Sound Quality. Sound Engineering.
PM1000
II
FAA-Approved
4-Place, Panel Mounted Intercom
Operator's and Installation Manual
Part Number 11920 (with Crew) and 11922 (without Crew)
FAA-TSO C50c
PS E
Phone (865) 988-9800 FAX (865) 988-6619
NOTICE: In certified aircraft, warranty is not
valid unless this product is installed by an
Authorized
PS Engineering dealer.
NGINEERING, INCORPORATED
9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
Document Number 200-123-0003
Revision 5, Feb. 29, 2012
Revision 5, Feb. 2012 Page 1 200-123-0003
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 contact the Publications Manager at PS Engineering, Inc., 9800 Martel
PS Engineering, Inc. 2012©
Copyright Notice
Road, Lenoir City, TN 37772. Phone (865) 988-9800
Section I General Information
1.1 Introduction
The PM1000II, is an FAA-TSO approved, panel
mounted, 4-place 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 11920, Front Panel
1.2 Scope
This manual contains installation and operational instructions for the following PS Engineering units:
Model Description Part Number
PM1000II 4-place intercom system w/Pilot ISO 11922
PM1000II Same as above w/internal crew 11920
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
multiple 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.
“CREW” (11920 only) allows the pilot and copilot
positions to hear the aircraft radios and use the intercom, while the rear passengers can have their own
intercom conversation without disturbing the crew.
This also activates music 2 input.
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 the
unit off.
1.4 Approval Basis
The PM1000II, part numbers 11920 and 11922 are
FAA-approved under TSO-C50c.
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 Mic Frequency Response: 350 Hz — 6000 Hz
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)
Environmental and technical qualifications:
RTCA DO-160B/DO-170
Temperature -20ºC to +55ºC
Altitude 50,000 ft.
1.6 Equipment required but not supplied
A.Headphones, 150Ω monaural, up to four as required
B.Microphones, up to four, as required
C.Interconnect wiring
D.Circuit Breaker—1 Amp.
PM1000II Operation/Installation Manual Page 2 Revision 5, Feb 2012
1.7 License Requirements
None
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 43.13-2. It is the installer's responsibility
to determine the approval basis for this installation. An
FAA From 337, or other approval may be required.
See Appendix B for example of FAA Form 337.
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
425-025-00095 25 pin Sub-d connector shell 1
425-020-5089 Male Pins– Crimp 25
625-025-0001 Connector hood 1
575-002-0004
575-002-0002
11910 4-place mono jack kit ,(incl. phones and
202-123-0001 Pilot’s Guide 1
Reversible aluminum face plate
Reversible face plate w/crew
mic jack, insulating washers and 1/8”
music jack)
11922
11920
1
1.2 in
0.838 in
Ø0.125 in
Ø0.265 in
Ø0.25 in
Ø0.375 in
0.32 in
0.5 in
PM1000II Hole spacing (Not to scale)
3.Place the aluminum face-plate over the knob shafts
and secure, using the two # 4-40 round head
screws provided.
4.Install the knobs over the volume and squelch control shafts.
2.4 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.
If the aircraft already has pilot and copilot 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 be removed for any reason, these jacks provide access to the aircraft radio system.
NOTE: Auxiliary microphone and headset
jacks are required for a complete installation.
These provide troubleshooting and a back-up
access to the aircraft radios.
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).
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.
2.Insert the PM1000II from behind the instrument
panel, aligning the holes for the knobs, LED, and
switch.
Revision 5, Feb. 2012 Page 3 200-123-0003
2.4.1 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 po wer supplies, etc.). However, installation combinations can
occur where minor interference is possible. The
PM1000II 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.
2.4.2 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.
2.4.3 Entertainment 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.
The 11920 has two entertainment inputs.
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.
In the ALL or ISO modes, Music #1 is heard by everyone (except by the pilot in ISO mode). In the CREW
mode, pilot and copilot will hear Music #1 while the
passengers will hear entertainment #2.
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.
2.4.4 External PTT hook-up
Part of the installation includes the installation of PTT
(Push To Talk) switches that allow radio transmissions
from pilot and copilot positions.
