................
Appendix A – PAC45 Installation Drawings ............................................................. A
Appendix B – Radio Interconnect Wiring B
Appendix C – Intercom Interconnect Wiring ............................................................C
Appendix D – Control Head Interconnect Wiring ..................................................... D
Appendix E, Unit Connector Wiring Reference ......................................................... E
10.1 J451 CONNECTIONS ............................................................................................................................................. E
10.2 J452 CONNECTIONS ............................................................................................................................................. E
10.3 J453 CONNECTIONS ............................................................................................................................................. E
10.4 J454 CONNECTIONS ............................................................................................................................................. E
Appendix F – Instructions for FAA Form 337 and continuing airworthiness ............... F
11.1 INSTRUCTIONS FOR FAA FORM 337, AUDIO CONTROLLERS ............................................................................................. F
11.2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS, AUDIO SYSTEM ................................................................................... F
Appendix G – RTCA DO160G Environmental Qualification Form .............................. G
12.1 MODEL NUMBER PAC45 AUDIO SELECTOR PANEL/INTERCOM REMOTE HUB ..................................................................... G
12.2 MODEL NUMBER CTL45, AUDIO SELECTOR CONTROL PANEL ......................................................................................... G
Rev
Date
Change
New
May 2017
Initial Draft Manual
1
June 2017
Release for TSO Submittal
2
July 2017
Production-TSOA Release
3
February 2018
Change part number on 26-pin connector housing §1.6
Added PA PTT output (S/N Gxxxx and above)
4
June 2018
Added detail on power consumption §1.5, clarification of DIP switch logic settings §2.5.3
5
August 2018
Added Receive Indication Function (-RXI) and updated installation kits.
Correct PAX 5 & 6 connections
6
November 2018
Updated dimming adjustment (Configuration Level BBGAA and up)
7
May 2019
Redesignate transmit seats from Pass 1 & 2 to Observer 1 & 2 in wiring diagram
Update §2.5.3.6 for DIP Sw 10
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-1 Rev. 7, May 2019
Section I – GENERAL INFORMATION
1.1 INTRODUCTION
The PAC45 represents a revolutionary step in cockpit audio control and intercommunications
utility. MultiTalker™, using licensed U.S. Air Force patented technology, provides True Dimensional Sound, helping pilots to more easily discern from simultaneous radio receptions. Our patented IntelliVOX® design, programmable MultiTalker™ and alert configurations, 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 PAC45.
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.
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
PAC45-series of Audio Selector Panel/Intercom Systems. This includes the following units:
Model
Number
Description
PS Engineering
Part Number
NVIS Compatible
Part Number
PAC45
Panel-mounted Audio Control System with
dual CVR outputs, Includes integrated control head and Audio Hub, with standard
bezel label, includes install kit 250-045-0100,
qty. 2, 26 pin connectors.
050-045-0001
050-045-6001
PAC45
Panel-mounted Audio Control System with
single CVR and speaker out, Includes integrated control head and Audio Hub, with
standard bezel label, includes install kit 250045-0100, qty. 2, 26 pin connectors.
050-045-0002
050-045-6002
HUB45R
Remote-mounted Audio Hub for analog I/O
and processing with dual CVR
050-045-0100
N/A
HUB45R
Remote-mounted Audio Hub for analog I/O
and processing with single CVR and speaker
out
050-045-0102
N/A
CTL45P
Panel Mounted Control Head for Flight Crew
050-045-0200
050-045-6200*
CTL45M
Panel-mounted Control Head for Mission
Personnel
050-045-0300
050-045-6300*
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-2 Rev. 7, May 2019
PAC45 Optional Install
Kit
For installs that are not replacing “third
party” audio controllers, includes 50 & 37
pin connectors/hardware.
250-945-0500
Label45
Customizable bezel label program
575-045-XXXX
1.3 EQUIPMENT DESCRIPTION
The PAC45 is a state-of-the-art audio isolation amplifier and audio selector that contains an automatic voice activated (VOX) intercom system. It can switch six transceivers (Com 1 - 6) and six
receivers (Nav 1, Nav 2, MKR, and three additional inputs that can be individually labeled, for
use with ADF, DME, AUX, etc.).
There are four unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or
radar altimeter warning.
A wired input is available for Satellite or Cellular telephone.
In addition, three field programmable alerts can be triggered by external sources to provide additional capability.
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 PAC45. This system has PS Engineering’s patented IntelliVOX® circuitry that eliminates manual adjustments. The intercom sys-
tem incorporates pilot isolate, all and crew modes, a stereo music input with "SoftMute™".
In the PAC45, a Bluetooth® wireless interface is available for wireless telephone and music connection.
1.4 APPROVAL BASIS FAA TSO
FAA TSO The PAC45-series Audio Selector Panels is FAA authorized under TSO C139A (Audio
Amplifiers). ED-14C/DO-160G (Environmental Conditions and Test Procedures for Airborne Equip-
ment), ED12B/DO-178C, Level D (Software Considerations for Airborne Equipment) and ED18/DO-214A (Audio Systems Characteristics and Minimum Operational Performance Standards
for Aircraft Audio Systems).
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.
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.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-3 Rev. 7, May 2019
1.5 SPECIFICATIONS
TSO COMPLIANCE
Audio Selector/Intercom:
FAA TSO-C139A
APPLICABLE DOCUMENTS:
RTCA/DO-214A
RTCA/DO-160G
RTCA/DO-178C
ENVIRONMENTAL Qualifications:
A1D1BABSXXXXXXZBABZATTMA3J33XXA
Temperature Range:
Operating:
Short Term Operating:
Survival:
-20º C to +55ºC
-20°C to +70°C
-55º C to +85ºC Cold soak to –40˚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 (PAC45): 7.38 in. (18.75 cm) including connectors
UNIT WEIGHT
PAC45 -001
HUB45
CTL45
2.0 lb. (0.90 kg)
1.0. (.45 kg)
1.0. (.45 kg)
POWER REQUIREMENTS :
Voltage:
18 to 33 VDC
Maximum Current:
Typical
Alert Power
Lighting
0.5 Amp (Externally protected by a 1 Amp circuit
breaker.)
PAC45 (Hub + CTL mated): 500mA
HUB45 only 350 mA
10 mA
CTL45 only: 150 mA
< 5mA
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-4 Rev. 7, May 2019
Audio Selector Specifications
Audio selector panel input impedance:
510
Input Isolation:
-60 dB (min.)
Switched Receiver Inputs:
11 (COM 1– COM 6, TEL, NAV 1, NAV 2, Marker, ADF)(Can be
relabled as desired)
Unswitched Inputs:
4
Transmitter Selections:
7 (COM 1, COM 2, COM 3, COM 4, COM 5, COM 6 plus Telephone) (Can be relabled as desired)
Headphone Impedance:
150 – 1000
Headphone Output:
100 mW into 150 each side (left and right) headset, no clipping <.5% THD typical
Speaker Output (-0002 & -0102 only)
3 V
rms
Maximum
Microphone Impedance:
150 - 600
PA Output
1 Vrms into 500Ω
Bluetooth Radio
Class 3, FCC ID QOQWT32AE
Intercom Specifications
Intercom Positions:
Up to 8 places (with individual IntelliVOX® circuits)
Music Inputs:
1 ( Stereo) plus Bluetooth
Music Muting:
>-30 dB "Soft Mute" when Com or intercom active.
Distortion:
<1% THD @ 100 mW into 150
Mic Freq. Response, 3 dB:
300 Hz - 6000 Hz
Stereo Music Freq. Response, 3 dB:
20 Hz – 16 kHz
1.6 EQUIPMENT SUPPLIED
The following units comprise the PAC45 System:
Model
Description
Standard
Part Number
NVIS Compatible
Part Number
PAC45
Single Panel-mounted System (HUB45 and CTL45P)
050-045-000X
050-045-600X
or
HUB45R
Remote-mounted Audio Hub for analog I/O and
processing
050-045-010X
N/A
CTL45P
Panel-mounted Control Head for Flight Crew
050-045-0200*
050-045-6200*
CTL45M
Panel-mounted Control Head for Mission Personnel
050-045-0300*
050-045-6300*
.*The part numbers shown are for “Standard” bezel label nomenclature. Custom bezel nomen-
clature is available, using the custom configuration program at:http://www.ps-
engineering.com/PAC45_custom_legend.shtml
PAC45 Standard Installation Kit 250-945-0500 (37 & 50 Pin)
Description
PSE Part Number
Qty.
