PS Engineering PAC45J User manual

9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
PAC45J
Audio Controller System
with MultiTalker® and IntelliVox®
Document P/N 200-045-2000
November 2020
Audio Control System with Intercom
System Installation and Operation Manual
FAA - TSO C139a
Patented under one or more of the following;
No. 4,941,187; 5,903,227; 6,160,496 and 6,493,450, 7,391,877
PS Engineering, Inc. 2020 ©
Copyright Notice
Any reproduction or retransmittal of this publication, or any portion thereof, without the expressed written permission of PS En-
gineering, Inc. is strictly prohibited. For further information, contact the Publications Manager at PS Engineering, Inc., 9800
Martel Road, Lenoir City, TN 37772. Phone [phone], email [e-mail].
In certified aircraft, 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
1.1.1 LIMITATIONS.....................................................................................................................1-1
1.2 SCOPE................................................................................................................................................................1-1
1.3 EQUIPMENT DESCRIPTION........................................................................................................................1-1
1.4 APPROVAL BASIS FAA TSO.........................................................................................................................1-2
1.1.2 LIMITATIONS.....................................................................................................................1-2
1.5 SPECIFICATIONS...........................................................................................................................................1-2
1.6 EQUIPMENT SUPPLIED................................................................................................................................1-3
1.8 CONFIGURATION .................................................................................................................................................1-5
1.9 LICENSE REQUIREMENTS..........................................................................................................................1-6
Section II –INSTALLATION .................................................................2-1
2.1 GENERAL INFORMATION...........................................................................................................................2-1
2.1.1 SCOPE..............................................................................................................................2-1
2.1.2 CERTIFICATION REQUIREMENTS ......................................................................................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 CONTROLLER CONNECTOR ASSEMBLY..................................................................2-2
2.4 CABLE HARNESS WIRING....................................................................................................................................2-2
2.4.1 ELECTRICAL NOISE...........................................................................................................2-2
2.4.2 POWER ..............................................................................................................................2-3
2.4.3 AUDIO CONTROLLER INTERFACE......................................................................................2-3
2.4.4 BACKLIGHTING.................................................................................................................2-4
2.4.5 UNSWITCHED INPUTS........................................................................................................2-4
2.4.6 COCKPIT VOICE RECORDER..............................................................................................2-4
2.4.7 SPEAKER OUTPUTS...........................................................................................................2-4
2.4.8 AUDIO ALERTS .................................................................................................................2-5
2.4.9 CTL45J WIRING................................................................................................................2-5
2.5 DISCRETE INPUTS ................................................................................................................................................2-6
2.5.1 REMOTE ICS MODE CONTROL.(J452-45).........................................................................2-6
2.5.1 OXY (P453-26) ................................................................................................................2-6
2.5.2 RECEIVE MUTE (J452-44).................................................................................................2-6
2.5.3 REMOTE ALERT ACKNOWLEDGE AND ALERT PROGRAMMING (P453-23).......................2-6
2.5.4 BACKLIGHT ADJUSTMENT ................................................................................................2-6
2.6 WIRED TELEPHONE/SATELLITE COMMUNICATION INPUT..................................................................................2-6
2.7 USER ADJUSTMENTS............................................................................................................................................2-7
2.7.1 UNSWITCHED AUDIO LEVEL ............................................................................................2-7
2.7.2 ADJUSTMENTS ..................................................................................................................2-7
2.7.3 LOGIC SWITCH OPTIONS...................................................................................................2-8
2.7.4 LOGIC SWITCH DETAILS.................................................................................................2-10
2.7.5 FAIL-SAFE AUDIO AND REVERSIONARY MODE .............................................................2-14
2.7.6 MICROPHONE SETTINGS..................................................................................................2-14
2.7.7 SIDETONE........................................................................................................................2-15
2.7.8 UNSWITCHED AUDIO......................................................................................................2-15
2.7.9 HEADPHONE OPTIONS ....................................................................................................2-15
2.7.10 RECEIVE SIGNAL INDICATOR........................................................................................ 2-15
2.7.11 MUSIC FUNCTIONS .......................................................................................................2-15
2.7.12 SPEAKER ALERT AUDIO ...............................................................................................2-16
2.7.13 BACKLIGHT DIMMER VOLTAGE ...................................................................................2-16
2.7.14 OTHER SHARED FUNCTIONS.........................................................................................2-16
2.8PAC45J PIN ASSIGNMENTS ...............................................................................................................................2-17
2.9 WIRING CHECKOUT ..........................................................................................................................................2-18

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page ii November 2020
2.10 OPERATIONAL CHECKOUT................................................................................................................................2-19
2.10.1 REQUIRED TEST EQUIPMENT........................................................................................ 2-19
2.10.2 AUDIO CONTROLLER TEST............................................................................................2-19
2.10.3 BLUETOOTH CHECKOUT...............................................................................................2-20
2.11 FINAL INSPECTION ............................................................................................................................................2-20
