PS Engineering PCD7100 Installation And Operation Manual
9800 Martel Road
Lenoir City, TN 37772
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High-fidelity Stereo IntelliVox® Intercom
System
With integral music system
FAA-TSO C50c
JAA-Approved JTSO-C50c
US Patent 6,493,450
Installation and Operation Manual
Warranty is not valid unless this product is installed by an Authorized
PS Engineering dealer or a PS Engineering harness is purchased.
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.
Document P/N 200-971-0005
Revision 5
January 2003
PS Engineering, Inc. 2002 ©
Copyright Notice
Table of Contents
SECTION I GENERAL INFORMATION........................................................................ 1-1
1.1 INTRODUCTION........................................................................................................... 1-1
1.2 SCOPE ............................................................................................................................. 1-1
1.3 EQUIPMENT DESCRIPTION ..................................................................................... 1-1
1.4 APPROVAL BASIS ........................................................................................................ 1-1
1.5 SPECIFICATIONS......................................................................................................... 1-2
1.6 EQUIPMENT SUPPLIED ............................................................................................. 1-3
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED .................................................... 1-3
1.8 LICENSE REQUIREMENTS ....................................................................................... 1-3
SECTION II - INSTALLATION........................................................................................ 2-1
2.1 GENERAL INFORMATION ........................................................................................ 2-1
2.1.1 SCOPE ...........................................................................................................................2-1
2.2 U
2.3 E
2.3.1 C
2.3.2 M
2.3.3 M
2.3.4 C
2.4 C
2.4.1 N
2.4.2 P
2.4.3 C
2.4.4 B
2.4.5 I
2.4.6 P
2.4.7 U
2.4.8 U
2.4.9 A
2.5 A
2.6 P
2.7 U
2.7.1 I
2.7.2 CD P
2.8 I
2.9 F
NPACKING AND PRELIMINARY INSPECTION
QUIPMENT INSTALLATION PROCEDURES
OOLING REQUIREMENTS
OUNTING REQUIREMENTS
OUNTING RACK INSTALLATION
ONNECTOR ASSEMBLY
ABLE HARNESS WIRING
OISE
............................................................................................................................. 2-2
OWER
............................................................................................................................ 2-2
OMMUNICATIONS PUSH-TO-TALK
ACKLIGHTING
NTERCOM WIRING
LAYBACK INSTALLATION
NSWITCHED AUDIO INPUT
NSWITCHED SUMMED AUDIO
UDIO MESSAGE SYSTEM
DJUSTMENTS
OST INSTALLATION CHECKOUT
NIT INSTALLATION
NTERCOM CHECKOUT
LAYER CHECKOUT
NTERNAL RECORDER CHECKOUT (OPTIONAL
INAL INSPECTION
.............................................................................................................. 2-3
(11950, 11951, 11956, 11957) .............................................. 2-3
.................................................................................................................. 2-4
........................................................................................................... 2-6
.............................................................................................. 2-1
........................................................................................... 2-1
.................................................................................. 2-1
................................................................................................ 2-2
................................................................................................ 2-2
............................................................................... 2-2
(11951, 11957) ................................................................... 2-4
(11950, 11951, 11956, 11957........................................... 2-4
(11952, 11953, 11958)................................................ 2-4
(11953, 11954
................................................................................... 2-5
........................................................................................................ 2-5
(11950, 11951
................................................................................................. 2-6
.................................................................... 2-1
ONLY
11956, 11957
................................................................ 2-1
) .......................................................... 2-4
)....................................................... 2-5
) ........................................................... 2-6
SECTION III OPERATION ............................................................................................... 3-1
3.1 SCOPE ............................................................................................................................. 3-1
3.2 P
3.3 I
3.3.1 I
3.3.2 I
3.3.3 M
3.3.4 I
3.4 O
3.5 I
3.5.1 O
OWER SWITCH (FAIL SAFE OPERATION
NTERCOM OPERATION
NTERCOM VOLUME CONTROL
NTELLIVOX
USIC 1 AND SOFT MUTE CONTROL
NTERCOM MODES
PERATING THE INTERNAL
NTERNAL RECORDER SYSTEM (OPTIONAL
PERATION
® VOX-S
..................................................................................................................... 3-4