Manufacturer
MFR Part
Number
50 pin connector backshell
625-050-1728
1
Amphenol
17E-1728-1
37 pin connector backshell
625-037-1727
1
Amphenol
17E-1727-1
Thumbscrew 4-40x1.94
475-002-0002
4
Lanpar Technologies, Inc.
B71E014256
Standard Density Female
Sockets
425-020-5090
50
Deutsch
M39029/63-368
50 Pin Female Conn, Housing
425-050-0967
1
Harting
09670504701
37 Pin Female Kit Connector
w/Pins
425-037-1757
1
TE Connectivity
1757820-9
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-5 Rev. 7, May 2019
PAC45 Retrofit Installation Kit: 250-045-0100
Description
PS E
Part Number
Quantity
Manufacturer
MFR Part Number
D-Sub housing 9 pin female
425-009-7709
1
Amphenol
L177-RR-E-09-S
D-sub Pins Male
425-020-5089
9
Deutsch
M39029/64-369
D-sub Pins Female
425-020-5090
9
Deutsch
M39029/63-368
D-Sub housing 26 pin female
425-026-1800
2
NorComp
180-026-273L000
Socket contact 22-28 AWG
425-030-7354
52
Amphenol
M39029/57-354
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
Deutsch
M39029/64-369
Backshell DB9
625-009-1724
1
Amphenol
17E-1724-1
Thumbscrew
475-002-0002
2
Lanpar Technologies,
Inc.
B71E014256
HUB45 Installation Kit 250-945-0100
Description
PS E
Part Number
Quantity
Manufacturer
MFR Part Number
15/26 pin connector backshell
625-015-1725
2
Amphenol
17E-1725-1
DB26 Female Connector HD
425-026-1800
2
NorComp
180-026-273L000
Female Socket
425-030-7354
52
Amphenol
M39029/57-354
Thumbscrew
475-002-0002
2
Lanpar Tech-
nologies, Inc.
B71E014256
Slide Lock Post*
475-045-6514
4
TE
5206514-6
*See §2.3.4
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-6 Rev. 7, May 2019
Remote Mount HUB45R retrofit Installation Kit 250-045-0300
Description
PS E
Part Number
Qty.
Manufacturer
MFR Part Number
9-Pin Male D-Sub Housing
425-009-0777
1
Amphenol
L777-RR-E-09-P
D-Sub male pins
425-020-5089
9
Deutsch
M39029/64-369
9-Pin D-Sub Female Housing
425-009-7709
1
Amphenol
L777-RR-E-09-S
D-Sub Female sockets
425-020-5090
9
Deutsch
M39029/64-368
Remote Mounting Flange LEFT
430-045-0120
1
PS Engineering
Remote Mounting Flange RIGHT
430-045-0125
1
PS Engineering
4-40 x 3/16” Phil-Pan w/EXT Star
Washer
475-440-0500
8
4-40 x 3/16” Phil-Flat Gold + Patch
Counter Sunk
475-442-2001
12
Connector Backshell DB9 Plastic
MODIFIED
625-009-1724
1
PS Engineering
Connector Backshell DB9 Plastic NONMODIFIED
625-009-1724
Thumbscrew
475-002-0002
2
Lanpar Technologies, Inc.
B71E014256
EQUIPMENT REQUIRED BUT NOT SUPPLIED
a. Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45, .05 A for CTL45s
b. Optional Circuit Breaker: 0.5 ea.; 1 amp PULL TYPE REQUIRED for PAC45 aural alerts
c. Headphone Jacks (Stereo, as Required)
d. Microphone Jacks (as Required)
e. Headphones, 150 (Stereo), as required
f. Microphones, as required
g. Interconnect Wiring
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-7 Rev. 7, May 2019
1.8 Configurations
The PAC45 System is comprised of three “building blocks” to facilitate flexibility as well as simplicity.
The simplest, single audio controller system is a PAC45 where the audio hub is attached to the
control head.
Figure 1-1 Single panel configuration
A second control head can be added, wired into the PAC45 either for a copilot (CTL45P) or as an
observer instead of a copilot, CTL45M.
Figure 1-2 Two control head configurations
The system is capable of supporting a total of three control heads, pilot, copilot and observer.
One control head can be attached to the audio hub (HUB45) or all three can be remote
mounted.
CTL45P
HUB45
CTL45P
HUB45
CTL45P
PILOT AND COPILOT CONTROL HEADS
PILOT/COPILOT and MISSSION
CONTROL HEADS
CTL45P
HUB45
CTL45
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 1-8 Rev. 7, May 2019
Figure 1-3 Three control head configurations
1.9 LICENSE REQUIREMENTS
None
PAC45 Bluetooth™ Radio approval:
• FCC ID: QOQWT32AE
• Industry Canada ID: 5123A-BGTWT32AE
• CE EMC Directive 89/336/EEC as amended by Directives 92/31/EEC and 93/68/EEC
NOTE
Unauthorized use of unapproved cellular telephone devices in aircraft is subject to FCC enforcement 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 (not touching the ground). When any aircraft leaves the ground, all cellular telephones on board that aircraft must be turned off.
PS Engineering, Inc. does not endorse using unapproved cellular telephone equipment in flight,
and takes no responsibility for the user’s action.
PS Engineering does not guarantee compatibility with personal cellular telephones.
CTL45P
HUB45
CTL45P
CTL45M
CTL45P
HUB45
CTL45P
CTL45M
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-1 Rev. 7, May 2019
Section II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnection instructions for the PS Engineering PAC45 Audio Selector Panel/Intercom.
Please read this manual carefully before beginning any installation to prevent damage and postinstallation 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 PAC45 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 2041A 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 PAC45 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 PAC45 must be rigidly mounted to the instrument panel of the aircraft structure, within
view and reach of the pilot position(s). The PAC45/CTL45 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.
To prevent noise, avoid installing the unit close to high current devices or systems with highvoltage pulse type outputs, such as DME or transponders. Avoid running the interconnecting
bundles near any high current wires.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-2 Rev. 7, May 2019
2.3.3 Audio controller Connector Assembly
The LRU connectors mate with one 50-pin, one 37-pin, and two 26-pin connectors in the PAC45.
The connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from table below (or equiv.).
Figure 2-1 - PAC45 Connector Layout
NOTE: The 50-pin and 37-pin connectors are pin-compatible with most NAT AMS-series and Jupiter JA95-series audio controllers. Refer to the connector pin maps to confirm compatibility.
The two 26-pin connectors are used to give the PAC45 systems added capability.
The PAC45 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
Daniels
AFM8
K42
M24308-1
ITT-Cannon
995-0001-584
995-0001-739
91067-1
Table 2-1 Connector Pin crimping tools
2.3.4 Thumbscrew and Slide Lock (AMS compliant) connector assembly
Existing installation may utilize slide-locking mechanisms on their connectors. PS Engineering
has included slide lock posts with the 26-pin connector kits for your convenience.
You can remove the 5mm hex standoffs from the 37 and 50-pin connectors and replace with the
5mm post to keep the existing connectors. Picture below shows slide lock post installed.
PS Engineering recommends that Loctite #425 be added to any thumbscrew that is removed and
reinstalled. Loctite #425 is added to the thumbscrew threads at the factory.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-3 Rev. 7, May 2019
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, MIL-spec 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 PAC45 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 PAC45 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.
2.4.1.1 Music Input and Noise
PAC45 units utilize a differential ground input to help prevent noise from entering the audio system. This feature is usually transparent to the installer; however, it is important that the appropriate music signal and ground connections are made directly to the dedicated music signal and
ground inputs on the PAC45. The power for IFE and audio controller should be a common bus.
