PS Engineering PMA7000M-S-CAP Installation And Operation Manual
Audio Control Panel, Marker Beacon Receiver and
Sound Quality. Sound Engineering
Stereo Intercom System
PMA7000M-S-CAP
Installation
and
Operation Manual
FAA-Approved TSO C50c, C35d
Manufactured with pride by:
Document P/N 200-072-0004
Revision 4, Sept. 2000
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
PS Engineering, Inc. 2000 ©
Copyright Notice
Table of Contents
1 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 - FAA ............................................................................................1-2
1.5 SPECIFICATIONS.........................................................................................................1-3
1.6 EQUIPMENT SUPPLIED.............................................................................................1-4
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED....................................................1-4
1.8 LICENSE REQUIREMENTS .......................................................................................1-4
2 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 ...............................................................................2-2
2.3.4 CONNECTOR ASSEMBLY .............................................................................................2-2
2.4 CABLE HARNESS WIRING ...............................................................................................2-2
2.4.1 NOISE ..........................................................................................................................2-2
2.4.2 EXISTING KMA-24 INSTALLATION.............................................................................2-3
2.4.3 EXISTING PMA6000 INSTALLATIONS.........................................................................2-3
2.4.4 POWER ........................................................................................................................2-4
2.4.5 RADIO PUSH-TO-TALK................................................................................................2-4
2.4.6 TRANSMIT INTERLOCK................................................................................................2-4
2.4.7 "SWAP" MODE FOR CIVIL AIR PATROL VERSIONS.....................................................2-4
2.4.8 BACKLIGHTING ...........................................................................................................2-5
2.4.9 UNSWITCHED INPUTS..................................................................................................2-5
2.4.10 INTERCOM WIRING ....................................................................................................2-5
2.4.11 COM 3 AUDIO............................................................................................................2-6
2.4.12 PA MUTE (J1, PIN 18)...............................................................................................2-7
2.4.13 P-T-T INTERCOM (J2, PIN 18, L AND M)..................................................................2-7
2.5 MARKER INSTALLATION (PMA7000M-S).....................................................................2-7
2.5.1 MIDDLE MARKER SENSE (PMA7000M-S).................................................................2-7
2.5.2 EXTERNAL MARKER LIGHTS (PMA7000M-S) ...........................................................2-7
2.5.3 MARKER ANTENNA INSTALLATION ............................................................................2-7
2.6 ADJUSTMENTS..................................................................................................................2-7
2.7 COMMUNICATIONS ANTENNA INSTALLATION NOTES ..................................................2-8
2.8 POST INSTALLATION CHECKOUT ...................................................................................2-8
2.9 UNIT INSTALLATION........................................................................................................2-8
2.9.1 OPERATIONAL CHECKOUT..........................................................................................2-9
2.9.2 RECEIVER SENSITIVITY.............................................................................................2-10
2.10 FINAL INSPECTION.......................................................................................................2-10
3 SECTION III OPERATION ............................................................................................... 3-1
3.1 SCOPE .............................................................................................................................3-1
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
3.2 AUDIO SELECTOR (ALL MODELS)...................................................................................3-1
3.2.1 SPEAKER AMPLIFIER...................................................................................................3-2
3.3 POWER SWITCH (FAIL SAFE OPERATION).....................................................................3-2
3.4 MICROPHONE SELECTOR................................................................................................3-2
3.5 SPLIT MODE .....................................................................................................................3-3
3.5.1 SPLIT MODE ICS.........................................................................................................3-3