Section III OPERATION .................................................................3-1
3.1 SCOPE................................................................................................................................................................3-1
3.2 POWER AND FAIL SAFE .......................................................................................................................................3-1
3.3 COMMUNICATIONS TRANSMIT (XMT) SELECTION ............................................................................................3-1
3.4 COM AUDIO SELECTOR AND VOLUME...............................................................................................................3-2
3.5 NAVAID SELECTION.............................................................................................................................................3-3
3.5.1 OXY (P453-26) ................................................................................................................3-3
3.5.2 RECEIVE MUTE (J452-44).................................................................................................3-3
3.6 INTERCOM OPERATION (8)..................................................................................................................................3-3
3.6.1 INTELLIVOX®INTERCOM VOX-SQUELCH........................................................................3-3
3.6.2 INTERCOM VOLUME CONTROL.........................................................................................3-3
3.6.3 INTERCOM MODES............................................................................................................3-4
3.7 SPEAKER OPERATION ..........................................................................................................................................3-4
3.8 BLUETOOTH®CONNECTION................................................................................................................................3-4
3.8.1 PAIRING AND UNPAIRING BLUETOOTH DEVICES ..............................................................3-5
3.8.2 BLUETOOTH®TELEPHONE MODE....................................................................................3-5
3.8.3 MUSIC MUTING CONTROL................................................................................................3-5
3.9 WIRED SATCOM/CELL PHONE INPUT..................................................................................................................3-6
3.10 ALERT AUDIO......................................................................................................................................................3-6
3.10.1 STORING ALERT AUDIO..................................................................................................3-6
Section IV –Warranty and Service .................................................................4-1
4.1 WARRANTY .........................................................................................................................................................4-1
4.2 FACTORY SERVICE ..............................................................................................................................................4-1
Appendix A –PAC45J Installation Drawings............................................................A
Appendix B –Radio Interconnect Wiring..................................................................B
Appendix C –Intercom Interconnect Wiring............................................................C
Appendix D –Control Head Interconnect Wiring ....................................................D
Appendix E, Unit Connector Wiring Reference........................................................E
9.1 J451 CONNECTIONS................................................................................................................................................E
9.2 J452 CONNECTIONS................................................................................................................................................E
9.3 J453 CONNECTIONS................................................................................................................................................E
9.4 J454 CONNECTIONS................................................................................................................................................E
9.5 J455 CONNECTIONS................................................................................................................................................E
Appendix F –Instructions for FAA Form 337 and continuing airworthiness........F
10.1 INSTRUCTIONS FOR FAA FORM 337,AUDIO CONTROLLERS..................................................................................F
10.2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS,AUDIO SYSTEM.....................................................................F
Appendix G –RTCA DO160G Environmental Qualification Form ...................... G
11.1 MODEL NUMBER PAC45J AUDIO SELECTOR PANEL/INTERCOM REMOTE HUB .................................................G
11.2 MODEL NUMBER CTL45J, AUDIO SELECTOR CONTROL PANEL .........................................................................G
Revision History
Rev
Date
Change
New
November 2020
Initial Draft Manual

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-1 November 2020
Section I – GENERAL INFORMATION
1.1 INTRODUCTION
The PAC45J represents a revolutionary step in cockpit audio control and intercommunications utility.
MultiTalker®, using licensed U.S. Air Force patented technology, provides True Dimensional Sound, help-
ing pilots to more easily discern from simultaneous radio receptions.
1.1.1 Limitations
This article meets the minimum performance and quality control standards required by a technical standard
order (TSO). Installation of this article requires separate approval. Refer to Advisory Circular 20-41A for
information on TSO installation approval.
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.
1.2 SCOPE
This manual provides installation and operation instructions for the PS Engineering PAC45J-series of Audio
Selector Panel/Intercom Systems. This includes the following units:
Model Number
Description
PS Engineering
Part Number
HUB45AR
Remote-mounted Audio Hub for analog I/O and processing
050-045-1001
CTL45J
Panel Mounted Control Head for Flight Crew Black
050-445-XXXX
CTL45J-NVG
Panel Mounted Control Head for Flight Crew, Night Vision
Compatible Black
050-446-XXXX
CTL45J
Panel Mounted Control Head for Flight Crew Gray
050-447-XXXX
CTL45J-NVG
Panel Mounted Control Head for Flight Crew Night Vision
Compatible -Gray
050-448-XXXX
1.3 EQUIPMENT DESCRIPTION
The PAC45J 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 eight transceivers (COM 1 to 8) and eight navigation
receivers (AUX 1 to 8) that can be configured as desired.
There are up to five unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or radar
altimeter warning.
In addition to a radio master volume, the individual volume controls select the receiver audio source provided
to the headphones when selected to the “out” position.
A nine-station voice activated (VOX) intercom is included in the PAC45J. This system has PS Engineering’s
patented IntelliVox® circuitry that eliminates manual adjustments. The intercom system incorporates pilot
isolate, all and crew modes, a stereo music input with "SoftMute™".
In the PAC45J, a Bluetooth® wireless interface is available for wireless telephone and music connection.
Up to nine programmable alerts can be triggered by external sources to provide additional capability.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-2 November 2020
1.4 APPROVAL BASIS FAA TSO
FAA TSO The PAC45J-series Audio Selector Panels is FAA authorized under TSO C139A (Audio Ampli-
fiers). ED-14C/DO-160G (Environmental Conditions and Test Procedures for Airborne Equipment),
ED12B/DO-178C, Level C (Software Considerations for Airborne Equipment) and ED- 18/DO-214A (Audio
Systems Characteristics and Minimum Operational Performance Standards for Aircraft Audio Systems).
