PS Engineering PCD7100-P Installation Manual

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Page 1

9800 Martel Road

Lenoir City, TN 37772

High-fidelity Stereo IntelliVox® Intercom

System

With integral music system

FAA-TSO C50c

US Patent 6,493,450

Document P/N 200-971-0006

Revision 8

January 16, 2015

Installation and Operation Manual

PS Engineering, Inc. 2006 ©

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.

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

Authorized PS Engineering dealer.

Page 2

Table of Contents

SECTION I GENERAL INFORMATION..........................................................................1-1

1.1 INTRODUCTION............................................................................................................. 1-1

1.2 SCOPE...............................................................................................................................1-1

1.3 EQUIPMENT DESCRIPTION .......................................................................................1-1

1.4 APPROVAL BASIS..........................................................................................................1-2

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 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 MOUNTING RACK INSTALLATION .................................................................................... 2-1

2.3.4 CONNECTOR ASSEMBLY .................................................................................................. 2-2

2.4 CABLE HARNESS WIRING .................................................................................................2-2

2.4.1 NOISE ............................................................................................................................... 2-2

2.4.2 POWER..............................................................................................................................2-2

2.4.3 COMMUNICATIONS PUSH-TO-TALK ................................................................................. 2-2

2.4.4 BACKLIGHTING................................................................................................................. 2-3

2.4.5 INTERCOM WIRING (11950, 11951 ONLY) ........................................................................ 2-3

2.4.6 PLAYBACK INSTALLATION (11951 ONLY)........................................................................2-4

2.4.7 UNSWITCHED AUDIO INPUT (11950, 11951 ONLY)..........................................................2-4

2.4.8 UNSWITCHED SUMMED AUDIO (11952, 11953 ONLY)..................................................... 2-4

2.4.9 AUDIO MESSAGE SYSTEM (11953 ONLY) ........................................................................ 2-4

2.5 ADJUSTMENTS....................................................................................................................2-4

2.6 POST INSTALLATION CHECKOUT .....................................................................................2-5

2.7 UNIT INSTALLATION..........................................................................................................2-5

2.7.1 INTERCOM CHECKOUT (11950, 11951 ONLY).................................................................. 2-5

2.7.2 CD PLAYER CHECKOUT ................................................................................................... 2-6

2.8 INTERNAL RECORDER CHECKOUT (OPTIONAL) ............................................................. 2-6

2.9 FINAL INSPECTION.............................................................................................................2-6

SECTION III OPERATION.................................................................................................3-1

3.1 SCOPE...............................................................................................................................3-1

3.2 POWER SWITCH (FAIL SAFE OPERATION).......................................................................3-1

3.3 INTERCOM OPERATION..................................................................................................... 3-1

3.3.1 INTERCOM VOLUME CONTROL ........................................................................................ 3-1

3.3.2 INTELLIVOX® VOX-SQUELCH ......................................................................................... 3-1

3.3.3 MUSIC 1 AND SOFT MUTE CONTROL ............................................................................... 3-2

3.3.4 INTERCOM MODES ........................................................................................................... 3-2

3.4 OPERATING THE INTERNAL CDPLAYER .........................................................................3-4

3.5 INTERNAL RECORDER SYSTEM (OPTIONAL)................................................................... 3-4

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page ii Rev. 8, Jan. 2015

3.5.1 OPERATION....................................................................................................................... 3-4

3.6 PCD7100-P CDPLAYER ONLY (PART NUMBER 11952 AND 11953)..............................3-5

3.6.1 POWER/VOLUME KNOB....................................................................................................3-5

3.6.2 OPERATING THE INTERNAL CD PLAYER .......................................................................... 3-5

3.6.3 TONE CONTROL................................................................................................................ 3-5

3.6.4 AUDIO MESSAGING SYSTEM (11953 ONLY) .....................................................................3-5

SECTION IV- WARRANTY AND SERVICE....................................................................4-1

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

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

APPENDIX A EXTERNAL PTT HOOK UP .......................................................................A

APPENDIX B – INSTALLATION DRAWING .............................................................B

APPENDIX C CONNECTOR INTERCONNECT................................................................C

7.1 PCD7100 W/INTERCOM (11950, 11951)..............................................................................C

7.2 PCD7100 W/OUT INTERCOM (11952, 11953) ......................................................................B

APPENDIX D- INSTRUCTIONS FOR FAA FORM 337 AND CONTINUING

AIRWORTHINESS ........................................................................................................................D

8.1 INSTRUCTIONS FOR FAAFORM 337, PCD7100S................................................................D

8.2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS, PCD7100S.......................................D

APPENDIX E RTCA DO160D/EUROCAE ED-14D ENVIRONMENTAL

QUALIFICATION FORM INTERCOM/CD PLAYER...........................................................E

Revision

Date

Reason

Jan 2003

Add MP3 Version

April 2006

Added compatability note

May 2008

Update installation kit description

January 2015

Removed reference to JTSO

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 1-1 Rev. 8, Jan. 2015

Section I GENERAL INFORMATION

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 com-

pact 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 adjust-

ments. 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 mu-

sic 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.

