PS Engineering PAC45D User guide

9800 Martel Road
Lenoir City, TN 37772
www.ps-engineering.com
PAC45D
Special Mission Audio Controller System with
MultiTalker® and IntelliVOX®
Document P/N 200-045-0100
January 2020
Audio Control System with MultiTalker Technology
High-fidelity Stereo 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.
PRELIMINARY

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 ...........................................................................................................................1-2
1.4 APPROVAL BASIS FAA TSO............................................................................................................................1-2
1.1.2 LIMITATIONS....................................................................................................................1-2
1.5 SPECIFICATIONS...........................................................................................................................................1-3
1.6 EQUIPMENT SUPPLIED .................................................................................................................................1-4
1.8 CONFIGURATIONS..............................................................................................................................................1-7
1.9 LICENSE REQUIREMENTS..............................................................................................................................1-7
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
2.3.4 THUMBSCREW AND SLIDE LOCK (AMS COMPLIANT)CONNECTOR ASSEMBLY..................................2-2
2.4 CABLE HARNESS WIRING.....................................................................................................................................2-3
2.4.1 ELECTRICAL NOISE.............................................................................................................2-3
2.4.2 POWER...........................................................................................................................2-4
2.4.3 AUDIO CONTROLLER INTERFACE ...........................................................................................2-4
2.4.4 TRANSMIT INTERLOCK........................................................................................................2-5
2.4.5 BACKLIGHTING .................................................................................................................2-5
2.4.6 UNSWITCHED INPUTS.........................................................................................................2-7
2.4.7 COCKPIT VOICE RECORDER..................................................................................................2-7
2.4.8 AUDIO ALERTS .................................................................................................................2-7
2.4.9 WIRED TELEPHONE/SATELLITE COMMUNICATION INPUT ...........................................................2-8
2.4.10 MUSIC INPUT.................................................................................................................2-8
2.4.11 RECEIVE ACTIVITY INDICATOR (-RXI)...................................................................................2-8
2.4.12 COCKPIT SPEAKER OUTPUT (PAC45D 050-045-0006 AND HUB45R 050-045-0103 ONLY) .......2-8
2.5 USER ADJUSTMENTS ..........................................................................................................................................2-8
2.5.1 UNSWITCHED AUDIO LEVEL.................................................................................................2-8
2.5.2 ADJUSTMENT POTS ...........................................................................................................2-9
2.5.3 LOGIC SWITCH OPTIONS.....................................................................................................2-9
2.6 PAC45D PIN ASSIGNMENTS .............................................................................................................................. 2-12
2.7 WIRING CHECKOUT..........................................................................................................................................2-13
2.8 OPERATIONAL CHECKOUT ..................................................................................................................................2-14
2.8.1 REQUIRED TEST EQUIPMENT .............................................................................................2-14
2.8.2 AUDIO CONTROLLER TEST .................................................................................................2-14
2.8.3 BLUETOOTH CHECKOUT....................................................................................................2-14
2.9 FINAL INSPECTION ........................................................................................................................................... 2-15
Section III OPERATION 3-1
3.1 SCOPE..........................................................................................................................................................3-1
3.2 POWER AND FAIL SAFE .......................................................................................................................................3-1
3.3 COMMUNICATIONS TRANSMIT (XMT) SELECTION .....................................................................................................3-2
3.4 COM AUDIO SELECTOR......................................................................................................................................3-2
3.4.1 MULTITALKER®HEAD RELATED TRANSFER FUNCTION (HRTF) ...................................................3-2
3.4.2 HRTF ON /OFF................................................................................................................3-2
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3.4.3 AUDIO LOCATION .............................................................................................................3-3
3.4.4 RECEIVER ACTIVITY INDICATION (-RXI)..................................................................................3-3
3.4.5 MONITOR MODE..............................................................................................................3-3
3.4.6 TELEPHONE CONTROL ........................................................................................................3-3
