PS Engineering PM1200 User Manual

Sound Quality. Sound Engineering.

PM1200

Panel Mounted Intercom with

IntelliVOX®

for High Noise Application

Part No. 11960

Includes 11961 & 11960-Exp

Operator's and Installation Manual

PS ENGINEERING, INCORPORATED

9800 Martel Road

Lenoir City, TN 37772

Phone [phone] FAX [phone]

www.ps-engineering.com

U. S. Patent 6,493,450

NOTICE: Warranty is not valid unless this product

is installed by an Authorized

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.,

PS Engineering dealer.

PS Engineering, Inc. 2013©

Copyright Notice

9800 Martel Road, Lenoir City, TN 37772. Phone [phone]

Document Number 200-196-0104

Rev 12, March. 2013

200-196-0104 Page 1 March 2013 Rev. 12

Section 1 General Information

1.1 Introduction

The PM1200 is a panel mounted, 2-place (expandable
with IntelliPAX p/n 11616R) monaural intercom system
(ICS) designed specifically for high-noise aircraft environ­ments. Please read this manual completely before installa­tion to minimize the risk of damage to the unit and to be­come familiar with all the features.

Both pilot and copilot have transmit capabilities over
the radio. The PM1200 allows only the person who presses
their radio PTT to be heard over the aircraft radio. If both
pilot and copilot press the PTT at the same time, the pilot
will have priority and override the copilot.

1.4 Approval Basis *None*

The PM1200, 11960, 11960-EXP, or 11961, is NOT
FAA Approved. It is the installers responsibility to deter­mine suitability for installation.

1.2 Scope

This manual contains installation and operational in-

structions for the following PS Engineering units:

Part Number Description

11960 Push to talk intercom for use in noisy cockpits

11961 Same as above but remote (blind) mounting

11960-Exp Same as above, but with expansion capability

1.3 Description

The PM1200 is a 2-place (unless expanded), panel­mounted intercom with PS Engineering‘s proprietary Intel­liVOX® intercom protocol. The audio has been further en­hanced with extra audio filtering for the microphones, and
added headphone audio power.

The PM1200 is backward compatible with PM1000II
units, P/N 11902, 11909 and 11922– contact factory for
details. However, the PM1000-series MUST be wired cor-
rectly per the manual, particularly the pilot radio PTT.

The unit can be used as either voice-activated, or push
to talk intercommunications, by simply pushing a front
panel switch.

The PM1200 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.

An entertainment input is provided, allowing the users
to listen to music during flight. During intercom or aircraft
radio traffic, this music is automatically muted to allow
communications without distraction. When the activity
ceases, the Soft Mute™ circuit gradually returns the music
to the original volume.

1.5 Specifications

Input power: 13.8 - 27.5 Volts DC
Current Drain: < 250 mA (Externally fused at 1 Amp)
Output 120 mW into 150Ω @ 27.5 VDC
70 mW @ 13.75 VDC
Headphone Impedance: 150-1000 ohms typical
Aircraft Radio Impedance: 500- 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 3.00" W x 5.80" D

(3.2 x 7.6 x 14.7 cm)
Temperature -20ºC to +55ºC
Altitude 50,000 ft.

1.6

A. Headphones, 150-300Ω monaural, up to two as required
B. Microphones, up to two, as required
C. Crimping Tool, AMP 601966-1 , and Positioner, 601966-

D. Appropriately constructed interconnect wiring
E. Circuit Protection, 1 Amp.
F. Radio PTT switches (1-pilot, 1-copilot)
G. Intercom PTT switches (if desired) 2 ea.

Equipment required but not supplied

5 (or equiv.)

Section 2 Installation

2.1 General Information

The PM1200 comes with all necessary mechanical
hardware for installation. Installation of the PM1200, using
the appropriate wiring and hardware, does not require spe­cial tools or knowledge other than described in FAA Advi­sory Circular 43.13–2B. Installers should be qualified in
accordance with 14 CFR 65.81(b).

It is the installer's responsibility to determine the ap­proval basis for this installation. An FAA From 337, or
other field approval may be required in a certified aircraft.
A custom-made wiring harness is available from PS Engi­neering, shipped within 5-business days of order. Visit

www.ps-engineering.com

2.2 Unpacking and inspection

The PM1200 was carefully inspected and thoroughly
tested before shipment. It should be free of electrical or cos­metic defect.

Upon receipt, verify that the parts kit includes:

for more information.

March 2013 Rev. 12 Page 2 200-196-0104

(11960 & 11960-Exp) Installation Kit P/N 250-120-0100

Part Number Description Quantity

350-990-0015 Foam Mic Muff 2

350-9909-0001 Leather Mic cover 2

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

625-003-0001 Soft Touch knobs 2

425-025-0009 25 pin Sub-d connector shell 1

625-025-0001 Connector hood 1

425-020-5089 Crimp Pins (Male) 25

575-120-0001 Reversible aluminum face plate 1

250-000-0002 2-place jack kit 1

200-196-00XX Operator's and Installation Manual 1

122-102-0001 Drill Template 1

475-002-0002 Thumbscrews 2

PM1200 Remote (11961) Installation Kit P/N 250-120-0200

Part Number Description Quantity

350-990-0015 Foam Mic Muff 2

350-9909-0001 Leather Mic cover 2

425-025-0009 25 pin Sub-d connector sell 1

625-025-0001 Connector hood 1

425-0205089 Crimp Pins (Male) 25

250-000-0002 2-place jack kit 1

200-196-00XX Operator's and Installation Manual 1

675-120-0103 Pilot volume pot w/Switch ¼” shaft 1

675-020-0103 Copilot volume pot ¼” shaft 1

731-001-0001 Switch, SPDT On-On 2

625-020-0005 Knob, Black 1/2” shaft 2

475-002-0002 Thumbscrews 2

PM1200 Standard and Expansion

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). The
intercom can be mounted horizontally or vertically with
supplied face plate.

2.Insert the PM1200 from behind the instrument panel,
aligning the holes for the knobs, LED, and switch.

0.840

1.200

0.320

PM1200 Hole spacing (Not to scale)

Ø0.25

Ø0.313

Ø0.125 Ø0.265

Dimensions in inches

Ø0.313

Ø0.125

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 (except in the case of the 11961).

NOTE: See Page 9 for PM1200 Remote (11961R) instal­lation diagram

2.2 Cable harness wiring

To complete the installation, a wire harness must be

made as shown in the appropriate diagram.

PS Engineering can make a custom-tailored wiring har-

ness for the installer. All harnesses use Mil-spec quality
components with professional techniques, and are fully
tested before shipment. Contact PS Engineering (865-988-

9800) 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.

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 PM1200. See the wiring dia­gram for all details of the wire harness interconnects.

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 cross­coupling 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 to-

day's general aviation aircraft, there is the potential of both
radiated and conducted noise interference. The PM1200 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 PM1200 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 PM1200 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

200-196-0104 Page 3 March 2013 Rev. 12