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 1-2 Rev. 8, Jan. 2015

1.4 APPROVAL BASIS

TSO Approval. The PCD7100, is FAA approved under TSO C50c (Audio Amplifiers), /DO-178B (Software Considera-

tions for Airborne Equipment) and DO-214 (Audio Systems Characteristics and Minimum Operational Performance Standards for Aircraft Audio Systems).

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 cockpit.

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 

Headphone Output:

35 mW each headset channel, no clipping <1% THD

Microphone Impedance:

150 - 600 

Intercom Positions (11950, 11951, 11954, 11956, 11957):

6 places (with individual IntelliVOX circuits) Music Inputs:

2 (Stereo)

Music Muting:

>-50 dB "Soft Mute" when Com or intercom active.

Distortion:

<1% THD @ 35 mW into 150

Mic Freq. Response, 3 dB:

300 Hz - 6000 Hz

Music Freq. Response, 3 dB:

20 Hz –20 kHz

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 1-3 Rev. 8, Jan. 2015

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

250-972-0400

Unit Part Number

11952, 11958

120-430-9701

Tray11

120-425-4402

44 Pin Connector Key 4/5

425-001-0002

Gold Plated Crimp Pins

475-440-0007

4-40x7/16" Phil-Pan w/Nylon Patch

475-630-0002

6-32 Clip Nut66

475-632-0012

6-32 x ½ Phil screw

200-971-00XX

Operator's and Installation Manual

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  (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

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-1 Rev. 8, Jan. 2015

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.

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-2 Rev. 8, Jan. 2015

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 FAIL-SAFE mode.

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-3 Rev. 8, Jan. 2015

CASE I: PTT is built into both pilot and copilot yokes. CASE II: PTT is in pilot yoke only. This configuration requires a modified external PTT switch plugged

into the copilot's microphone jack. (See Appendix A). When the copilot's PTT is pressed, the intercom switches the microphone audio from pilot to copilot mic.

CASE III: No built in PTT. This requires two built in PTTs to be installed, or modified external PTT switches to be used. Modify external PTT as required (See Appendix A).

No Push to Talk is required for CD-only (11952, 11953).

2.4.4 Backlighting

The PCD7100 has an automatic dimming of the pushbutton annunciator LEDs controlled by a photocell. A dimmer control allows the bezel text backlighting to be controlled by the aircraft dimmer. Connect the 14 V dimmer control to pin 1, the 28 V dimmer to pin A, as required.

2.4.5 Intercom wiring (11950, 11951, 11956, 11957 only)

See Appendix for intercom connection configurations. It is critical to the proper operation of this system to have this connector wiring made in accordance with these diagrams. Use 2- and 3-conductor, MIL-spec cable as shown. Connect the shields at the PCD7100 end only, and tie to the audio low inputs as shown.

NOTE: The harness can be custom made by PS Engineering, Inc. Simply call the factory or access

www.ps-engineering.com on the internet to obtain a wire harness work-sheet. The harness will be made to

your specifications and fully functionally tested. All hardware is included.

2.4.5.1 Entertainment 2 Input

NOTE: Use the low-level output of any entertainment device to connect to the PCD7100. Minimum of 1 VAC p-p, maximum signal level is 3 VAC p-p.

DO NOT use a speaker-level output, this will cause internal damage in the PCD7100 An additional stereo entertainment device (CD player, cassette player, etc.) can be connected to the unit.

Install a1/8-inch stereo jack in a convenient location so that the pilot can plug in the entertainment devices into the system. The audio signal at the entertainment input must be a minimum of 1 V P-P per channel for optimum music performance.

All external entertainment devices must be switched off for both takeoff and landing.

2.4.5.1.1 Entertainment distribution

Entertainment source #1 (CD player) provides music for the pilot and copilot positions in crew mode and everybody in ALL. Entertainment source #2 provides music for the four passenger positions in crew mode only. The PCD7100-system incorporates a "Soft Mute" for the CD player. This will mute the music during ICS or radio conversation.

Entertainment inputs #1 and #2 can be paralleled (connected together) so the internal CD entertainment source can serve both the passengers and the crew. However, we suggest that a switch (DPDT) is installed between the single entertainment device and entertainment input #1 to allow entertainment flexibility.

Caution: Local oscillators and internal signals from some entertainment 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.

Both entertainment devices must be switched off for both takeoff and landing.

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-4 Rev. 8, Jan. 2015

2.4.6 Playback Installation (11951, 11957 only)

To install the IRS, a momentary, normally open, push button switch is required. This switch can be located any where in cockpit convenient to the pilot's reach. The switch must be connected to pin Y of the PCD7100.