3.4.7 SPEAKER CONTROL (PAC45D 050-045-0002, HUB45R 050-045-0102 ONLY) .........................3-4
3.5 INTERCOM OPERATION (8) ..................................................................................................................................3-4
3.5.1 INTELLIVOX®INTERCOM VOX-SQUELCH...............................................................................3-4
3.5.2 PUSH TO TALK INTERCOM (PTT ICS) .....................................................................................3-5
3.5.3 INTERCOM VOLUME CONTROL.............................................................................................3-5
3.5.4 INTERCOM MODES............................................................................................................3-6
3.6 BLUETOOTH®CONNECTION..................................................................................................................................3-6
3.6.1 PAIRING AND UNPAIRING BLUETOOTH DEVICES........................................................................3-6
3.6.2 BLUETOOTH®TELEPHONE MODE .........................................................................................3-7
3.6.3 MUSIC MUTING CONTROL .................................................................................................3-7
3.7 WIRED SATCOM/CELL PHONE INPUT ......................................................................................................................3-7
3.8 ALERT AUDIO...................................................................................................................................................3-7
Section IV –Warranty and Service A
4.1 WARRANTY ........................................................................................................................................................A
4.2 FACTORY SERVICE.................................................................................................................................................A
Appendix A –PAC45D Installation Drawings ............................................................. A
Appendix B –Radio Interconnect WiringA
Appendix C –Intercom Interconnect Wiring.............................................................. A
Appendix D –Control Head Interconnect Wiring....................................................... A
Appendix E, Unit Connector Wiring Reference .......................................................... A
9.1 J451 CONNECTIONS .............................................................................................................................................A
9.2 J452 CONNECTIONS .............................................................................................................................................B
9.3 J453 CONNECTIONS .............................................................................................................................................C
9.4 J454 CONNECTIONS ............................................................................................................................................ D
Appendix F –Instructions for FAA Form 337 and continuing airworthiness .............. A
10.1 INSTRUCTIONS FOR FAA FORM 337, AUDIO CONTROLLERS .............................................................................................A
10.2 INSTRUCTIONS FOR CONTINUING AIRWORTHINESS,AUDIO SYSTEM ...................................................................................A
Appendix G –RTCA DO160G Environmental Qualification Form ............................... A
11.1 MODEL NUMBER PAC45D AUDIO SELECTOR PANEL/INTERCOM REMOTE HUB ...................................................................A
11.2 MODEL NUMBER CTL45, AUDIO SELECTOR CONTROL PANEL ..........................................................................................B
Rev Date Change
New January 2020 Release of PAC45D/CTL45D
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
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Section I – GENERAL INFORMATION
1.1 INTRODUCTION
The PAC45D represents a evolutionary step in cockpit audio control and intercommunications
utility. MultiTalker®, using licensed U.S. Air Force patented technology, provides True Dimen-
sional Sound, helping pilots to more easily discern from simultaneous radio receptions. Our pa-
tented IntelliVOX® design, programmable MultiTalker® and alert configurations, marks this
panel as the next level of audio control. The unit is designed for outstanding ergonomics and vis-
ually defined mode annunciation and selection.
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 PAC45D.
1.1.1 Limitations
This article meets the minimum performance and quality control standards required by a tech-
nical standard order (TSO). Installation of this article requires separate approval. Refer to Advi-
sory 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 detailed installation and operation instructions for the PS Engineering
PAC45D-series of Audio Selector Panel/Intercom Systems. This includes the following units:
Model
number
Description PS Engineering
Part Number
NVIS Compatible
Part Number
PAC45D Panel-mounted Audio Control System with
dual CVR outputs, includes integrated con-
trol head and Audio Hub, with standard
bezel label, includes install kit 250-045-
0100, qty. 2, 26 pin connectors.
050-045-0005 050-045-6005
PAC45D Panel-mounted Audio Control System with
single CVR and speaker out, includes inte-
grated control head and Audio Hub, with
standard bezel label, includes install kit
250-045-0100, qty. 2, 26 pin connectors.
050-045-0006 050-045-6006
HUB45R Remote-mounted Audio Hub for analog I/O
and processing with dual CVR
050-045-0101 N/A
HUB45R Remote-mounted Audio Hub for analog I/O
and processing with single CVR and
speaker out
050-045-0103 N/A
CTL45A Panel Mounted Control Head for Pilot and
Copilot
050-145-02XX* 050-145-62XX*
CTL45M Panel-mounted Control Head for Mission
Personnel
050-045-03XX* 050-045-63XX*
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Model
number
Description PS Engineering
Part Number
NVIS Compatible
Part Number
PAC45D Op-
tional Install
Kit
For installs that are not replacing “third
party” audio controllers, includes 50 & 37
pin connectors/hardware.
250-945-0500
Label45 Customizable bezel label program 575-045-XXXX
*The exact CTL45 part number depends upon the nomenclature applied to the
bezel label. Consult PS Engineering for specific LRU part number.