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PAC45 Audio Selector Panel and Intercom System
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200-045-0000 Page 2-4 Rev. 7, May 2019
NOISE NOTE
Adding a high-performance audio control system, particularly in conjunction with high-performance active noise canceling headsets, cannot improve on older avionics that were designed for
cabin-speaker use. PS Engineering makes no claim that the audio controller will provide a noisefree audio quality under all installation conditions, particularly with older avionics.
2.4.2 Power
The PAC45 is compatible with 28 Volt DC systems. A one (1) Amp circuit breaker is required for
all installations. Power and ground wires should be #22AWG connect 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 damage the units
2.4.2.1 Alert power, P451 Pin 16,
The PAC45 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 16.
When power to P451-16 is present, the message will play three times or until the remote
acknowledge is selected.
2.4.3 Audio controller interface
The PAC45 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.
2.4.3.1 Navaid wiring and selection
The PAC45 has NAV 1, NAV 2, and three additional auxiliary navaid inputs for ADF, DME, etc. The
three auxiliary audio inputs on P452 pins 9, 10 and 11 will be presented with the center audio
control on the bottom row is selected.
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PAC45 Audio Selector Panel and Intercom System
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200-045-0000 Page 2-5 Rev. 7, May 2019
2.4.3.2 Hand microphone
The PAC45 system can support six passenger intercom stations, in addition to the pilot and copilot. The input to the PAC45 P451 6, 23, 40 can be used as a hand mic, or as passenger 6, with
transmit capability on the selected radio.
The hand microphone transmitter selection is as follows:
Configuration
Hand Microphone connected to
Single Control Head
Selected radio
Two Control Heads
Copilot selected radio
Three Control Heads
Observer selected radio
Passenger 2 (Observer 2) can use this hand mic as a transmit seat.
2.4.3.3 Passenger 5 and 6
Passenger 6 is an intercom station input on P454-16 wrt 25.
The headphone outputs 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 PAC45
can be installed monaurally by using the LEFT audio connections only (left side contains Fail-Safe
audio). Do NOT short left and right headphone outputs together.
NOTE: Mono headsets that short the tip and ring (i.e. older models) may introduce audio dis-
tortion when used. Modern, stereo headsets are recommended in all positions.
2.4.4 Transmit Interlock
Some communications transceivers use a transmit-interlock system. To fully utilize the multiuser transmit capability, this function must be disabled. Consult the radio manufacturer's installation manual.
2.4.5 Backlighting
Control of the unit backlighting is through the aircraft avionics dimmer Connect P452 Pins 19 to
the aircraft dimmer bus. All control heads dimming is control by the HUB. The audio controller
can be configured for either 5VDC or 28V dimmer installations. The default setting is 28V from
the factory. The ratio of white to green indicator intensity is adjustable, see §2.5.2.1.
Units with configuration status BBGAA and above:
The green/white pot has been changed, and now works as follows:
By default, adjustments to the pot change the minimum trip point for the dimmer input to full
bright. The pot permits adjustment from 0V to nominal dimmer voltage (28V or 5V depending
on configuration).
A long press (3 seconds) of HRTF and ACK on pilot panel will cause the #2 potentiometer to adjust 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 pressed at any time to exit (if you want to adjust green but not white for example)
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-6 Rev. 7, May 2019
2.4.6 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 510Ω inputs can be used for altimeter
DH audio, GPS waypoint audio, autopilot disconnect tones, or any other critical audio signal.
Unswitched #1 is always presented to the crew headphones, and is available to the pilot in failsafe (off) mode.
Unswitched
Input
Input Pins
Hear in
Fail Safe
Hear in
Crew Headset
Adjustable at
installation
1
P452 - 13 WRT 32
Yes
Yes
Yes
2
P452 - 1 WRT 20
No
Yes
Yes
3
P454 - 14 WRT 23
No
Yes
Yes
4
P454 - 13 WRT 22
No
Yes
Yes
Table 2-2 Unswitched inputs
2.4.7 Cockpit Voice Recorder
The PAC45 audio controller contains a Cockpit Voice Recorder output for the pilot and copilot.
Pilot CVR output is P454-12; Copilot CVR output is P454-2, both with respect to CVR low, P454
21
The CVR output is consistent with RTCA DO-214A §1.5.7,
2.4.8 Audio Alerts
The PAC45 contains an independent audio alerting systems that will play up to three alert audio
messages that can be stored by the user (see §3.11.1).
The alert system has a power input (P451-16) that will keep the systems operable if the PAC45
systems power source is removed. Alert audio is provided in Fail-safe when power is on P451-
16.
Alert Input
Input Pins
1
P451 – 11
2
P451 – 12
3
P451 – 13
Alert Power
P451 – 16
Remote
Acknowledge
P454-9
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 front panel Acknowledge button (ACK)
is pressed (or the remote ACK P454-9 grounded).
Alerts with level trigger will play three times or until the front panel Acknowledge button (ACK)
is pressed (or the remote ACK P454-9 grounded), or the input level reverts.
When power is applied to the alerts and not the PAC45 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.
2.4.8.1 Remote ICS mode control.
When a momentary, normally open, push-button switch is connected between pin P454-18 and
ground, it will change the intercom mode on the Pilot’s PAC45.
2.4.9 Wired Telephone/Satellite Communication input
The PAC45 can accommodate a wired cell phone interface on P454 Pins 17, 26 and 7.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-7 Rev. 7, May 2019
Both Bluetooth and wired Telephone and be accommodated, however, only ONE can be active
at a time.
Low impedance satellite phones might require a tactical radio adapter, PS Engineering P/N
12100.
2.4.10 Music Input
NOTE
Use the low- level output of any additional Music device to connect to the audio controller. Maximum signal level is 3 VAC p-p. DO NOT use a speaker -level
output, this will cause internal damage in the audio controlle r.
CAUTION
Local oscillators and internal signals from Music equipment can cause undesired 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)
PAC45 systems (HUB45 Serial Number DH1069 and above) have a Receive Activity Indicator that
flashes the selected receiver indicator when a signal is present on that receiver. This function is
set at the factory at the installer’s request, and can only be changed at the factory.
2.5 User Adjustments
The PAC45 is factory set for typical installation. However, several installation adjustments
are available. No computer is required.
2.5.1 Unswitched Audio Level
Unswitched inputs one through four are installation adjustable through the side of the
PAC45 unit.
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-8 Rev. 7, May 2019
2.5.2 Adjustments
On the side of the PAC45/HUB45R are six adjustment potentiometers.
1. Alert volume (adjusts the level of the internal audio alerts and annunciations
generated by the PAC45)
2. White & Green text backlight level adjust (see §2.5.2.1)
3. Unswitched input 1 volume
4. Unswitched input 2 volume
5. Unswitched input 3 volume
6. Unswitched input 4 volume
2.5.2.1 Green and White lighting adjustment
The #2 potentiometer adjusts the white intensity by default.
The green indication level can be adjusted to match the white level or for user preference. This
should be done before adjusting the white, as setting the green will overwrite the white setting.
1. Hold the ACK and HRTF buttons at the same time until a chime is heard in the headset.
2. Adjust the #2 potentiometer (see §2.5.2, above).
3. Push ACK to exit the green adjust mode, and return to white adjustment.
4. Adjust the white text lighting as desired with #2 potentiometer.
2.5.2.2 Green and White lighting adjustment (Configuration BBGAA)
Units with Configuration BBGAA and above, the dimming has been modified to set a
minimum level:
• By default, adjustments to the pot change the minimum trip point for the 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 HRTF 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 HRTF and ACK on pilot panel will adjust the
white level
• Another long press (3 seconds) of HRTF and ACK to exit
• Also, ACK can be pressed at any time to exit (if you want to adjust green but not
white for example)
2.5.3 Logic Switch Options
The PAC45 has several switches accessible through the side of the HUB45 to set specific functions
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-9 Rev. 7, May 2019
Power must be cycled after selections are completed.
