PS Engineering PAC45A Installation And Operation Instructions Manual

9800 Martel Road

Lenoir City, TN 37772

www.ps-engineering.com

PAC45A

Special Mission Audio Controller System

with MultiTalker™ and IntelliVox®

Document P/N 200-045-1000

Revision 2, March 2019

Audio Control System with Intercom

System Installation and Operation Manual

Patented under one or more of the following;

No. 4,941,187; 5,903,227; 6,160,496 and 6,493,450, 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 [phone], email [e-mail].

In certified aircraft, warranty is not valid unless this product is installed by an

Authorized PS Engineering dealer.

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 ........................................................................................................................ 1-1

1.4 APPROVAL BASIS FAA TSO (PENDING) ....................................................................................................... 1-2

1.1.2 LIMITATIONS..................................................................................................................... 1-2

1.5 SPECIFICATIONS ........................................................................................................................................... 1-2

1.6 EQUIPMENT SUPPLIED ................................................................................................................................ 1-3

1.8 CONFIGURATION ................................................................................................................................................. 1-5

1.9 LICENSE REQUIREMENTS .......................................................................................................................... 1-5

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

2.4.3 AUDIO CONTROLLER INTERFACE ...................................................................................... 2-4

2.4.4 BACKLIGHTING ................................................................................................................. 2-4

2.4.5 UNSWITCHED INPUTS ........................................................................................................ 2-4

2.4.6 COCKPIT VOICE RECORDER.............................................................................................. 2-5

2.4.7 AUDIO ALERTS ................................................................................................................. 2-5

2.5 DUSCRETE INPUTS ............................................................................................................................................... 2-5

2.5.1 REMOTE ICS MODE CONTROL. ......................................................................................... 2-5

2.5.1 OXY (P453-26) ................................................................................................................ 2-6

2.5.2 RECEIVE MUTE (J452-44) ................................................................................................. 2-6

2.6 WIRED TELEPHONE/SATELLITE COMMUNICATION INPUT .................................................................................. 2-6

2.7 USER ADJUSTMENTS ............................................................................................................................................ 2-7

2.7.1 UNSWITCHED AUDIO LEVEL ............................................................................................ 2-7

2.7.2 ADJUSTMENTS .................................................................................................................. 2-7

2.7.3 LOGIC SWITCH OPTIONS ................................................................................................... 2-9

2.8 PAC45A PIN ASSIGNMENTS .............................................................................................................................. 2-10

2.9 WIRING CHECKOUT .......................................................................................................................................... 2-11

2.10 OPERATIONAL CHECKOUT ................................................................................................................................ 2-12

2.10.1 REQUIRED TEST EQUIPMENT ........................................................................................ 2-12

2.10.2 AUDIO CONTROLLER TEST............................................................................................ 2-12

2.10.3 BLUETOOTH CHECKOUT ............................................................................................... 2-13

2.11 FINAL INSPECTION ............................................................................................................................................ 2-13

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

3.5 NAVAID SELECTION ............................................................................................................................................. 3-2

3.5.1 OXY (P453-26) ................................................................................................................ 3-2

3.5.2 RECEIVE MUTE (J452-44) ................................................................................................. 3-2

3.6 INTERCOM OPERATION (8) .................................................................................................................................. 3-2

3.6.1 INTELLIVOX® INTERCOM VOX-SQUELCH ........................................................................ 3-2

3.6.2 INTERCOM VOLUME CONTROL ......................................................................................... 3-3

PS Engineering

PAC45A Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-045-1000 Page ii Rev. 2, March 2019

3.6.3 INTERCOM MODES ............................................................................................................ 3-3

3.7 SPEAKER OPERATION .......................................................................................................................................... 3-4

3.8 ALERT AUDIO ...................................................................................................................................................... 3-4

Section IV – Warranty and Service ................................................................. 4-1

4.1 WARRANTY ......................................................................................................................................................... 4-1

4.2 FACTORY SERVICE .............................................................................................................................................. 4-1

Appendix A – PAC45A 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

9.1 J451 CONNECTIONS ................................................................................................................................................ E

9.2 J452 CONNECTIONS ................................................................................................................................................ E

9.3 J453 CONNECTIONS ................................................................................................................................................ E

9.4 J454 CONNECTIONS ................................................................................................................................................ E

9.5 J455 CONNECTIONS ................................................................................................................................................ E

Appendix F – Instructions for FAA Form 337 and continuing airworthiness ........ F

10.1 INSTRUCTIONS FOR FAA FORM 337, AUDIO CONTROLLERS .................................................................................. F

10.2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS, AUDIO SYSTEM ..................................................................... F

Appendix G – RTCA DO160G Environmental Qualification Form ...................... G

11.1 MODEL NUMBER PAC45A AUDIO SELECTOR PANEL/INTERCOM REMOTE HUB ................................................ G

11.2 MODEL NUMBER CTL45, AUDIO SELECTOR CONTROL PANEL ........................................................................... G

Rev

Date

Change

New

Jan. 2019

Initial Draft Manual

1

January 2019

After Internal Review

2

March 2019

Release for publication

200-045-1000 Page 1-1 Rev. 2, March 2019

Section I – GENERAL INFORMATION

1.1 INTRODUCTION

The PAC45A 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..

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 installation and operation instructions for the PS Engineering PAC45A-series of Audio
Selector Panel/Intercom Systems. This includes the following units:

Model Number

Description

PS Engineering

Part Number

HUB45R

Remote-mounted Audio Hub for analog I/O and processing

050-045-1001

CTL45A

Panel Mounted Control Head for Flight Crew

050-045-2000

GTL45A-M

Panel Mounted Control Head for Mission Observers

050-045-3000

CTL45A-NVG

Panel Mounted Control Head for Flight Crew, Night Vision
Compatible

050-045-4000

GTL45A-M

NVG Panel Mounted Control Head for Mission Observers,
Night Vision Compatible

050-045-5000

1.3 EQUIPMENT DESCRIPTION

The PAC45A is a state-of-the-art audio isolation amplifier and audio selector that contains an automatic voice
activated (VOX) intercom system. It can switch up to eight transceivers (COM 1 to 8) and eight navigation
receivers (AUX 1 to 8) that can be configured as desired.

