9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
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Document P/N 200-550-0100
Rev. 1, January 2011
Audio Selector Panel with 4-Place IntelliVox® Stereo Intercom
System Installation and Operation Manual
Patented under one or more of the following;
No. 4,941,187; 5,903,227; 6,160,496 and 6,493,450
PS Engineering, Inc. 2011 ©
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, email contact@ps-engineering.com.
For use in Experimental/Non-certified aircraft ONLY
Not intended for installation in certified aircraft
The product warranty is not valid unless this product is installed by an
Authorized PS Engineering dealer.
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 **NONE**.................................................................................................. 1-2
1.5 SPECIFICATIONS.................................................................................................................... 1-2
1.6 EQUIPMENT SUPPLIED......................................................................................................... 1-3
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED.................................................................. 1-3
1.8 OPTIONAL ITEMS................................................................................................................... 1-3
1.9 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 AUDIO PANEL MOUNTING RACK INSTALLATION........................................................... 2-1
2.3.4 AUDIO PANEL TRAY AND CONNECTOR ASSEMBLY....................................................... 2-1
2.4 CABLE HARNESS WIRING ............................................................................................................ 2-2
2.4.1 NOISE.......................................................................................................................... 2-2
2.4.2 POWER ........................................................................................................................ 2-3
2.4.3 COMMUNICATIONS PUSH-TO-TALK.............................................................................. 2-3
2.4.4 AUDIO PANEL INTERFACE ............................................................................................ 2-3
2.4.5 TEL (DUPLEX) FUNCTION FOR CELL PHONES .............................................................. 2-3
2.4.6 TRANSMIT INTERLOCK................................................................................................. 2-4
2.4.7 "SWAP" MODE............................................................................................................. 2-4
2.4.8 BACKLIGHTING............................................................................................................ 2-4
2.4.9 UNSWITCHED INPUTS................................................................................................... 2-4
2.5 INTERCOM WIRING ...................................................................................................................... 2-5
2.5.1 ENTERTAINMENT INPUTS............................................................................................. 2-5
2.5.2 ENTERTAINMENT MUTING............................................................................................ 2-6
2.5.3 ALTERNATE MUSIC DISTRIBUTION (J2 PIN 22) ............................................................. 2-6
2.6 ADJUSTMENTS ............................................................................................................................. 2-6
2.6.1 MICROPHONE GAIN SELECTION ................................................................................... 2-7
2.7 COMMUNICATIONS ANTENNA INSTALLATION NOTES .................................................................. 2-7
2.8 PMA5000EX PIN ASSIGNMENTS.................................................................................................. 2-8
2.9 POST INSTALLATION CHECKOUT................................................................................................. 2-9
2.10 UNIT INSTALLATION.................................................................................................................. 2-9
2.11 OPERATIONAL CHECKOUT ........................................................................................................ 2-9
2.11.1 AUDIO PANEL TEST ................................................................................................... 2-9
2.11.2 TEL CHECKOUT ...................................................................................................... 2-10
2.12 FINAL INSPECTION................................................................................................................... 2-10
Section III OPERATION .........................................................................................3-1
3.1 SCOPE ....................................................................................................................................... 3-1
3.2 POWER ON-OFF EMG (1)............................................................................................................. 3-1
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page ii Rev. 1 Jan. 2011
3.3 COMMUNICATIONS TRANSMIT (XMT) SELECTION (2) ................................................................ 3-1
3.3.1 SPLIT MODE ................................................................................................................ 3-2
3.3.2 COM RADIO MONITOR (3)........................................................................................... 3-2
3.3.3 SWAP MODE (SWITCH FROM COM 1 TO COM 2 REMOTELY) ......................................... 3-2
3.4 AUDIO SELECTOR (4)................................................................................................................... 3-2
3.5 TELEPHONE (TEL) (9)................................................................................................................. 3-3