1-3: Alert polarity (ground or voltage trigger)
4-6: Alert type (edge or trigger)
7: Dimmer mode (5VDC or 28VDC)
8: Mic sensitivity (High noise applications)
9: Passenger HRTF enable (MultiTalker™ audio)
10: Offside Transmit Mute
11: Copilot Control Head installed
12: Passenger Control Head installed
12 11 10 9 8 7 6 5 4 3 2
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-10 Rev. 7, May 2019
2.5.3.1 Alert Trigger Logic (1 – 3)
Switches 1-3 set alert logic. DOWN for active high, UP for active low.
2.5.3.2 Alert Trigger Type (Switches 4 – 6)
Switches 4-6 set alert type. UP for level triggered, DOWN for edge
triggered.
As shown: Alert 1 Edge Triggered, Alerts 2-3 Level Triggered (default
from factory)
2.5.3.3 Back light dimmer voltage (Switch 7)
Switch 7 sets dimmer mode. UP for 5V, DOWN for 28V
As shown: 28V dimmer (default from factory).
2.5.3.4 Microphone Sensitivity (Switch 8)
Switch 8 sets mic sensitivity. UP for low noise (standard), DOWN 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 transmits on the radio. This allows other crewmembers to
listen to other radios while one trasmits. (shipped from factory in this mode. Serial
Number DH01069 and above).
NOTE: This may result in crosstalk if multiple radios are tuned to close frequencies.
2.5.3.7 Copilot Control head (Switch 11)
Switch 11 indicates that a CTL45P is installed as a copilot control head.
UP for copilot CTL45P not installed, DOWN for copilot control head present.
2.5.3.8 Mission/Observer Control head (Switch 12)
Switch 12 indicates that a CTL45M is installed as the Observer/Mission control
head.
UP for CTL45M not installed, DOWN for observer/mission position control head
present.
As shown: Observer Control Head in System
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
P
UP
12 11 10 9 8 7 6 5 4 3 2 1
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-11 Rev. 7, May 2019
2.6 PAC45 Pin assignments
P451
P452
Pin
FUNCTION
PIN
FUNCTION
1
COM2 KEY
1 UNSWITCHED AUDIO 2
2
COM1 KEY
2 COM 2 AUDIO HI
3
COM3 KEY
3 COM 1 AUDIO HI
4
COM4 KEY
4 COM 3 AUDIO HI
5
COM5 KEY
5 COM 4 AUDIO HI
6
OBSERVER PAX 6/HAND MIC KEY
6 COM 5 AUDIO HI
7
PILOT MIC KEY
7 NAV 1 AUDIO HI
8
COPILOT MIC KEY
8 NAV 2 AUDIO HI
9
PILOT ICS PTT
9 ADF 1 AUDIO HI*
10
COPILOT ICS PTT
10
ADF2 AUDIO HI*
11
ALERT 1 TRIGGER
11
DME AUDIO HI*
12
ALERT 2 TRIGGER
12
MKR AUDIO HI
13
ALERT 3 TRIGGER
13
UNSWITCHED AUDIO 1
14
PA MIC OUTPUT HI
14
MUSIC LEFT HI
15
PA MIC LO
15
MUSIC RIGHT HI
16
ALERT POWER
16
NO CONNECTION
17
AIRCRAFT POWER
17
COPILOT PHONES (L) HI
18
COM2 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
PAX 4 MIC AUDIO
29
ADF 2 AUDIO LO
30
PAX 1/OBSERVER HP OUT
30
DME AUDIO LO
31
PAX 2 HP OUT
31
MKR AUDIO LO
32
PAX 3 HP OUT
32
UNSWITCHED AUDIO 1
33
PAX 4 HP OUT
33
MUSIC LEFT LO
34
AIRCRAFT GND
34
MUSIC RIGHT LO
35
COM 2 LO
35
NO CONNECTION
36
COM 1 LO
36
COPILOT PHONES LO
37
COM 3 LO
37
PILOT PHONES LO
38
COM 4 LO
39
COM 5 LO
40
PAX 6/HAND MIC LO
41
PILOT MIC LO
42
COPILOT MIC LO
43
PAX 1 MIC LO
44
PAX 2 MIC LO
45
PAX 3 MIC LO
46
PAX 4 MIC LO
47
PAX 1 PHONE LO
48
PAX 2 PHONE LO
49
PAX 3 PHONE LO
50
PAX 4 PHONE LO
*Audio presented on same switch/volume control
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-12 Rev. 7, May 2019
P453 P454
1
SERIAL TX2-
1 PA KEY (S/N CHB0XXX
and up)
2
SERIAL TX2+
2 COPILOT CVR/Low Level
SPR out (-0102 only)
3
PAX 5 ICS PTT
3 PAX 6 ICS PTT
4
PAX1 ICS PTT
4 NC 5 PAX2 ICS PTT
5 NC 6 PAX3 ICS PTT
6 NC 7 PAX4 ICS PTT
7 TEL MIC AUD
8
COM 6 KEY
8 SWAP
9
PAX 1 MIC KEY
9 ACKNOWLEDGE
10
SERIAL TX3 -
10
COPILOT HP RT
11
SERIAL RX2 -
11
PILOT HP RT
12
SERIAL RX2 +
12
PILOT CVR OUT
13
PAX 1 HP RT
13
UNSW 4 AUD IN
14
PAX 2 HP RT
14
UNSW 3 AUD IN
15
PAX 3 HP RT
15
COM 6 AUD IN
16
PAX 4 HP RT
16
PAX 5 MIC AUD
17
COM 6 MIC HI
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
COM 6 AUD LOW
25
PAX HP LOW
25
PAX 5 MIC AUD LOW
26
COM 6 MIC LOW
26
TEL AUD LOW
Table 2-3: PAC45 Pin Assignments
NOTE: Serial TX2 for Copilot Control Head, TX 3 for Mission Observer Control Head
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 2-13 Rev. 7, May 2019
2.7 Wiring Checkout
After wiring is complete, verify power is ONLY on pin 16 &17 of J451and airframe ground on pin
34. Failure to do so will cause serious internal damage and void PS Engineering's warranty.
CAUTION: Do not connect or disconnect (HOT SWAP) any components with power applied, this
will damage the units
2.8 Operational Checkout
2.8.1 Required Test Equipment
In order to return an aircraft to service after installation of the PAC45, 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.
Use of a Stereo headset is required to obtain full effect of MultiTalker processing.
1. Apply power to the aircraft and avionics.
2. Plug stereo headsets into the pilot, copilot, and occupied passenger positions, or monaural
if not using HRTF feature.
3. Verify fail-safe operation by receiving and transmitting on com 1 from the pilot position,
with the audio controller power off /EMG mode. The Com audio will be present in one ear
cup only if stereo headset and both ear cups if using monaural headsets.
4. Switch on the unit by turning the XMT select knob to the full CCW position (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 copilot position, noting that the copi-
lot PTT switch allows proper transmission on the selected transceiver. Verify that the Xmt
legend flashes green when the copilot is transmitting.
8. Rotate the XMT knob to the next transceiver position and verify the indicators change to
track the selection, and Com 2 receiver is heard.
9. Repeat for remaining transceivers.
10. Verify proper operation of all receiver sources by selecting them using the appropriate knob.
11. Verify proper Intercom system operation in the ALL, ISO and CREW modes (see Table 3-1).
12. Verify that the audio selector panel system does not adversely affect any other aircraft sys-
tem by systematically switching the unit on and off, while monitoring the other avionics and
electrical equipment on the aircraft.
2.8.3 Bluetooth Checkout
Verify that the PAC45 will “pair” with a Bluetooth device, and interface with cellular phone and
Music source. See § 3.7.2 for more information.
If PAC45 is not connecting, resetting the Bluetooth memory might be required. Hold down HRTF
& ICS buttons for 3 seconds until there is a chime in pilot headset.
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2.8.3.1 TEL Checkout
Pair the PAC45 with a Bluetooth telephone device. Verify that the pilot headset is connected to
the cellular telephone system (if installed). The telephone function will allow any person heard
by the pilot on the intercom, also heard on the telephone.
To make or receive a phone call, you must press the TEL switch in the OUT position on the audio
controller panel and verify the volume is turned to an acceptable volume.