There are up to five unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or radar
altimeter warning.

In addition, nine programmable alerts can be triggered by external sources to provide additional capability.
In addition to a radio master volume, the individual volume controls select the receiver audio source provided

to the headphones when selected to the “out” position.
A nine-station voice activated (VOX) intercom is included in the PAC45A. This system has PS Engineering’s

patented IntelliVox® circuitry that eliminates manual adjustments.

200-045-1000 Page 1-2 Rev. 2, March 2019

1.4 APPROVAL BASIS FAA TSO (Pending)

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.

1.5 SPECIFICATIONS

TSO COMPLIANCE

Audio Selector/Intercom:

FAA TSO-C139A

APPLICABLE DOCUMENTS:

RTCA/DO-214A
RTCA/DO-160G
RTCA/DO-178C

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:

CTL45A: Height: 1.88 in. (4.78cm) Width: 4.90 in. (12.45 cm)
Depth behind panel: 2.35 in. (5.97)
HUB45R: Height: 1.9” Width: 5.88 w/mounting flanges, Length

7.22”, 12” w/ all connectors. See Figure 5-6

UNIT WEIGHT
HUB45R
CTL45A

2.0 lbs. (.91 kg)

1.0. (.45 kg)

POWER REQUIREMENTS :

Voltage:

18 to 33 VDC

Maximum Current:

Typical Current
Alert Power
Lighting

HUB45R 1.5 Amp (Externally protected by a 5 Amp circuit breaker.)
CTL45 500 mA (Externally protected by a 1 Amp circuit breaker)
750 mA
<20 mA
< 5mA

Audio Selector Specifications

Audio selector panel input impedance:

510 

Input Isolation:

-60 dB (min.)

Switched Receiver Inputs:

16 (COM 1– COM 8, AUX 1- 8)

Unswitched Inputs:

5

Transmitter Selections:

8 (COM 1, 2, 3, 4, 5, 6, 7, 8)

Headphone Impedance:

150 – 600  or 8 Ω

Headphone Output:

200 mW into 150 or 8Ω headset, no clipping <.5% THD
typical

Microphone Impedance:

150 - 600 

PA Output, Cockpit speaker output

10W @4 Ω

Intercom Specifications

Intercom Positions:

Up to 9 places (with individual IntelliVox® circuits)

Distortion:

<1% THD @ 200 mW into 150

Mic Freq. Response, ±3 dB:

300 Hz - 6000 Hz

200-045-1000 Page 1-3 Rev. 2, March 2019

1.6 EQUIPMENT SUPPLIED

The following units comprise the PAC45A System:

Model

Description

Part Number

HUB45AR

Remote-mounted Audio Hub for analog I/O and processing

050-045-1001

CTL45A

Control Head for pilot or copilot positions

050-045-2000

CTL45A-M

Panel-mounted Control Head for Observers

050-045-3000

CTL45A-NVG

NVG Panel-mounted Control Head for pilot and copilot po-

sitions

050-045-4000

CTL45M-NVG

NVG Panel-mounted Control Head for Observers

050-045-5000

PAC45A Installation Kit: 250-045-0801

Male Connector Kit 250-045-8177 (P452, P454)

Part Number

Description

MFR

MFR PN

Quantity

625-015-9215

Connector Backshell DB26 pin

3M

3357-9215

1

625-037-9237

Connector Backshell DB62 pin

3M

3357-9237

1

425-026-5601

Male Connector Shell DB26 pin

Harting

9562005601

1

425-062-8177

Male Connector Shell DB62 pin

Harting

9564005601

1

425-044-2043

Hi-density Male Pins

AMP

204370-2

88

475-045-3341

Thumbscrew Kit for DB Connector

3M

3341-7

4

Female Connector Kit 250-045-8277 J451, J453)

Part Number

Description

MFR

MFR PN

Quantity

625-015-9215

Connector Backshell DB26 pin

3M

3357-9215

1

625-037-9237

Connector Backshell DB62 pin

3M

3357-9237

1

425-026-1800

Female Connector Shell DB26 pin

Norcomp

180-026-273L000

1

425-062-4701

Female Connector Shell DB62 pin

Harting

99564004701

1

425-030-7354

Hi-density Female Pins

Amphenol

M39029/57-354

88

475-045-3341

Thumbscrew Kit for DB Connector

3M

3341-7

4

9-Pin Connector Kit 250-045-0009 ( P455)

Part Number

Description

MFR

MFR PN

Quantity

625-009-1724

Connector Backshell DB9 pin

3M

3357-9209

1

425-009-0777

Male Connector Shell DB9 pin

Amphenol

L777-RR-E-09-P

9

425-020-5089

Standard Density Male Pins

Deutsch

M39029/64-369

9

475-045-3341

Thumbscrew Kit for DB Connector

3M

3341-7

2

CTL45 9-Pin Female Connector Kit 250-543-0100 ( J455)

Part Number

Description

MFR

MFR PN

Quantity

200-045-1000 Page 1-4 Rev. 2, March 2019

625-009-9209

Connector Backshell DB9

3M

3357-9209

1

425-009-7709

Connector Female Shell DB9

Amphenol

L177-RR-E-09-S

1

425-020-5090

Standard density female pins

Deutsch

M39029/63-368

9

475-045-3341

Thumbscrew Kit for DB Connector

3M

3341-7

2

External Bluetooth Antenna

Part Number

Description

MFR

MFR PN

Quantity

300-045-1351

Bluetooth Coaxial Cable SMA ST BH JK to
ST Plug RG 174/U 36

Amphenol

135110-02-36”

1
510-045-9602

Bluetooth Antenna

Taoglas

GW.26.0112.HT

1

EQUIPMENT REQUIRED BUT NOT SUPPLIED

a. Circuit Breakers: 1 ea.; 5 amp PULL TYPE REQUIRED for HUB45G, 1 A for CTL45As
b. Optional Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45A aural alerts, 1 ea. 1 A for

failsafe power

c. Headphone Jacks (as Required)
d. Microphone Jacks (as Required)
e. Headphones, as required
f. Microphones, as required
g. Interconnect Wiring

200-045-1000 Page 1-5 Rev. 2, March 2019

1.8 Configuration

The PAC45A System is comprised of a single PAC45A HUB (HUB45R) and up to four CTL45 Control
Head “building blocks” to facilitate flexibility as well as simplicity.