3.5.1 CELL PHONE SIDETONE................................................................................................ 3-3
3.6 INTERCOM OPERATION ............................................................................................................... 3-3
3.6.1 INTELLIVOX® VOX-SQUELCH...................................................................................... 3-3
3.6.2 INTERCOM VOLUME CONTROL (7)............................................................................... 3-4
3.6.3 INTERCOM MODES (8) ................................................................................................. 3-4
3.7 MUSIC MUTING (6)...................................................................................................................... 3-5
3.7.1 MUSIC 2 MUTE CONTROL............................................................................................ 3-5
3.7.2 MUSIC IN PILOT ISO MODE .......................................................................................... 3-5
3.8 MUSIC VOLUME (5) ..................................................................................................................... 3-5
3.9 TELEPHONE MODE (9)................................................................................................................. 3-6
3.9.1 CELLULAR TELEPHONE SIDETONE ................................................................................ 3-6
3.10 UTILITY JACK ........................................................................................................................... 3-6
3.10.1 CELLULAR PHONE...................................................................................................... 3-6
3.10.2 AUDIO ADVISORY INPUT............................................................................................ 3-6
3.10.3 MUSIC INPUT............................................................................................................. 3-7
3.10.4 ALTERNATE MUSIC DISTRIBUTION............................................................................. 3-7
3.10.5 MUSIC 1 VOLUME...................................................................................................... 3-8
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 – PMA5000EX Installation Drawings...................................................... B
Appendix C – J1 Connector Interconnect.................................................................... C
Appendix D – J2 Connector Interconnect ................................................................... D
Rev
Date
Change
New
1/11/2010
New Release
1
1/11/2011
Improved installation of grounding lug
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 1-1 Rev. 1 Jan. 2011
Section I – GENERAL INFORMATION
1.1 INTRODUCTION
The PMA5000EX is designed to provide the basic audio control and intercom features most desire for the
Experimental / Light Sport Aircraft owner/pilot. Features like cellular telephone interface, music input
with custom muting schemes, and PS Engineering’s legendary IntelliVox® make this the perfect unit for
many light aircraft.
For use in Experimental/Non-certified aircraft ONLY
This unit is NOT INTENDED FOR INSTALLATION IN CERTIFIED AIRCRAFT
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 PMA5000EX.
1.2 SCOPE
This manual provides detailed installation and operation instructions for the PS Engineering
PMA5000EX-series of Audio Selector Panel/Intercom Systems. This includes the following units:
Model
Description
Part Number
PMA5000EX
Stereo Audio Selector Panel with 4-place IntelliVox® Stereo
Intercom and utility jack.
050-550-0200
1.3 EQUIPMENT DESCRIPTION
The PMA5000EX is a state-of-the-art audio isolation amplifier and audio selector that contains a 4-place
automatic voice activated (VOX) intercom system. It can switch two transceivers (Com 1, Com 2) and five
navigation receivers (Nav 1, Nav 2, AUX 1, AUX 2 and DME). Pushbuttons select the receiver audio
source provided to the headphones (DME is paired with AUX 2).
A full duplex TEL mode allows the PMA5000EX to act as an audio interface between aircraft headphone
and microphones and specific aircraft approved (FAA/FCC) cellular telephone equipment, through the
front mounted jack.
Warning: Use of non-aviation approved cellular telephone equipment may be prohibited by regulation.
PS Engineering is not responsible for unauthorized airborne use of cellular telephones.
For airborne use, the PMA5000EX must be interfaced with an approved system.
There are five unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or radar altimeter warning, with the fifth unswitched input through a front-mounted utility jack, when configured to
act as a fifth unswitched input.
Pushbutton switches select one of the communication transceivers for the pilot and copilot position, and
allows radio transmission. In "Split Mode,” the PMA5000EX has the ability to allow the pilot to transmit
on Com 1 while the copilot can transmit on Com 2. A fail -safe mode connects the pilot headphone and
microphone to COM 1 if power is removed for any reason, or if the power switch is placed in the Off
(Fail-safe) position. Unswitched input #1 is also provided to the pilot headphone in fail -safe
A four-station voice activated (VOX) intercom is included in the PMA5000EX. This system has PS Engineering’s patented IntelliVox® circuitry that eliminates manual adjustments. The intercom system incorporates pilot isolate, all and crew modes, two independent stereo music inputs with "SoftMute™". Intercom volume control is through two concentric front panel knobs and a pushbutton intercom mode switch.
The small volume knob controls the intercom level for the pilot and copilot, while the large knob controls
the passenger intercom volume. Intercom squelch is automatic.
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 1-2 Rev. 1 Jan. 2011
1.4 APPROVAL BASIS **None**
The PMA5000EX is NOT INTENDED OR APPROVED for installation or use in a certified aircraft.
