PS Engineering PM1000 User Manual

Sound Quality. Sound Engineering.

PM1000II

Specialty Panel Mounted

Intercoms

Part No. 11909 (PTT ICS For open cockpit)

Operator's and Installation Manual

PS ENGINEERING, INCORPORATED

Phone [phone] FAX [phone]

9800 Martel Road

Lenoir City, TN 37772

www.ps-engineering.com

NOTICE: In certified aircraft, warranty is

not valid unless this product is installed by an
Authorized

Sept. 2007 Page 1 200-125-0100

PS Engineering dealer.

Document Number 200-125-0100

Sept. 2007

Section I General Information

1.1 Introduction

The PM1000II, is a panel mounted, 4-place

monaural intercom system (ICS). Please read
this manual completely before installation to
minimize the risk of damage to the unit and to
become familiar with all the features.

PM1000II, p/n 11909, Front Panel

1.2 Scope

This manual contains installation and
operational instructions for the following PS
Engineering unit:

Part Number Description
11909 Push to talk intercom for use in noisy cockpits

1.3 Description

The PM1000II is a 4-place, panel mounted
intercom with individual volume and squelch
controls for the pilot and copilot. The copilot's
squelch control adjusts the trip level of the
copilot and passengers.

A front panel mode switch allows the pilot
to select two intercom configurations:

"ISO" mode isolates the pilot from the
intercom and connects to the aircraft radio. The

passengers can continue to communicate with
each other and listen to entertainment without
distracting the pilot. They do not hear radio
communications.

"ALL" mode places all headsets on a party

line. Each one hears aircraft radio, entertainment
and can use the intercom.

The PM1000II has an automatic fail-safe

interconnect to the aircraft radio. If power to the
intercom is disrupted, an internal relay will
connect the pilot's headset to the aircraft radio.
This allows continuous radio communications.
Note: The copilot will no longer hear aircraft
radio when power is removed.

The 2-color LED shows green when power is
on and red during radio transmissions. This
functions as a stuck mic indicator.

An auxiliary input is provided, allowing the
pilot, copilot and passengers the option to listen
to music during flight. During intercom or aircraft
radio activity, this music is automatically muted
to allow communications without distraction.
When the activity ceases, the Soft Mute circuit
will gradually return the music to the original
listening volume.

The "ISO" mode provides uninterrupted
aircraft radio communications for the Pilot.
Because the pilot's intercom volume control does
not affect the aircraft radio volume, it is possible
to select various balances of volume level
between the ICS and the aircraft radio while in
the ALL mode. Reducing the intercom volume,
the pilot places the aircraft radio in the
foreground while the ICS is in the background.

Both pilot and copilot have transmit
capabilities over the radio. The PM1000II allows
only the person who presses their PTT to be heard
over the aircraft radio. If both pilot and copilot
press the PTT at the same time, the copilot will
override (Ideally suited for training
environments). Pilot regains priority by switching

PM1000II with PTT-ICS, p/n 11909

1A

Power In
Ground

A/C Radio Phone Audio Hi
A/C Radio Phone Audio Lo

Aircraft Radio PTT
Aircraft Mic Audio Hi
Aircraft Mic Audio Lo

Copilot, Pax 1 & 2 Phones Hi
Copilot, Pax 1 & 2 Phones Lo

Pilot Phone Audio Hi
Pilot Phone Audio Lo

Pass 1 Mic Audio Hi
Pass 1 Mic Audio Lo

Pass 2 Mic Audio Hi
Pass 2 Mic Audio Lo

Copilot Mic PTT
Copilot Mic Audio Hi
Mic Audio Lo

Copilot ICS PTT
Copilot ICS PTT

Pilot ICS PTT
Pilot ICS PTT

Pilot Mic PTT
Pilot Mic Audio Hi
Pilot Mic Audio Lo

Music Input Hi
Music Input Lo

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Any reproduction or retransmittal of this publication, or any portion thereof, without the expressed written permission of PS Engi neering, Inc. is strictly

prohibited. For further information conta ct the Publications Manager at PS Engineering, Inc., 9800 Martel Road, Lenoir City, TN 37772. Phone (865) 988-

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Copilot
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Pass ICS PTT

