PS Engineering 11645R User manual

9800 Martel Road
Lenoir City, TN 37772
IntelliPAX Intercom Expansion Unit
Unit Part Numbers
11645R
for use with PAC45
Passenger Intercom System
With IntelliVox®
Installation and Operation Manual
US Patent No. 6,493,450
Document P/N 200-250-0045
February 2022
PS Engineering, Inc. 2022 ©
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 [phone] www.ps-engineering.com

Table of Contents
SECTION I –GENERAL INFORMATION 1-1
1.1 INTRODUCTION 1-1
1.2 SCOPE 1-1
1.3 DESCRIPTION 1-1
1.4 APPROVAL BASIS 1-1
1.5 SPECIFICATIONS 1-2
1.6 EQUIPMENT REQUIRED BUT NOT SUPPLIED 1-2
SECTION II –INSTALLATION 2-1
2.1 GENERAL INFORMATION 2-1
2.2 UNPACKING AND PRELIMINARY INSPECTION 2-1
2.3 EQUIPMENT INSTALLATION PROCEDURES 2-1
2.4 CABLE HARNESS WIRING 2-2
2.4.1 ELECTRICAL NOISE ISSUES 2-2
2.4.2 POWER REQUIREMENTS 2-2
2.4.3 INTERCONNECTION WITH MAIN UNIT 2-2
2.4.4 AUXILIARY INPUTS 2-2
2.5 POST INSTALLATION CHECKOUT 2-3
SECTION III –OPERATION 3-1
3.1 POWER 3-1
3.2 ADJUSTING THE VOLUME 3-1
3.3 INTELLIVOX®SQUELCH 3-1
3.4 MUSIC MUTE 3-1
SECTION IV WARRANTY AND SERVICE 4-1
4.1 WARRANTY 4-1
4.2 FACTORY SERVICE 4-1
APPENDIX A INSTRUCTIONS FOR FAA FORM 337 AND AIRWORTHINESS A
5.1 SAMPLE TEXT FOR FAA FORM 337 A
5.2 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS: A
APPENDIX B WIRING INFORMATION B
Rev
Date
Change
New
Feb 2022
Release dedicated 11645R manual

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 1-1 February 2022
Section I – General Information
1.1 Introduction
The IntelliPAX is a panel mounted, multi-place intercom expansion unit used to add up to six extra
stations to an intercom system. Please read this manual completely before installation to minimize the risk
of damage to the unit and to become familiar with all the features.
1.2 Scope
This manual contains installation and operational instructions for the following PS Engineering units:
Model Description Part Number
IntelliPAX Remote blind- mount intercom expansion unit for PAC45 11645R
1.3 Description
The IntelliPAX (11645R) is a remote, or blind mounting intercom expansion unit with intercom volume
control for the passengers. This unit is designed to work in combination with the PAC45 system.
1.4 Approval Basis **NONE**
None. It is the installer’s responsibility to determine the applicable approval basis for this installation. This
unit is not designed for use in any flight crew situations, and has no effect on any critical aircraft systems.
There is no significant weight or electrical load presented to the aircraft.

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 1-2 February 2022
1.5 Specifications
Input power: from main unit
Headphone Impedance: 150-1000 typical
Audio Distortion: <10% @ 35 mW into 150 load
Aircraft Radio Impedance: 1000 typical
3 dB Mic Frequency Response: 350 Hz —6000 Hz
3 dB Music Frequency Response: 200 Hz to 15 kHz
Unit weight: 7.2 Ounces (0.20 kg)
Dimensions: 1.25" H x 3.00" W x 5.50" D (3.2 x 6.6 x 14 cm)
1.6 Equipment required but not supplied
A. Headphones, 150stereo, up to six as required
B. Microphones, up to six, as required
C. Interconnect wiring
D. Intercom, PAC24, or PMA7000, primary unit
E. Headphone and microphone jacks (up to 6, as required)