HUB45AR

Pilot Copilot

Passenger 1

RS422 RS422 RS422RS422

Hand

Observer 1Crew 3 Observer 2

Passenger 2

Passenger 3 Passenger 4

CVR CP

PA

COM1-8

NAV 1-2

Aux 3-8

UNSW1-5

Telephone

Music

Bluetooth

Telephone

Bluetooth

Music

CVR P

Pilot

CopilotAmp

Figure 1-1 Baseline configuration

1.9 LICENSE REQUIREMENTS

None

200-045-1000 Page 2-1 Rev. 2, March 2019

Section II - INSTALLATION

2.1 GENERAL INFORMATION

2.1.1 SCOPE

This section provides detailed installation and interconnection instructions for the PS Engineering PAC45A
Audio Selector Panel/Intercom.

Please read this manual carefully before beginning any installation to prevent damage and post-installation
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 PAC45A 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 20-41A 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 PAC45A 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 HUB45R must be rigidly mounted to the aircraft structure in an avionics-rated location. The CTL45 is
designed for Dzus-rail mounting within view and reach of the flightcrew position(s). 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 high-voltage pulse
type outputs, such as DME or transponders. Avoid running the interconnecting bundles near any high current
wires.

200-045-1000 Page 2-2 Rev. 2, March 2019

2.3.3 Audio controller connector assembly

The HUB45R LRU connectors mate with two 62-pin, and two 26-pin connectors. One of each gender. The
connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from table below (or
equiv.).

P451

P453

J454J452

121

22

43

62

42

1

21

22

43

62

42

1 9

19 26

10 18

19

26

10

18

19

Figure 2-1 - PAC45A Connector Layout

Figure 2-2 - Connector assembly
NOTE: Pass the wire bundle through the Cover Nut before inserting pins in the connector shell.

Insert the screw or thumbscrews through the top half of the shell (B), and apply the E-Ring to the unthreaded
portion, and bend the E-ring holder back and forth to break it from the holder. Repeat for the other side.

Place the harness and connector in the bottom portion (A), and fold the retaining pars over the wires. Install
the top shell (B) by inserting the screws the screws through the connector, and snapping the top over the
bottom until the lances are in the cutouts. Be sure to align the lip of the shell over the connector edge before
snapping in place. Slide the cover nut over the two haves and screw in place.

Ensure that proper strain relief and chafing precautions are made during wiring and installation.

200-045-1000 Page 2-3 Rev. 2, March 2019

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

2.4 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, MIL­spec 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 PAC45A 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 PAC45A 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 2­or 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.

2.4.2 Power

The PAC45A is compatible with 28 Volt DC systems. A five (5) Amp circuit breaker is required for all
installations. Power and ground wires should be #22AWG connect power to P451 Pin 42. Connect airframe
ground to P451 Pin 20 and 21 only.

Power consumption is as follows:
At 28V:

 Control head Only: 400 mA
 Hub Only: 750 mA
 Alert audio power: 20mA

200-045-1000 Page 2-4 Rev. 2, March 2019

At minimum input voltage (20V):

 Control head: 600mA
 Hub Only: 950mA

Lighting input: <5mA

CAUTION: Do not connect or disconnect (HOT SWAP) any components with power applied, this may
damage the units

2.4.2.1 Alert power, P451 Pin 41,

The PAC45A 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 41.

When power to P451-42 is present, the message will play three times or until the remote acknowledge is
selected.

2.4.2.2 Failsafe Power P451 Pin 62 and O2 Enable P453 Pin 26

When connected to the aircraft bus, it allows for the use of Oxygen microphones in failsafe, when the O2
microphone discrete, J453 Pin 26 is grounded.

2.4.3 Audio controller interface

The PAC45A 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 Installation with Monaural Headsets

Not recommended, because the benefit of MultiTalker is lost.

However, if desired, the PAC45A can be installed monaurally by using the right and left
outputs together. However the HUB45AR DIP switches must be set for Mono configura-

tion. See §2.5.3.

2.4.4 Backlighting

Control of the unit backlighting is through the aircraft avionics dimmer, each control head is independent.
Connect J455 Pin 6 to the aircraft dimmer bus. The ratio of white to green indicator intensity is adjustable,
see §2.5.3. Backlight voltages of 5 VDC, 14 VDC and 28 VDC are configurable. See §2.5.2.

2.4.5 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, TAWS audio, TCAS
audio or any other critical audio signal.

Unswitched #1 is always presented to the crew headphones, and is available to the pilot in fail-safe (off)
mode. Unswitched 2 is presented to the copilot in fail-safe.

Unswitched

Input

Input Pins

Hear in

Fail Safe

Hear in

Headset

1

P452 - 55 WRT 15

Pilot

Pilot

2

P452 - 35 WRT 16

Copilot

Copilot

3

P452 - 56 WRT 17

No

Pilot & Copilot

4

P452 - 36 WRT 18

No

Pilot & Copilot

5

P452 -57 WRT 19

No

Pilot & Copilot

200-045-1000 Page 2-5 Rev. 2, March 2019

Table 2-2 Unswitched inputs

2.4.6 Cockpit Voice Recorder

The PAC45A audio controller contains a Cockpit Voice Recorder output for the pilot, copilot and observer
positions.

Pilot CVR output is J452-60; Copilot CVR output is P4542-61, Observer 1 CVR output P452-39, and Ob­server 2 P452-40, all with respect to any available audio low on J452.

The CVR output is consistent with RTCA DO-214A §1.5.7,

2.4.7 Audio Alerts

The PAC45A contains an independent audio alerting systems that will play up to 9 alert audio messages that
can be stored by the user (see §3.11.1).

The alert system has a power input (P451-41) that will keep the systems operable if the PAC45A systems
power source is removed. Alert audio is provided in Fail-safe when power is on P451-62.