1.3 EQUIPMENT DESCRIPTION
The PAC45D is a state-of-the-art audio isolation amplifier and audio selector that contains an au-
tomatic voice activated (VOX) intercom system. It can switch six transceivers (Com 1 - 6) and six
receivers (Nav 1, Nav 2, MKR, and three additional inputs that can be individually labeled, for
use with ADF, DME, AUX, etc.).
There are four unswitched inputs, available for traffic or EGPWS, autopilot disconnect, and/or
radar altimeter warning.
A wired input is available for Satellite or Cellular telephone.
In addition, three alerts can be triggered by external sources to provide additional capability.
The individual volume controls select the receiver audio source provided to the headphones
when selected.
An eight-station voice activated (VOX) intercom is included in the PAC45D. 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 PAC45D, a Bluetooth® wireless interface is available for wireless telephone and music
connection.
Figure 1-1 CTL45D
1.4 APPROVAL BASIS FAA TSO
FAA TSO The PAC45D-series Audio Selector Panels is FAA authorized under TSO C139A (Audio
Amplifiers). ED-14C/DO-160G (Environmental Conditions and Test Procedures for Airborne Equip-
ment), ED12B/DO-178C, Level D (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 tech-
nical 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:
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PAC45 Audio Selector Panel and Intercom System
Installation and Operator’s Manual
200-045-0100 Page 1-3 January 2020
This device may not cause harmful interference.
This device must accept any interference received, including interference that may cause unde-
sired operation.
1.5 SPECIFICATIONS
TSO COMPLIANCE
Audio Selector/Intercom: FAA TSO-C139A
APPLICABLE DOCUMENTS: RTCA/DO-214A
RTCA/DO-160G
RTCA/DO-178C
ENVIRONMENTAL Qualifications: A1D1BABSXXXXXXZBABZATTMA3J33XXA
Temperature Range:
Operating:
Short Term Operating:
Survival:
HUB45
-45° C to +55°C
-45° C to +71°C
-55° C to +85°C
CTL45
-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: Height: 1.9 in. (4.8 cm) Width: 5.75 in. (14.6 cm)
Depth behind panel (PAC45D): 7.38 in. (18.75 cm) in-
cluding connectors
UNIT WEIGHT
PAC45D -001
HUB45
CTL45
2.0 lb. (0.90 kg)
1.0. (.45 kg)
1.0. (.45 kg)
POWER REQUIREMENTS:
Voltage: 18 to 33 VDC
Maximum Current:
Typical
Alert Power
Lighting
0.5 Amp (Externally protected by a 1 Amp circuit
breaker.)
PAC45D (Hub + CTL mated): 500mA
HUB45 only 350 mA
10 mA
CTL45D only: 150 mA
< 5mA
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PAC45 Audio Selector Panel and Intercom System
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Audio Selector Specifications
Audio selector panel input impedance: 510 
Input Isolation: -60 dB (min.)
Switched Receiver Inputs: 10 (COM 1–COM 5, TEL, NAV 1, NAV 2, Marker, ADF)(Can be
relabled as desired)
Unswitched Inputs: 4
Transmitter Selections:6 (COM 1, COM 2, COM 3, COM 4, COM 5, plus Telephone)
(Can be relabled as desired)
Headphone Impedance: 150 –1000 
Headphone Output: 100 mW into 150each side (left and right) headset, no clip-
ping <.5% THD typical
Speaker Output (-0002 & -0102 only) 3 Vrms Maximum
Microphone Impedance:150 - 600 
PA Output 1 Vrms into 500Ω
Bluetooth Radio Class 3, FCC ID QOQWT32AE
Intercom Specifications
Intercom Positions: Up to 8 places (with individual IntelliVOX® circuits)
Music Inputs: 1 (Stereo) plus Bluetooth
Music Muting: >-30 dB "Soft Mute" when Com or intercom active.