2.4.7 Unswitched Audio Input (11950, 11951, 11956, 11957 only)

The PCD7100-I has an audio input that is provided to the pilot headset. Pins 16 (right) and 18 (left) with respect to audio low (pin E) are presented to the pilot headset through an audio buffer.

2.4.8 Unswitched Summed Audio (11952, 11953, 11954, 11958 only)

PCD7100-P, player units have four audio inputs that are summed together and presented to the aural warning output, J1 pin 18 WRT V.

NOTE: These can be used to implement additional audio warnings when connected to the appropriate Unswitched audio input of an audio panel. This includes Autopilot warnings, TAWS, GPS alerts, Radio Altimeter, etc.

2.4.9 Audio Message System (11953, 11954 only)

The audio message installation requires inputs from an external annunciator, such as an Electronics International engine gage system. A falling edge (input pulled low) when applied to the appropriate pin of the con-

nector will cause the message to be played, repeating every two seconds, until the acknowledge (“ACK”)

button is pushed. Install the “ACK” button in a location convenient to the pilot and copilot position. This switch is a momen-

tary SPST switch between Pin 4 and signal ground (18). The following table contains information regarding various inputs.

Function

EGT or CHT

Fuel

Flow or

Level

Oil Pres-

sure or

temperature

Volt/

Amp

RPM

Manifold

Pressure

PCD7100 Pin

58697

Message Number

12345

Message Text

“Check temperature”

“Check fuel”

“Check oil”

“Check battery”

“Check en- gine speed”

“Check boost”

Other combinations can be created at additional cost. NOTE: PS Engineering can only provide input information at this time. Approval basis is the responsibil-

ity of the installer. Contact PS Engineering for more information.

2.5 Adjustments

The PCD7100 is factory adjusted to accommodate the typical requirements for most aircraft configurations. The only service adjustment is passenger headset volume control. These are set for maximum at the factory, but may be attenuated at installation if desired by accessing two adjustment pots.

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-5 Rev. 8, Jan. 2015

Figure 2-1- PCD7100 Adjustments

2.6 Post Installation Checkout

After wiring is complete, verify power is ONLY on pin 21 of the connector, and airframe ground on bottom connector pin 22. Failure to do so will cause serious internal damage and void PS Engineering's warranty.

2.7 Unit Installation

To install the PCD7100, gently slide the unit into the mounting rack until the hold-down screw is engaged. While applying gentle pressure to the face of the unit, tighten the 3/32" hex-head in the unit until it is secure. DO NOT OVER TIGHTEN.

Warning: Do not over-tighten the lock down screw while installing the unit in tray.

Internal damage will result.

Play/Pause Skip-FF Repeat-RW Stop Eject

2.7.1 Intercom Checkout (11950, 11951, 11956, 11957)

1. Apply power to the aircraft and avionics. Leave PCD7100 off.

2. Plug headsets into the pilot, copilot, and occupied passenger positions.

3. Verify correct fail-safe operation by listening and transmitting on the aircraft radios in the pilot’s headset with the unit off. The audio will only be presented to the pilot’s right ear, in stereo mode.

4. Switch on the PCD7100. Verify that the STOP LED (Light Emitting Diode) shows green if there is a CD in the unit, or the Eject LED if there is not a CD inside.

5. Verify proper transmit and receive operation from the pilot and copilot positions, noting that the copilot PTT switch allows proper transmission on the selected transceiver.

6. Verify proper Intercom system operation in the ALL, ISO and CREW modes (see Table 3-1).

Passenger Intercom

volume (L)

Passenger Intercom

volume (R)

Front of Unit

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PS Engineering

PCD7100 Series Intercom System with Integral Music System

Installation and Operator’s Manual

200-971-0006 Page 2-6 Rev. 8, Jan. 2015

7. Verify that the PCD7100 system does not adversely affect any other aircraft system by systematically switching the unit on and off and changing modes, while monitoring the other avionics and electrical equipment on the aircraft.

2.7.2 CD Player Checkout

8. Insert CD, and verify that the player accepts the disk with about ½ of the diameter in the unit. The player should pull the disk smoothly and drop into place.

9. The CD player will begin to play, automatically.

10. If the CD is inside at power-up, push the “play” button.

11. Verify that all CD modes operate.

12. Push the “Eject” button and verify that the disc is ejected within about 10 seconds.

2.8 Internal Recorder Checkout (Optional)

With headset plugged into pilot’s side jacks, tune aircraft radio to local frequency, such as FSS or ATC

ground. Select Com 1 on mic selector switch, and record at least five incoming radio transmissions. This audio should only appear in one side of the pilot’s headset, and it should be radio (or sidetone) tra ffic. Depress the panel or yoke mounted playback switch, and verify that all five messages play, in the order re-

ceived.