The PAC45 has the ability to turn the telephone audio completely off by turning the TEL volume
knob all the way CCW.
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.
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-1 Rev. 7, May 2019
Section III OPERATION
3.1 SCOPE
This section provides detailed operating instructions for the PS Engineering PAC45, 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 PAC45 systems.
They are Communications Transceiver Selection, Audio Selector, Intercom, and special functions, including the Bluetooth® functionality in the PAC45.
COM 4COM 1 COM 2 COM 3 COM 5 COM 6
TEL ADF MKR
COM 4
COM 1
COM 2
COM 3
COM 6
PA
COM 5
COM
RECEIVER
SELECTION
& VOLUME
TRANSMIT
SELECTION
RECEIVER
SELECTION & VOLUME
NAVAID
RECEIVER
SELECTION
& VOLUME
Intercom
volume
Control
Push for PTT
ICS
Multi-Talker
Selection
ACKNOWLEDGE
INTERCOM
MODE
SELECTOR
Telephone
selection and
volume
Figure 3-1 PAC45 Operating Controls
3.2 Power and Fail Safe
Unit power is controlled by the transmitter (XMT) selector knob. In the "EMG" or OFF (fully
clockwise) position, 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 failsafe 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.
3.3 Communications Transmit (XMT) Selection
The PAC45 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 six available.
The radio is automatically selected to receive incoming radio calls when the XMT is selected.
With a PAC45, 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.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
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200-045-0000 Page 3-2 Rev. 7, May 2019
3.4 COM Audio Selector
The communications receiver audio sources are controlled by a combination push on-push-off
switch/volume control. Communication audio from another radio, not selected for transmit, can
be heard by pressing 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 com 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.
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. “MultiTalker” (US Patent #7,391,877) specifies up to nine loca-
tions. This helps the crew to better comprehend speech by locating it in a manner more easily
differentiated by the human brain.
Intercom and other audio is not spatially processed, only the six communications transceivers.
NOTE: YOU MUST USE STEREO HEADSETS, IN STEREO MODE FOR THIS FEATURE.
This adjustment allows the six Spatial Audio inputs to be “relocated” on any of nine (9) pre-de-
fined “Head Related Transfer Function” (HTRF) locations.
MultiTalker places the communications receiver audio in one of nine apparent locations in the
crew’s headset. This has been scientifically shown to allow the brain to focus on multiple conversations and improve comprehension for the listener.
3.4.2 HRTF On /Off
Pressing the HRTF button toggles
the PAC45 MultiTalker spatial function on in stereo headset, (receiver
sources distributed) or off (receiver
audio sources neutral).
3.4.3 Audio Location
The pilot panel can control the locations
for the six receive audio locations. Press
and hold the HRTF button for > 1 second
on the pilot’s panel until the HRTF button
and all COM nomenclature start blinking
green.
Rotate the COM receive volume knob so
the pointer indicates the approximate location of the desired location. A voice
announcement will accompany the knob
rotation with the clock positions. Received audio shall then be presented from that location. Repeat for other communication radios
as desired.
Figure 3-2 Spatial Audio Locations and Voice Annunciations
Press the HRTF button again to exit the mode. The audio Controller will remember last state
through power cycles.
HRTF REQUIRES Stereo
Headsets. If monaural headsets are used, the received au-
dio will sound “distant” or
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-3 Rev. 7, May 2019
3.4.4 Receiver Activity Indication (-RXI)
PAC45 systems (HUB45 Serial Number DH1069 and above) have a Receive Activity Indicator that
flashes the selected receiver indicator when a signal is present on that receiver. This allows the
user 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.
3.5 Navaid Selection
Navigation receivers are selected in the same manner
as the communication receiver, push on/push off the
knob associated with the desired navigational aid,
and rotate to adjust the receiver volume.
3.5.1 Telephone control
The volume control selector connects the audio controller to either a Bluetooth-enabled cell
phone or a wired cellular/satellite phone.
Push to pop out the volume control to select (answer or make phone call) and
adjust the receive audio volume.
To hear the ringer of the Bluetooth phone, the volume control should be around
the 12 o’clock position. Selecting the TEL switch in the OUT position is not required for Bluetooth connections, but will be required if TEL is being used for satellite phone.
3.5.2 Speaker Control (PAC45 050-045-0002, HUB45R 050-045-0102 only)
Press and hold the ICS button on either to pilot or copilot control head to toggle the
output ON/OFF. When the speaker output is “ON”, all alerts, unswitched inputs and all
switched inputs selected by the pilot will be present. Intercom, telephone and music
will never be present.
When the speaker output is “OFF”, only alerts and unswitched inputs will be present
3.6 Intercom Operation (8)
3.6.1 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.
For optimum microphone performance, PS Engineering recommends installation of a Microphone Muff Kit from Oregon Aero (1-800-888-6910). This will not only optimize VOX performance, but will improve the overall clarity of all your communications.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-4 Rev. 7, May 2019
Manufacturer
Model
Mic Muff™ Part Number
Bose
Dynamic
Electret
M87 Dynamic
90010
90015
90020
David Clark
H10-30
H10-20, H10-40
H10-13.4
90010
90015
90015
Lightspeed
All
90015
Peltor
7003
7004
90010
90015
Pilot
11-20 & 11-90
90015
Sennheiser 90015
Telex
Airman 750, Echelon
AIR3000
90015
90010
Table 3-1 Mic Muff ™ Part Numbers
3.6.2 Push to talk intercom (PTT ICS)
Pressing the intercom volume knob (ICS VOL) will place the system (all headsets) into the Pushto-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 and the systems (all headsets) toggles back to voice activation. The mode is shown by the green indication in the text.
3.6.3 Intercom Volume Control
The intercom 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.
In a single control panel installation the volume control adjusts pilot, copilot, and
any passengers.
In 2-control (pilot & copilot) panel installation, the pilot panel controls pilot intercom volume
only, copilot panel controls copilot and passenger intercom volume. In a 2-panel installation
with one crew panel and one mission panel, the crew volume control controls the intercom volume for pilot and copilot, and the mission/observer panel controls passenger intercom volume.
In a 3-control panel installation, the pilot, copilot, and mission panel volume control adjusts the
intercom associated with that control head.
3.6.3.1 Monaural headsets
The pilot and copilot positions work with stereo or mono headsets. However, MultiTalker will
not be presented correctly unless stereo headsets are used, and oriented correctly on the head,
left and right.
NOTE: For the full effect of MultiTalker Dimensional Sound, stereo headsets must be used,
and the left/right orientation observed.
Some passenger headsets are connected in parallel. Therefore, if a monaural headset is plugged
in to a PAC45 Stereo installation, one channel may be shorted. Although no damage to the unit
will occur, all passengers with stereo headsets will not hear one channel, unless they switch to
the “MONO” mode on their headset.
NOTE: Mono headsets that short the tip and ring (i.e. older models) will introduce some au-
dio distortion when used. Modern, stereo headsets are recommended in all positions.
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-5 Rev. 7, May 2019
3.6.4 Intercom Modes
3.6.4.1 Single Unit/Control Head
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, ALL CRW, ALL. A
green indicator shows which mode is currently active.
ISO: 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, intercom and music. Passengers will have intercom and music.
ALL: All parties will hear the aircraft radio, intercom and music. During any radio or intercom
communications, the music volume automatically decreases. The music volume increases gradually 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.
3.6.4.2 Remote ICS Mode Control (P454 connector pin 18)
An optional external switch can act as a remote intercom mode selector. Pressing the switch will
increment the intercom mode selector from ISO-ALL-CRW-ALL, etc. each time the button is
pressed.
3.7 Bluetooth® connection
The PAC45 has an internal Bluetooth module (FCC ID: QOQWT32AE), no external boxes required. The audio controller is always “discoverable,” so you just need to search for the PAC45
from your Bluetooth-equipped phone or music source. Default access code is not required. Once
the PAC45 has been “paired” with your Bluetooth device, the TEL distribution will act as de-
scribed in § 3.7.2.