Distortion: <1% THD @ 100 mW into 150
Mic Freq. Response, 3 dB: 300 Hz - 6000 Hz
Stereo Music Freq. Response, 3 dB: 20 Hz –16 kHz
1.6 EQUIPMENT SUPPLIED
The following units comprise the PAC45D System:
Model Description Standard
Part Number
NVIS Compatible
Part Number
PAC45D Single Panel-mounted System (HUB45 and CTL45D) 050-045-000X 050-045-600X
Or
HUB45R Remote-mounted Audio Hub for analog I/O and
processing
050-045-010X N/A
CTL45D Panel-mounted Control Head for Pilot and Copilot 050-045-0200* 050-045-6200*
CTL45M Panel-mounted Control Head for Mission Personnel 050-045-0300* 050-045-6300*
CTL45P Panel-mounted Control Head for Flight Crew
Inverted
050-045-1200* 050-045-6600*
CTL45M Panel-mounted Control Head for Mission Personnel
Inverted
050-045-1300* 050-045-6700*
. *The part numbers shown are for “Standard” bezel label nomenclature. Custom bezel nomen-
clature is available, using the custom configuration program at:http://www.ps-
engineering.com/PAC45D_custom_legend.shtml
PAC45 Standard Installation Kit 250-945-0500 (37 & 50 Pin)
Description PSE Part Number Qty. Manufacturer MFR Part
Number
50 pin connector backshell 625-050-1728 1 Amphenol 17E-1728-1
37 pin connector backshell 625-037-1727 1 Amphenol 17E-1727-1
Thumbscrew 4-40x1.94 475-002-0002 4 Lanpar Technolo-
gies, Inc.
B71E014256
Standard Density Female
Sockets
425-020-5090 50 Deutsch M39029/63-368
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PAC45 Audio Selector Panel and Intercom System
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Description PSE Part Number Qty. Manufacturer MFR Part
Number
50 Pin Female Conn, Housing 425-050-0967 1 Harting 09670504701
37 Pin Female Kit Connector
w/Pins
425-037-1757 1 TE Connectivity 1757820-9
PAC45 Retrofit Installation Kit: 250-045-0100
Description PS E
Part Number Quantity Manufacturer MFR Part Number
D-Sub housing 9 pin female 425-009-7709 1 Amphenol L177-RR-E-09-S
D-sub Pins Male 425-020-5089 9 Deutsch M39029/64-369
D-sub Pins Female 425-020-5090 9 Deutsch M39029/63-368
D-Sub housing 26 pin female 425-026-1800 2 NorComp 180-026-273L000
Socket contact 22-28 AWG 425-030-7354 52 Amphenol M39029/57-354
D-Sub Latch slide clip 475-045-5206 4 Tyco Electronics 5206942-1
Backshell DB9 625-009-5750 1 Tyco Electronics 5750100-1
Backshell DB26 625-015-5206 2 Tyco Electronics 5206478-2
HUB45R Remote Hub Retrofit Installation Kit: 250-045-0200
Description PS E
Part Number
Qty. Manufacturer MFR Part Number
D-Sub housing 9 pin male 425-009-0777 1 Amphenol L777-RR-E-09-P
D-sub Pins Male 425-020-5089 9 Deutsch M39029/64-369
Backshell DB9 625-009-1724 1 Amphenol 17E-1724-1
Thumbscrew 475-002-0002 2 Lanpar Technologies,
Inc.
B71E014256
HUB45 Installation Kit 250-945-0100
Description PS E
Part Number
Quantity Manufacturer MFR Part Number
15/26 pin connector backshell 625-015-1725 2 Amphenol 17E-1725-1
DB26 Female Connector HD 425-026-1800 2 NorComp 180-026-273L000
Female Socket 425-030-7354 52 Amphenol M39029/57-354
Thumbscrew 475-002-0002 2 Lanpar Tech-
nologies, Inc.
B71E014256
Slide Lock Post* 475-045-6514 4 TE 5206514-6
*See §2.3.4
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Remote Mount HUB45R retrofit Installation Kit 250-045-0300
Description PS E
Part Number
Qty. Manufacturer MFR Part Number
9-Pin Male D-Sub Housing 425-009-0777 1 Amphenol L777-RR-E-09-
P
D-Sub male pins 425-020-5089 9 Deutsch M39029/64-369
9-Pin D-Sub Female Housing 425-009-7709 1 Amphenol L777-RR-E-09-S
D-Sub Female sockets 425-020-5090 9 Deutsch M39029/64-368
Remote Mounting Flange LEFT 430-045-0120 1 PS Engineering
Remote Mounting Flange RIGHT 430-045-0125 1 PS Engineering
4-40 x 3/16” Phil-Pan w/EXT Star
Washer 475-440-0500 8
4-40 x 3/16” Phil-Flat Gold + Patch
Counter Sunk 475-442-2001 12
Connector Backshell DB9 Plastic
MODIFIED 625-009-1724 1 PS Engineering
Connector Backshell DB9 Plastic NON-
MODIFIED 625-009-1724
Thumbscrew 475-002-0002 2 Lanpar Tech-
nologies, Inc.
