PS Engineering PCD7100-P Installation Manual
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 ©
Copyright Notice
Any reproduction or retransmittal of this publication, or any portion thereof, without the expressed written permission of PS Engineering, Inc. is strictly prohibited. For further information contact the Publications Manager at PS Engineering, Inc., 9800 Martel
Road, Lenoir City, TN 37772. Phone (865) 988-9800.
In certified aircraft, warranty is not valid unless this product is installed by an
Authorized PS Engineering dealer.
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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
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
5
Jan 2003
Add MP3 Version
6
April 2006
Added compatability note
7
May 2008
Update installation kit description
8
January 2015
Removed reference to JTSO
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.
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
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
1
1
425-001-0002
Gold Plated Crimp Pins
35
10
475-440-0007
4-40x7/16" Phil-Pan w/Nylon
Patch
2
2
475-630-0002
6-32 Clip Nut66
475-632-0012
6-32 x ½ Phil screw
6
6
200-971-00XX
Operator's and Installation
Manual
1
1
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
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.
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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