2.9 Final Inspection

Verify that the wiring is bundled away from all controls and no part of the installation interferes with aircraft control operation. Move all controls through their full range while examining the installation to see that no mechanical interference exists. Verify that the cables are secured to the aircraft structure in accordance with good practices, with adequate strain relief. Ensure that there are no kinks or sharp bends in the cables and coaxial cables. Verify that the cables are not exposed to any sharp edges or rough surfaces, and that all contact points are protected from abrasion.

Complete logbook entry, FAA Form 337, weight and balance computation and other documentation as required. 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.

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-1 Rev. 8, Jan. 2015

Section III OPERATION

GENERAL INFORMATION

3.1 SCOPE

This section provides detailed operating instructions for the PS Engineering PCD7100-I, Intercom Systems with integrated Compact Disc (CD) player, and PCD7100-P, CD player only. Please read it carefully before using the equipment so that you can take full advantage of its capabilities.

Figure 3-1 PCD7100 controls

3.2 Power Switch (Fail Safe Operation)

Unit power is turned on and off by pushing the intercom volume knob. In the OFF or "EMG" position, the pilot is connected directly to the aircraft radios. This allows communication capability regardless of unit condition. Any time power is removed or the unit turned OFF, the intercom will be placed in the fail-safe mode.

3.3 Intercom Operation

3.3.1 Intercom Volume Control (11950, 11951, 11956, 11957)

The ICS volume control knob (left side) adjusts the loudness of the intercom for the pilot and copilot only. It has no effect on selected radio levels, music input levels or passengers' volume level.

Adjust the radios and intercom volume for a comfortable listening level for the pilot. Most general aviation headsets today have built-in volume controls; therefore, passenger volume can be adjusted at the headset.

3.3.2 IntelliVox® VOX-Squelch

No adjustment of the IntelliVox® squelch control is necessary. Through independent signal processors on each microphone, the ambient noise appearing in all microphones is constantly being sampled. Non-voice signals are blocked. When someone speaks, only their microphone circuit opens, placing their voice on the intercom.

The system is designed to block continuous tones, therefore people humming or whistling in monotone may be blocked after a few moments.

For best performance, the headset microphone must be placed within ¼ inch of your lips, preferably against them. 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.

For optimum microphone performance, PS Engineering, Inc. recommends installation of a Microphone Muff Kit from Oregon Aero (1-800-888-6910). This will not only optimize VOX performance, but will improve the overall clarity of all your communications.

INTERCOM VOLUME

MUSIC VOLUME

PLAY SKIP FWD SKIP BACK STOP EJECT

INTERCOM MODE

PUSH ON-

PUSH MUTE

CONTROL

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-2 Rev. 8, Jan. 2015

Table 3-1 Mic Muff ® Part Numbers

Manufacturer

Model

Mic Muff® Part

Number

Bose

Dynamic Electret M87 Dynamic

90010 90015 90020

David Clark

H10-30 H10-20, H10-40 H10-13.4

90010 90015 90015

Lightspeed

15K & 20K

90015

Peltor

7003 7004

90010 90015

Pilot

11-20 & 11-90

90015

Sennheiser

90015

Telex

Airman 750 AIR3000

90015 90010

3.3.3 Music 1 and Soft Mute Control

The right-side volume knob controls the loudness of the internal CD player. The volume knob controls the music volume only, it has no effect on the intercom or radio volume, or the

secondary music input level. This knob is also the Soft Mute control for the CD player. Normally, the music is instantly muted during

radio or intercom conversation, and returns gradually to full volume when conversation stops. Pushing the knob once will inhibit the soft mute, enabling a “Karoake” mode, where the music remains at he normal level for a sing-along. Push again to return to a soft muting mode.

3.3.3.1 Mono headsets in Stereo Installation

Plugging a mono headset into the pilot or copilot jacks has no effect other than there will be no stereo left and right separation. Since all passenger headsets are connected in parallel, if a monaural headset is plugged in to a PCD7100 Stereo installation, one channel will be shorted. Although no damage to the unit will occur, all stereo-equipped passengers will lose one channel. PS Engineering modifies headsets to add stereo capability, using high-fidelity speakers. Contact factory for details (865-988-9800 or www.psengineering.com).

3.3.4 Intercom Modes

On the left side of the intercom-versions is a 3-position mode switch that allows the pilot to tailor the intercom function to best meet the current cockpit situation.

ISO: (Up Position): The pilot is isolated from the intercom and is connected only to the aircraft radio system. He will hear the aircraft radio reception (and sidetone during radio transmissions). Copilot and passengers will hear intercom and CD player. Neither will hear aircraft radio receptions or pilot transmissions.