3.7.1 Pairing and unpairing Bluetooth devices
The PAC45 can be paired with up to eight individual devices, but will only connect to one at a
time. When that number is exceeded, the PAC45 will drop a device to allow the new device to
be added.
Once paired, the audio controller should connect automatically.
Hint, if your devices are not recognized by the PAC45, you may need to cycle Bluetooth on or off
from your device. If that does not help, you may need to reset the Bluetooth module, Press and
hold HRTF and ICS buttons for more than three (>3) seconds. Then “forget” the audio controller
from your device, and repair.
3.7.2 Bluetooth® Telephone Mode
The PAC45 serves as a full duplex interface for telephone systems such as portable cellular
phones with Bluetooth connectivity.
Warning:
United States FCC Regulations contained in 47 CFR § 22.925 currently contain 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 (not touching the ground). When any aircraft leaves the ground, all cellular telephones on
board that aircraft must be turned off.”
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PAC45 Audio Selector Panel and Intercom System
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200-045-0000 Page 3-6 Rev. 7, May 2019
To answer an incoming call, or initiate a call from the PAC45, select the TEL volume control to
the out position.
In ALL intercom mode, all crew and passengers will be heard on the phone when they speak.
In CREW mode, the pilot and copilot are connected to the telephone.
In ISO intercom mode, when the PAC45 is in the TEL mode, the pilot position is in the "Phone
Booth." Only the pilot will hear the telephone, and only he will be heard.
NOTE
PS Engineering does not guarantee compatibility with personal cellular telephones.
3.7.2.1 Bluetooth Reset
To reset the Bluetooth module, clearing out the connected devices, press HRTF and ICS for more
than three seconds.
3.8 Wired Satcom/Cell Phone input
The PAC45 can accommodate a wired telephone input as well as a Bluetooth connection. This
operates the same as the Bluetooth Telephone (see §3.7.2)
3.9 Dual Control Panel Operation/Pilot & Copilot
Figure 3-3 Pilot Control Head, Dual configuration
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-7 Rev. 7, May 2019
Figure 3-4 Copilot Audio controller, Dual Configuration CTL45P
3.9.1.1 Intercom Operation, Two (Pilot, Copilot) Control Heads
If two control heads are used, the following rules apply:
• System defaults to ALL-ALL at power up.
• Either panel can select ISO, and be removed from intercom, while the other remains
with the passengers.
• Either panel can select CRW, and place both panels in Crew mode
• Either panel can select ALL and add everybody to the intercom and radio
3.10 Observer/Mission Control Panel Operation
Some configurations utilize a CTL45M, Observer/Mission control head.
RECEIVED VOLUME CONTROL
• MISSION
COM 4COM 1 COM 2 COM 3 COM 5 COM 6
TEL ADF MKR
COM 4
COM 1
COM 2
COM 3
COM 6
PA
COM 5
text
TRANSMIT SELECTION
MISSION
CALL
ICS CALL
• MISSION ALERTS PILOT
OFF
text
HRTF PROCESSING
• MISSION
INTERCOM MODE CONTROL
• ISOLATE
• ALL
• CREW
INTERCOM VOLUME & SQUELCH CONTROL
• MISSION
• VOICE ACTIVATED OR PTT ICS( PUSH)
Figure 3-5 Third (Mission/Observer) Control Head Configuration
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PAC45 Audio Selector Panel and Intercom System
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200-045-0000 Page 3-8 Rev. 7, May 2019
The CTL45M has the same operation as the crew controller, except this controller cannot make
public address announcements. The CTL45M has an ICS CALL button to alert the crew that the
observer positions(s) want to be on the intercom with the crew.
3.10.1.1 Intercom Operation, Two Control Heads (Pilot, Mission)
In this configuration, the pilot and copilot crew positions have one control head (CTL45P) and
the Mission personnel have another, CTL45M.
• System defaults to ALL -ALL at power up.
• Either panel can select ISO, and be removed from the intercom.
• The crew panel can select CRW, and place their panel in Crew mode, while the observer
audio controller is forced to ISO.
• The crew panel can select ALL and add everybody to the intercom.
• The Mission Observer panel can select ISO, and then select ALL, unless a crew panel has
selected ISO or CREW. If the crew audio controller has selected ISO or CRW, the mission
observer panel must use the intercom CALL function to be added to the intercom
3.10.1.2 Intercom Operation, Three Control Heads (Pilot, Copilot & Mission)
If three control heads are used, the following rules apply:
• System defaults to ALL-ALL-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 both panels in Crew mode, while
the observer audio controller is forced to ISO.
• Either pilot or copilot panel can select ALL and add everybody to the intercom.
• The Mission Observer panel can select ISO, and then select ALL, unless a pilot or copilot
has selected ISO or CREW.
With the CTL45M installed, the observer/mission personnel can isolate their audio feed from the
crew by pressing the ICS button. When the CTL45M is in ISO mode, the observer/passengers
will have intercom among themselves, and be able to use the selected radios.
If the flight crew selects ISO or Crew modes, the CTL45M will automatically enter the ISO mode,
and will not change modes unless the crew changes their state. If the observer personnel desire
to communicate with the crew, pressing “CALL” will activate an ICS call light and a chime in the
crew headsets.
3.11 Alert Audio
The PAC45 incorporates an independent alert audio system that can store three audio messages
recorded by the user, and played back when triggered by an external source.
Once triggered, the alert audio will continue until the ACK button (front panel or external) on
the CTL45 control panel is pushed, or the trigger input returns to normal. Edge-triggered alerts
will play 3 times or until ACK is pushed, whichever occur first.
3.11.1 Storing Alert Audio
The PAC45 systems can store three audio alerts. You must record all three when the unit is in audio program mode. You cannot change only one at a time. If you wish to replace just one mes-
sage, we recommend you write down all the messages before starting the procedure.
To record messages from the pilot’s headset:
1. Press & Hold “ACK” until a chime is heard in the headset, and then release the
button.
2. COM1 will blink, to indicate the recording of ALERT #1.
3. Start speaking message.
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-9 Rev. 7, May 2019
4. When finished with Alert #1, press the “ACK”.
5. Now COM2 will blink, to indicate the recording of ALERT #2.
6. Speak message.
7. When finished with Alert #2, press the “ACK”
8. Now COM3 blinks, to indicate the recording of ALERT #3.
9. Speak message.
10. When finished with Alert #3, press the “ACK”
11. A chime indicates that recording is now finished.
NOTE: If ACK is not pressed to indicate end of recording, it will record for five seconds, and then
advance to next alert. After all three time slots are timed out, the PAC45 will exit the alert recording mode.
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-1 Rev. 7, May 2019
3.12 Intercom Operation Block Diagrams
These block diagrams illustrate the audio distribution for intercom and radios in four different configurations, single panel, dual panel pilot/copilot,
dual panel pilot-copilot/observer, and three control head.
3.12.1 Single Control Panel
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-2 Rev. 7, May 2019
3.12.2 Dual Control Head, Pilot CTL45P and Copilot CTL45P
Pilot Control Panel
Copilot Control Panel
PILOT
COPILOT
PASSENGERS
ISO
ALL
CRW
ISO
ALL
CRW
Pilot Control Panel
Copilot Control Panel
PILOT
COPILOT
PASSENGERS
ISO
ALL
CRW
ISO
ALL
CRW
Pilot Control Panel
Copilot Control Panel
PILOT
COPILOT
PASSENGERS
ISO
ALL
CRW
ISO
ALL
CRW
Selected Radios
Selected Radios
Passenger Intercom
Selected Radios
Passenger Intercom
Selected Radios
Selected Radios
Copilot Intercom
Passenger Intercom
Selected Radios
Pilot Intercom
Passenger Intercom
Selected Radios
Pilot Intercom
Copilot Intercom
Passenger Intercom
Copilot ‘s Selected
Radios
Copilot Intercom
Passenger Intercom
Pilot Control Panel
Copilot Control Panel
PILOT
COPILOT
PASSENGERS
ISO
ALL
CRW
ISO
ALL
CRW
Selected Radios
Copilot Intercom
Passenger Intercom
Selected Radios
Pilot Intercom
System defaults to ALL-ALL at power up.