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 Appendix A) 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 may be
required. (See Appendix A)
2.5 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.
PM1000II Operation/Installation Manual Page 4 Revision 5, Feb 2012
2.Plug headsets into the pilot, copilot and passenger positions.
3.Verify that the pilot position can transmit and
receive with the PM1000II in the OFF position (left hand volume knob fully counte r clockwise).
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 operati on f or pi l ot, 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, ISO And CREW (if equipped) 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.
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
allowing an additional degree of aircraft radio listening
flexibility.
control the volume of the aircraft radio,
PM1000II w/crew, p/n 11920
copilot's volume control adjusts the volume for the
copilot.
In the 11920 units, the volume level for both passengers can be adjusted by a screwdriver adjusted potentiometer located on the left hand side of the intercom as
viewed from the front. It is possible to adjust the overall output power to the passenger headsets by changi n g
this potentiometer. Rotating the potentiometer counterclockwise increases the passenger volume.
3.2 Squelch Control (2)
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 circuits, 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.
PM1000II w/out crew, p/n 11922
3.1 Adjusting The Volume (1)
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
Revision 5, Feb. 2012 Page 5 200-123-0003
3.3 Mode Select (3)
The center switch is a three position mode control that
allows the pilot to tailor the intercom 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). The pilot will not hear anything when he speaks into the mic on intercom. Copi-
lot 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 completed.
CREW (Down Position) (ONLY version with crew,
part number 11920 ): Pilot and copilot are connected
on one intercom channel while the passengers are on a
separate and independent channel. The pilot and copilot are connected to the aircraft radio and may listen to
Music #1. Passengers can continue to communicate
with themselves without disturbing the pilot and copilot and may listen to Music #2.
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 sale. 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.
4.2 Factory Service
The PM1000II is covered by a one-year limited warranty. See warranty information.
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 Road
Lenoir City, TN 37772
(865) 988-9800 FAX (865) 988-6619.
NOTE:
PS Engineering is not responsible for units shipped US
Mail.
If no method of payment is provided, the units will be
returned COD.
Appendix A
PTT 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. When the PTT is between the intercom and the headset, the intercom function will not work until the PTT switch is depressed. A
simple modification can be performed to allow proper
intercom operation. NOTE: This mod does not alter
normal operation. The following are sample procedures for common PTT switches. Contact the PTT
manufacturer if you require more information.
Procedures for the David Clark PTT
1.Unscrew the round black plastic cover from the
jack.
2.Connect the joined black wires to the red wire
3.Replace the black plastic cover
Procedures for the Telex PT-200
1.Unscrew the round black plastic cover from the
jack.
2.Cut the red wire in the middle of the wire
3.Strip both ends of the insulation
4.Solder the two ends to the ground lug to the PTT
jack
5.Replace the plastic cover
PM1000II Operation/Installation Manual Page 6 Revision 5, Feb 2012
Procedures for the Telex PT-300
1.Unscrew the round black plastic cover from the
jack
2.Remove the heat shrink material from the joined
black wires
3.Solder these two wires to the lug that has a
white wire already soldered to it.
4.Replace the black plastic cover
Appendix B
Instructions for FAA Form 337
It is up to the installer to determine if the installation is
a major or minor aircraft alteration. (Refer to AC 20-
177). One possible method of airworthiness approval
is through an FAA Form 337, Major Repair and Al-
teration (Airframe, Powerplant, Propeller, or Appliance) In the case of the PM1000II , you may use the
following text as a guide.
Installed 4-place intercom, PS Engineering
PM1000II, part number (xxxxx) in ( loca-
tion ) at station . Installed per
AC43.13-2B, Chapter 2,. Installed per PS
Engineering Installation Operators Manual p/
n 200-123-0003, revision 1, dated ________.
This unit is FAA-Approved under TSO C50c
for audio amplifiers, and meets environmental
tests outlined in RTCA DO-170B as appropriate or this aircraft.
Interface to existing aircraft radios in accordance with installation manual and in compliance with practices listed in AC43.13-2B,
Chapter 2. All wires are Mil-Spec 22759 or
27500. No connection to the aircraft dimmer
bus is required. Power is supplied to the unit
through a 1A circuit breaker (type and part
number), and total electrical load does not
exceed % of the electrical system capacity with the PM1000II added.