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
WEIGHT
PMA5000EX Unit
Rack with connectors
1.34 lb. (0.61 kg)
0.51 lb. (0.24 kg)
POWER REQUIREMENTS (Including Internal Lighting):
Voltage:
11 to 33 VDC
Maximum Current:
2.5 Amp (Externally protected by a 5A pull-type
breaker)
Audio Selector Specifications
Audio selector panel input impe dance:
510
Input Isolation:
-60 dB (min.)
Receiver Inputs:
6 (Com 1, Com 2, TEL, AUX 1, AUX 2, DME)
Unswitched Inputs:
5 (including front jack)
Transmitter Selections:
4 (Com 1, Com 2, TEL
Com1/2)
Headphone Impedance:
150 – 1000
Headphone Output:
38 mW each headset, no clipping <1% THD typical
Microphone Impedance:
150 - 600
Intercom Specifications
Intercom Positions:
4 places (with individual IntelliVox® circuits)
Music Inputs:
2, (Independent, Stereo)
Music Muting:
>-30 dB "Soft Mute" when Com or intercom active.
Distortion:
<1% THD @ 38 mW into 150
Mic Freq. Response, 3 dB:
300 Hz - 6000 Hz
Music Freq. Response, 3 dB:
10 Hz – 26 kHz
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 1-3 Rev. 1 Jan. 2011
1.6 EQUIPMENT SUPPLIED
1 ea. of the following units:
Model
Description
Part Number
PMA5000EX
PMA5000EX Audio Panel with Stereo intercom.
050-550-0200
PMA5000EX Installation Kit: 250-890-0000
Description
Quantity
Part
Number
Installation rack assembly
1
430-890-0040
Rack back plate
1
430-890-0050
44-pin connector kit
2
120-891-2045
Backshell, connector
2
625-025-2465
Backshell Retainer
2
431-881-0100
4 40 X 7/16 screw w/nylon patch
4
475-440-0007
4 40 X 3/8 screw w/nylon patch
4
475-440-1038
4-40 x ¼” screw with lock washer
2
475-440-0001
Solder Lug
2
475-009-0001
Cable Clamp
1
625-001-0002
#6-32 x ½” Flat head Philips screw
6
475-632-0012
#6-32 Clip Nut
6
475-630-0002
Parts ID Sheet
1
002-890-0404
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED
a. Circuit Breaker: 1 ea; 5 amp PULL TYPE REQUIRED for PMA5000EX
b. Headphone Jacks (Stereo, as Required)
c. Microphone Jacks (as Required)
d. Headphones, 150 (Stereo), up to 6 as required
e. Microphones, up to 4 as required
f. Interconnect Wiring (contact PS Engineering for more information on custom wiring har-
nesses).
1.8 OPTIONAL ITEMS
a. Cell Phone Patch Cord, 2.5mm to 2.5mm, PS Part Number 425-006-7026
b. Music Patch Cord, 3.5mm to 5.5mm, PS Part Number 425-006-2535
c. Phone patch cord for iPhone or Blackberry 3.5 mm 4-conductor to 2.5 mm
(Phone only, no music) 425-006-0354
1.9 LICENSE REQUIREMENTS
None
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 2-1 Rev. 1 Jan. 2011
Section II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnection instructions for the PS Engineering
PMA5000EX Audio Selector Panel/Intercom.
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 as required by
14 CFR 65.81 (b).
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. If any claim is to be made, save the shipping mat erial
and contact the freight carrier. Do NOT return units damaged in shipping to PS Engineering. If the unit
or accessories show any sign of external shipping damage, contact PS Engineering to arrange for a r eplacement. 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 PMA5000EX is not required. However, the units should be kept away from heat
producing sources (i.e. defrost or heater ducts, dropping resistors, heat producing avionics) without ad equate cooling air provided.
2.3.2 Mounting Requirements
The PMA5000EX must be rigidly mounted to the instrument panel of the aircraft structure, within view
and reach of the pilot position(s). Installation should comply with FAA Advisory Circular AC 43.13-2B.
The unit may be mounted in any area where adequate clearance for the unit and associated wiring bundle
exist.
To prevent noise, avoid installing the unit close to high current devices or systems with high-voltage pulse
type outputs, such as DME or transponders. Avoid running the interconnecting bundles near any high
current wires.