Either panel can select ISO, and be removed from intercom while
the other remains with passengers.
Either panel can select CRW, and place both panels in Crew
mode
Either panel can select ALL and add everybody to the intercom
and radio
Pilot Control Panel
Copilot Control Panel
PILOT
COPILOT
PASSENGERS
ISO
ALL
CRW
ISO
ALL
CRW
Selected Radios
Passenger Intercom
Selected Radios
Pilot’s Selected Radios
Pilot Intercom
Passenger Intercom
ALL - ALL MODE PILOT ISOLATE MODE
COPILOT ISO MODECREW MODE
ISO-ISO MODE
DUAL CONTROL HEAD INTERCOM MODES
PILOT PRESSES ICS
EITHER PRESSES
ICS
COPILOT PRESSES
ICS
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-3 Rev. 7, May 2019
3.12.3 Dual Control Head Pilot & Copilot CTL45P plus Observer CTL45M
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 3-4 Rev. 7, May 2019
3.12.4 Three Control Head, Pilot CTL45, Copilot CTL45P and Mission Observer CTL45M
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Page 4-1 Rev. 7, May
2019
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 two-year 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: support@ps-engineering.com
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.
Page 40
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix A Rev. 7, May 2019
Appendix A – PAC45 Installation Drawings
Figure 5-1 – PAC45 Rear/Connector View (not to scale)
Figure 5-2 – PAC45 Side View
Figure 5-3 - PAC45/CTL45 Front View
J451: 50-PIN
FEMALE ON
HARNESS
J452: 37-PIN
FEMALE ON
HARNESS
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix A Rev. 7, May 2019
PAC45 Overall
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix A Rev. 7, May 2019
CTL45 Top View
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix A Rev. 7, May 2019
HUB45R Top View
Figure 5-4 - HUB45R Side View
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix A Rev. 7, May 2019
Appendix B – Radio Interconnect Wiring
Page 45
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
Appendix C – Intercom Interconnect Wiring
Pilot Mic Aud io Hi
Pilot Mic Lo
24
41
Pilot Phones Jac k
P451 P452
Copilot Mic Au dio Hi
Copilot Mic PT T
Copilot Mic Lo
25
42
PAX 1 Mic Audio Hi
PAX 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
18
37
11 PIL PH N (R)
PIL PH N (L)
PIL PH N Low
Copilot Phones Jack
17
36
10
COPIL PH N (L)
COPIL PH N (R)
COPIL PH N Low
PAX 1 (OBSVR 1) Phones J ack
30
47
13
PAX /OBS 1PHN (L)
PAX /OBS1 PH N (R)
PAX/OBS1 PHN Low
PAX 2 Phones Jack
31
48
14
PAX 2 PHN (L)
PAX 2 PHN (R)
PAX 2 PHN Low
PAX 3 Phones Jack
32
49
15
PAX 3 PHN (L)
PAX 3 PHN (R)
PAX 3 PHN Low
PAX 4 Phones Jack
33
50
16
PAX 4 PHN (L)
PAX 4 PHN (R)
PAX 4 PHN Low
PAX 6/Hand Mic Au dio Hi
PAX 6/Hand Mic PT T
PAX 6/Hand Mic Lo
23
6
40
P451
P453
P454
PAX 1 ICS-PTT
PAX 4 ICS-PTT
PAX 2 ICS-PTT
PAX 3 ICS-PTT
4
5
6
7
PAX 5 ICS-PTT
3
Swap
8
PAX 5 Mic Audio Hi
PAX 5 Mic Lo
16
25
Remote ISO18
Pilot Mic PTT
8
7
17
34
+28V ACRFT POWER
POWER GROUND
Pilot ICS PTT
9
Copilot ICS PTT
10
+28VDC Dimm er
14
15
PA KEY
PA AUD OU T
PA AUD LO W
Public Address
Music (Left)
Music (Right)
Music Lo
15
14
34
Music
Jack
19
P453
9
PAX 1 Mic PTT
9
Remote ACK
Hand Mic or
Passenger 5 Mic
PAX 5 Phones Jack
PAX 5 PHN (L)
PAX 5 PHN (R)
PAX 5 PHN Low
PAX 6 Phones Jack
PAX 6 PHN (L)
PAX 6 PHN (R)
PAX 6 PHN Low
1
PAX 6 ICS-PTT3
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PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
Appendix D – Control Head Interconnect Wiring
J455
1
2
3
4
5
6
7
8
9
P455
PILOT
CTL45P HEAD
PAC45
HUB LRU
RX- RS422 TX -
RX+ RS422 TX +
TX- RS422 RX -
TX+ RS422 RX +
GND
NO CONNECTION
POWER
AIRCRAFT GND
NO CONNECTION
1
2
3
4
5
6
7
8
9
J453
11
12
1
2
22
COPILOT
P455
COPILOT
CTL45P HEAD
PAC45
HUB LRU
RX- RS422 TX RX+ RS422 TX +
TX- RS422 RX TX+ RS422 RX +
GND
NO CONNECTION
AIRCRAFT POWER
AIRCRAFT GND
NO CONNECTION
1
2
3
4
5
6
7
8
9
OBSR
P455
1
2
3
4
5
6
7
8
9
OBSERVER
CTL45M HEAD
J451
17
34
20
21
10
19
24
RX- RS422 TX RX+ RS422 TX +
TX- RS422 RX -
TX+ RS422 RX +
GND
NO CONNECTION
POWER
AIRCRAFT GND
NO CONNECTION
+28V ACRFT POWER
0.5 Amp
Page 47
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
Appendix E, Unit Connector Wiring Reference
9.1 J451 Connections
C om 1 M ic K ey
Commun ications
Transmitter #1
P ilot Mic Au dio Hi
P ilot Mic Lo
19
2
36
C om 1 M ic A ud io H i
24
41
PAC45 Connectors, J451
P451
C om 1 M ic Low
C om 2 M ic K ey
Commun ications
Transmiter #2
18
1
35
C om 2 M ic A ud io H i
C om 2 M ic Low
C om 3 M ic K ey
Commun ications
Transmitter # 3
20
3
37
C om 3 M ic A ud io H i
C om 3 M ic Low
C om 4 M ic K ey
Commun ications
Transmitter # 4
21
4
38
C om 4 M ic A ud io H i
C om 4 M ic Low
C om 5 M ic K ey
Commun ications
Transceiver #5
22
5
39
C om 5 M ic A ud io H i
C om 5 M ic Low
C opil ot Mic Audio H i
C opil ot Mic PTT
C opil ot Mic Lo
25
42
P AX /OB S 1 Mic A ud io H i
P AX /OB S 1 Mic Lo
26
43
P AX 2 Mic A udio H i
P AX 2 Mic Lo
27
44
P AX 3 Mic A udio H i
P AX 3 Mic Lo
28
45
P AX 4 Mic A udio H i
P AX 4 Mic Lo
29
46
P AX 6/H and M ic A ud io H i
P AX 6/H and M ic P TT
Mic L o
23
6
40
P451
P ilot Mic PT T
8
7
11
12
13
16
ALERT 1
ALERT 2
ALERT 3
ALERT P W R
17
34
+28V ACRFT POWER
POWER GR OUND
P ilot ICS P TT
9
C opil ot ICS PT T
10
14
15
P A M IC A U D O UT
P A A UD LO W
P ubli c A dde ss
P AX 1P hones Jac k
30
47
P AX 1 P HN (L )
P AX 1 P HN Lo w
P AX 2 P hones Jac k
31
48
P AX 2 P HN (L )
P AX 2 P HN Lo w
P AX 3 P hones Jac k
32
49
P AX 3 P HN (L )
P AX 3 P HN Lo w
P AX 4 P hones Jac k
33
50
P AX 4 P HN (L )
P AX 4 P HN Lo w
P AX 5 P hones Jac k
P AX 5 P HN (L )
P AX 5 P HN Lo w
P AX 6 P hones Jac k
P AX 6 P HN (L )
P AX 6 P HN Lo w
1A
Page 48
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
9.2 J452 Connections
Com 1 Audio Hi
Com 1 Lo
Communications
Receiver #1
Nav 1 Audio Hi
Nav 1 Audio Lo
VHF Nav 1
Nav 2 Audio Hi
Nav 2 Audio Lo
VHF Nav 2
7
26
8
27
ADF 1 Audio Hi
ADF 1 Audio Lo
ADF 1
9
28
PAC45 Connector, J452
3
22
P452
Com 2 Audio Hi
Com 2 Audio Low
Communications
Receiver #2
2
21
Com 3 Audio Hi
Com 3 Audio Low
Communications
Receiver
#3
4
23
Com 4 Audio Hi
Com 4 Audio Low
Communications
Receiver
#4
5
24
Com 5 Audio Hi
Com 5 Audio Low
Communications
Receiver #5
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 Jack
17
36
COPIL PHN (L)
COPIL PHN Low
ADF 2 Audio Hi
ADF 2 Audio Lo
ADF 2
10
29
DME Audio Hi
DME Audio Lo
DME
11
30
Page 49