)..................................................................... 3-1
................................................................................................... 3-1
...................................................................................... 3-1
QUELCH
....................................................................................... 3-1
............................................................................. 3-2
......................................................................................................... 3-2
LAYER
CD P
....................................................................... 3-4
) ................................................................. 3-4
3.6 PCD7100-P CD P
3.6.1 P
3.6.2 O
3.6.3 T
3.6.4 A
OWER/VOLUME KNOB
PERATING THE INTERNAL
ONE CONTROL
UDIO MESSAGING SYSTEM
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
LAYER ONLY (PART NUMBER
PS Engineering
11952
AND
11953) ............................ 3-5
.................................................................................................. 3-5
LAYER
CD P
........................................................................ 3-5
.............................................................................................................. 3-5
(11953
ONLY
)................................................................... 3-5
SECTION IV- WARRANTY AND SERVICE.................................................................. 4-1
4.1 W
4.2 F
APPENDIX B – INSTALLATION DRAWING
7.1 PCD7100 W/I
7.2 PCD7100 W/
ARRANTY
ACTORY SERVICE
...................................................................................................................... 4-1
.......................................................................................................... 4-1
APPENDIX A EXTERNAL PTT HOOK UP......................................................................A
........................................................... B
APPENDIX C CONNECTOR INTERCONNECT..............................................................C
NTERCOM
OUT INTERCOM
(11950, 11951) ............................................................................C
(11952, 11953) .................................................................... B
APPENDIX D- INSTRUCTIONS FOR FAA FORM 337 AND CONTINUING
AIRWORTHINESS ......................................................................................................................D
8.1 I
8.2 I
NSTRUCTIONS FOR
NSTRUCTIONS FOR CONTINUING AIRWORTHINESS
FAA F
APPENDIX E RTCA DO160D/EUROCAE ED-14D ENVIRONMENTAL
ORM
337, PCD7100S..............................................................D
, PCD7100S....................................D
QUALIFICATION FORM INTERCOM/CD PLAYER .........................................................E
200-971-0005 Page ii Rev. 5, Dec. 2002
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
PS Engineering
Section I GENERAL INFORMATIO
N
1.1 INTRODUCTION
Quality cockpit and cabin entertainment has long been an elusive dream in general aviation. From marginal
performance to unapproved parts, pilots couldn’t enjoy the same music in their aircraft as they could in the
family car.
The PCD7100-Series represents such a product. This one unit combines intercommunications and a compact disk player for ultimate functionality. Using proprietary IntelliVox® design, this intercom eliminates
the requirements for intercom squelch adjustments. The CD player is designed for simple operation, avoiding any increase in cockpit workload from complicated controls.
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 PCD7100.
1.2 SCOPE
This manual provides detailed installation and operation instructions for the PS Engineering PCD7100series of CD Player/Intercom Systems. This includes the following units:
Model Part Number Description
PCD7100-I 11950 CD Player w/6-place ICS
PCD7100-I 11951 CD Player w/6-place ICS and /Internal Recorder
PCD7100-P 11952 CD Player only
PCD7100-P 11953 CD Player only w/Audio Warning System
PCD7100-P 11954 CD/MP3 Player Only w/Audio Warning System
PCD7100-I 11956 CD/MP3 Player w/6-place ICS
PCD7100-I 11957 CD/MP3 Player w/6-place ICS and /Internal Recorder
PCD7100-P 11958 CD/MP3 Player only
Where the functions are identical to all units, it will be referred to herein as a PCD7100. Otherwise, the
applicable units will be specified.
1.3 EQUIPMENT DESCRIPTION
The PCD7100-series is a state of the art intercom with PS Engineering’s proprietary IntelliVox® automatic
voice activated (VOX) intercom system, that contains an integrated Compact Disk (CD) player.
A six-station voice activated (VOX) intercom is included in the PCD7100-I (p/n 11950, 11951, 11954,
11956). This system has PS Engineering’s exclusive IntelliVox® circuitry that eliminates manual adjustments. The system contains six separate VOX mic circuits, and only opens the microphone channel in use.
The intercom system incorporates pilot isolate and crew modes.
There are two stereo music inputs with "Soft Mute." SoftMute is a circuit that automatically mutes the
music during radio or intercom activity, and then slowly returns the music to full volume after the activity
ceases.
Intercom control is through front panel-mounted volume knobs and 3-position mode switch. A single volume controls intercom level for the pilot and copilot. Passenger headphone volume is factory set, and adjusted in flight with headset-mounted volume controls. Passenger volume control is further adjustable
through screwdriver access in the top of the unit. Intercom squelch is automatic.