2.3.3 Audio Panel Mounting Rack Installation
Remove the unit from the mounting tray by unscrewing the 3/32" hex-head screw that is in the center of
the unit. Use caution to avoid hitting the photo-detector lens. Carefully slide the unit free of the tray. Set
the unit aside in a safe location until needed. Install the tray using six clip nuts (475 -630-0002), and six
FHP 6-32 x ½" screws (475-632-0012). The audio selector panel must be supported at front and rear of
the mounting tray.
2.3.4 Audio Panel Tray and Connector Assembly
The rack connectors mate with two 44-pin connectors in the PMA5000EX. The connectors are a subminiature crimp-type, and require the use a hand crimp tool, from table below (or equiv.). The connectors
are mounted to the tray back plate with #4 -40 screws (475-440-1038), from the inside of the tray and the
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 2-2 Rev. 1 Jan. 2011
mounting block, 431-891-0100. Ensure that proper strain relief and chafing precautions are made du ring
wiring and installation, using the cable clamp (625-001-0002).
Two grounding lugs are provided, which may be attached to the rear mounting plate with 2 ea #4 -40 x ¼”
screws with captivated lock washers. These provide a convenient location to connect the shield ground
terminations.
Manufacturer
Crimping Tool
Positioner
Extraction tool
AMP
601966-1
601966-6
91067-1
Daniels
AFM8
K42
M24308-1
ITT-Cannon
995-0001-584
995-0001-739
91067-1
Table 2-1 Connector Pin crimping tools
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 43.13-2B 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.
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 PMA5000EX 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 13.8 VDC present at the
connector, J2 pins 8 & 9, of the PMA5000EX 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 PMA5000EX was designed in a RFI hardened chassis and has internal Electromagnetic Interference (EMI) filters on all inputs and ou tputs.
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 ensur e a
minimum of ground loop potential. Use only Mil Spec shielded wires (MIL-C-275000, or better). Under
no circumstances combine a microphone and headphone wiring into the same shielded bundle. Always
use a 2- or 3-conductor, shield wire as shown on the installation-wiring diagram.
The shields can be daisy-chained together, and then connected to the ground lugs mounted on the back
plate shown in Appendix B.
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.
2.4.1.1 Music Inputs and Noise
PMA5000EX units utilize a differential input to help prevent noise from entering the music system. This
feature is usually transparent to the installer, however, it is important that the appropriate music signal
PS Engineering
PMA5000EX Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-550-0100 Page 2-3 Rev. 1 Jan. 2011
and ground connections are made directly to the dedicated music signal and grou nd inputs on the
PMA5000EX. The power for IFE and audio panel should be a common bus.
If a music jack instead of a music source is installed for Music 1 or 2, we recommend grounding the jack
to airframe ground.
NOTE
Adding a high-performance audio control system, particularly in conjunction with high-performance active noise canceling headsets, cannot improve on older avionics that were designed for cabin -speaker use.
PS Engineering makes no claim that the audio panel will provide a noise -free audio quality under all installation conditions, particularly with older avionics.
2.4.2 Power
The PMA5000EX is compatible with both 14 and 28 Volt DC systems. A five (5) Amp circuit breaker is
required for all installations. Power and ground wires should be #22 connected to J2 Pins 8 and 9. Connect airframe ground to J2 Pin 10 and 11 only. No dropping resistors are required.
2.4.3 Communications Push-to-Talk
An important part of the installation 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
PMA5000EX is in the OFF/EMG mode.
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.
2.4.4 Audio Panel interface
The PMA5000EX is designed to interface with standard aircraft avionics, and presents a 510 receiver
impedance. For best results, a twisted-shielded cable is recommended from the avionics audio source to
the audio panel, with the shield grounded at the audio panel end.
Some avionics do not provide a separate audio low, and may introduce additional electrical noise into the
system. For best results, connect the audio low from the audio panel to the radio ground, using one conductor of the twisted-shielded cable.
2.4.5 TEL (Duplex) Function for Cell Phones
The TEL mode in the PMA5000EX is compatible with many cellular telephones with hands -free headset
interfaces. The front panel 3/32” utility jack can be used as the interface to the Cell Phone, or a 3/32” jack
can be installed somewhere on the aircraft panel. The wired interface jack i s connected with the
PMA5000EX as shown: A patch cord (3/32” to 3/32”) is available from PS Engineering under P/N 425006-7026.
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