B71E014256
CTL45 Installation Kit 250-043-0100
Description PS E
Part Number
Qty. Manufacturer MFR Part Number
(Modified) Connector Plastic Back-
shell DB9
625-009-1724 1 PS Engineering
Connector Female Shell DB9 425-009-7709 1Amphenol L777-RR-E-09-S
Standard Density Female Pins 425-020-5090 9 Deutsch M39029/64-368
EQUIPMENT REQUIRED BUT NOT SUPPLIED
a. Circuit Breakers: 1 ea.; 1 amp PULL TYPE REQUIRED for PAC45D,0.5 A for CTL45s
b. Optional Circuit Breaker: 0.5 ea.; 1 amp PULL TYPE REQUIRED for PAC45D aural alerts
c. Headphone Jacks (Stereo, as Required)
d. Microphone Jacks (as Required)
e. Headphones, 150 (Stereo), as required
f. Microphones, as required
g. Interconnect Wiring
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1.8 Configurations
The PAC45D System is comprised of three “building blocks” to facilitate flexibility as well as sim-
plicity.
The simplest, single audio controller system is a PAC45D where the audio hub is attached to the
control head.
or
Figure 1-2 Single panel configuration
1.9 LICENSE REQUIREMENTS
None
PAC45D Bluetooth™ Radio approval:
•FCC ID: QOQWT32I
•Industry Canada ID: 5123A-BGTWT32I
•CE EMC Directive 89/336/EEC as amended by Directives 92/31/EEC and 93/68/EEC
NOTE
Unauthorized use of unapproved cellular telephone devices in aircraft is subject to FCC enforce-
ment action, which may include a $10,000 fine per incident.
FCC Regulation 47 CFR § 22.925 Prohibition on airborne operation of cellular telephones.
Cellular telephones installed in or carried aboard airplanes, balloons or any other type of aircraft
must not be operated while such aircraft are airborne (not touching the ground). When any air-
craft leaves the ground, all cellular telephones on board that aircraft must be turned off.
PS Engineering, Inc. does not endorse using unapproved cellular telephone equipment in flight,
and takes no responsibility for the user’s action.
PS Engineering does not guarantee compatibility with personal cellular telephones.
CTL45D
HUB45
HUB45
CTL45D
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PAC45 Audio Selector Panel and Intercom System
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Section II - INSTALLATION
2.1 GENERAL INFORMATION
2.1.1 SCOPE
This section provides detailed installation and interconnection instructions for the PS Engineer-
ing PAC45D 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 in-
staller knowledge as required by 14 CFR 65.81 (b).
2.1.2 Certification Requirements NOTE
The PAC45D requires specialized knowledge and tools for an effective installation. An appropri-
ately rated Certified Aircraft Repair Station must install this equipment in accordance with appli-
cable regulations. PS Engineering, Incorporated warranty is not valid unless the equipment is in-
stalled 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.
This article meets the minimum performance and quality control standards required by a tech-
nical 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 cor-
rect quantity of components 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 En-
gineering 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 PAC45D is not required. However, the units should be kept away from
heat producing sources (i.e. defrost or heater ducts, dropping resistors, heat producing avionics)
without adequate cooling air provided.
2.3.2 Mounting Requirements
The PAC45D must be rigidly mounted to the instrument panel of the aircraft structure, within
view and reach of the pilot position(s). The PAC45D/CTL45 is designed for Dzus-rail mounting.
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.
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To prevent noise, avoid installing the unit close to high current devices or systems with high-
voltage pulse type outputs, such as DME or transponders. Avoid running the interconnecting
bundles near any high current wires.
2.3.3 Audio controller Connector Assembly
The LRU connectors mate with one 50-pin, one 37-pin, and two 26-pin connectors in the
PAC45D. The connectors are a sub-miniature crimp-type, and require the use a hand crimp tool,
from table below (or equiv.).
Figure 2-1 - PAC45D Connector Layout
NOTE: The 50-pin and 37-pin connectors are pin-compatible with most NAT AMS-series and Ju-
piter JA95-series audio controllers. Refer to the connector pin maps to confirm compatibility.
The two 26-pin connectors are used to give the PAC45D systems added capability.
The PAC45D LRU Hub can be remote mounted, and connections to control head(s) CTL45.
Ensure that proper strain relief and chafing precautions are made during wiring and installation.