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PS Engineering, Inc. 2002©

Copyright Notice

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9800

11-33 VDC

To Aircraft Radio
Phone Hi

AUX Headphone Jack

To Aircraft Radio
Phone Low

Passenger 1
Phones

Pilot Headphone Jack

Pass 1 Mic

Pass ICS PTT

Copilot ICS PTT

Pilot Mic Jack

Pilot PTT

Music Jack

9800 MARTEL ROAD, LENOIR CITY TN 37772

TITLE:

SIZE

DATE:
ECO

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Aircraft Radio PTT

Aux Mic Jack

To Aircraft Radio Mic Audio Lo

To A/C Radio Mic Audio Hi

Passenger 2
Phones

Pass 2 Mic

Copilot Mic Jack

Copilot PTT

Pilot ICS PTT

PM1000II w/PTT-ICS (11909) WIRING

DOCUMENT NUMBER:

120-129-0000

08/11/98

SHEET OF

1

REV

1

1

PM1000II Specialty Intercom Manual Page 2 Sept. 2007

Sept. 2007 Page 9 200-125-0100

4.2 Factory Service

H

The PM1000II is covered by a one-year limited

warranty. See warranty information.

Call PS Engineering, Inc. at [phone]
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 Road

Lenoir City, TN 37772

[phone] FAX [phone].

NOTE:

PS Engineering is not responsible for units

shipped US Mail.

If no method of payment is provided, the units
will be returned COD. If no RMA or description of
problem is present, the shipment will be refused.

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11909 Connector layout, viewed from rear

the unit off.

43.13-2. It is the installer's responsibility to
determine the approval basis for this installation. .

1.4 Approval Basis *None*

The PM1000II, part number 11909 is

NOT FAA Approved. It is the installers
responsibility to determine suitability for use.

1.5 Specifications

Input power: 13.8 - 27.5 Volts DC
Current Drain: < 250 mA (Externally fused at 1 Amp)
Headphone Impedance: 150-1000 ohms typical
Audio Distortion: <10% @ 75 mW into 150 Ω load
Aircraft Radio Impedance: 1000 Ω typical
3 dB Music Frequency Response: 200 Hz to 15 kHz
Unit weight: 12 Ounces (0.342 kg)
Dimensions: 1.25" H x 2.60" W x 5.50" D

(3.2 x 6.6 x 14 cm)
Temperature -20ºC to +55ºC
Altitude 50,000 ft.

1.6 Equipment required but

2.2 Unpacking and inspection

The PM1000II was carefully inspected

mechanically and thoroughly tested electronically
before shipment. It should be free of electrical or
cosmetic defect.

Upon receipt, verify that the parts kit includes

the following:

Part Number Description Quantity

475-442-0002 #4-40 Machine screws, black 2

625-002-0001 Concentric inner knobs 2

625-002-0002 Outer knobs w pointer 2

425-025-0095 25 pin Sub-d Shell 1

not supplied

A. Headphones, 150Ω monaural, up to four as

6789

19202122

12345

1415161718

required
B. Microphones, up to four, as required
C. Interconnect wiring
D. Circuit Protection 1 Amp.

1.7 License Requirements

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Section 2 Installation

2.1 General Information

The PM1000II comes with all necessary
hardware for installation.

Installation of the PM1000II, using the
available wiring and hardware supplied, does
not require special tools or knowledge other
than described in FAA Advisory Circular

425-020-5089 Male Pins—Crimp 25
625-025-0001 Connector hood 1
575-002-0004 Reversible aluminum face plate 1

11910 4-place mono jack kit (incl. phones

1
and mic jack, insulating washers and
1/8” music jack)

200-125-0100 Operator's and Installation Manual WEB

122-102-0001 Drill Template 1

2.3 Equipment installation pro­cedures

1. Using the template, drill six holes in the
instrument panel in a location convenient to
the pilot position(s).

2. Insert the PM1000II from behind the
instrument panel, aligning the holes for the
knobs, LED, and switch.

3. Place the aluminum face-plate over the knob

PM1000II Specialty Intercom Manual Page 8 Sept. 2007

Sept. 2007 Page 3 200-125-0100

shafts and secure, using the two # 4-40
round head screws provided.

4. Install the knobs over the volume and
squelch control shafts.

5.

1.2 in

0.838 in

Ø0.25 in

Ø0.125 in

Ø0.265 in

Ø0.375 in

PM1000II Hole spacing (Not to scale)

2.2 Cable harness wiring

To complete the installation, a wire harness

must be made as shown in Appendix D.