1.1.2 Limitations
This article meets the minimum performance and quality control standards required by a technical standard
order (TSO). Installation of this article requires separate approval.
Refer to Advisory Circular 20-41A for information on TSO installation approval.
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
TSO COMPLIANCE
Audio Selector/Intercom:
FAA TSO-C139A
APPLICABLE DOCUMENTS:
RTCA/DO-214A
RTCA/DO-160G
RTCA/DO-178C
Temperature Range:
Operating:
Short Term Operating:
Survival:
HUB45AR
-45° C to +55°C
-45° C to +71°C
-55° C to +85°C
CTL45J
-20°C to +55°C
-40° C to +70°C
-55° C to +85°C
Altitude:
Up to 55,000 feet in a non-pressurized area of the cockpit.
DIMENSIONS:
CTL45J: Height: 2.62 in. (6.65cm) Width: 4.90 in. (12.45 cm)
Depth behind panel: 2.35 in. (5.97)
HUB45AR: Height: 1.9” Width: 5.88 w/mounting flanges, Length
7.22”, 12” w/ all connectors. See Figure 5-6
UNIT WEIGHT
HUB45AR
CTL45J
2.0 lbs. (.91 kg)
1.3 (.60 kg)
POWER REQUIREMENTS:
Voltage:
18 to 33 VDC
Maximum Current:
Typical Current
Alert Power
Lighting
HUB45AR 1.5 Amp (Externally protected by a 5 Amp circuit breaker.)
CTL45J 500 mA (Externally protected by a 1 Amp circuit breaker)
750 mA
<20 mA
< 5mA
Audio Selector Specifications
Audio selector panel input impedance:
510 
Input Isolation:
-60 dB (min.)
Switched Receiver Inputs:
16 (COM 1–COM 8, AUX 1- 8)
Unswitched Inputs:
5
Transmitter Selections:
8 (COM 1, 2, 3, 4, 5, 6, 7, 8)
Headphone Impedance:
150 –600 or 8 Ω
Headphone Output:
200 mW into 150or 8Ω headset, no clipping <.5% THD typical
Microphone Impedance:
150 - 600 
PA Output, Cockpit speaker output
10W @4 Ω

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-3 November 2020
Intercom Specifications
Intercom Positions:
Up to 9 places (with individual IntelliVox® circuits)
Distortion:
<1% THD @ 200 mW into 150
Mic Freq. Response, ±3 dB:
300 Hz - 6000 Hz
Music Inputs:
1 (Stereo) plus Bluetooth
Music Muting:
>-30 dB "Soft Mute" when Com or intercom active.
1.6 EQUIPMENT SUPPLIED
The following units comprise the PAC45J System:
Model
Description
Part Number
HUB45AR
Remote-mounted Audio Hub for analog I/O and processing
050-045-1001
CTL45J
Control Head for pilot or copilot positions
050-445-XXXX
CTL45J
Control Head for pilot or copilot positions –Gray
050-446-XXXX
CTL45J-NVG
NVG Panel-mounted Control Head for pilot and copilot positions
Black
050-447-XXXX
CTL45J-NVG
NVG Panel-mounted Control Head for pilot and copilot positions
–Gray
050-448-XXXX
PAC45J Installation Kit: 250-045-0811
Male Connector Kit 250-045-8377 (P452, P454)
Part Number
Description
MFR
MFR PN
Quantity
625-015-1503
Connector Back shell DB26 pin
Harting
09-70-015-0343
1
625-037-3703
Connector Back shell DB62 pin
Harting
09-67-037-0343
1
425-026-5601
Male Sub-D Connector Shell DB26 pin
Harting
95-62-005-601
1
425-062-8177
Male Sub-D Connector Shell DB62 pin
Harting
95-64-005-601
1
425-044-2043
Hi-density Male Pins
AMP
204370-2
88
Female Connector Kit 250-045-8477 J451, J453)
Part Number
Description
MFR
MFR PN
Quantity
625-015-1503
Connector Back shell DB26 pin
Harting
09-70-015-0343
1
625-037-3703
Connector Back shell DB62 pin
Harting
09-67-037-0343
1
425-026-1800
Female Sub-D Connector Shell DB26 pin
Norcomp
180-026-273L000
1
425-062-4701
Female Sub-D Connector Shell DB62 pin
Harting
99-56-400-4701
1
425-030-7354
Hi-density Female Pins
Amphenol
M39029/57-354
88
9-Pin Connector Kit 250-045-0019 (P455)
Part Number
Description
MFR
MFR PN
Quantity
625-009-9034
Connector Back shell DB9 pin
Harting
09-67-009-0343
1
425-009-0777
Male Sub-D Connector Shell DB9 pin
Amphenol
L777-RR-E-09-P
9
425-020-5089
Standard Density Male Pins
Deutsch
M39029/64-369
9

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-4 November 2020
CTL45J 9-Pin Female Connector Kit 250-543-0100 (J455)
Part Number
Description
MFR
MFR PN
Quantity
625-009-9209
Connector Back shell DB9
Harting
09-67-009-0343
1
425-009-7709
Connector Sub-D Female Shell DB9
Amphenol
L177-RR-E-09-S
1
425-020-5090
Standard density female pins
Deutsch
M39029/63-368
9
External Bluetooth Antenna
Part Number
Description
MFR
MFR PN
Quantity
300-045-1351
Bluetooth Coaxial Cable SMA ST BH JK to
ST Plug RG 174/U 36
Amphenol
135110-02-36”
1
510-045-9602
Bluetooth Antenna
Taoglas
GW.26.0112.HT
1
EQUIPMENT REQUIRED BUT NOT SUPPLIED
a. Circuit Breakers: 1 ea.; 5 amp PULL TYPE REQUIRED for HUB45AR, 1 A for CTL45Js
b. Optional Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45J aural alerts, 1 ea. 1 A for
failsafe power
c. Stereo Headphone Jacks (as Required)
d. Microphone Jacks (as Required)
e. Stereo Headphones, as required
f. Microphones, as required
g. Interconnect Wiring

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-5 November 2020
1.8 Configuration
The PAC45J System is comprised of a single PAC45J HUB (HUB45AR) and up to four CTL45J or a com-
bination of CTL45A Control Heads “building blocks” to facilitate flexibility as well as simplicity.