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 2-1 February 2022
Section II – Installation
2.1 General Information
The IntelliPAX comes with all necessary hardware for a typical installation. The unit is installed either in
the panel (11606, 11616, 11626) or mounted blindly (11606R, 11616R, 11626R, 11636R or 11645). If
panel mounted, it can be installed near the main unit, or near the passengers. If blind mounted, it can be
mounted nearly anywhere. The 11606R and 11616R volume control for the passengers is factory set for a
balanced output, but can be field adjusted through the holes in the side of the unit.
Installation of the IntelliPAX, using the available wiring and hardware supplied, does not require special
tools or knowledge other than described in 14 CFR 65.81(b) and FAA Advisory Circular 43.13-2B
It is the installer's responsibility to determine the approval basis for this installation. An FAA Form 337, or
other approval may be required. See Appendix B for example of FAA Form 337.
2.2 Unpacking and preliminary inspection
The IntelliPAX was carefully inspected mechanically and thoroughly tested electronically before
shipment. It should be free of electrical or cosmetic defect.
Upon receipt, verify that the parts kit includes the following:
250-250-0001 IntelliPAX Remote Mount Installation Kit
250-250-0001
Part Number
Description
11645R
475-442-0002
#4-40 Machine screws, black
625-003-0001
Soft Touch Knob “D” shaft
575-250-0001
IntelliPAX Faceplate
425-025-0009
25 pin Sub-D connector shell
1
425-020-5089
Male Crimp Pins
25
625-025-0001
Connector hood
1
475-002-0002
Connector Thumbscrews
2
2.3 Equipment installation procedures
Blind mounting: (11645R)
1. Install the unit on an avionics shelf or other appropriate structure.
2. If desired, the volume can be adjusted at installation, there are two holes in the side of the unit, one for
left, and another for right channel.
3. If desired, a remote switch (not included) can be installed to override the SoftMute™ function. This
should be located convenient to the passengers.

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 2-2 February 2022
2.4 Cable harness wiring
To complete the installation, a wire harness must be made as shown in Appendix C. PS Engineering can
make a custom-tailored wiring harness for the installer. All harnesses use Mil-spec quality components
with professional techniques, and are fully tested before shipment. Contact PS Engineering for more
information. The IntelliPAX connects to the main unit through a 4- or 5-conductor, shielded cable.
2.4.1 Electrical Noise Issues
WARNING: You must use separate shielded cables for the microphone and headphone jacks. Combining
these two wires WILL cause loud oscillations and degrade the intercom function. The oscillation is caused
by the cross-coupling between the large headphone signal and the small microphone signal. The resulting
feedback is a high-pitched squeal that varies with the volume controls.
Shielding can protect the system from radiated noise (rotating beacon, power supplies, etc.). However,
installation combinations occur where minor interference is possible. The IntelliPAX was designed in an
interference -protected chassis and has internal filter capacitors on all input lines.
Ground loop noise occurs when there are two different return paths for the same signal, such as airframe
and ground return wire. Large cyclic loads such as strobes, inverters, etc., can inject audible signals onto
the airframe return path. Follow the wiring diagram very carefully to help insure a minimum of ground
loop potential. Radiated signals can be a factor when low level mic signals are bundled with current
carrying power wires. Keep these cables separated.
Insulating washers are required on all mic and headphone jacks to isolate them from aircraft ground.
2.4.2 Power Requirements
The IntelliPAX was designed to work with the main intercom unit. No other power is required.
The Stand Alone unit is connected to a 1A breaker to the avionics bus (2A for dual).
2.4.3 Interconnection with main unit
Interface between the IntelliPAX and the main intercom is through a 4-wire shielded cable.
Function
IntelliPAX
PAC45
HUB45
ExpansionPower
1
A/C
Expansion
Ground
14
A/C
Audio Input
(rt)
Audio Input
(lt)
2
15
Audio Output
3
J451-29
2.4.4 Auxiliary Inputs
An entertainment device can be connected to the IntelliPAX. Install a 1/8" music jack convenient to the
passengers to connect the stereo entertainment device into the system. A "Soft Mute" system is installed in
the IntelliPAX that will mute the music during conversation on the local intercom. Radio traffic or
conversation on the main intercom will not mute the music.
A second, monaural input is provided for other purposes, such as public address cabin briefing, or
providing radio interface for cases where the intercom does not have radio on the expansion bus (PM1000D
for example).