PS Engineering can make a custom-tailored

wiring harness for the installer. All harnesses use
Mil-spec quality components with professional
techniques, and are fully tested before shipment.
Contact PS Engineering for more information.

NOTE: Auxiliary microphone and headset

jacks are required for a complete installation.

These provide troubleshooting and a back-up

headset jacks installed, you may re-use them.
Remove and discard all wires from the copilot
headset jacks. You may use the existing pilot
headset jacks as the Auxiliary Aircraft Radio
Headset Jacks, but they should be moved to a
new location to avoid confusion with the pilot's
headphone jacks. In the event the intercom has to

access to the aircraft radios.

If the aircraft already has pilot and copilot

0.5 in

be removed for any reason, these jacks provide
access to the aircraft radio system.

To connect intercom into the aircraft audio
system, parallel the appropriate set of cables
from the intercom to the Auxiliary Aircraft
Radio Headset Jacks. Finally, install new
headset jacks into the aircraft and connect them
directly to the appropriate pins of the
PM1000II. See the wiring diagram for all
details of the wire harness interconnects.

0.32 in

2.2.1 Electrical Noise Issues

WARNING: You must use separate
shielded cables for the microphone and
headphone jacks. Combining these two wires
WILL cause loud oscillations and degrade the
intercom function. The oscillation is caused by
the cross-coupling between the large headphone
signal and the small microphone signal. The
resulting feedback is a high-pitched squeal that
varies with the volume controls.

Due to the variety of the radio equipment
found in today's general aviation aircraft, there
is the potential of both radiated and conducted
noise interference. The PM1000II has a
specially designed power supply to reduce
conducted electrical noise on the power bus of
the aircraft by at least 50dB. Although this is a
very large amount of attenuation, it does not
eliminate all noise when the amount is
excessive. There must be at least 12 Volts DC
present at the PM1000II for the power supply
to work within its designed regulation.
Otherwise, it will not be able to attenuate noise
properly.

Shielding can protect the system from
radiated noise (rotating beacon, electric gyros,
switching power supplies, etc.). However,
installation combinations can occur where
minor interference is possible. The PM1000II

PM1000II, p/n 11909

function to suit flight conditions. Regardless of
configuration, the pilot will always hear the
aircraft radio. NOTE: If there is a power failure
to the PM1000II, or if the power switch is
turned off, the copilot will not hear the aircraft
radio. Only the pilot is connected directly to the
aircraft radio.

ISO (Up Position): The pilot is isolated

from the intercom and is connected only to the
aircraft radios. He will hear the aircraft radio
reception (and sidetone during radio
transmissions). Copilot and passengers will hear
themselves and music but not the aircraft radio
traffic.

ALL (Middle position): All parties will

hear the aircraft radio, intercom, and music.
However, during any ICS or radio
communications, the music volume
automatically mutes. The music volume
increases gradually back to the original level
after communications have been compl et e d.

3.5 PTT-ICS (11909 only)

The 11909 provides positive control over

the intercom through a separate intercom key
switch that is installed convenient to the pilot or
copilot. When this switch is open, no
microphone audio is passed to the intercom. For
best results, turn the intercom squelch fully
CCW and use the PTT-ICS switch to talk on the

intercom.

In many cases it is possible to revert to
VOX intercom if ambient noise is reduced (such
as during cruise). Place the PTT-ICS switch in
latched position (if equipped ) .

Section 4

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 year from the date of installation.
During this one year warranty period, PS
Engineering, Inc., at its option, will send a
replacement unit at our expense if the unit should be
determined to be defective after consultation with a
factory technician. The customer is responsible for
return shipment costs.

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 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.

PM1000II Specialty Intercom Manual Page 4 Sept. 2007

Sept. 2007 Page 7 200-125-0100

3. Verify that the pilot position can transmit

and receive with the PM1000II in the OFF
position (left hand volume knob fully
counterclockwise).

4. Rotate the pilot volume clockwise, about
half way. Verify that the Pwr/Xmt light
comes on, and shows green. If the LED is
red, stop testing and trouble-shoot the
microphone PTT installation.

5. Verify that the pilot can transmit and
receive on the com transceivers.

6. Verify that the LED in the intercom
changes from green to red when a
microphone is keyed.

7. Verify proper intercom operation for pilot,
copilot and passengers. For more
information, consult Section III.

8. Verify proper transmit and receive
operation on the copilot position, noting
that the copilot PTT switch allows proper
transmission on the selected transceiver.