1.4 APPROVAL BASIS
TSO Approval.
200-971-0005 Page 1-1 Rev. 5, Dec. 2002
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
PS Engineering
The PCD7100, is FAA approved under TSO C50c (Audio Amplifiers), /DO-178B (Software Considerations for Airborne Equipment) and DO-214 (Audio Systems Characteristics and Minimum Operational
Performance Standards for Aircraft Audio Systems). In addition, the system is approved under Joint Avia-
tion Authorities JTSO C50c.
All systems comply with relevant portions of EUROCAE ED-14D/DO-160D (Environmental Conditions
and Test Procedures for Airborne Equipment), ED12B/DO-178B (Software Considerations for Airborne
Equipment) and ED- 18/DO-214 (Audio Systems Characteristics and Minimum Operational Performance
Standards for Aircraft Audio Systems).
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: C50c, Class A
APPLICABLE DOCUMENTS: RTCA/DO-214
RTCA/DO-160D
RTCA/DO-178B (Level E)
ENVIRONMENTAL Qualifications: B1CABSRXXXXXXABBBBTMXXE2
Temperature Range:
Operating:
Storage:
-15º C to 55ºC
-40º C to 85ºC
Altitude: Up to 25,000 feet in an non-pressurized area of the cock-
pit.
DIMENSIONS: Height: 2.0 in. (5.1 cm) Width: 6.25 in. (15.9 cm)
Depth: 7.8 in. (19.8 cm)
WEIGHT (With Rack & Connectors): 2.2 lb. (1.0 kg)
POWER REQUIREMENTS (Including Internal Lighting):
Voltage: 11 to 33 VDC
Maximum Current:
11950, 11951
11952, 11953
2.0 Amp (Externally protected by a 3 Amp pull type
circuit breaker.
1.5 Amp (Externally protected by a 2 Amp circuit pulltype breaker.)
Typical operating current: 800 mA
Intercom Specifications
Headphone Impedance:
150 - 1000 Ω
Headphone Output: 35 mW each headset channel, no clipping <1% THD
Microphone Impedance:
Intercom Positions (11950, 11951,
150 - 600 Ω
6 places (with individual IntelliVOX circuits)
11954, 11956, 11957):
Music Inputs: 2 (Stereo)
Music Muting: >-50 dB "Soft Mute" when Com or intercom active.
Distortion:
<1% THD @ 35 mW into 150Ω
Mic Freq. Response, 3 dB: 300 Hz - 6000 Hz
Music Freq. Response, 3 dB: 20 Hz –20 kHz
200-971-0005 Page 1-2 Rev. 5, Dec. 2002
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
PS Engineering
1.6 EQUIPMENT SUPPLIED
1 ea. of the following units:
Model Part Number Description
PCD7100-I 11950 CD w/6-place ICS
PCD7100-I 11951 CD w/6-place ICS w/IRS
PCD7100-P 11952 CD only
PCD7100-P 11953 CD only w/AWS
PCD7100-P 11954 CD/MP3 Player Only w/Audio Warning System
PCD7100-I 11956 CD/MP3 Player w/6-place ICS
PCD7100-I 11957 CD/MP3 Player w/6-place ICS and /Internal Recorder
PCD7100-P 11958 CD/MP3 Player only
PCD7100 Installation Kit: 250-971-0001 or 250-972-0400 as shown
Part Number Description 250-971-0001
Unit Part Number
11950, 11951, 11953,
11954, 11956, 11957
120-430-9701 Tray 1 1
120-425-4402 44 Pin Connector Key 4/5 1 1
425-001-0002 Gold Plated Crimp Pins 35 10
475-440-0007 4-40x7/16" Phil-Pan w/Nylon
Patch
475-630-0002 6-32 Clip Nut 4 4
200-971-00XX Operator's and Installation
Manual
2 2
1 1
250-972-0400
Unit Part Number
11952, 11958
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED
a) Circuit Breaker, PULL TYPE: 1 ea. 3 amp (11950, 11951, 11954, 11956, 11957) or 2 amp
(11952, 11953, 11958)
b) Headphone Jacks (Stereo, up to 6 as required)
c) Microphone Jacks (up to 6 as required)
d) Headphones, 150 Ω (Stereo), up to 6 as required
e) Microphones, up to 6 as required
f) Interconnect Wiring
g) Intercom or audio system (11952, 11958, 11953, 11954)
1.8 LICENSE REQUIREMENTS
None
200-971-0005 Page 1-3 Rev. 5, Dec. 2002
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
PS Engineering
Section II - Installation
2.1 GENERAL INFORMATION
2.1.1 SCOPE
These sections provide detailed installation and interconnect instructions for the PCD7100-Series Intercom
System with internal Compact Disc (CD) Player.