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
2.3.4 Thumbscrew and Slide Lock (AMS compliant) connector assembly
Existing installation may utilize slide-locking mechanisms on their connectors. PS Engineering
has included slide lock posts with the 26-pin connector kits for your convenience.
You can remove the 5mm hex standoffs from the 37 and 50-pin connectors and replace with the
5mm post to keep the existing connectors. Picture below shows slide lock post installed.
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PS Engineering recommends that Loctite #425 be added to any thumbscrew that is removed and
reinstalled. Loctite #425 is added to the thumbscrew threads at the factory.
2.4 Cable Harness Wiring
Referring to the appropriate Appendix, assemble a wiring harness as required for the installa-
tion. All wires must be MIL-SPEC in accordance with current regulations. Two- and three-con-
ductor shielded wire must be used where indicated, and be MIL-C-27500 or equivalent specifica-
tion. Proper stripping, shielding and soldering technique must be used at all times. It is
imperative that correct wire be used.
Refer to FAA Advisory Circular 43.13-2B for more information. Failure to use correct techniques
may result in improper operation, electrical noise or unit failure. Damage caused by improper
installation will void the PS Engineering warranty.
See Appendix C and D for intercom connection configurations. It is critical to the proper opera-
tion 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 PAC45D 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, in-
stallation combinations can occur where interference is possible. The PAC45D was designed in
an 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 dia-
gram very carefully to help ensure a minimum of ground loop potential. Use only Mil Spec
shielded wires (MIL-C-275000, or better). Under no circumstances combine a microphone and
headphone wiring into the same shielded bundle. Always use a 2- or 3-conductor, shield wire as
shown on the installation-wiring diagram.
The shields can be daisy-chained together, and then connected to the ground.
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
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insulated washers to isolate the ground return path from the airframe to all headphone and mi-
crophone jacks.
2.4.1.1 Music Input and Noise
PAC45D units utilize a differential ground input to help prevent noise from entering the audio
system. This feature is usually transparent to the installer; however, it is important that the ap-
propriate music signal and ground connections are made directly to the dedicated music signal
and ground inputs on the PAC45D. The power for IFE and audio controller should be a common
bus.
NOISE NOTE
Adding a high-performance audio control system, particularly in conjunction with high-perfor-
mance active noise canceling headsets, cannot improve on older avionics that were designed for
cabin-speaker use. PS Engineering makes no claim that the audio controller will provide a noise-
free audio quality under all installation conditions, particularly with older avionics.
2.4.2 Power
The PAC45D is compatible with 28 Volt DC systems. A one (1) Amp circuit breaker is required for
all installations. Power and ground wires should be #22AWG connect power to P451 Pin 17.
Connect airframe ground to P451 Pin 34 only.
Power consumption is as follows:
At 28V:
•Hub + Control Head: 500 mA
•Control head Only: 150 mA
•Hub Only: 350 mA
•Alert audio power: 10mA
At minimum input voltage (18V):
•Hub + Control Head: 750mA
•Control head Only: 200mA
•Hub Only: 500mA
Lighting input: <5mA
CAUTION: Do not connect or disconnect (HOT SWAP) any components with power applied, this
will damage the units
2.4.2.1 Alert power, P451 Pin 16,
The PAC45D 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 16.
When power to P451-16 is present, the message will play three times or until the remote
acknowledge is selected.
2.4.3 Audio controller interface
The PAC45D is designed to interface with standard aircraft avionics, and presents a 510 re-
ceiver impedance. For best results, a twisted-shielded cable is recommended from the avionics
audio source to the audio controller, 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.
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2.4.3.1 Navaid wiring and selection
The PAC45D has NAV 1, NAV 2, and three additional auxiliary navaid inputs for ADF, etc. The
three auxiliary audio inputs on P452 pins 9, 10 and 11 will be presented with the audio control
on the bottom row is selected.
2.4.3.2 Additional transmit position or passenger 6 (P451-6, 23, 40)
The PAC45D system can support six passenger intercom stations, in addition to the pilot and co-
pilot. The input to the PAC45D P451 6, 23, 40 can be used as an additional transmit position, or
a hand microphone, or as passenger 6, with transmit capability on the selected radio.
This microphone transmitter follows the last control head selection as follows:
Configuration Microphone connected to
Single Control Head Selected radio
Two Control Heads Copilot selected radio
Three Control Heads Observer selected radio
Passenger 2 (Observer 2) can use this hand mic as a transmit seat.