HUB45AR
Pilot Copilot
Passenger 1
RS422 RS422 RS422RS422
Hand
Observer 1Crew 3 Observer 2
Passenger 2
Passenger 3 Passenger 4
CVR CP
PA
COM1-8
NAV 1-2
Aux 3-8
UNSW1-5
Telephone
Music
Bluetooth
Telephone
Bluetooth
Music
CVR P
Pilot
CopilotAmp
Figure 1-1 Baseline configuration

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 1-6 November 2020
1.9 LICENSE REQUIREMENTS
None
Hub
Pilot
EFIS INTERFACE
COM1-8
Copilot
EFIS INTERFACE
Observer 1
Control Head
Observer 2
Control Head
Passenger 2 Passenger 3
Passenger 1
RS422 RS422 RS422RS422
Hand
NAV 1-2
Marker1-2
ADF1-2
DME1-2
UNSW 1-5
Telephone
CVRO2
CVRO1
CVRCP
CVRP
PA
Cockpit
Pilot
O2 Copilot O2

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-1 November 2020
Section II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnection instructions for the PS Engineering PAC45J
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, test equipment (refer to §2.12.1) and installer knowledge
as required by 14 CFR 65.81 (b).
2.1.2 Certification Requirements NOTE
The PAC45J requires specialized knowledge and tools for an effective installation. 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 is installed by an authorized PS Engi-
neering, 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.
This article meets the minimum performance and quality control standards required by a technical standard
order (TSO). Installation of this article requires separate approval. Refer to AC 20-41A for information
regarding Substitute TSO Aircraft Equipment.
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 com-
ponents supplied with the list in §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 show
any sign of external shipping damage, contact PS Engineering to arrange for a replacement. Under no cir-
cumstances 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 PAC45J is not required. However, the units should be kept away from heat produc-
ing sources (i.e. defrost or heater ducts, dropping resistors, heat producing avionics) without adequate cooling
air provided.
2.3.2 Mounting Requirements
The HUB45AR must be rigidly mounted to the aircraft structure in an avionics-rated location. The CTL45J
is designed for Dzus-rail mounting within view and reach of the flight crew position(s). Installation must
comply with FAA Advisory Circular AC 43.13-2B, or other FAA-approved aircraft technical data. 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.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-2 November 2020
2.3.3 Audio controller connector assembly
The HUB45AR LRU connectors mate with two 62-pin, and two 26-pin connectors. One of each gender. The
connectors are a sub-miniature crimp-type, and require the use a hand crimp tool, from table below (or
equiv.).
P451 P453
J454J452
121
22
43
62
42
121
22
43
62
42
1 9
19 26
10 18
19
26
10
18
19
Figure 2-1 - PAC45J HUB45AR Connector Layout
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 sol-
dering technique must always be used. 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.
See Appendix C and D for intercom connection configurations. It is critical to the proper operation of this
system to have this connector wiring made in accordance with these diagrams. Use 2- and 3-conductor, MIL-
spec cable as shown. Connect the shields at the audio controller end only, and tie to the audio low inputs as
shown.
2.4.1 Electrical Noise
Due to the variety and the high power of radio equipment often found in today's aircraft, there is a potential
for both radiated and conducted noise interference.
The PAC45J 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. 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 PAC45J was designed in an RFI hardened chassis and has internal Electromagnetic Interfer-
ence (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 air-

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-3 November 2020
frame that are detected by the audio system. Follow the wiring diagram very carefully to help ensure a min-
imum 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.
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.
2.4.2 Power
The PAC45J is compatible with 28 Volt DC systems. A five (5) Amp circuit breaker is required for all
installations. Power and ground wires should be #22AWG connect power to P451 Pin 42. Connect airframe
ground to P451 Pin 20 and 21 only.