Alert Input

Input Pins

1

P453 – 10

2

P453 – 11

3

P453 – 12

4

P453 – 13

5

P453 – 14

6

P453 – 19

7

P453 – 20

8

P453 – 21

9

P453 – 22

Alert Power

P451 – 41

Remote Acknowledge

P453 – 23

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 continuously until the Acknowledge button (ACK) is pressed (remote
ACK P454-23 grounded).

Alerts with level trigger will play continuously until the Acknowledge button (ACK) is pressed (remote ACK
P454-23 grounded), or the input level reverts.

When power is applied to the alerts and not the PAC45A audio controller, it will play the message continu­ously 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 CTL45A wiring

The PAC45 supports up to 4 CTL45A control heads. Three can be connected to the rear connectors, and the
fourth to J455. For convenience, either the pilot or observer *2 can be connected to J454.

Each CTL45A has a separate dimming input, and can be configured for 28VDC or 5 VDC.
Set J7 switches to: off/off/on/off/off/off for 28 VDC Lighting
Set J7 switches to: on/on/on/off/off/off for 5 VDC Lighting

2.5 Discrete inputs

2.5.1 Remote ICS mode control.

When a momentary, normally open, push-button switch is connected between pin J452-45 and ground, it will
change the intercom mode on the Pilot’s PAC45A.

200-045-1000 Page 2-6 Rev. 2, March 2019

2.5.1 OXY (P453-26)

Activates the Oxygen Mask microphone inputs if configured.

2.5.2 Receive Mute (J452-44)

When J452-44 is grounded through a remote switch, all receive audio is muted. If this switch remains closed
for more than 30 seconds (i.e. a stuck switch), the received audio will return to normal

2.6 Wired Telephone/Satellite Communication input

The PAC45A can accommodate a wired cell phone interface on J452 Pins 58, 59, and 38. 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.

200-045-1000 Page 2-7 Rev. 2, March 2019

2.6.1 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 controller.

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.

2.7 User Adjustments

The PAC45A is factory set for typical installation. However, several installation adjustments are avail­able. No computer is required.

2.7.1 Unswitched Audio Level

Unswitched inputs one through five are installation adjustable through the side of the PAC45A unit.

2.7.2 Adjustments

On the side of the PAC45A/HUB45R are 15 adjustment potentiometers.

1. Unswitched input 5 volume

2. Unswitched input 4 volume

3. Unswitched input 3 volume

4. Unswitched input 2 volume

5. Unswitched input 1 volume

6. Speaker Amplifier Volume

7. PA Amplifier Volume

Volume

200-045-1000 Page 2-8 Rev. 2, March 2019

8. Line level audio volume out or telephone output volume)

9. Cockpit Voice Recorder Volume

10. External PA Sidetone

11. External COM 1 Sidetone

12. External COM 2 Sidetone

13. Alert volume (adjusts the level of the internal audio alerts and annunciations generated by

the PAC45A)

14. Green backlight level

15. White backlight level

200-045-1000 Page 2-9 Rev. 2, March 2019

2.7.3 Logic Switch Options

The PAC45A has switches accessible through the side of the HUB45R to set specific functions