Please read this manual carefully before beginning any installation to prevent damage and post-installation
problems. Installation of this equipment requires special tools and knowledge.
NOTE: 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.
2.2 Unpacking and Preliminary Inspection
Use care when unpacking the equipment. Inspect the units and parts supplied for visible signs of shipping
damage. Examine the unit for loose or broken buttons, bent knobs, etc. Verify the correct quantity of components supplied with the list in Section 1.6 (B). If any claim is to be made, save the shipping material and
contact the freight carrier. Do NOT return units damaged in shipping to PS Engineering. If the unit or accessories shows 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 PCD7100 is not required. However the unit 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 PCD7100 must be rigidly mounted to the instrument panel or other structure of the aircraft structure
and within view and reach of the persons wishing access. Installation must comply with FAA Advisory
Circular AC 43.13-2A (or later revision). The unit may be mounted in any area where adequate clearance
for the unit and associated wiring bundle exist.
The unit must be installed within ±30° of horizontal along the pitch axis, and ±10° of horizontal along the
roll axis in level flight.
Avoid installing the PCD7100 close to high current devices or systems with high-voltage, pulse type outputs, such as DME or transponders.
2.3.3 Mounting Rack Installation
Remove the unit from the mounting tray by unscrewing the 3/32" hex-head screw that is near the left edge
of the unit. Carefully slide the unit free of the tray. Set the unit aside in a safe location until needed. Install
the tray using six FHP 6-32 x ½" screws. The unit must be supported at front and rear of the mounting tray.
200-971-0005 Page 2-1 Rev. 5, Dec. 2002
PCD7100 Series Intercom System with Integral Music System
Installation and Operator’s Manual
PS Engineering
2.3.4 Connector Assembly
The unit connector mates directly with the circuit boards in the PCD7100. The connector is a Molex crimptype, and requires the use of a Molex hand crimp tool, EDP P/N 11-01-0203, CR6115B (or equiv.). The
connector is mounted to the unit tray with #4-40 screws, from the inside of the tray. Ensure that proper
strain relief and chafing precautions are made during wiring and installation.
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 43.13-2A 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. PS Engineering can provide a custom made harness, visit www.ps-
engineering.com for more information.
2.4.1 Noise
Due to the variety and the high power of radio equipment often found in today's general aviation aircraft,
there is a potential for both radiated and conducted noise interference.
The PCD7100 power supply is specifically designed to reduce conducted electrical noise on the aircraft
power bus by at least 50dB. Although this is a large amount of attenuation, it may not eliminate all noise,
particularly if the amplitude of noise is very high. There must be at least 12 VDC present at the connector
pin 21, of the PCD7100 for the power supply to work in its designed regulation. Otherwise, it cannot adequately attenuate power line noise. Shielding can reduce or prevent radiated noise (i.e., beacon, electric
gyros, switching power supplies, etc.) However, installation combinations can occur where interference is
possible. The PCD7100 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).
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 PCD7100-Series units are compatible with both 14 and 28 Volt DC systems. A three- (3) Amp PULLTYPE circuit breaker is required for p/n 11950, 11951, or two (2) Amp PULL-TYPE breaker for p/n
11951, or 11952. Power and ground wires must be a twisted
#18 AWG pair. Connect airframe power
ground to Pin 22 only.
2.4.3 Communications Push-to-Talk
An important part of the standard intercom installation (11950, 11951) is the PTT (Push-To-Talk) switches
that allow the use of your aircraft communications radio for transmissions. There are three typical configurations that can be used. Select the case that best fits the installation. Only the person who presses their
PTT switch will be heard over the radio. If the pilot and copilot both use the PTT, the only pilot position
has access to the radio. The pilot position will have PTT control regardless of the mic selector switch or
copilot PTT when the PCD7100 is in the F
200-971-0005 Page 2-2 Rev. 5, Dec. 2002
AIL-SAFE
mode.
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