3.5.2 SWAP MODE................................................................................................................3-3
3.6 INTERCOM........................................................................................................................3-4
3.6.1 INTELLIVOX®VOX-SQUELCH.....................................................................................3-4
3.6.2 VOLUME CONTROL .....................................................................................................3-5
3.6.3 INTERCOM MODES ......................................................................................................3-5
3.7 P-T-T INTERCOM MODE.................................................................................................3-7
3.8 MARKER BEACON (PMA7000M-S)................................................................................3-7
4 SECTION IV- WARRANTY AND SERVICE ................................................................... 4-1
4.1 WARRANTY ......................................................................................................................4-1
4.2 FACTORY SERVICE ..........................................................................................................4-1
5 APPENDIX A EXTERNAL PTT HOOK UP ...................................................................... A
6 APPENDIX B INSTALLATION DRAWING ...................................................................... B
7 APPENDIX C BOTTOM CONNECTOR INTERCONNECT ........................................... C
8 APPENDIX D TOP CONNECTOR INTERCONNECT ..................................................... D
9 APPENDIX E- INSTRUCTIONS FOR FAA FORM 337 AND CONTINUING
AIRWORTHINESS ...................................................................................................................... E
9.1 INSTRUCTIONS FOR FAA FORM 337, AUDIO PANELS..................................................... E
INSTRUCTIONS FOR CONTINUING AIRWORTHINESS, AUDIO PANELS .................. E
10 APPENDIX F RTCA DO160C ENVIRONMENTAL QUALIFICATION FORM ......... F
200-072-0004 Page ii Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
Section I -- GENERAL INFORMATION
1.1 INTRODUCTION
The PMA7000M-S represents the next step in cockpit audio control and intercommunications. Using proprietary IntelliVox® design, this unit eliminates the requirements for
intercom squelch adjustments. The unit is designed for outstanding ergonomics and visually defined mode annunciation and selection. These units were custom designed to meet
the requirements of the Civil Air Patrol in the SAR environment.
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 PMA7000M-S.
1.2 SCOPE
This manual provides detailed installation and operation instructions for the PS Engineering PMA7000M-S-units provided to the Civil Air Patrol:
Model Description Part Number
PMA7000S-CAP Stereo Audio Panel with special CAP functions 7000S-CAP
PMA7000M-S-CAP Stereo Audio Panel with Marker with special CAP
functions
Option 1 added to any unit Same as above, with optional recorder and mes-
sage system
Option 3 added to any system Black bezel (no silver trim) Opt 3
Other options may be applied for exclusive use by specific aircraft manufacturers, under Type Certifica-
tion Call for information.
7000MS-CAP
Opt.1
1.3 EQUIPMENT DESCRIPTION
The PMA7000-series is a state-of-the-art audio isolation amplifier and audio selector that
contains an automatic voice activated (VOX) intercom system. It can switch up to three
transceivers (Com 1, Com 2 and Com 3) and five receivers (Nav 1, Nav 2, ADF, DME,
and MKR).
There are two unswitched inputs, for autopilot disconnect, and/or radar altimeter warning.
Push buttons select the receiver audio source provided to the headphones. A SPR button
allows the user to listen to the receiver(s) selected on the cabin speaker. Except for the
unswitched inputs, all speaker audio is muted during transmit.
A rotary switch selects one of the three communication transceivers for the pilot and copilot position, and allows radio transmission. In "Split Mode" the PMA7000M-S has the
ability to allow the pilot and copilot to operate three different transceivers independently.
In concert with the swap mode, six combinations of three transceivers are possible
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.
A six-station voice activated (VOX) intercom is included in the PMA7000-Series. This
system has PS Engineering’s exclusive IntelliVox® circuitry that eliminates manual ad-
200-072-0004 Page 1-1 Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
justments. 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, two stereo music inputs
with "Soft Mute," and LED indicators for swap and transmit indications. Intercom control is through front panel-mounted knob 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.
A 3-light Marker Beacon receiver is integrated in the PMA7000M-S. This provides the
necessary Marker Beacon lights and audio indications necessary for an Instrument Landing System (ILS) approach.
1.4 APPROVAL BASIS - FAA
TSO Approval.
The PMA7000M-S, and PMA7000S Audio Selector Panels are FAA approved under
TSO C50c (Audio Amplifiers) and TSO C35d (Marker Beacon Receivers). In addition,
they are approved by the Joint Airworthiness Authorities under JTSO C50C and JARTSO 2C35d.