TOP ROW

BOTTOM ROW

SWITCH

FUNCTION

POSITION

SWITCH

FUNCTION

POSITION

1

FAILSAFE ALERTS TO CREW

UP

25

COPILOT CONTROL HEAD

INSTALLED

UP

2

FAILSAFE ALERTS TO

OBSERVERS

UP

26

OBSVR 1 CONTROL HEAD

INSTALLED

UP 3 ALERTS TO CREW

UP

27

OBSVR 2 CONTROL HEAD

INSTALLED

UP

4

ALERTS TO OBSERVERS

UP

28

REVERSIONARY MODE

UP

5

ALERT 1 TRIGGER

EDGE UP, LEVEL DN

29

TRANSMIT MUTE

DN 6 ALERT 1 POLARITY

POS UP, NEG DN

30

STUCK MIC ENABLE

UP 7 ALERT 2 TRIGGER

EDGE UP, LEVEL DN

31

HIGH MIC SENS

DN 8 ALERT 2 POLARITY

POS UP, NEG DN

32

PAX 1 & 2 = 02 MICS

DN 9 ALERT 3 TRIGGER

EDGE UP, LEVEL DN

33

PAX 3 & 4 = OBSR 02 MICS

DN

10

ALERT 3 POLARITY

POS UP, NEG DN

34

COM 7 COM 1 Sidetone

DN

11

ALERT 4 TRIGGER

EDGE UP, LEVEL DN

35

PA SIDETONE

DN

12

ALERT 4 POLARITY

POS UP, NEG DN

36

UNSW 1 & 2 SPLIT

DN

13

ALERT 5 TRIGGER

EDGE UP, LEVEL DN

37

UNSW OBSVR

UP

14

ALERT 5 POLARITY

POS UP, NEG DN

38

STEREO OBSVR

UP

15

ALERT 6 TRIGGER

EDGE UP, LEVEL DN

39

STEREO CREW

UP

16

ALERT 6 POLARITY

POS UP, NEG DN

40

8 OHM HEADSETS

UP

17

ALERT 7 TRIGGER

EDGE UP, LEVEL DN

41

RECEIVER INDICATOR ON

UP

18

ALERT 7 POLARITY

POS UP, NEG DN

42

MUSIC MUTE

UP

19

ALERT 8 TRIGGER

EDGE UP, LEVEL DN

43

COPILOT MUSIC ENABLE

UP

20

ALERT 8 POLARITY

POS UP, NEG DN

44

OBSERVER 1 MUSIC ENABLE

UP

21

ALERT 9 TRIGGER

EDGE UP, LEVEL DN

45

OBSERVER 2 MUSIC ENABLE

UP

22

ALERT 9 POLARITY

POS UP, NEG DN

46

ALERTS ON SPEAKER

UP

23

RESERVED

DN

47

DIMMER 28V

UP

24

RESERVED

DN

48

DIMMER 28V

UP

200-045-1000 Page 2-10 Rev. 2, March 2019

2.8 PAC45A Pin assignments

P451

J452

Pin

Description

Pin

Description

1

Ground

1

Lighting Common

2

Ground

2

Music Ground

3

Ground

3

Ground

4

Ground

4

Ground

5

Ground

5

Ground

6

Ground

6

Ground

7

Ground

7

Ground

8

Ground

8

Ground

9

Ground

9

Ground

10

Ground

10

Ground

11

Ground

11

Ground

12

Ground

12

Ground

13

Ground

13

Ground

14

Ground

14

Ground

15

Ground

15

Ground

16

Ground

16

Ground

17

Ground

17

Ground

18

Ground

18

Ground

19

Ground

19

Ground

20

Aircraft Ground

20

Speaker Ground

21

Aircraft Ground

21

PA Ground

22

Pilot Hand Mic

22

Lighting In

23

Pilot Mic

23

Music Left

24

Copilot Mic

24

Expansion Power Out

25

Observer 1 Mic

25

Expansion Out

26

Observer 2 Mic

26

Passenger 5/Expansion Mic

27

COM1 Mic

27

COM1

28

COM2 Mic

28

COM2

29

COM3 Mic

29

COM3

30

COM4 Mic

30

COM4

31

COM5 Mic

31

COM5

32

COM6 Mic

32

COM6

33

COM7 Mic

33

COM7/COM1 Sidetone

34

COM8 Mic

34

COM8/COM2 Sidetone

35

Pilot Left/Mono Headset

35

UNSW2

36

Copilot Left/Mono Headset

36

UNSW4

37

Observer 1 Left/Mono Headset

37

PA Sidetone

38

Passenger 1, Observer 2 Left, Mono
Headset

38

Telephone Out
39

Passenger 2,3 Left/Mono Headset

39

CVR Observer 1

40

Passenger 4,5 Left/Mono Headset

40

CVR Observer 2

41

Alert Power

41

Speaker Pilot

42

Aircraft Power

42

PA Out

43

Pilot Hand TX PTT

43

Music Right

44

Pilot TX PTT

44

Radio Mute

45

Copilot TX PTT

45

Pilot ICS

46

Observer 1 TX PTT

46

Call

47

Observer 2 TX PTT

47

NAV1

48

COM1 Key

48

NAV2

49

COM2 Key

49

AUX3

50

COM3 Key

50

AUX4

51

COM4 Key

51

AUX5

52

COM5 Key

52

AUX6

53

COM6 Key

53

AUX7

54

COM7 Key

54

AUX8

55

COM8 Key

55

UNSW1

56

Pilot Right Headset

56

UNSW3

57

Copilot Right Headset

57

UNSW5

58

Observer 1 Right Headset
58

Telephone In

59

Passenger 1, Observer 2 Right Head­set

59

Telephone Key
60

Passenger 2,3 Right Headset

60

CVR Pilot

61

Passenger 4,5 Right Headset

61

CVR Copilot

62

Failsafe Power

62

PA Key

200-045-1000 Page 2-11 Rev. 2, March 2019

P453

J454

Pin

Description

Pin

Description

1

Ground

1

TX- Observer 2

2

Ground

2

TX+ Observer 2

3

Ground

3

RX- Observer 2

4

Ground

4

RX+ Observer 2

5

Ground

5

Ground

6

Ground

6

Ground

7

Ground

7

Ground

8

Ground

8

Ground

9

Ground

9

Ground

10

Alert 1

10

TX- Observer 1

11

Alert 2

11

TX+ Observer 1

12

Alert 3

12

RX- Observer 1

13

Alert 4

13

RX+ Observer 1

14

Alert 5

14

Passenger 5 ICS PTT

15

Passenger 1 Mic Hi/ pilot O2 Mic

15

Passenger 4 ICS PTT

16

Passenger 2 Mic Hi/ Copilot O2 Mic

16

Passenger 3 ICS PTT

17

Passenger 3 Mic/ Observer 1 O2 Mic

17

Passenger 2 ICS PTT

18

Passenger 4 Mic /Observer 2 O2 Mic

18

Passenger 1 ICS PTT

19

Alert 6

19

TX- Copilot

20

Alert 7

20

TX+ Copilot

21

Alert 8

21

RX- Copilot

22

Alert 9

22

RX+ Copilot

23

Alert Ack

23

Observer 2 ICS PTT

24

No Connect

24

Observer 1 ICS PTT

25

Swap

25

Copilot ICS PTT

26

Oxygen Mask Enable

26

Pilot ICS PTT

J455 (HUB45R)

P455 (CTL45)

Pin

Description

Pin

Description

1

RX- 1

TX-

2

RX+ 2

TX+

3

TX- 3

RX- 4 TX+ 4

RX+

5

Lighting Ground

5 Lighting Common

6

Lighting Out

6 Lighting In

7

CTL Power out

7 Aircraft Power

8

Aircraft Ground

8 Aircraft Ground

9

Open 9

Open

Table 2-3: PAC45A Pin Assignments

2.9 Wiring Checkout

After wiring is complete, verify power is ONLY on pins 41, 42 & 62 of J451 and airframe ground on pins
20 & 21. 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

200-045-1000 Page 2-12 Rev. 2, March 2019

2.10 Operational Checkout

2.10.1 Required Test Equipment

In order to return an aircraft to service after installation of the PAC45A, 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.

2.10.2 Audio controller Test

PAC45A NVG Genesys Crew Control Head (P/N 050-045-4200/NVG 6400)

PAC45A NVG Observer / Mission Control Head (P/N 050-045-4300/NVG 6500)

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.

1. Apply power to the aircraft and avionics.

2. Verify fail-safe operation by receiving and transmitting on COM 1 from the pilot position, with the audio

controller power off /EMG mode (XMT Selector fully CW).

3. Switch on the unit by turning the XMT select knob to the full CCW position (COM 1).

4. 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.

5. Verify proper transmit and receive operation from the pilot position, noting that the copilot PTT switch

allows proper transmission on the selected transceiver. Verify that the Selected XMIT legend flashes
green when transmitting.

6. Rotate the XMT knob to the COM 2 transceiver position and verify the indicators change to track the

selection, and COM 2 receiver is heard.