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-3 Rev. 8, Jan. 2015

ALL: (Middle Position): All parties will hear the aircraft radio, CD music and intercom. During any radio or intercom communications, the music volume automatically decreases (unless the mute is inhibited). The music volume will gradually return to the original level after communications have been completed.

CREW (Down Position): Pilot and copilot are connected on one intercom channel and have exclusive access to the aircraft radios. They may also listen to CD music. Passengers can continue to communicate with themselves without interrupting the Crew and also may listen to Entertainment 2. Entertainment 2 may be connected to the CD player during installation if so desired.

3.3.4.1 Soft Mute and Soft Mute inhibit

The Soft Mute feature assures that the aircraft radio transmissions will not be missed due to entertainment playing. When there is radio reception or intercom conversation, the music level is dropped to a low, or background level. When the radio or intercom traffic ceases, the level gradually returns to normal.

The front panel “MUTE” switch controls muting of the CD player. Pushing the music volume knob places the ICS in Karoake (or sing along) mode, which inhibits the soft mute feature. This allows the music to continue uninterrupted by intercom or radio traffic when cockpit workload is appropriate. Pushing the knob again will release the mute inhibit function.

Table 3-2 Intercom Modes

Mode

Pilot Hears

Copilot Hears

Passenger Hears

Comments

Isolate

A/C Radios

Pilot Sidetone (during radio transmission) CD is Muted

Copilot and passenger intercom CD player

Passenger and Copilot intercom CD Player

This mode allows the pilot to communicate without the others bothered by the conversations. Copilot and passengers can continue to communicate and listen to music

All

Pilot Copilot A/C Radio Passengers CD player

Copilot Pilot A/C Radio Passengers CD player

Passengers Pilot Copilot A/C Radio CD player

This mode allows all on board to hear radio reception as well as communicate on the intercom. Music is muted during intercom and radio communications

Crew

Pilot Copilot A/C Radio CD Player

Copilot Pilot A/C Radio CD Player

Passengers Entertainment #2*

This mode allows the pilot and copilot to concentrate on flying, while the passengers can communicate amongst themselves. Two separate music inputs are possible.

3.3.4.2 Secondary Entertainment Input

The PCD7100 has provisions for an additional entertainment input. The primary music volume control does not affect secondary music level.

While in the CREW mode, pilot and copilot will hear entertainment input #1 while the passengers may listen to entertainment input #2.

It is also possible to use only one entertainment input device for both entertainment inputs. It is suggested however, that a switch (DPDT) is installed between the single entertainment device and entertainment input #1. This will allow the passengers to play the CD while in the Crew mode.

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-4 Rev. 8, Jan. 2015

3.4 Operating the internal disc Player

The single-disk CD player is designed for simple operation. There are five buttons with the following functions.

► (Play) Plays disc, push again to pause ►► (Jump Forward) Push to jump to the next track, hold to fast forward in current track ◄◄ (Jump Backward) Push to jump to the previous track, hold to rewind in current track

 (Stop) Stops playback

▲ (Eject) Ejects disc

The CD player will begin to play automatically when a CD is inserted. Press the play button to pause the track.

The jump forward button advances to the next track. Jump backwards selects the previous track. On MP3 units (11954, 11956, 11957, 11958), pressing the Jump Forward and Jump Backward buttons at

the same time will toggle the unit into a random play mode. Random Mode is particularly useful if the disc contains a large number of files.

Stop ceases play, and Eject removes the disk from the CD player.

3.5 Internal Recorder System (Optional)

The Intercom Recording System (referred to here as the IRS) is a digital recording system allowing automatic storage and immediate playback of all incoming aircraft radio receptions.

Operating as a continuous loop recorder, (first message received will be the last heard), the recorder has one minute of recording time divided into as many as 16 messages. With its own built-in VOX circuit, there are no buttons to press to start recording. The system automatically begins to record the instant the radio becomes active. Only aircraft radio audio in pilot’s headset is recorded and only the pilot will hear the playback audio, in one ear.

3.5.1 Operation

Recording is automatic; there is no action required by the pilot. To play back the last recorded message, simply press the momentary switch associated with the IRS. Each additional press of the button will play the preceding recorded message.

To stop playback, hold the playback button for two seconds. The next push will then play the prior message.

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-5 Rev. 8, Jan. 2015

3.6 PCD7100-P CD Player Only (Part Number 11952, 11953, 11958 and 11959)

3.6.1 Power/Volume Knob

Pushing the right-hand knob switches the PCD7100-P on. Push again to turn off. Rotate the knob to increase volume on the music output.

3.6.2 Operating the internal CD Player

The single-disk CD player is designed for simple operation. There are five buttons with the following functions.

► (Play) Plays CD, push again to pause ►► (Jump Forward) Push to jump to the next track, hold to fast forward in current track ◄◄ (Jump Backward) Push to jump to the previous track, hold to rewind in current track

 (Stop) Stops playback

▲ (Eject) Ejects disc

The CD player will begin to play automatically when a CD is inserted. Press the play button to pause the track.