2.4.3.3 Passenger 5 and 6
Passenger 6 is an intercom station input on P454-16 wrt 25.
The headphone outputs for passenger 5 and 6 are paralleled from passenger 1 and passenger 2.
NOTE: Do not parallel headphones to passenger 3 or 4.
2.4.3.4 Installation with Monaural Headsets
Not recommended, because the benefit of MultiTalker is lost. However, if desired, the PAC45D
can be installed monaurally by using the LEFT audio connections only (left side contains Fail-Safe
audio). Do NOT short left and right headphone outputs together.
NOTE: Mono headsets that short the tip and ring (i.e. older models) may introduce audio dis-
tortion when used. Modern, stereo headsets are recommended in all positions.
2.4.4 Transmit Interlock
Some communications transceivers use a transmit-interlock system. To fully utilize the multi-
user, transmit capability, this function must be disabled. Consult the radio manufacturer's in-
stallation manual.
2.4.5 Backlighting
Control of the unit backlighting is through the aircraft avionics dimmer Connect P452 Pins 19 to
the aircraft dimmer bus. All control heads dimming is control by the HUB. The audio controller
can be configured for either 5VDC or 28V dimmer installations. The default setting is 28V from
the factory. The ratio of white to green indicator intensity is adjustable, see §2.5.2.1.
Units with configuration status BBGAA and above:
The green/white pot has been changed, and now works as follows:
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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).
A long press (3 seconds) of HRTF and ACK on pilot panel will cause the #2 potentiometer to ad-
just the green backlight level, when in this mode the green LEDs will get brighter or dimmer.
Another simultaneous long press (3 seconds) of HRTF and ACK on pilot control panel will adjust
the white backlight level.
Another long press (3 seconds) of HRTF and ACK to exit
Also, ACK can be pressed at any time to exit (if you want to adjust green but not white for exam-
ple)
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2.4.6 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, GPS waypoint audio, autopilot disconnect tones, 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
Input
Input Pins Hear in
Fail Safe Hear in
Crew Headset Adjustable at
installation
1 P452 - 13 WRT 32 Yes Yes Yes
2 P452 - 1 WRT 20 No Yes Yes
3 P454 - 14 WRT 23 No Yes Yes
4 P454 - 13 WRT 22 No Yes Yes
Table 2-2 Unswitched inputs
2.4.7 Cockpit Voice Recorder
The PAC45D audio controller contains a Cockpit Voice Recorder output for the pilot and copilot
(PAC45D, -0005 and HUB45R -0101 only).
Pilot CVR output is P454-12; Copilot CVR output is P454-2, both with respect to CVR low, P454
21
A single pilot CVR output is available on PAC45D with a cockpit speaker output (PAC45D, -0006
and HUB45R -0103 only).
The CVR output is consistent with RTCA DO-214A §1.5.7,
2.4.8 Audio Alerts
The PAC45D contains an independent audio alerting system that will play up to three alert audio
messages. These messages are spoken words “ALERT”, “MASTER CAUTION” and an audio chime.
The alert system has a power input (P451-16) that will keep the systems operable if the PAC45D
systems power source is removed. Alert audio is provided in Fail-safe when power is on P451-
16.
Alert Trigger Input Audio Input Pins
1 “ALERT” P451 –11
2 “MASTER
CAUTION”
P451 –12
3 CHIME P451 –13
Alert Power P451 –16
Remote
Acknowledge
P454-9
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 op-
tions.
Alerts with edge triggers will play three times or until the front panel Acknowledge button (ACK)
is pressed (or the remote ACK P454-9 grounded).
Alerts with level trigger will play three times or until the front panel Acknowledge button (ACK)
is pressed (or the remote ACK P454-9 grounded), or the input level reverts.
When power is applied to the alerts and not the PAC45D audio controller, it will play the mes-
sage three times or until the remote acknowledge is selected.
Audio alerts are inhibited for the first 30 seconds after power up to reduce nuisance triggers.
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2.4.8.1 Remote ICS mode control.
When a momentary, normally open, push-button switch is connected between pin P454-18 and
ground, it will change the intercom mode on the Pilot’s PAC45D.
2.4.9 Wired Telephone/Satellite Communication input
The PAC45D can accommodate a wired cell phone interface on P454 Pins 17, 26 and 7.
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.
2.4.10 Music Input NOTE
Use the low-level output of any additional Music device to connect to the au-
dio 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,
immediately switch off the entertainment devices.