Power consumption is as follows:
At 28V:
•Control head Only: 400 mA
•Hub Only: 750 mA
•Alert audio power: 20mA
At minimum input voltage (20V):
•Control head: 600mA
•Hub Only: 950mA
Lighting input: <5mA
CAUTION: Do not connect or disconnect (HOT SWAP) any components with power applied, this may
damage the units
2.4.2.1 Alert power, P451 Pin 41,
The PAC45J has an independent alert system with the ability to play alerts even when the audio controller is
powered off. To take full advantage of this isolation a separate one (1) Amp circuit breaker is required. Power
should be #22AWG connect power to P451 Pin 41.
When power to P451-42 is present, the message will play three times or until the remote acknowledge is
selected.
2.4.2.2 Failsafe Power P451 Pin 62 and O2Enable P453 Pin 26
When connected to the aircraft bus, it allows for the use of Oxygen microphones in failsafe, when the O2
microphone discrete, J453 Pin 26 is grounded.
2.4.3 Audio controller interface
The PAC45J 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 con-
troller, with the shield grounded at the audio controller 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 controller to the radio ground, using one
conductor of the twisted-shielded cable.
2.4.3.1 Front Panel Nomenclature and Audio Inputs
Due to the PAC45J flexibility with label nomenclature (custom labels) the naming of the inputs and respec-
tive control locations can change. See Appendix B –Radio Interconnect Wiring, and §2.8, Pin Assignments
for the Switch Positions associated with the respective inputs.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-4 November 2020
2.4.3.2 Installation with Monaural Headsets
Not recommended, because the benefit of MultiTalker is lost.
However, if desired, the PAC45J can be installed monaurally by using the right and left
outputs together. However, the HUB45AR DIP switches must be set for Mono configura-
tion. See §2.5.3.
NOTE These companies adapt monaural helmets and headsets to stereo:
Lightspeed Avionics
Phone: [phone]
www.lightspeedaviation.com
Acousticom
Phone: [phone]
www.acousticom.com
FLIGHTHELMET.COM
Phone: [phone]
www.FlightHelmet.com
Headsets Inc.
Phone: [phone]
www.headsetsinc.com
2.4.4 Backlighting
Control of the unit backlighting is through the aircraft avionics dimmer through a single connection to the
HUB45A. A serial message is sent to the control heads to adjust the dimming.
For lighting control, connect J452-22, wrt J452-1 to aircraft dimmer.
Backlight voltages of 5 VDC, 14 VDC and 28 VDC are configurable. See §2.5.4.
2.4.5 Unswitched inputs
These inputs are presented to the pilot and copilot regardless of the audio configuration and will always mute
the crew entertainment inputs. These 510Ω inputs can be used for altimeter DH audio, TAWS audio, TCAS
audio or any other critical audio signal.
Unswitched #1 is always presented to the crew headphones and is available to the pilot in fail-safe (off) mode.
Unswitched 2 is presented to the copilot in fail-safe.
Unswitched Input
Input Pins
Hear in Fail Safe
Hear in Headset
1
P452 - 55 WRT 15
Pilot
Pilot & Copilot
2
P452 - 35 WRT 16
Copilot
Copilot
3
P452 - 56 WRT 17
No
Pilot & Copilot
4
P452 - 36 WRT 18
No
Pilot & Copilot
5
P452 -57 WRT 19
No
Pilot & Copilot
Table 2-2 Unswitched inputs
2.4.6 Cockpit Voice Recorder
The PAC45J audio controller contains independent Cockpit Voice Recorder outputs for the pilot, copilot and
observer positions. The CVR output is consistent with RTCA DO-214A §1.5.7.
Pilot CVR output is J452-60; Copilot CVR output is P452-61, Observer 1 CVR output P452-39, and Observer
2 P452-40, all with respect to any available audio low on J452.
NOTE: Observer 1 and Observer 2 CVR outputs are dual purpose and mutually exclusive with Copilot
speaker output and Observer speaker outputs.
See §2.7.14 for information on selecting low-level speaker or CVR outputs.
2.4.7 Speaker Outputs
The HUB45A is capable of providing three separate speaker outputs, plus Public Address. However, two are
dual purpose and mutually exclusive with copilot and observer CVR outputs.
Cockpit Speaker, P452-41 a 4Ω, 10W output, with the radio audio selected by the Pilot’s CTL45J Control
Panel.
When enabled, P452-40 is a low-level (10KΩ, 2Vpp max) speaker output with the radio audio selected on
the Copilot’s CTL45J Control Panel.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-5 November 2020
When enabled, P452-39 is a low-level (10KΩ, 2Vpp max) speaker output with the radio audio selected on
the Observer 1 CTL45J Control Panel.
Low Level audio can be amplified to 4Ω, 10W speaker output with a PS Engineering PSA210, Dual Channel
speaker amplifier, P/N 050-230-0000 (call PS Engineering for pricing). See §2.7.14 for information on se-
lecting CVR or low-level speaker outputs.
Speaker output volume control is with the master radio volume, left inner knob.
2.4.8 Audio Alerts
The PAC45J contains an independent audio alerting systems that will play up to 9 messages that can be stored
by the user (see §3.11.1). Factory stored default audio is shown below.
The alert system has a power input (P451-41) that will keep the systems operable if the PAC45J systems
power source is removed. Alert audio is provided in Fail-safe when power is on P451-62.