The jump forward button advances to the next track. Jump backwards selects the previous track. On MP3 units (11954, 11956, 11957, 11958), pressing the Jump Forward and Jump Backward buttons at

the same time will toggle the unit into a random play mode. Random Mode is particularly useful if the disc contains a large number of files.

Stop ceases play, and Eject removes the disk from the CD player.

3.6.3 Tone Control

Turning the left-hand knob modifies the bass/treble of the music output to suit individual tastes.

3.6.4 Audio Messaging system (11953 and 11954 only)

When this option is installed, the PCD7100-P contains six stored messages. An outside annunciator, such as an Electronics International engine gage system triggers these messages. When there is an announcement, it will be repeated every two seconds until the remote- mounted ACK button is pushed. This stops the played annunciation, until the next announcement is required (the next falling edge).

PLAY SKIP FWD SKIP BACK STOP EJECT

PUSH

ON-OFF

MUSIC

TONE

MUSIC

VOLUME

ACK

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 3-6 Rev. 8, Jan. 2015

3.6.4.1 Push ACK (11953, 11954 only)

Pushing the left-hand will acknowledge and silence a playing Aural Warning, if this feature is implemented (Part number 11953 only).

3.7 Creating MP3s from an Audio CD

1. Start MusicMatch JukeBox.(www.musicmatch.com) Press the recorder button, which is the small red dot located in the top right corner. This will open the recorder window located at the bottom of the screen.

2. Insert an audio CD into the CD drive. MusicMatch will automatically read the disc and display the contents in the recorder window. Press the REFRESH button to check the Internet database for CD information, such as artist, song title, or album. If this information is available, it will automatically be updated in the file.

3. Select Options->Recorder->Format and select either MP3 or MP3PRO format. You may also set the MP3 file quality under the Options->Recorder->Quality menu.

4. Select the tracks to be copied to MusicMatch by checking the box next to the desired track. Press the record button in the lower left corner when complete

5. MusicMatch will then convert the files from the audio CD to MP3 and display them in the Music Library box located in the middle of the screen

6. To edit the MP3 information, select a file in the Music Library and press the TAG button in the top right corner of the Music Library box. This will display the MP3 tagged information screen. Select the General tab to show the information that can be modified for the PXE7300.

7. The PXE7300 can display song name, artist, album, and filename. This corresponds to the Track title, Artist, Album, and Track Filename fields shown on the screen. Each of these fields can be modified to the user’s preference. Note: The PXE7300 is limited to displaying up to 22 characters in each of these fields. Click on the appropriate field to modify the track title, artist, or album. To modify the filename, select the Rename Files button in the lower left corner. Click on the field labeled New File Name and press OK to change the file name. Press the Apply and OK buttons to update the information

Page 19

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Page 4-1 Rev. 8, Jan. 2015

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-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 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 one (1) year from the date of installation as recorded in aircraft logbook and/or on FAA Form 337. During the twelve (12) months, 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.

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 dissemble 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 unit is covered by a one-year limited warranty. See warranty information. Call PS Engineering, Inc. at (865) 988-9800 before you return the unit. This will allow the service technician to provide any other suggestions for identifying the problem and recommend possible solutions.

After discussing the problem with the technician and you obtain a Return Authorization Number, ship product to:

PS Engineering, Inc. Attn: Service Department 9800 Martel Rd Lenoir City, TN 37772 (865) 988-9800 FAX (865) 988-6619

Email: support@ps-engineering.com

NOTE: PS Engineering will not be responsible for any units shipped in the U. S. Mail. Units received without either a Return Authorization or a contact telephone number will be refused

and returned to the sender.

Page 20

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix A Rev. 8, Jan. 2015

Appendix A External PTT Hook Up

This section applies to PCD7100-I units (with internal intercom). Part of the installation includes the installation of PTT (Push To Talk) switches that allow the use of your aircraft radio for communications transmissions.

There are three configurations that can be used, you must select the case that best fits your installation. NOTE: Only the person who presses their PTT switch will be heard over the radio.

CASE I

The PTT is built into the pilot and copilot yokes

Simply install the plugs from the headset into the aircraft headphone jacks. Then use the yoke mounted PTT to transmit. No other action is required.

CASE II

Built in PTT only on the pilot side only

This configuration requires a modified external PTT switch plugged into the copilot's mic jack. (See Details Below) When the copilot's PTT is depressed, this activates an internal relay that switches the mic audio to the aircraft radio from the pilot to the copilot.

Case III

No built in PTT switch at all.