200-045-1000 Page 2-13 Rev. 2, March 2019

7. Repeat for any other installed communications radios (up to 8 total).

8. Verify proper operation of all receiver sources (NAV 1, NAV 2, and AUX 3 through 8) by selecting

them by pulling the appropriate knob to the out position. Turn the knob and verify that the audio level
changes.

NOTE: Navaid selection is as follows:

 Aux 1, Aux 5 controlled via AUX 1 knob (NAV 1).
 Aux 2, Aux 6-8 controlled via AUX 2 knob (NAV 2).

9. With several sources selected, verify that the volume level of the radios in the headset is controlled by

the INNER concentric knob.

10. If configured for Oxygen mask mics, activate the remote OXY switch; verify that the microphone audio

source is the Oxygen Masks.

11. Verify proper crew Intercom system operation in the ALL, ISO and CREW modes.

12. With the intercom in ISO mode, activate the CALL switch request from observer stations, and observe

that the CALL light illuminates, and a chime is heard in crew headset.
Verify that switching the intercom into ALL mode on either crew control head will cancel the CALL

function.

13. Verify that the volume level of the intercom is controlled by the inner concentric volume knob.

14. Verify that the audio selector panel system does not adversely affect any other aircraft system by sys-

tematically switching the unit on and off, while monitoring the other avionics and electrical equipment
on the aircraft.

15. Repeat for the other aircraft crew stations.

2.10.3 Bluetooth Checkout

Verify that the PAC45A will “pair” with a Bluetooth device, and interface with cellular phone and Music
source. See § 3.7.2 for more information.

If PAC45A 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.

2.10.3.1 Bluetooth TEL Checkout

Pair the PAC45A 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 pull the TEL knob on the audio controller panel.

2.11 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.

PS Engineering

PAC45A Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-045-1000 Page 3-1 Rev. 2, March 2019

Section III OPERATION

3.1 SCOPE

This section provides basic operating instructions for the PS Engineering PAC45A, Audio Selector Panel/In­tercom Systems. Please read it carefully before using the equipment so that you can take full advantage of its
capabilities.

Figure 3-1 PAC45A Typical Operating Controls

3.2 Power and Fail Safe

Unit power is controlled by the transmitter (XMT) rotary 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.

The power controls all audio selector panel functions, and intercom.

3.3 Communications Transmit (XMT) Selection

The PAC45A 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 eight available.

The radio is automatically selected to receive incoming radio calls when the XMT is selected. With a
PAC45A, 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.

3.4 COM Audio Selector

The communications receiver audio sources are controlled by a combination pull-on-push-off switch/volume
control. Communication audio from another radio, not selected for transmit, can be heard by pulling 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 off the selected receive audio all the way.

The volume of the received source is adjusted by rotating the knob.

3.4.1 Multi-Talker™ 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 locations. This helps the

crew to better comprehend speech by locating it in a manner more easily differentiated by the human brain.

PS Engineering

PAC45A Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-045-1000 Page 3-2 Rev. 2, March 2019

Intercom and other audio is not spatially processed, only the eight communications transceivers.
NOTE: You must use stereo headsets, in stereo mode for this feature.
This adjustment allows the eight Spatial Audio inputs to be “relocated” on any of nine (9) pre-defined “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

Activating the HRTF toggles the
PAC45A MultiTalker™ spatial function
in a stereo headset, (receiver sources dis­tributed) or off (receiver audio sources
neutral).

3.4.3 Audio Location

The pilot controller can adjust the locations for the eight 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.

Press the HRTF button again to exit the mode. The
audio controller will remember last state through
power cycles.

Figure 3-2 Spatial Audio Locations and Voice
Annunciations

3.5 Navaid Selection

Navigation receivers are selected in the same manner as the communication receiver, pull on/push off the
knob associated with the desired navigational aid, and rotate to adjust the receiver volume.

There are three navaid controls, and up to eight navaid inputs available. Selection is:

 Aux 1, Aux 3-5 controlled via AUX 1 knob (NAV 1).
 Aux 2, Aux 6-8 controlled via AUX 2 knob (NAV 2).

3.5.1 OXY (P453-26)

Activates the Oxygen Mask microphone inputs if configured.

3.5.2 Receive Mute (J452-44)

When J452-44 is grounded through a remote switch, all receive audio is muted. If this switch remains closed
for more than 30 seconds (i.e. a stuck switch), the received audio will return to normal

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.

HRTF REQUIRES Stereo Head­sets. If monaural headsets are
used, the received audio will sound

“distant” or somewhat distorted.

PS Engineering

PAC45A Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-045-1000 Page 3-3 Rev. 2, March 2019

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.

3.6.2 Intercom Volume Control

The outer concentric 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.

3.6.3 Intercom Modes

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 bottom to top, then top to bottom: ALL CRW ISO, CRW. A green indicator shows
which mode is currently active.

ISO: Each control head has their own ISOLATE selection. The control head is isolated from the intercom
stations and is connected only to the aircraft radio’s that are selected system. They will hear the aircraft radio
reception (and sidetone during radio transmissions).

ALL: Each control head has their own ALL selection. When in the ALL mode, all parties will hear the aircraft
radio, intercom and music. The pilot or copilot control head will decide when the system will be in the ALL
mode by pressing their ICS switch. 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.

CREW: Pilot and copilot are connected on one intercom channel and have exclusive
access to the aircraft radios. The pilot or copilot control head will decide when the
system will be in the ALL mode by pressing their ICS switch. The observers can
communicate with each other and passengers in ALL or OBS mode, or select ISO mode.

3.6.3.1 Intercom Operation

If four control heads are used, the following rules apply:

 System defaults to 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.
 Either pilot or copilot panel can select ALL and add everybody to the intercom.
 The Observer 1 and Observer 2 panels can leave and return to ALL, unless a pilot or copilot has

selected ISO or CREW.

The observer/mission personnel can isolate their audio feed from the crew by pressing the ICS button. When
the CTL45A is in ISO mode, the observer/passengers will have intercom among themselves, and be able to
use the selected radios.

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.

PS Engineering

PAC45A Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-045-1000 Page 3-4 Rev. 2, March 2019

3.7 Speaker operation

To activate the cockpit speaker, press and hold the ICS button for one second. This will place all received
audio over the cockpit speaker.