Alert Input
Input Pins
Alert Audio
1
P453 –10
“Master Caution”
2
P453 –11
“Alert”
3
P453 –12
Chime
4
P453 –13
1000 Hz tone
5
P453 –14
Doorbell Chime
6
P453 –19
Ring Tone
7
P453 –20
“Timer at Zero”
8
P453 –21
“Intercom Call”
9
P453 –22
“Check Engine Instruments”
Alert Power
P451 –41
Remote
Acknowledge
P453 –23
The alert triggers can be configured to be Active High (>4.5 VDC) or Active Low (<0.5 VDC), and trigger
at the leading-edge transition or by the voltage level. See §2.5.3 for configuration options.
Alerts with edge triggers will play continuously until the Acknowledge button (ACK) is pressed (remote
ACK P454-23 grounded).
Alerts with level trigger will play continuously until the Acknowledge button (ACK) is pressed (remote ACK
P454-23 grounded), or the input level reverts.
When power is applied to the alerts and not the PAC45J audio controller, it will play the message continu-
ously until the remote acknowledge is selected.
The volume level of the alerts is adjustable with potentiometer 13 on the side of the HUB45AR (See §2.7.2)
Audio alerts are inhibited for the first 30 seconds after HUB power up to reduce nuisance triggers.
2.4.9 CTL45J wiring
The PAC45J supports up to 4 CTL45J control heads. Three can be connected to the rear connectors, and the
fourth to J455. For convenience, either the pilot or observer #2 can be connected to J454 (See §2.7.14).
CTL45J can be configured for 28VDC or 5 VDC dimming.
Set J5 switches to: off/off/off/off/off/off for 28 VDC Lighting.
Set J5 switches to: off/off/off/off/on/off for 14 VDC Lighting
Set J5 switches to: off/off/off/off/on/on for 5 VDC Lighting.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-6 November 2020
2.5 Discrete inputs
2.5.1 Remote ICS mode control. (J452-45)
When a momentary, normally open, push-button switch is connected between pin J452-45 and ground, it will
change the intercom mode on the Pilot’s PAC45J.
2.5.1 OXY (P453-26 or Front Panel Selection)
Activates the Oxygen Mask microphone inputs if configured.
2.5.2 Receive Mute (J452-44)
When J452-44 is grounded through a remote switch, all receive audio is muted. If this switch remains closed
for more than 30 seconds (i.e. a stuck switch), the received audio will return to normal
2.5.3 Remote Alert Acknowledge and Alert Programming (P453-23)
A momentary switch connected to P453-23 serves as a remote Alert Acknowledge switch, and must be used
to program the Audio Alerts. We recommend installing provisions for this switch is audio alerts are ever
used.
There is a front panel ACK button to acknowledge the alert audio, but it will not allow message programming.
2.5.4 Backlight voltage and adjustment
The white (text) and green (indication) lighting can be adjusted independently.
See §2.7.2 for locations.
Adjustment Pot #14 changes the Green LED intensity
Adjustment Pot #15 changes the White LED intensity
See Set switches 47 & 48 ON for dimmer 28V
Set switch 47 –OFF & 48- ON for 14V dimmer
Set switches 47 & 48 OFF for 5VDC dimmer
See §2.7.3 for locations
By default, adjustments to the pot change the minimum trip point for the dimmer input to full bright. The pot
permits adjustment from 0V to nominal dimmer voltage (28V or 5V depending on configuration).
2.6 Wired Telephone/Satellite Communication input
The PAC45J can accommodate a wired cell phone interface on J452 Pins 58, 59, and 38. Both Bluetooth and
wired Telephone and be accommodated, however, only ONE can be active at a time. Low impedance satellite
phones might require a tactical radio adapter, PS Engineering P/N 12100.
2.6.1 Music Input NOTE
Use the low-level output of any additional Music device to connect to the audio
controller. Maximum signal level is 3 VAC p-p. DO NOT use a speaker-level
output; this will cause internal damage in the audio controller.
CAUTION
Local oscillators and internal signals from Music equipment can cause undesired interference
with other aircraft systems. Before takeoff, operate the entertainment devices to determine if there
is any adverse effect within the aircraft systems. If any unusual operation is noted in flight, imme-
diately switch off the entertainment devices.
All additional entertainment devices must be switched off for both takeoff and landing.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-7 November 2020
2.7 User Adjustments
The PAC45J is factory set for typical installation. However, several installation adjustments are avail-
able. No computer is required.
2.7.1 Unswitched Audio Level
Unswitched inputs one through five are installation adjustable through the side of the PAC45J unit.
2.7.2 Adjustments
On the side of the PAC45J/HUB45AR are 15 installation adjustment potentiometers. These are
ALL 30-turn pots.
1. Unswitched input 5 volume (J452-57)
2. Unswitched input 4 volume (J452-36)
3. Unswitched input 3 volume(J452-56)
4. Unswitched input 2 volume(J452-35)
5. Unswitched input 1 volume (J452-55)
6. Speaker Amplifier Volume (J452-41)
7. PA Amplifier Volume (J452-42)
8. Copilot and observer speaker output (if configured) and satcom telephone output volume
(J452-38)
9. Cockpit Voice Recorder Volume (J452-60, 61)
10. External PA Sidetone (J452-37)
11. External COM 1 Sidetone (J452-33) See Section 2.7.7.1 for details
12. External COM 2 Sidetone (J452-34) See Section 2.7.7.1 for details
13. Alert volume (adjusts the level of the internal audio alerts and annunciations generated by
the PAC45J)
14. Green LED backlight level, see §2.5.3
Volume
CP/OBSVR Speaker & Satcom Volume

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-8 November 2020
15. White LED backlight level
2.7.3 Logic Switch Options
The PAC45J has switches accessible through the side of the HUB45AR to set specific functions.