Two built-in PTT must be installed, or two external, modified PTT switches will be required for both the pilot and copilot. Modifications to the PTT are required. (See details below)

Push To Talk Modifications

When received from the manufacturer, an after-market PTT switch opens the mic audio path to the "ring" connection of the PTT mic plug until the button is pressed. When the PTT is between the intercom and the headset, the intercom function will not work unless the PTT switch is depressed. A simple modification can be performed to allow proper intercom operation. NOTE: This mod does not alter normal operation.

Below are some examples of typical modifications. Contact PS Engineering or the PTT manufacturer for more details if necessary.

Procedures For David Clark PTT

Unscrew the round black plastic cover from the jack. Connect the joined black wires to the red wire. Replace the round black plastic cover.

Procedures for Telex PT-200

Unscrew the round black plastic cover from the jack. Cut the red wire in the middle of the wire. Strip both ends of the insulation. Solder the two ends to the ground lug to the PTT jack. Replace the round black plastic cover.

Procedures for Telex PT-300

Unscrew the round black plastic cover from the plug jack. Remove the heat shrink material from the joined black wires. Solder these two wires to the lug that has a white wire already soldered to it. Replace the round black plastic cover

Page 21

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix B Rev. 8, Jan. 2015

Appendix B – Installation Drawing

6.31in (160.3 mm)

Cutout size for front mount installation

2.00 in (5.08 mm)

Weight: 2.2 lb with tray and connectors ( 1.0 kg)

Connector viewed from the rear

ZYXWVUTSRPNMLKJHFEDCB

2221201918171615141312111098765432A1

Connector Key

6.21

1.99

6.95

0.80

0.99

1.98

0.33

0.60

Z Y X W V U T S R P N M L K J H F E D C B

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2A1

Connector viewed from the FRONT of unit tray

Page 22

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix C Rev. 8, Jan. 2015

Appendix C Connector Interconnect

7.1 PCD7100 w/Intercom (11950, 11951, 11956, 11957 )

Entertainment Loopback Detail

Ent. #2 Audio Lo

Ent. #2 Audio Input (R)

Ent. #2 Audio Input (L)

14 T

CD Audio Lo

CD Audio Out (R)

CD Audio Out (L)

3 C

2 B

AUX Headphone Jack

To Aircraft Radio Mic Audio Lo

To Aircraft Radio Phone Low

Aircraft Radio PTT

To A/C Radio Mic Audio Hi

Aux Mic Jack

To Aircraft Radio Phone Audio Hi

Copilot PTT

Copilot Mic Jack

Copilot Mic Lo

Copilot PTT

Copilot Mic Audio

N 11

Pilot Phones Lo

Pilot Phones (R)

Pilot Phones (L)

F 5

Audio Lo

Aircraft Ground

Pass. 4 Phones Jack

Pass. 2 Phones Jack

Pass. Phones Lo

Pass Phones (R)

Pass. Phones (L)

L 9

1. All phone and mic jacks must be floating from ground. Shields connected to PCD7100 only.

2. All audio wiring must be MIL 22750 or 27500 24 AWG minumum..

3. Power and Ground #18AWG Mil-Spec Tefzel minimum. Lighting #22 AWG minum.

4. Music 1 is heard in pilot and copilot positions in ALL and Crew mode. Music 1 is heard in passenger positions in ALL mode. Music 2 is heard in passenger positions only in crew mode. To provide CD music to passengers in all modes, loop back as shown, install SPDT switch to control distribution if desired.

5. Key between pins 4 and 5.

6. Playback optional for units with internal recorder. Use Normally Open Momentary switch.

7. MUST USE PULL Type circuit breaker

PCD7100 J1 CONNECTOR

Ent. #2 Audio Lo

Ent. #2 Audio In (R)

Ent. #2 Audio In (L)

Note 1

Playback

14 T

Ent. #2 Input

CD Player Output

CD Audio Lo

CD Audio Out (R)

CD Audio Out (L)

Pilot Mic Jack

Pilot PTT

Pilot Mic Lo

Pilot PTT

Pilot Mic Audio

D 4

Pass. Mic Hi Pass. Mic Lo

Pass. 4 Mic Jack

Pass. Mic Hi Pass. Mic Lo

Pass. 3 Mic Jack

Pass. 3 Phones Jack

Pass. Mic Hi Pass. Mic Lo

Pass. 2 Mic Jack

Pass. 1 PhonesJack

Pass. Mic Hi Pass. Mic Lo

Pass. 1 Mic Jack

Pass. Phones Lo

Pass Phones (R)

Pass. Phones (L)

J 8

14- 28 VDC Aircraft Power - 3A PULL-TYPE Breaker

Copilot Phones Lo

Copilot Phones (R)

Copilot Phones (L)

H 7

Notes:

3 C

14 V Dimmer

28 V Dimmer

16 18

Unswitched AUX Audio Input (L)

Unswitched AUX Audio Input (R)

Note 6

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PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix C Rev. 8, Jan. 2015

7.2 PCD7100 w/out Intercom (11952, 11953, 11954, 11958)

1. All audio wiring must be MIL 22750 or 27500 24 AWG minumum..

2. Power and Ground #18AWG Mil-Spec Tefzel minimum. Lighting #22 AWG minum.

3. Use 2A pull-type cicruit breaker.

4. Optional Alert Messages for units with internally stored AWS messages. Apply a ground to activate the specific message. Close acknowledge switch to cancel.