All systems comply with relevant portions of EUROCAE RTCA MPS WG No. 7/70,
DO-143 and (Marker Beacon Receivers), ED-14C/DO-160C (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.
200-072-0004 Page 1-2 Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
1.5 SPECIFICATIONS
TSO COMPLIANCE
Marker Beacon: C35d, Class A
Audio Selector/Intercom: C50c, Class A
APPLICABLE DOCUMENTS: RTCA/DO-214
RTCA/DO-143
RTCA/DO-160C
RTCA/DO-178B Level D
ENVIRONMENTAL Qualifications: A1D1/CA(MN)XXXXXXBBBBTBKXX
Temperature Range:
Operating:
Storage:
Altitude: Up to 50,000 feet in an non-pressurized area
DIMENSIONS: Height: 1.3 in. (3.3 cm) Width: 6.25 in. (16.9
WEIGHT (With Rack & Connectors): 1.5 lb. (0.54 kg)
POWER REQUIREMENTS (Including Internal Lighting):
Voltage: 11 to 33 VDC
Maximum Current: 2.5 Amp (Externally protected by a 3 Amp
Typical operating current:
Speaker off:
Speaker on, 28V, full radio volume
Audio Selector Specifications
Audio selector panel input impedance:
Input Isolation: -60 dB (min.)
Speaker Muting: -60 dB (min.)
Speaker Output (into 4 Ω) with no clipping
14 VDC:
28 VDC:
Receiver Inputs: 8
Unswitched Inputs: 2
Transmitter Selections: 9
Speaker Impedance:
Headphone Impedance:
Headphone Output: 38 mW each headset, no clipping <1% THD
Microphone Impedance:
-15º C to 55ºC
-20º C to 85ºC
of the cockpit.
cm)
Depth: 6.8 in. (17.3 cm)
circuit breaker.)
350 mA
750 mA
2.5 A
510 Ω
3 Watts (min.)
10 Watts (min.)
(Com 1, Com 2, Com 3, Nav 1, Nav 2, ADF,
DME, MKR)
(examples: GPS WPT, Autopilot Disconnect,
Altimeter DH)
(Com 1, Com 2, Com 3
Com1/Com2, Com 1/3, Com 2/3 and by swap
switch, Com2/1, Com 3/1, Com 3/2)
4 Ω
150 - 1000 Ω
70 mW each headset with < 10% THD
150 - 600 Ω
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PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
Intercom Positions: 6 places (with individual IntelliVox® circuits)
Music Inputs: 2 (Stereo)
Music Muting: >-30 dB "Soft Mute" when Com or intercom active.
Distortion:
Mic Freq. Response, 3 dB: 300 Hz - 6000 Hz
Music Freq. Response, 3 dB: 100 Hz - 18kHz
MARKER BEACON RECEIVER: PMA7000M-S only
Frequency: 75 MHz Crystal Controlled
Sensitivity:
Low:
High:
Selectivity: -6 dB at ±10 kHz
External Lamp Output: 9.0 (±1.5 at maximum brightness, unloaded) VDC
MM Sense: Active high (4.7 VDC ± 0.5V) during Middle
PS Engineering
Intercom Specifications
<1% THD @ 38 mW into 150Ω
<10% THD @ 70mW into 150 Ω
Capable of: (preset at factory for field application)
1000 µVolts (Hard)
200 µVolts (Hard)
-40 dB at ±120 kHz
positive when active, max. current 125 mA
Marker acquisition, for autopilot use.