3.8 Alert Audio

The PAC45A incorporates an independent alert audio system that can store nine audio messages recorded by
the user, and played back when triggered by an external source.

200-045-1000 Page 4-1 Rev. 2, March 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 [phone] 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
[phone] FAX [phone]
Email: [e-mail]

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.

200-045-1000 Appendix A Rev. 2, March 2019

Appendix A – PAC45A Installation Drawings

Figure 5-1 - CTL45A Front View

Figure 5-2 CTL45A Top View

200-045-1000 Appendix A Rev. 2, March 2019

Figure 5-3 - HUB45AR Top View

P451

P453

J454J452

121

22

43

62

42

1

21

22

43

62

42

1 9

19 26

10 18

19

26

10

18

19

Figure 5-4 - HUB45AR Rear Connector View

200-045-1000 Appendix A Rev. 2, March 2019

J455

Figure 5-5 HUB4A5R Front View

Figure 5-6 - HUB45AR Side Views

BLUETOOTH

ANT CONN

200-045-1000 Appendix B Rev. 2, March 2019

Appendix B – Radio Interconnect Wiring

Com 1 Audio Hi

Com 1 Mic Key

Com 1 Lo

Nav 1 Audio Hi
Nav 1 Audio Lo

Nav 2 Audio Hi

Nav 2 Audio Lo

Com 1 Mic Audio Hi

J451

Com 1 Mic Low

P452

Com 2 Mic Key

Com 2 Mic Audio Hi

Com 2 Mic Low

AUX 3 Audio Hi
AUX 3 Audio Lo

Unswitched Input #1 Hi

Unswitched Audio Lo

Unswitched Input #2 Hi

Unswitched Audio Lo

Unswitched Input #3 Hi

Unswitched Audio Lo

Unswitched Input #4 Hi

Unswitched Audio Lo

Com 2 Audio Hi

Com 2 Audio Low

Unswitched Input #5 Hi

Unswitched Audio Lo

Com 3 Audio Hi

Com 3 Mic Key

Com 3 Lo

Com 3 Mic Audio Hi

Com 3 Mic Low

Com 4 Mic Key

Com 4 Mic Audio Hi

Com 4 Mic Low

Com 4 Audio Hi

Com 4 Audio Low

Com 5 Audio Hi

Com 5 Mic Key

Com 5 Lo

Com 5 Mic Audio Hi

Com 5 Mic Low

Com 6 Mic Key

Com 6 Mic Audio Hi

Com 6 Mic Low

Com 6 Audio Hi

Com 6 Audio Low

Com 7 Audio Hi

Com 7 Mic Key

Com 7 Lo

Com 7 Mic Audio Hi

Com 7 Mic Low

Com 8 Mic Key

Com 8 Mic Audio Hi

Com 8 Mic Low

Com 8 Audio Hi

Com 8 Audio Low

AUX 4 Audio Hi
AUX 4 Audio Lo

AUX 5 Audio Hi
AUX 5 Audio Lo

AUX 6 Audio Hi
AUX 6 Audio Lo

AUX 7 Audio Hi
AUX 7 Audio Lo

AUX 8 Audio Hi
AUX 8 Audio Lo

P452

200-045-1000 Appendix Rev. 2, March 2019

Appendix C – Intercom Interconnect Wiring

Pilot Mic Audio Hi

Pilot Mic Lo

Copilot Mic Audio Hi

Copilot Mic Lo

OBSR 1 Mic Audio Hi

OBSR 1 Mic PTT

Mic Lo

Pilot Mic PTT

Copilot Mic PTT

OBSR 2 Mic Audio Hi

OBSR 2 Mic PTT

Mic Lo

PILOT PHN AUD HI (L, MONO)

PHN AUD LO

OBS 1 PHN AUD HI (R)

PAX 1/OBS 2 PHN AUD (R) HI

P451

HAND MIC AUDIO

HAND MIC PTT

Mic Lo

PILOT PHN AUD HI (R)

COPILOT PHN AUD HI (L, MONO)

PHN AUD LO

COPILOT PHN AUD HI (R)

OBS 1 PHN AUD HI (L, MONO)

PHN AUD LO

PAX 1/OBS 2 PHN AUD HI (L, MONO)

PHN AUD LO

PAX 2 & 3 PHN AUD (R) HI

PAX 2 & 3 PHN AUD HI (L, MONO)

PHN AUD LO

PAX 4 & 5 PHN AUD (R) HI

PAX 4 & 5 PHN AUD HI (L, MONO)

PHN AUD LO

P453

PAX 4 ICS-PTT

PAX 3 ICS-PTT

P454

OBS 2 I CS-PTT

OBS 1 I CS-PTT

PILOT I CS-PTT

COPILOT I CS-PTT

No Connect

No Connect

200-045-1000 Appendix Rev. 2, March 2019

Appendix D – Control Head Interconnect Wiring

J455

1
2
3
4
5
6
7
8
9

P455

PILOT

CTL45 HEAD

P455

PAC45G
HUB LRU

RX- RS422 TX ­RX+ RS422 TX +
TX- RS422 RX ­TX+ RS422 RX +

GND

LIGHTING

POWER

AIRCRAFT GND

ON CTL

1
2
3
4
5
6
7
8
9

J454

21
22
19
20
9

COPILOT

P455

PAC45
HUB LRU

RX- RS422 TX ­RX+ RS422 TX +
TX- RS422 RX ­TX+ RS422 RX +

GND

LIGHTING IN

AIRCRAFT POWER

AIRCRAFT GND

NO CONNECTION

1
2
3
4
5

6
7

8
9

OBSR 1
P455

1
2
3
4
5

6
7

8
9

12
13
10
11
8

RX- RS422 TX -

RX+ RS422 TX +

TX- RS422 RX -

TX+ RS422 RX +

GND

LIGHTING IN

POWER

AIRCRAFT GND

NO CONNECTION

OBSR2

1
2
3
4
5

6
7

8
9

3
4
1
2
9

RX- RS422 TX ­RX+ RS422 TX +

TX- RS422 RX ­TX+ RS422 RX +

GND

LIGHTING IN

POWER

AIRCRAFT GND

NO CONNECTION

200-045-1000 Appendix Rev. 2, March 2019

Appendix E, Unit Connector Wiring Reference

9.1 J451 Connections

C om 1 Mic K ey

P ilot Mic Au dio Hi

P ilot Mic Lo

C om 1 Mic A udio H i

P451

C om 1 Mic L ow

C om 2 Mic K ey

C om 2 Mic A udio H i

C om 2 Mic L ow

C opilot M ic Aud io Hi

C opilot M ic Lo

OB S R 1 Mi c A udio H i

OB S R 1 Mi c P TT

Mic L o

P ilot Mic PTT

+28 V ACRF T POW ER

POW ER GROUND

C opilot M ic PTT

OB S R 2 Mi c A udio H i

OB S R 2 Mi c P TT

Mic L o

P ILO T PHN AU D HI (L, MONO )