5. Unswitched audio is summed and presented to AWS output.

6. While the output of this device is designed to work the majority of intercoms and audio panels, PS Engineering can not guarantee satisfactory results for all devices.

PCD7100-P J1 CONNECTOR

Notes:

C 3 6

5 9 7 10 8 11

1 A

Note 4

15 S 14 R 13 P 12 N

Unswitched Audio Input 1 Hi Unswitched Audio Input Lo Unswitched Audio Input 2 Hi Unswitched Audio Input Lo Unswitched Audio Input 3 Hi Unswitched Audio Input Lo Unswitched Audio Input 4 Hi Unswitched Audio Input Lo

Note 5

Page 24

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix D Rev. 8, Jan. 2015

Appendix D- Instructions for FAA Form 337 and continuing air-

worthiness

8.1 Instructions for FAA Form 337, PCD7100s

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 PCD7100, you may use the following text as a guide.

Installed audio selector and 6-place intercom, PS Engineering PCD7100, part number 1195 (X) 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 200-971-(XXXX), revision (), dated ( ).

This unit is FAA-Approved under TSO C50c for audio amplifiers, and meets appropriate environmental qualifications outlined in RTCA DO-160D 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 __A circuit breaker (type and part number), and total electrical load does not exceed % of the electrical system capacity with the PCD7100 added.

Aircraft equipment list, weights and balance amended. Compass compensation checked. A copy of the operation instructions, contained in PS Engineering document 200-971-( ), revision ( ), dated ( ), is placed in the aircraft records. All work accomplished listed on Work Order .

8.2 Instructions for Continuing Airworthiness, PCD7100s

Sample ICA Checklist for PS Engineering PCD7100s:

Section

Item

Information

Introduction

Installation of intercommunications system.

Description

Installation as described in manufacturer’s installation manual referenced on

FAA Form 337, including interface with other avionics audio as required.

Controls

See installation and operator’s guide referenced on FAA Form 337.

Servicing

None Required

Maintenance Instructions

On Condition, no special instructions

Troubleshooting

In the event of a unit problem, place the unit into “off,” “fail-safe” and/or “emergency” mode. This allows pilot communications using aircraft radios.

Follow checkout instructions in the installation manual referenced on the FAA Form 337. For a specific unit fault, contact the manufacturer at (865) 988-9800 for special instructions.

Removal and replacement information

Removal: Using a 3/32” Allen-head wrench, carefully unscrew the locking screw located in the center of the unit. While turning the wrench CCW, gently pull on the EDGES of the bezel until the unit is free from the mounting tray. Installation: Engage the locking screw at the back. Turn the locking screw CW, while applying slight pressure to the edges of the bezel. Do not over tighten!

Diagrams

Not applicable

Special Inspection Requirements

Not Applicable

Protective Treatments

Not Applicable

Structural Data

Not Applicable

Special Tools

None

Not Applicable

Recommended Overhaul Periods

None

Airworthiness Limitations

Not Applicable

Revision

To be determined by installer

Page 25

PS Engineering

PCD7100 Series Audio Selector Panel and Intercom System

Installation and Operator’s Manual

200-971-0006 Appendix E Rev. 8, Jan. 2015

Appendix E RTCA DO160D/EUROCAE ED-14D Environmental Qualification Form Intercom/CD Player

Part Number: 1195 ( ) FAA TSO Number: C50c 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 B1

-55° C Storage, -20°C Low Operating +85°C Storage, +70°C High Operating Not Applicable, no cooling required

25,000’ unpressurized

Not Applicable Not Applicable

Temperature variation

5.2

Equipment tested to Category C

Humidity

6.0

Equipment tested to Category A

Shock

7.0

Equipment tested to Operational test only

Operational

7.2

Equipment tested Category B Crash Safety

7.3

Vibration

8.0

Equipment tested to Category S R

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 B

Voltage Spike

17.0

Equipment tested to Category B

Audio Frequency Susceptibility

18.0

Equipment tested to Category B

Induced Frequency Susceptibility

19.0

Equipment tested to Category B

Radio Frequency Susceptibility

20.0

Equipment tested to Category T Radio Frequency Emission

21.0

Equipment tested to Category M

Lightning Induced Transient Susceptibility

22.0

Equipment tested to Category XXE2 Lightning Direct Effects

23.0

Category X not tested

Icing

24.0

Category X, not tested