9. Verify proper Intercom system operation
in the ALL and ISO modes.

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

11. PTT ICS– Verify that the mic audio is
heard when the intercom push to talk
switch is activated. Ensure that the squelch
is turned to the full counterclockwise
position to prevent missed syllables in
flight.

Section III OPERATION

With the installation complete, turn the

PM1000II on by rotating pilot's volume control.
This also engages the automatic fail-safe system.

The pilot's volume control does not control the
volume of the aircraft radio, allowing an
additional degree of aircraft radio listening
flexibility.

3.1 Adjusting the Volume

The pilot's volume control knob adjusts the
loudness of the intercom and music for the pilot's
headset only. It has no effect on aircraft radio
volume level. The copilot's volume control adjusts
the volume for the copilot and passengers.

3.2 Squelch Control

The PM1000II provides individual VOX
circuits for the pilot and copilot. The ability to
adjust the trip level of these VOX circuits
(squelch control) allows the use of dissimilar
headsets without the frustration of clipping the
first syllables. The PM1000II has three squelch
circuits, one for the pilot, copilot, and one for the
passengers. With individual VOX circuit s,
background noise is dramatically reduced.

With the engine running, set the squelch
control knob by slowly rotating the squelch
control knob clockwise until you no longer hear
the background noise in the earphones. When the
microphone is positioned properly near the lips,
normal speech levels should open the channel.
When you have stopped talking, there is a delay of
about one second before the channel closes. This
prevents squelch closure between words, and
helps eliminates choppy intercom conversations.

3.3 Mode Select

The center switch is a three position mode
control that allows the pilot to tailor the intercom

was designed in an interference -protected chassis
and has internal filter capacitors on all input lines.

Ground loop noise occurs when there are two
different return paths for the same signal, such as
airframe and ground return wire. Large cyclic
loads such as strobes, inverters, etc., can inject
audible signals onto the airframe return path.
Follow the wiring diagram very carefully to help
insure a minimum of ground loop potential.
Radiated signals can be a factor when low level
mic signals are bundled with current carrying
power wires. Keep these cables separated.

Insulating washers are required

on all mic and
headphone jacks to isolate them from aircraft
ground. The use of a conductor instead of a shield
for ground return eliminates these ground loop
paths.

2.2.2 Power Requirements

The PM1000II was designed to work with

either 12/28 volt DC negative ground systems.
The PM1000II must be externally protected with
a one ampere (1A) circuit breaker or fuse.

2.2.3 PTT-ICS (11909 only)

The part number 11909 is designed for noisy
installations, such as open cockpit aircraft. In this
part number unit, no pilot mic audio is passed to
the intercom unless pin 3 or 16, or copilot mic

Alternate ICS-PTT using a
momentary-off-latching switch

Pilot ICS PTT
Pilot ICS PTT

CopiIot ICS PTT
Copilot ICS PTT

3
16

2
15

Alternate ICS-PTT Switching for VOX operation

On
Off
Mom

On
Off
Mom

audio unless pins 2 and 15 are connected
together.

It may be desirable to install a On-off-mom
switch, which will allow the PTT ICS to “latch”
and give VOX operation. In this mode, the
VOX adjustment operates conventionally

2.2.5 Auxiliary Input

Entertainment devices can be connected to
the PM1000II. Install 1/8" jacks convenient the
pilot to connect the entertainment device into
the system. A "Soft Mute" system is installed in
the PM1000II that will mute the music during
intercom or radio activity.

In the ALL or ISO modes, Music #1 is
heard by everyone (except by the pilot in ISO
mode).

WARNING: Local oscillators and other
internal signals from CD or radio equipment
can cause undesired interference with VHF
navigation and communication equipment.
Before takeoff, operate the entertainment device
to determine if there is any adverse effect on
aircraft systems. If any unusual operation is
noted in flight, immediately switch the
entertainment device off.

2.3 Post installation checkout

After wiring is complete, verify power is
ONLY on pin 14 of the connector, and airframe
ground on pin 1. Failure to do so will cause
internal damage and void PS Engineering's
warranty.

1. Apply power to the aircraft and avionics.

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

Note: Use the low level (or line) output from any music

device to connect to the PM1000II. Maximum input level is 2 V

peak-to-peak.

DO NOT USE SPEAKER OUTPUT.

These levels will cause internal damage.

PM1000II Specialty Intercom Manual Page 6 Sept. 2007

Sept. 2007 Page 5 200-125-0100