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
9.3 J453 Connections
PAC45 Connectors, J453
Com 6 Mic Key
Communications
Transmitter
#6
17
8
26
Com 6 Mic Audio Hi
Com 6 Mic Low
P453
1
2
11
12
22
Serial TX Serial TX +
Serial RX +
Serial RX Ground
ACFT Power
PAX 1 ICS-PTT
PAX 4 ICS-PTT
PAX 2 ICS-PTT
PAX 3 ICS-PTT
4
5
6
7
PAX 5 ICS-PTT
3
10
19
20
21
PAX/OB S 1 Phones Jack
13
24
PAX/OB S 1 PHN (R )
PAX/OB S 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
Copilot
CTL45
Obsver
Serial TXSerial TX +
Serial TX+
Serial RXGround
ACFT Power
PAX 1 Radio-P TT
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
CONNECT TO AIRCRAF T POWER
THROUGH CIRCUIT PROTECTI O N
EACH CTL45 DRAWS 150 mA
Page 50
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix C Rev. 7, May 2019
9.4 J454 Connections
Com 6 Audi o Hi
Com 6 Audi o Low
C o mmu n ic at io ns
R ec ei v er #6
TE L Audio Hi
TE L Audio Low
SAT/com
Transceiver
TE L Mic Audio Hi
17
26
7
14
23
PAX 5 Mic Audio Hi
PAX 5 Mic Lo
16
25
COPILOT C VR OUT
Remote ISO
18
11
20
PIL P HN (R)
PIL P HN Low
Copil ot P hones Jack
10
19
COPIL PHN (R)
COPIL PHN Low
15
24
13
22
UNSW 3
Unsw itched Input #3 Hi
Unsw itched Audio Lo
UNSW 4
Unsw itched Input #4 Hi
Unsw itched Audio Lo
Pilot Phones Jack
12
2
21
PILOT CVR OUT
Coc kpit
Voice
Rec order
8
Swap
9
Remote ACK
CVR LOW
PA Key Output
1 P A System
3
PAX 6 ICS PTT
J454 Connections with Single CVR and Speaker Output (050-045-0002 and 050-045-0102)
Com 6 Audio Hi
Com 6 Audio Low
Communications
Receiver
#6
TE L Audi o Hi
TE L Audi o Low
SAT/com
Transceiver
TE L Mic Au dio Hi
17
26
7
14
23
PAX 5 Mic Au dio Hi
PAX 5 Mic Lo
16
25
SPR OUT (LOW LEV EL)
Remote ISO
18
11
20
PIL PHN (R)
PIL PHN Low
Copilot Pho nes J ack
10
19
COPIL PHN (R)
COPIL PHN Low
15
24
13
22
UNSW 3
Unswi tched Input #3 Hi
Unswi tched Audi o Lo
UNSW 4
Unswi tched Input #4 Hi
Unswi tched Audi o Lo
Pil ot Phones J ack
12
21
PILOT CVR OUT
Cockpit
Voice
Recorder
8
Swap
9
Remote ACK
CVR LOW
Cockpit
Speaker Amp
2
SPR L O
3
PAX 6 ICS PTT
Page 51
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix F Rev. 7, May 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, Propeller, or Appliance) In the case of the PAC45, you may use the following text as a guide.
Installed audio selector and 6-place intercom, PS Engineering PAC45, part number 050-045-(XXXX) in ( location ) 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 3A circuit breaker (type and part number), and total
electrical load does not exceed % of the electrical system capacity with the PAC45 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 PAC45 Audio System:
Section
Item
Information
1
Introduction
Installation of audio control panel with intercommunications system, with integrated 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 operator’s guide referenced on installation documenta-
tion. 4 Servicing
None Required
5
Maintenance Instructions
On Condition, no special instructions
6
Troubleshooting
In the event of a unit problem, place the unit into “off,” “fail-safe” and/or
“emergency” mode. This allows pilot communications using COM 1, and un-
switched audio for critical alerts, copilot communications on COM 2, pilot navigation audio 1 if stereo headsets are used,. 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.
7
Removal and replacement information
Removal: The PAC45/CTL45 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.
8
Diagrams
Not applicable
9
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
Page 52
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix E Rev. 7, May 2019
Appendix G – RTCA DO160G Environmental Qualification Form
11.1 Model Number PAC45 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
Section
Conducted Tests
Temperature and Altitude
Low Temperature
High Temperature
In-flight Loss of Cooling
Altitude
Decompression
Overpressure
4.0
4.5.1
4.5.2
4.5.4
4.6.1
4.6.2
4.6.3
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
Temperature variation
5.2
Equipment tested to Category B
Humidity
6.0
Equipment tested to Category A
Shock
7.0
Equipment tested to Category B Standard operational 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 tested
Salt Spray
14.0
Category X, not tested
Magnetic Effect
15.0
Equipment tested to Category Z
Power input
16.0
Equipment tested to Category Z (28V)
Voltage Spike
17.0
Equipment tested to Category A (600V)
Audio Frequency Susceptibility
18.0
Equipment tested to Category Z
Induced Frequency Susceptibility
19.0
Equipment tested to Category ZC
Radio Frequency Susceptibility
20.0
Equipment tested to Category T
Radio Frequency Emission
21.0
Equipment tested to Category B
Lightning Induced Transient
Susceptibility
22.0
Equipment tested to Category A3J33
Lightning Direct Effects
23.0
Category X, not tested
Icing
24.0
Category X, not tested
ESD
25.0
Category A
Page 53
PS Engineering
PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0000 Appendix E Rev. 7, May 2019
11.2 Model Number CTL45, Audio Selector Control Panel
Part Number: 050-045-(02XX, -03XX, -62XX, -63XX )
FAA TSO Number: C139a
Manufacturer: PS Engineering Incorporated 9800 Martel Road Lenoir City TN 37772
Conditions
Section
Conducted Tests
Temperature and Altitude
Low Temperature
High Temperature
In-flight Loss of Cooling
Altitude
Decompression
Overpressure
4.0
4.5.1
4.5.2
4.5.4
4.6.1
4.6.2
4.6.3
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
Temperature variation
5.2
Equipment tested to Category B
Humidity
6.0
Equipment tested to Category B (Severe)
Shock
7.0
Equipment tested to Category B Standard operational 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
Category X, not tested
Magnetic Effect
15.0
Equipment tested to Category Z
Power input
16.0
Equipment tested to Category Z (28V)
Voltage Spike
17.0
Equipment tested to Category A (600V)
Audio Frequency Susceptibility
18.0
Equipment tested to Category Z
Induced Frequency Susceptibility
19.0
Equipment tested to Category ZC
Radio Frequency Susceptibility
20.0
Equipment tested to Category T
Radio Frequency Emission
21.0
Equipment tested to Category B
Lightning Induced Transient
Susceptibility
22.0
Equipment tested to Category A3J33
Lightning Direct Effects
23.0
Category X, not tested
Icing
24.0
Category X, not tested
ESD
25.0
Category A
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