Switch functions and positions as shipped from the factory. The color coding denotes similar groups of
functonality.

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-9 November 2020
TOP ROW
BOTTOM ROW
SWITCH
FUNCTION
POSITION*
SWITCH
FUNCTION
POSITION*
1
FAILSAFE ALERTS TO
CREW
ON
25
COPILOT CONTROL
HEAD INSTALLED
ON
2
FAILSAFE ALERTS TO
OBSERVERS
ON
26
OBSVR 1 CONTROL
HEAD INSTALLED
ON
3
ALERTS TO CREW
ON
27
OBSVR 2 CONTROL
HEAD INSTALLED
ON
4
ALERTS TO
OBSERVERS
ON
28
REVERSIONARY MODE
ON
5
ALERT 1 TRIGGER
EDGE ON, LEVEL
OFF
29
TRANSMIT MUTE
OFF
6
ALERT 1 POLARITY
POS ON, NEG
OFF
30
STUCK MIC ENABLE
ON
7
ALERT 2 TRIGGER
EDGE ON, LEVEL
OFF
31
HIGH MIC SENS
OFF
8
ALERT 2 POLARITY
POS ON, NEG
OFF
32
PAX 1 & 2 = 02MICS
OFF
9
ALERT 3 TRIGGER
EDGE ON, LEVEL
OFF
33
PAX 3 & 4 = OBSVR 02
MICS
OFF
10
ALERT 3 POLARITY
POS ON, NEG
OFF
34
COM 7 COM 8 Au-
dio/COM 1 COM 2
SIDETONE
OFF
11
ALERT 4 TRIGGER
EDGE ON, LEVEL
OFF
35
PA SIDETONE
OFF
12
ALERT 4 POLARITY
POS ON, NEG
OFF
36
UNSW 1 & 2 SPLIT
OFF
13
ALERT 5 TRIGGER
EDGE ON, LEVEL
OFF
37
UNSW OBSVR
ON
14
ALERT 5 POLARITY
POS ON, NEG
OFF
38
STEREO OBSVR
ON
15
ALERT 6 TRIGGER
EDGE ON, LEVEL
OFF
39
STEREO CREW
ON
16
ALERT 6 POLARITY
POS ON, NEG
OFF
40
8 OHM HEADSETS
OFF
17
ALERT 7 TRIGGER
EDGE ON, LEVEL
OFF
41
RECEIVER INDICATOR
ON
ON
18
ALERT 7 POLARITY
POS ON, NEG
OFF
42
MUSIC MUTE
ON
19
ALERT 8 TRIGGER
EDGE ON, LEVEL
OFF
43
COPILOT MUSIC ENABLE
ON
20
ALERT 8 POLARITY
POS ON, NEG
OFF
44
OBSERVER 1 MUSIC
ENABLE
ON
21
ALERT 9 TRIGGER
EDGE ON, LEVEL
OFF
45
OBSERVER 2 MUSIC
ENABLE
ON
22
ALERT 9 POLARITY
POS ON, NEG
OFF
46
ALERTS ON SPEAKER
ON
23
RESERVED
OFF
47
DIMMER 28V
ON
24
RESERVED
OFF
48
DIMMER 28V
ON

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-10 November 2020
2.7.4 Logic Switch Details
SWITCH
NUMBER
FUNCTION
ON
OFF
1
FAILSAFE ALERTS TO
CREW
PILOT AND COPILOT HEAR
ALERTS IN FAILSAFE MODE
NO ALERT AUDIO IN
FAILSAFE (RADIOS
ONLY)
2
FAILSAFE ALERTS TO
OBSERVER
OBSERVER STATIONS HEAR
ALERTS IN FAILSAFE MODE
NO AUDIO IN FAILSAFE
3
ALERTS TO CREW
PILOT AND COPILOT HEAR
ALERT AUDIO
PILOT AND COPILOT DO
NOT HEAR ALERT
AUDIO
4
ALERTS TO OBSERVERS
OBSERVER STATIONS HEAR
ALERT AUDIO
OBSERVER STATIONS
DO NOT HEAR ALERT
AUDIO
5, 7, 9, 11, 13,
15, 17, 19, 21
ALERT TRIGGER
EDGE TRIGGERED
LEVEL TRIGGERED
6, 8, 10, 12, 14,
16, 18, 20, 22
ALERT POLARITY
ACTIVE HI TRIGGER
(5 TO 28 VDC)
ACTIVE LOW TRIGGER
(GROUND)
23, 24
RESERVED
DO NOT TOUCH
MUST BE OFF
25
COPILOT CONTROL
HEAD INSTALLED
COPILOT CONTROL HEAD IN
USE
NO COPILOT CONTROL
HEAD
26
OBSVR 1 CONTROL
HEAD INSTALLED
OBSERVER 1 CONTROL HEAD
IN USE
NO OBSERVER
CONTROL HEAD
27
OBSVR 2 CONTROL
HEAD INSTALLED
OBSERVER 2 CONTROL HEAD
IN USE
NO OBSERVER 2
CONTROL HEAD
28
REVERSIONARY MODE
SEE §2.7.4.1
USER STATIONS “REVERT” TO
OTHER CONTROL HEADS
WHEN FAILED
USER STATIONS IN
FAILSAFE WHEN FAILED
29
TRANSMIT MUTE
COM RECEIVE AUDIO MUTES
FOR ALL HEADSETS
TRANSMITTING WHEN ANY
TX PTT IS PRESSED. COM TX
IS STILL HEARD (PREVENTS
SQUEALING ON CLOSE
FREQS)
SELECTED COM AUDIO
IS HEARD DURING
TRANSMIT
30
STUCK MIC ENABLE
IGNORES PTT IF GROUNDED
FOR MORE THAN 35 SEC.