All additional entertainment devices must be switched off for both takeoff and landing.
2.4.11 Receive Activity Indicator (-RXI)
PAC45D systems have an optional Receive Activity Indicator that flashes the selected receiver
indicator when a signal is present on that receiver. This function is set at the factory at the in-
staller’s request, and can only be changed at the factory.
2.4.12 Cockpit Speaker Output (PAC45D 050-045-0006 and HUB45R 050-045-0103
only)
A low-level output is available to drive a separate speaker amplifier (such as PSA210) and con-
tains received audio. This output is P454 Pin 2.
2.5 User Adjustments
The PAC45D is factory set for typical installation. However, several installation adjust-
ments are available. No computer is required.
2.5.1 Unswitched Audio Level
Unswitched inputs one through four are installation adjustable through the side of the
PAC45D unit.
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2.5.2 Adjustment Pots
On the side of the PAC45D/HUB45R are six adjustment potentiometers.
Alert volume (adjusts the level of the internal audio alerts and annunciations generated
by the PAC45D)
1. White & Green text backlight level adjust (see §2.5.2.1)
2. Unswitched input 1 volume
3. Unswitched input 2 volume
4. Unswitched input 3 volume
5. Unswitched input 4 volume
2.5.2.1 Green and White lighting adjustment
•By default, adjustments to the pot change the minimum trip point for the dim-
mer input to full bright. The pot permits adjustment from 0V to nominal dimmer
voltage (28V or 5V depending on configuration).
•Long press (3 seconds) of TEL and ACK on pilot panel will cause the #2 potenti-
ometer to adjust the green level, when in this mode the green LEDs will get
brighter or dimmer.
•Another long press (3 seconds) of TEL and ACK on pilot panel will adjust the
white level
•Another long press (3 seconds) of TEL and ACK to exit
•Also, ACK can be pressed at any time to exit (if you want to adjust green but not
white for example)
2.5.3 Logic Switch Options
The PAC45D has several switches accessible through the side of the HUB45 to set specific func-
tions
Figure 2-2—Adjustment potentiometers (NOTE these are all 30-Turn
pots
, and may require 10-15 turns to notice any change)
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Power must be cycled after selections are completed.
1-3: Alert polarity (ground or voltage trigger)
4-6: Alert type (edge or trigger)
7: Dimmer mode (5VDC or 28VDC)
8: Mic sensitivity (High noise applications)
9: Passenger HRTF enable (MultiTalker® audio)
10: Offside Transmit Mute
11: Copilot Control Head installed
12: Mission Observer Control Head installed
2.5.3.1 Alert Trigger Logic (1 –3)
Switches 1-3 set alert logic. DOWN for active high, UP for active low.
2.5.3.2 Alert Trigger Type (Switches 4 –6)
Switches 4-6 set alert type. UP for level triggered, DOWN for edge
triggered.
As shown: Alert 1 Edge Triggered, Alerts 2-3 Level Triggered (default
from factory)
2.5.3.3 Back light dimmer voltage (Switch 7)
Switch 7 sets dimmer mode. UP for 5V, DOWN for 28V
As shown: 28V dimmer (default from factory).
2.5.3.4 Microphone Sensitivity (Switch 8)
Switch 8 sets mic sensitivity. UP for low noise (standard), DOWN for high noise
environment.
As shown: High noise
2.5.3.5 Passenger Head Related Transfer Function (HRTF) Disable
(Switch 9)
Switch 9 enables HRTF mode for passengers. UP disabled, DOWN enabled.
Disable only if headsets are monaural.
2.5.3.6 Offside com audio active during transmit –(Switch 10)
When this switch is in the “UP”position, the receive audio on other radios is not muted
when one crew member transmits on the radio. This allows other crewmembers to
listen to other radios while one trasmits. (shipped from factory in this mode. Serial
Number DH01069 and above).
NOTE: This may result in crosstalk if multiple radios are tuned to close frequencies.
2.5.3.7 Copilot Control head (Switch 11)
Switch 11 indicates that a CTL45P is installed as a copilot control head.
UP for copilot CTL45P not installed, DOWN for copilot control head present.
2.5.3.8 Mission/Observer Control head (Switch 12)
Switch 12 indicates that a CTL45M is installed as the Observer/Mission control
head.
UP for CTL45M not installed, DOWN for observer/mission position control head
present.
12 11 10 9 8 7 6 5 4 3 2
1
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
P UP
12 11 10 9 8 7 6 5 4 3 2 1
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