Aircraft equipment list, weight and balance
amended. Compass compensation checked. A
copy of the operation instructions, contained
in PS Engineering document 202-123-0001,
revision _, Dated:_____, is placed in the aircraft records. All work accomplished listed
on Work Order .
Appendix C
Instructions for Continuing Air-
worthiness
The PM1000II is considered an “on-condition” maintenance item. It is checked prior to each flight during
normal operation. There are no additional considerations for continuing airworthiness other than the practices detailed in AC 43.13-1A, Chapter 11. This includes, inspecting the unit to be sure it is securely fastened in its location, and that the wiring harness is not
chafed or pinched, and remains secure. All panel jacks
should be checked at each periodic inspection to ensure that they are tight and not in contact with other
items behind the instrument panel.
Revision 5, Feb. 2012 Page 7 200-123-0003
PM1000II with crew, p/n 11920
11920 Sub-D DB-25 Female (Sockets) on unit
Power In
Ground
A/C Radio Phone Audio Hi
A/C Radio Phone Audio Lo
14
1
17
4
Aircraft Radio PTT
Aircraft Mic Audio Hi
Aircraft Mic Audio Lo
Pass 1 & 2 Phones Hi
Pass 1& 2 Phones Lo
Copilot Phones Hi
Copilot 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
12
25
13
15
2
19
6
18
5
9
8
no connection
1A
11-33 VDC
To Aircraft Radio
Phone Hi
AUX Headphone Jack
To Aircraft Radio
Phone Low
Passenger 1
Phones
Copilot Headphone Jack
Pilot Headphone Jack
Pass 1 Mic
no connection
Pass 2 Mic
Aircraft Radio PTT
Aux Mic Jack
To Aircraft Radio Mic Audio Lo
To A/C Radio Mic Audio Hi
Passenger 2
Phones
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9800 MARTEL ROAD, LENOIR CITY TN 37922
TITLE:
PM1000II (11920) WIRING DIAGRAM
DOCUMENT NUMBER:SIZE
120-192-0000
DATE:
06/25/98 1 1
REV
SHEET OF
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PM1000II (11920) with CREW Function
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PM1000II Operation/Installation Manual Page 8 Revision 5, Feb 2012
PM1000II NO crew, p/n 11922
(p
)
11922 Sub-D DB-25-- Unit has female (socket)
Power In
Ground
A/C Radio Phone Audio Hi
A/C Radio Phone Audio Lo
14
1
17
4
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
Pilot Mic PTT
Pilot Mic Audio Hi
Pilot Mic Audio Lo
Music Input Hi
Music Input Lo
12
25
13
19
6
18
5
9
8
22
21
10
24
23
11
20
7
Copilot
Phones
1A
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 2 Mic
Pilot Mic Jack
Music Jack
Aircraft Radio PTT
Aux Mic Jack
To Aircraft Radio Mic Audio Lo
To A/C Radio Mic Audio Hi
Passenger 2
Phones
Copilot Mic Jack
Pilot PTT
Copilot PTT
Expansion Power
Expansion Audio In
Expansion Audio Out
Ground
15
3
16
2
To Pin 1 of 11616 expansion module
To Pin 3 of 11616
To Pin 2 and 15 of 11616
To Pin 14 of 11616
Used with 11922 and
Expansion module only
These pins used for expansion modules only
.
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12345
11922 Connector lay-
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9800 MARTEL ROAD, LENOIR CITY TN 37772
TITLE:
PM1000II (11922) WIRING DIAGRAM
DOCUMENT NUMBER:
SIZE
DATE:
ECO
A
120-120-0000
07/25/98
SHEET OF
1
REV
0
1
11922, PM1000II without CREW
Microphone
out, viewed from rear
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Monaural Headset Jack Details
Revision 5, Feb. 2012 Page 9 200-123-0003
TIP
(PTT)
TIP
hone audio
Headphone
Ring
(mic audio)
Barrel
(gnd)
Barrel
(audio
gnd)
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