NO STUCK MIC
TIMEOUT
31
MICROPHONE
SENSITIVITY
REDUCED MIC SENSITIVITY
FOR LOUD COCKPITS
NORMAL MIC
SENSITIVITY
32
PASSENGER 1, 2 OR
CREW OXYGEN MIC
P453-15 BECOMES PILOT O2
MIC
P453-16 BECOMES COPILOT
O2MIC
P453-15 BECOMES PASS
1 MIC
P453-16 BECOMES PASS
2 MIC
33
PASSENGER 1, 2 OR
OBSERVER OXYGEN MIC
P453-17 BECOMES OBSVR 1
O2MIC
P453-18 BECOMES OBSVR 2
O2MIC
P453-17 BECOMES PASS
3 MIC
P453-18 BECOMES PASS
4 MIC
34
COM 7 & COM 8 AUDIO
OR COM 1 & COM 2
SIDETONE
J452-33 IS COM 1 SIDETONE
INPUT
J452-34 IS COM 2 SIDETONE
J452-33 IS COM 7
AUDIO INPUT

PS Engineering
PAC45J Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-2000 Page 2-11 November 2020
SWITCH
NUMBER
FUNCTION
ON
OFF
J452-34 IS COM 8
AUDIO INPUT
35
PA SIDETONE
SIDETONE FROM EXTERNAL
PA IS ACTIVE
LOCAL SIDETONE FOR
EXTERNAL PA
36
UNSWITCHED 1 & 2
SPLIT
UNSWITCHED #1 IS NOT
PROVIDED TO COPILOT
UNSWITCHED #2 IS NOT
PROVIDED TO PILOT
UNSWITCHED #1 AND 2
PROVIDED TO BOTH
CREWMEMBERS
37
UNSWITCHED TO
OBSERVER
UNSWITCHED AUDIO
PROVIDED TO OBSERVER
POSITIONS
NO UNSWITCHED
AUDIO AT OBSERVER
POSITIONS
38
STEREO OBSERVER
OBSERVER POSITIONS ARE
STEREO (LEFT & RIGHT
CHANNELS ACTIVE)
OBSERVER POSITIONS
ARE MONO (LEFT
OUTPUT)
39
STEREO CREW
CREW POSITIONS ARE
STEREO (LEFT & RIGHT
CHANNELS ACTIVE)
CREW POSITIONS ARE
MONO (LEFT OUTPUT)
40
8Ω HEADSETS
AUDIO OUTPUTS
COMPATIBLE WITH LOW
IMPEDANCE HEADPHONES
AUDIO OUTPUTS
COMPATIBLE WITH
HIGH IMPEDANCE
(150Ω TO 300Ω)
HEADPHONES
41
RECEIVER INDICATION
INDICATOR BLINKS WHEN
AUDIO SIGNAL IS PRESENT
ON A SELECTED RECEIVER
NO RECEIVER
INDICATION
42
MUSIC MUTE
MUSIC WILL MUTE WHEN
RADIO OR INTERCOM IS
ACTIVE
MUSIC MUTES ONLY
WHEN RADIO IS ACTIVE
43
COPILOT MUSIC ENABLE
COPILOT POSITION CAN
HEAR MUSIC
COPILOT POSITION
WILL NEVER HEAR
MUSIC
44
OBSERVER 1 MUSIC
ENABLE
OBSERVER 1 POSITION CAN
HEAR MUSIC
OBSERVER 1 WILL
NEVER HEAR MUSIC
45
OBSERVER 2 MUSIC
ENABLE
OBSERVER 2 POSITION CAN
HEAR MUSIC
OBSERVER 2 WILL
NEVER HEAR MUSIC
46
ALERTS ON SPEAKER
AURAL ALERT AUDIO IS
PRESENTED ON COCKPIT
SPEAKER
AURAL ALERT AUDIO IS
NOT PRESENTED ON
COCKPIT SPEAKER
47
BACKLIGHT VOLTAGE
ON FOR 28VDC
OFF FOR 14 OR 5 VDC
48
BACKLIGHT VOLTAGE
ON FOR 28 OR 14 VDC
OFF FOR 5 VDC