PS Engineering IntelliPAX 11606 User manual

9800 Martel Road
Lenoir City, TN 37772
I
In nt te el ll li iP PA AX X I In nt te er rc co om m E Ex xp pa an ns si io on n U Un ni it t
Unit Part Numbers
11606, 11606R
for use with PMA7000-Series and PAC24
11626 11626R
for use with PM1000-DAP
11636R
for use with PMA8000D
Passenger Intercom System
Installation and Operation Manual
US Patent No. 6,493,450
Document P/N 200-250-0005
Revision 14, January 2012
PS Engineering, Inc. 2012 ©
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

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0005 Page ii Rev. 14, Jan. 2012
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 2-2
2.4 CABLE HARNESS WIRING 2-2
2.4.1 ELECTRICAL NOISE ISSUES 2-2
2.4.2 POWER REQUIREMENTS 2-3
2.4.3 INTERCONNECTION WITH MAIN UNIT 2-3
2.4.4 AUXILIARY INPUTS 2-3
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
5 11/2005 Corrected Karaoke description in section 3.4
6 10/2006 Corrected PMA4000 interconnect
7 12/2006 Added 11626 for use with PM1000DAP
8 8/2007 Added PM1200 remote installation drawing and picture
9 4/15/08 Added installation kit part numbers
11 11/19/08 Changed PAC24 applicability from 11606 to 11616
12 2/26/09 Change PAC 24 BACK to 11606
13 7/13/09 Refer PAC24 wiring to PAC24 IM for details
14 1/23/12 Added 11636 for PMA8000D

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-00085 Page 1-1 Rev. 14, Jan. 2012
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 intercom expansion unit for PMA7000 and PAC24 Series 11606
IntelliPAX Remote blind-mount expansion unit for PMA7000- and PAC24 Series 11606R
IntelliPAX Remote blind-mount intercom expansion unit 11616R
IntelliPAX intercom expansion unit for PM1000 Dual (DAP) 11626
IntelliPAX Remote blind-mount intercom expansion unit for PM1000DAP 11626R
IntelliPAX Remote blind- mount intercom expansion unit for PMA8000E 11636R
1.3 Description
The IntelliPAX (11606) is an intercom expansion unit with intercom volume control for the passengers.
This unit is designed to work in combination with the PMA7000-Series audio panel. It contains PS
Engineering’s proprietary intercom protocol, IntelliVox®. This system uses digital processing on each of
the six individual microphones to eliminate manual squelch adjustments. Because of the automatic
squelch, the unit can be blind mounted, and the 11606R is designed to be remote-mounted, with the
volume control removed. The volume control is factory set for optimum level. Part numbers, 11616 and
11616R units are designed to be used with the PM1000II ( 11922 )
and specifically modified PM1200 intercoms to provide up to 6 additional passenger stations.
The Part Number 11626 (11626R) is specifically designed for use with the PM1000-DAP, allowing
entertainment in the expansion unit, while not available in the crew portion.
The part number “R” version is designed for remote, or blind mounting.
The part number 11636R is for expanding the PMA8000E system to 6 or 12 places. This unit is only
available as a remote unit.
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
200-250-00085 Page 1-2 Rev. 14, Jan. 2012
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 per expansion unit
B. Microphones, up to six, as required
C. Interconnect wiring
D. Intercom, PMA8000E, PAC24, or PMA7000, primary unit
E. Headphone and microphone jacks (as required)

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-00085 Page 2-1 Rev. 14, Jan. 2012
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 or 11626R). 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:
250-250-0000 IntelliPAX Panel Mount Installation Kit
250-250-0001 IntelliPAX Remote Mount Installation Kit
250-250-0000 250-250-0001
Part Number Description 11606 11616 11626 11606R 11616R 11626R 11636R
475-442-0002 #4-40 Machine screws, black 2 2 2
625-003-0001 Soft Touch Knob “D” shaft 1 1 1
575-250-0001 IntelliPAX Faceplate 1 1 1
425-025-0009 25 pin Sub-D connector shell 1 1 1 1 1 1
425-020-5089 Male Crimp Pins 25 25 25 25 25 25
625-025-0001 Connector hood 1 1 1 1 1 1
475-002-0002 Connector Thumbscrews 2 2 2 2 2 2
Also, a PM1000II w/Crew faceplate, P/N 575-002-0002 is included with the intercom expansion units,
Part Numbers 11616, 11616R, 11626, 11626R

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-00085 Page 2-2 Rev. 14, Jan. 2012
2.3 Equipment installation procedures
2 ea. 0.125
2.40”
NOT TO SCALE
For panel mounted installation (11606, 11616, 11626)
1. Using the template, drill three holes in the instrument panel in a location convenient to the pilot or
passengers position(s).
2. Insert the IntelliPAX from behind the instrument panel, aligning the holes for the knobs.
3. Place the aluminum faceplate over the knob shaft and secure, using the two # 4-40 round head screws
provided.
4. Install the volume knob over the volume control shafts.
Blind mounting: (11606R, 11616R, 11626R, 11606-SA 11636R)
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.
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.