P HN AU D LO

OB S 1 P HN A UD HI (R)

P AX 1/OBS 2 PH N A UD (R) H I

Alert Power

FAILSAFE POWER

H AN D M IC AU DIO

H AN D M IC PT T

Mic L o

C om 3 Mic K ey

C om 3 Mic A udio H i

C om 3 Mic L ow

C om 4 Mic K ey

C om 4 Mic A udio H i

C om 4 Mic L ow

C om 5 Mic K ey

C om 5 Mic A udio H i

C om 5 Mic L ow

C om 6 Mic K ey

C om 6 Mic A udio H i

C om 6 Mic L ow

C om 7 Mic K ey

C om 7 Mic A udio H i

C om 7 Mic L ow

C om 8 Mic K ey

C om 8 Mic A udio H i

C om 8 Mic L ow

P ILO T PHN AU D HI (R)

C OP ILO T PHN AU D HI (L, MON O)

P HN AU D LO

C OP ILO T PHN AU D HI (R)

OB S 1 P HN A UD HI (L, MONO )

P HN AU D LO

P AX 1/OBS 2 PH N A UD H I (L, MONO )

P HN AU D LO

P AX 2 & 3 PH N A UD (R) H I

P AX 2 & 3 PH N A UD H I (L, MONO )

P HN AU D LO

P AX 4 & 5 PH N A UD (R) H I

P AX 4 & 5 PH N A UD H I (L, MONO )

P HN AU D LO

200-045-1000 Appendix Rev. 2, March 2019

9.2 J452 Connections

Com 1 Audi o Hi

Com 1 Lo

Nav 1 Audio Hi

Nav 1 Audio Lo

Nav 2 Audio Hi

Nav 2 Audio Lo

AUX 3 Audio Hi

Audi o Lo

PAC45 CONNECTOR J452
MALE ON HARNESS

Com 2 Audi o Hi

Com 2 Audi o Low

Unswi tched Input #1 Hi

Unswi tched Au dio Lo

Unswi tched Input #2 Hi

Unswi tched Au dio Lo

Unswi tched Input #3 Hi

Unswi tched Au dio Lo

Unswi tched Input #4 Hi

Unswi tched Au dio Lo

CVR Out Pilot

Remote Pilot ICS Mode

Call

Com 3 Audi o Hi

Com 3 Audi o Lo

Com 4 Audi o Hi

Com 4 Audi o Low

Com 5 Audi o Hi

Com 5 Lo

Com 6 Audi o Hi

Com 6 Audi o Low

Com 7 Audi o Hi

Com 7 Audi o Lo

Com 8 Audi o Hi

Com 8 Audi o Low

AUX 4 Audio Hi

Audi o Lo

AUX 5 Audio Hi

Audi o Lo

AUX 6 Audio Hi

Audi o Lo

AUX 7 Audio Hi

Audi o Lo

AUX 8 Audio Hi

Audi o Lo

Unswi tched Input #5 Hi

Unswi tched Au dio Lo

TE L Audio Hi

TE L Key

TE L Audio Lo

TE L MIC Hi

Music Input Left
Music Input Right

Music Lo

PA PTT

CVR Out Obs erver 1

CVR Out Obs erver 2

CVR Out Copilot

Speaker Out
Speaker Ground

PA Out
PA Ground

Expansi on Power

Expansi on I n

Expansi on Ground

Expansi on Out

+28V Di mmer

Dimmer Lo

Radio Mute

200-045-1000 Appendix Rev. 2, March 2019

9.3 J453 Connections

P453 FEMALE ON HARNESS

9.4 J454 Connections

J454 MALE ON HARNESS

COPILOT
CTL45A

OBSERVER 1
CTL45A

PILOT
OR
OBSERVER 2*
CTL45A

*

PILOT AND OBSVR #2
CONNECTIONS CAN BE
REVERSED. SEE SECT. 2.

200-045-1000 Appendix Rev. 2, March 2019

9.5 J455 Connections

J455
MALE ON HARNESS

1
2
3
4
5
6
7
8
9

P455
FEMALE ON HARNESS

*OBS #2 OR PILOT

CTL45 HEAD

PAC45G
HUB LRU

RX- RS422 TX -

RX+ RS422 TX +

TX- RS422 RX -

TX+ RS422 RX +

GND

LIGHTING

POWER

AIRCRAFT GND

ON CTL

1
2
3
4
5
6
7
8
9

* PILOT AND OBSVR #2
CONNECTIONS CAN BE
REVERSED. SEE SECT. 2.

200-045-1000 Appendix F Rev. 2, March 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 PAC45A, you may use the following text as a guide.

Installed audio selector and 6-place intercom, PS Engineering PAC45A, 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 PAC45A 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 PAC45A 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 in-
stallation documentation (FAA Form 337, etc.), including interface with other
avionics audio as required.

3

Controls

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

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 VHF. Follow
checkout instructions in the installation manual referenced on the FAA Form

337. For a specific unit fault, contact the manufacturer at [phone] for
special instructions.

7

Removal and replacement infor­mation

Removal: The 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

200-045-1000 Appendix E Rev. 2, March 2019

Appendix G – RTCA DO160G Environmental Qualification Form

11.1 Model Number PAC45A 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

200-045-1000 Appendix E Rev. 2, March 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