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 2-3 February 2022
A soft mute inhibit switch (not included) can be installed between IntelliPAX connector pins 12 and 24.
Closing this switch places the IntelliPAX into Karoake mode.
WARNING: Local oscillators and other internal signals from CD or radio equipment can cause undesired
interference with VHF navigation and communication equipment. Before takeoff, operate the entertainment
device to determine if there is any adverse effect on aircraft systems. If any unusual operation is noted in
flight, immediately switch the entertainment device off.
2.5 Post Installation Checkout
After wiring is complete, verify power is ONLY on pin 1 of the connector, and ground on pin 14 (with
main unit operating. Failure to do so will cause serious internal damage and void PS Engineering's
warranty. With all units plugged in and operating, verify that all active stations can communicate on the
intercom, and that any music sources are present, and the SoftMute inhibit control operates correctly (if
installed).

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 3-1 February 2022
Section III – OPERATION
3.1 Power
Switching on the intercom or audio panel automatically activates the IntelliPAX unit. The Stand Alone unit
is active when power is applied to the Avionics Bus.
3.2 Adjusting the Volume
The Remote (11645) version has a service adjustable volume, which is accessible through a pair of
openings on the side of the unit. These are 20-turn potentiometers, so may require many turns to make a
difference. The volume is set to maximum at the factory. Users can reduce the volume at individual stereo
headsets.
3.3 IntelliVox® Squelch
No adjustment of the IntelliVox® squelch control is required or possible. Through independent processors
on each microphone, the ambient noise appearing in all microphones is constantly being sampled. Non-
voice signals are blocked. When someone speaks, only their microphone circuit opens, placing their voice
on the intercom.
For best performance, the headset microphone must be placed within ¼ inch of your lips, preferably
against them. It is also a good idea to keep the microphone out of a direct wind path. Moving your head
through a vent air stream may cause the IntelliVox® to open momentarily. This is normal.
PS Engineering, Inc. recommends installation of a Microphone Muff Kit from Oregon Aero (1-800-888-
6910). This will optimize IntelliVox® performance.
3.4 Music Mute
If a remote switch is installed between pins 12 and 24, the “SoftMute” will be enabled. When the switch is
closed, the music will mute whenever there is intercom conversation in the IntelliPAX. Audio coming from
the main unit, such as radio or intercom, will not mute the IntelliPAX music.
Opening the switch places the unit music, “Karaoke Mode,” and music muting is inhibited.
For the 11606 and PMA7000-Series, intercom audio in the expansion unit will not mute music in the audio
panel.

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page 4-1 February 2022
Section IV Warranty and Service
4.1 Warranty
In order for the factory warranty to be valid, the installations in a certified aircraft must be accomplished by
a FAA- certified avionics shop and authorized PS Engineering dealer. If the unit is being installed by a
non-certified individual in an experimental aircraft, a dealer-made harness must be used for the warranty to
be valid.
PS Engineering, Inc. warrants this product to be free from defect in material and workmanship for a period
of one year from the date of sale. During this one-year warranty period, PS Engineering, Inc., at its option,
will send a replacement unit at our expense if the unit should be determined to be defective after
consultation with a factory technician.
This warranty is not transferable. Any implied warranties expire at the expiration date of this warranty. PS
Engineering SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This
warranty does not cover a defect that has resulted from improper or unreasonable use or maintenance as
determined by us. This warranty is void if there is any attempt to dissemble this product without factory
authorization. This warranty gives you specific legal rights, and you may also have other rights that may
vary from state to state. Some states do not allow the exclusion of limitation of incidental or consequential
damages, so the above limitation or exclusions may not apply to you.
4.2 Factory Service
The IntelliPAX is covered by a one-year limited warranty. See warranty information.
Contact PS Engineering, Inc. at [phone] or www.ps-engineering.com/support.shtml before you
return the unit. This will allow the service technician to provide any other suggestions for identifying the
problem and recommend possible solutions.
After discussing the problem with the technician and you obtain a Return Authorization Number, ship
product via an approved carrier (do not ship U.S. Mail) to:
PS Engineering, Inc.
Customer Service Department
9800 Martel Road
Lenoir City, TN 37772
[phone] FAX [phone]