1.6 EQUIPMENT SUPPLIED
1 ea. of the following units:
Model Part Number
PMA7000S Special CAP version 7000S- CAP
PMA7000M-S Special CAP version with Marker Beacon Receiver 7000M-S- CAP
PMA7000M-S Installation Kit: 250-007-002
Part Number Description Quantity
120-430-0420 Tray Assembly 1
120-425-4400 Bottom connector, key between 7/8 1
120-425-4402 Top connector (Stereo), key between 5 1
655-000-0001 Gold Plated Crimp Pins 88
200-072-0004 Operator's and Installation Manual (CAP) 1
475-440-0007 #4 x 40 screw w/nylon patch 4
1.7 EQUIPMENT REQUIRED BUT NOT SUPPLIED
a) Circuit Breaker: 1 ea. 3 amp (28V)
b) Speaker, 4 Ω
c) Stereo Headphone Jacks (as required)
d) Microphone Jacks (as required)
e) Stereo Headphones, 150 Ω, up to 6 as required
f) Microphones, up to 6 as required
g) Marker Antenna (75 MHz, VSWR <1:1.5, and appropriate for the airspeed)
h) Interconnect Wiring
1.8 LICENSE REQUIREMENTS
None
200-072-0004 Page 1-4 Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
Section II - Installation
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnect instructions for the PS Engineering PMA7000M-Series Audio Selector Panel/Intercom System with internal Marker
Beacon.
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 installation is supervised 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. 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 PMA7000M-S 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 PMA7000M-S must be rigidly mounted to the instrument panel of the aircraft structure and within view and reach of the pilot position(s). Installation must comply with
FAA Advisory Circular AC 43.13-2A. The unit may be mounted in any area where adequate clearance for the unit and associated wiring bundle exist.
200-072-0004 Page 2-1 Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
Avoid installing the audio panel close to high current devices or systems with highvoltage 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
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 FHP 6-32 x ½" screws. The audio selector panel must be supported at front
and rear of the mounting tray.
NOTE: The mounting hole configuration for the PMA7000M-S is identical to the
PMA6000 series and KMA-24 Audio Selector Panels.
2.3.4 Connector Assembly
The unit connectors mate directly with the circuit boards in the PMA7000M-S. The connectors are a Molex crimp-type, and require the use of a Molex hand crimp tool, EDP P/N
11-01-0203, CR6115B (or equiv.). The connectors are mounted to the unit tray with #440 screws, from the inside of the tray. Ensure that proper strain relief and chafing precautions are made during wiring and installation.
2.4 Tray Assembly
Attach the connectors to the tray from the inside, using the #4x40 screws provided. The
bottom connector is keyed at pin 8, and top connector at pin 5. The lettered row of pins
faces the top of the unit.
2.5 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 with shield 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.
2.5.1 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 PMA7000M-S 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 nominal aircraft voltage present at the bottom connector, pin
200-072-0004 Page 2-2 Rev. 4, Sept. 2000
PMA7000M-S Series Audio Selector Panel and Intercom System
Civil Air Patrol Version Installation and Operator’s Manual
PS Engineering
20, of the PMA7000M-S 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 PMA7000M-S 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-27500, 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.
Adding a high-performance audio control system, particularly in conjunction with highperformance 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.
2.5.2 Existing KMA-24 Installation
If the installation replaces a KMA-24 (part number -01, -02 or -03), the existing 44 pin
connector can be used for the bottom connector of the PMA7000M-S tray as is, providing
it is properly installed and wired. No other changes are required except for external
marker lights (see Section 3.7.2 for details), OR unless additional transceivers must be
added. The "key" in the existing connector must be located between pins 7 and 8. This
connector will be used in the bottom connector position. (See Appendix C and D for
complete wiring harness details.)
The existing ground bus may be reused for radio shield connections, if it was constructed
so it can be relocated to the PMA7000M-S tray.
2.5.3 Existing PMA6000 installations
In 28-Volt aircraft, the dropping resistor may be removed; however, the 2 Amp breaker
should be changed to 3 Amp. If the old unit is stereo (PMA6000S or PMA6000MS), no
rewiring is necessary unless additional features are added.
2.5.3.1 Stereo PMA7000M-S installations into monaural PMA6000, PMA6000M.
Installations replacing PMA6000 or PMA6000M require re-wiring of the top connector to
accommodate the stereo configuration. See appendix for detailed interconnect information.
200-072-0004 Page 2-3 Rev. 4, Sept. 2000
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