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-00085 Page 2-3 Rev. 14, Jan. 2012
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 PMA7000 PM1200 PM1000
Series
PAC24 PMA8000E
Expansion 1
PMA8000E
Expansion 2
Expansion
Power
C 8 15 a J2 39 J2 41
Expansion
Ground
R 4 2 c J2 36 J2 38
Audio Input
(rt)
Audio Input
(lt)
S 16 23
J1 41
J1 40
J1 41
J1 40
Audio Output P 3 3 22 J2 35 J2 37
On the PMA8000D, the expansion is connected to the copilot’s audio panel, except for paralleling pin 3 to
the pilot audio panel. The PMA8000D can support two expansion units, for up to 12 passenger stations.
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).
NOTE:
The PM1000D is not compatible with a music input, due to the specialized interface nature. If this is
used, connect the entertainment input to the IntelliPAX (11626) alone.
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
200-250-00085 Page 3-1 Rev. 14, Jan. 2012
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
For the P/N 11606R, operating with a PMA7000B or copilot’s PMA8000D, the audio panel’s Passenger
volume control (PASS) affects the expansion intercom volume.
The 11616 volume control only affects the headsets connected to the IntelliPAX directly, and not the main
unit. The Remote (11616R) versions have 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.
When combined with a PAC24, the expansion volume should be set near minimum, and the copilot knob
on the PAC24 should be used to adjust the volume.
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.
For the PMA8000D, the music sources connected to the copilot’s audio panel are fed into the expansion
unit, and if the expansion unit music is also playing, BOTH sources will be heard. Refer to the
PMA8000D installation manual for more information.

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-00085 Page 4-1 Rev. 14, Jan. 2012
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 factory-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
200-250-0005 Page A Rev. 14, Jan. 2012
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
200-250-0005 Page B Rev. 14, Jan. 2012
Appendix B Installation
4.725
A A
A
5.480
4.000 3.500
Ø0.136
Figure 6-1 Remote unit outline

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0005 Page C Rev. 14, Jan. 2012
Appendix C Wiring Information
1
2
15
3
14
IntelliPAX Unit has Female Sub-D DB-25
Pass 1 Mic
Expansion Power In
Expansion Audio In (R)
Expansion Audio In (L)
Expansion Audio Output
Expansion Ground
Pass 1 Mic Audio Hi
Pass 1 Mic Audio Lo
16
4
Pass 2 Mic
Pass 2 Mic Audio Hi
Pass 2 Mic Audio Lo
17
5
9800 MARTEL ROAD, LENOIR CITY TN 37772
1
1
11/20/08
7
120-250-0000
IntelliPAX WIRING DIAGRAM
SIZE DOCUMENT NUMBER:
TITLE:
SHEET OF
DATE:
REV
1. All wire must conform to MIL-22759
or 27500. Minumum 24 gage shielded wire.
2. Use 2-, 3-, and 4-conductor with shield
as indicated.
3. Use insulating washers on all jacks. Jacks
must be electrically floating.
4. Connect shields at intercom end only
5. Consult main unit Installation manual for
remaining installation information.
6. Do not connect music to PM1000D, 11626/R only.
7. Mono AUX input can be used to feed aircraft radio
from pilot or copilot phones in 119626/R
NOTES:
Expansion Ground
Audio to Main Unit
Audio (R) from Main Unit
Expansion Power
25
13
Music (L)
Music (R)
Entertainment Input
(NOTE 6)
Pass 1 & 3 Phones (L) Hi
Pass 1 & 3 Phones (R) Hi
Headphone Lo
8
20
Pass 2 & 4 Phones (L) Hi
Pass 2 & 4 Phones (R) Hi
Headphone Lo
9
21
Pass 3 Mic
Pass 3 Mic Audio Hi
Pass 3 Mic Audio Lo
18
6
Pass 4 Mic
Pass 4 Mic Audio Hi
Pass 4 Mic Audio Lo
19
7
Mono Aux Input, See Note 7
(tape recorder, etc)
Mono Aux input 22
23
11
10
Soft Mute Control
(Switch not included)
Inhibit Switch 2
Inhibit Switch 1 24
12
See unit Installation manual
for complete information
NOTE
6
15
16
3
2
PM1000
Series
8
13
3
4
PM1200
Audio (L) from Main Unit
C
S
P
R
PMA7000 Series
J2
Pass 5 Mic
Pass 6 Mic
Pass 5 Mic Audio Hi
Pass 5 Mic Audio Lo
Pass 6 Mic Audio Hi
PAC24
Standard
SEE PAC24 IM
Figure 7-1 IntelliPAX Wiring (11606, 11606R, 11616, 11616R, 11626, 11626R)

PS Engineering, Inc.
IntelliPAX Expansion Unit
200-250-0005 Page E Rev. 14, Jan. 2012
PMA8000E Dual Audio Panel Expansion
35
37 35
36
39
Expansion Unit #1
11636
Expansion Lo
Expansion Audio Input
Ground Lug
10
11
40
41
15
2
3
14
1
Expansion Audio Output (L)
Expansion Audio Output (R)
Copilot Panel
J1
Expansion Power
37
38
41
Expansion Unit #2
11636
Expansion Lo
Expansion Audio Input
15
2
3
14
1
Expansion Audio Output (L)
Expansion Audio Output (R)
Expansion Power
Pilot Audio Panel
J2
Copilot Audio
Panel
J2
See PMA8000D Installation Manual, Document 200-890-0304 for complete information