PS Engineering Inc - Support
User Manual for PS Engineering models including: IntelliPAX, Intercom Expansion Unit, IntelliPAX Intercom Expansion Unit, Expansion Unit
PS Engineering Inc
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DocumentDocument9800 Martel Road Lenoir City, TN 37772 IntelliPAX Intercom Expansion Unit Unit Part Numbers 11616, 11616R for use with intercom systems 11636R for use with PMA8000E Passenger Intercom System With IntelliVox® Installation and Operation Manual US Patent No. 6,493,450 Document P/N 200-250-0006 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 (865) 988-9800 www.ps-engineering.com 200-250-0006 Page i February 2022 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 2-4 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 0 Feb 2022 New manual for current units 200-250-0006 Page i 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 IntelliPAX IntelliPAX Remote IntelliPAX Remote Description intercom expansion unit for other intercom/audio systems blind-mount intercom expansion unit blind- mount intercom expansion unit for PMA8000E Part Number 11616 11616R 11636R 1.3 Description The IntelliPAX (11616 series) is an intercom expansion unit that works with the PM1000II and PM1200 intercoms while the 11636 series works with the PMA8000E and PAC45A. These expansion units contain PS Engineering's proprietary intercom protocol, IntelliVox®. This system a patented technique that provides automatic VOX for each of the six individual microphones, eliminating manual squelch adjustments. Because of the automatic squelch, the unit can be blind mounted. The "R" designates the remote mounted version. Part number 11636R is intended to function with PMA8000E. The part number "R" version is designed for remote, or blind mounting. 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. 200-250-0006 Page 1-1 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) 200-250-0006 Page 1-2 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: 250-250-0000 IntelliPAX Panel Mount Installation Kit 250-250-0001 IntelliPAX Remote Mount Installation Kit Part Number Description 250-250-0000 11616 250-250-0001 11616R 11636R 475-442-0002 #4-40 Machine screws, black 2 625-003-0001 Soft Touch Knob "D" shaft 1 575-250-0001 IntelliPAX Faceplate 1 425-025-0009 25 pin Sub-D connector shell 1 1 1 425-020-5089 Male Crimp Pins 25 25 25 625-025-0001 Connector hood 1 1 1 475-002-0002 Connector Thumbscrews 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, 11636R 200-250-0006 Page 2-1 February 2022 2.3 Equipment installation procedures 2.40" 2 ea. 0.125 NOT TO SCALE For panel mounted installation (11616,) 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: (11616R, 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 SoftMuteTM 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. 200-250-0006 Page 2-2 February 2022 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 IntelliPA PM1200 PM1000II Series PMA8000C & PMA8000E X PMA8000E Expansion 2 Expansion 1 Expansion Power 1 8 15 J2-41 J2 41 Expansion Ground 14 4 2 J2-38 J2 38 Audio Input J1 41 (rt) 2 Audio Input 15 13 16 J1-41 J1-40 J1 40 (lt) Audio Output 3 3 3 J2-37 J2 37 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. 200-250-0006 Page 2-3 February 2022 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). 200-250-0006 Page 2-4 February 2022 3.1 Power Section III OPERATION 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 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. For the P/N 11636R operating with the copilot's PMA8000E, the audio panel's Passenger volume control (PASS) affects the expansion intercom 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. Nonvoice 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 (1-800-8886910). 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. 200-250-0006 Page 3-1 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 (865) 988-9800 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 (865) 988-9800 FAX (865) 988-6619 200-250-0006 Page 4-1 February 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 Section 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Instructions for Continued Airworthiness: Introduction Description Item Controls Servicing Maintenance Instructions Troubleshooting Removal and replacement information Diagrams Special Inspection Requirements Protective Treatments Structural Data Special Tools Not Applicable Recommended Overhaul Periods Airworthiness Limitations Revision Information Installation of passenger intercommunications system. Installation as described in manufacturer's installation manual referenced on FAA Form 337, including interface with other avionics audio as required. See installation and operator's guide referenced on FAA Form 337. None Required On Condition, no special instructions 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 (865) 988-9800 for special instructions. 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. Not applicable Not Applicable Not Applicable Not Applicable None Not Applicable None Not Applicable To be determined by installer 200-250-0006 Page A February 2022 Appendix B Installation 5.480 A 4.000 Ø0.136 3.500 A A 4.725 200-250-0006 Page B February 2022 Appendix C Wiring Information IntelliPAX Unit has Female Sub-D DB-25 Expansion Power In 1 Expansion Audio In (R) 2 Expansion Audio In (L) 15 Expansion Audio Output 3 Expansion Ground 14 Expansion Power Audio (R) from Main Unit Audio (L) from Main Unit Audio to Main Unit Expansion Ground PM1200 8 13 3 4 Music (L) 25 Music (R) 13 Entertainment Input PM1000 Series 15 16 3 2 See unit Installation manual for complete information Pass 1 & 3 Phones (L) Hi 8 Pass 1 & 3 Phones (R) Hi 20 Headphone Lo Pass 2 & 4 Phones (L) Hi 9 Pass 2 & 4 Phones (R) Hi 21 Headphone Lo Mono Aux input 22 Pass 1 Mic Audio Hi 16 Pass 1 Mic Audio Lo 4 Pass 2 Mic Audio Hi 17 Pass 2 Mic Audio Lo 5 Pass 3 Mic Audio Hi 18 Pass 3 Mic Audio Lo 6 Pass 4 Mic Audio Hi 19 Pass 4 Mic Audio Lo 7 Pass 5 Mic Audio Hi 23 Pass 5 Mic Audio Lo 11 Pass 6 Mic Audio Hi 10 Inhibit Switch 1 24 Inhibit Switch 2 12 Mono Aux Input, See Note 7 (tape recorder, etc) NOTES: Pass 1 Mic Pass 2 Mic 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 mustbe electricaly floating. 4. Connect shields at intercom end only 5. Consult main unit Installation manual for remaining installation information. Pass 3 Mic Pass 4 Mic Pass 5 Mic Pass 6 Mic Soft Mute Control (Switch not included) 9800 MARTEL ROAD, LENOIR CITY TN 37772 T IT LE: IntelliPAX WIRINGDIAGRAM SIZE DOCUMENT NUMBER: 120-250-0000 REV 8 DATE: 02/01/22 SHEET 1 OF 1 Figure 1 IntelliPAX Wiring (11616, 11616R, 11636R) 200-250-0006 Page C February 2022 IntelliPAX Unit has Female Sub-D DB-25 Expansion Power In 1 Expansion Audio In (R) 2 Expansion Audio In (L) 15 Expansion Audio Output 3 Expansion Ground 14 PMA8000C PMA8000E Expansion Power Audio (R) from Main Unit Audio (L) from Main Unit Audio to Main Unit Expansion Ground J2-41 J1-41 J1-40 J2-37 J2-38 See unit Installation Manuals for complete information Figure 2 - Expansion Interface with PMA8000C or PMA8000E 200-250-0006 Page D February 2022