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page AFebruary 2022
Appendix A Instructions for FAA Form 337 and Airworthiness
5.1 Sample text for FAA Form 337
One method of airworthiness approval is through an FAA Form 337, Major Repair and Alteration (Airframe,
Powerplant, Propeller, or Appliance) In the case of the IntelliPAX part number 116( ), you may use the
following text as a guide.
Installed intercom expansion unit, PS Engineering IntelliPAX, part number 11616 in ( location ) at
station . Installed per AC43.13-2B, Chapter 2, Installed per PS Engineering Installation
Operators Manual p/n 200-250-xxxx, revision X, dated ( ).
Interface to existing audio system in accordance with installation manual and in compliance with
practices listed in AC43.13-2B, Chapter 2. All wires are Mil-Spec 22759 or 27500. No connection to
the aircraft dimmer bus is required. No additional connection to aircraft power is made.
Aircraft equipment list, weight and balance amended. Compass compensation checked. A copy of the
operation instructions, contained in PS Engineering document 200-250-( ), revision ( ), Dated ( ), is
placed in the aircraft records. All work accomplished listed on Work Order .
5.2 Instructions for Continued Airworthiness:
Section
Item
Information
1
Introduction
Installation of passenger intercommunications system.
2
Description
Installation as described in manufacturer’s installation manual referenced on
FAA Form 337, including interface with other avionics audio as required.
3
Controls
See installation and operator’s guide referenced on FAA Form 337.
4
Servicing
None Required
5
Maintenance Instructions
On Condition, no special instructions
6
Troubleshooting
In the event of a unit problem, place the main unit into “OFF,” the fail-safe
mode. This allows normal pilot communications using COM 1. Follow checkout
instructions in the installation manual referenced on the FAA Form 337. For a
specific unit fault, contact the manufacturer at [phone] for special
instructions.
7
Removal and replacement
information
Removal: Remove Volume knob (if equipped (11606, 11616), 2 ea. then #4-40
black machine screws mounting the unit. Remove unit from behind panel. Place
metal faceplate in a safe area.
Installation: Align the volume knob shaft (if equipped, 11606, 11616) and the
mounting holes with the panel and front plate. Secure using 2 ea. #4-40 black
screws, provided.
8
Diagrams
Not applicable
9
Special Inspection Requirements
Not Applicable
10
Protective Treatments
Not Applicable
11
Structural Data
Not Applicable
12
Special Tools
None
13
Not Applicable
Not Applicable
14
Recommended Overhaul Periods
None
15
Airworthiness Limitations
Not Applicable
16
Revision
To be determined by installer

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0045 Page BFebruary 2022
Appendix B Installation
4.725
A A
A
5.480
4.000 3.500
Ø0.136
Appendix C Wiring Information
IntelliPAX
11645R
2
15
3
1
14
AUDIO TO EXP (LEFT)
AUDIO TO EXP (RIGHT)
EXP AUD TO PAC45
+28v AIRCRAFT POWER
AIRCRAFTGND
33
29
HUB45
J451
16
15
J453
1A
NOTE: Switch must be
installed for crew isolation
Figure 1 PAC45 system Interface