ps PM1200 Panel Mounted Intercom Instruction Manual
- June 9, 2024
- PS
Table of Contents
ps PM1200 Panel Mounted Intercom
Introduction
The PM1200 is a panel-mounted, 2-place (expandable with IntelliPAX p/n 11616R) monaural intercom system (ICS) designed specifically for high-noise aircraft environments. Please read this manual completely before installa-tion to minimize the risk of damage to the unit and to become familiar with all the features.
Scope
This manual contains installation and operational in-structions for the
following PS Engineering units:
Description
- The PM1200 is a 2-place (unless expanded), panel-mounted intercom with PS Engineering‘s proprietary Intel-liVOX® intercom protocol. The audio has been further en-hanced with extra audio filtering for the microphones, and added headphone audio power.
- The PM1200 is backward compatible with PM1000II units, P/N 11902, 11909 and 11922– contact factory for details. However, the PM1000-series MUST be wired cor-rectly per the manual, particularly the pilot radio PTT.
- The unit can be used as either voice-activated, or push to talk intercommunications, by simply pushing a front pan-el switch.
- The PM1200 has an automatic fail-safe interconnect to the aircraft radio. If power to the intercom is disrupted, an internal relay will connect the pilot’s headset to the aircraft radio. This allows continuous radio communications. Note: The copilot will no longer hear aircraft radio when power is removed.
- An entertainment input is provided, allowing the users to listen to music during flight. During intercom or aircraft radio traffic, this music is automatically muted to allow communications without distraction. When the activity ceases, the Soft Mute™ circuit gradually returns the music to the original volume.
- Both pilot and copilot have transmit capabilities over the radio. The PM1200 allows only the person who presses their radio PTT to be heard over the aircraft radio. If both pilot and copilot press the PTT at the same time, the pilot will have priority and override the copilot.
Approval Basis None
The PM1200, 11960, 11960-EXP, or 11961, is NOT FAA Approved. It is the
responsibility of the installer to deter-mine suitability for installation.
Specifications
- Input power: 13.8 – 27.5 Volts DC
- Current Drain: < 250 mA (Externally fused at 1 Amp)
- Output 120 mW into 150@ 27.5 VDC 70 mW @ 13.75 VDC
- Headphone Impedance: 150-1000 ohms typical
- Aircraft Radio Impedance: 500- 1000 typical
- 3 dB Music Frequency Response: 200 Hz to 15 kHz
- Unit weight: 12 Ounces (0.342 kg)
- Temperature -20ºC to +55ºC
- Altitude 50,000 ft.
Equipment required but not supplied
- A. Headphones, 150-300 monaural, up to two as required
- B. Microphones, up to two, as required
- C. Crimping Tool, AMP 601966-1 , and Positioner, 601966- 5 (or equiv.)
- D. Appropriately constructed interconnect wiring
- E. Circuit Protection, 1 Amp.
- F. Radio PTT switches (1-pilot, 1-copilot)
- G. Intercom PTT switches (if desired) 2 ea.
Installation
General Information
The PM1200 comes with all the necessary mechanical hardware for installation.
Installation of the PM1200, using the appropriate wiring and hardware, does
not require special tools or knowledge other than described in FAA Advisory
Circular 43.13–2B. Installers should be qualified in accordance with 14 CFR
65.81(b).
It is the installer’s responsibility to determine the approval basis for this
installation. An FAA From 337, or other field approval may be required in a
certified aircraft. A custom-made wiring harness is available from PS
Engineering, and shipped within 5 business days of order. Visit
www.psengineering.com for more information.
IntelliVox®
The PM1200 has both automatic VOX (IntelliVox® and PTT-ICS. For open cockpit
aircraft and the majority of warbirds, using the PM1200 in PTT-ICS (Push-To-
Talk Intercom Mode) is required. Turning either IntelliVox® or PTT-ICS
function on and off you simply depress the Copilot Volume control knob. In one
mode it will work with the Voice Operated Relay (VOX) automatically. Pressing
the knob again will place the intercom into the PIT-ICS mode. While in
IntelliVox® mode, there must be some background noise so that the circuits
that makes the automatic VOX work knows what noise is so then it can determine
when a voice is present.
PM1200 Standard and Expansion
(11960 & 11960-Exp) Installation Kit P/N 250-120-0100
Part Number| Description| Quantity
350-990-0015| Foam Mic Muff| 2
350-9909-0001| Leather Mic cover| 2
475-442-0002| #4-40 Machine screws,
black| 2
625-003-0001| Soft Touch knobs| 2
425-025-0009| 25 pin Sub-d connector shell| 1
625-025-0001| Connector hood| 1
425-020-5089| Crimp Pins (Male)| 25
575-120-0001| Reversible aluminum face plate| 1
250-000-0002| 2-place jack kit| 1
200-196-00XX| Operator’s and Installation Manual| 1
122-102-0001| Drill Template| 1
475-002-0002| Thumbscrews| 2
PM1200 Remote (11961) Installation Kit P/N 250-120-0200
Part Number| Description| Quantity
350-990-0015| Foam Mic Muff| 2
350-9909-0001| Leather Mic cover| 2
425-025-0009| 25 pin Sub-d connector sell| 1
625-025-0001| Connector hood| 1
425-0205089| Crimp Pins (Male)| 25
250-000-0002| 2-place jack kit| 1
200-196-00XX| Operator’s and Installation Manual| 1
675-120-0103| Pilot volume pot w/Switch ¼” shaft| 1
675-020-0103| Copilot volume pot ¼” shaft| 1
731-001-0001| Switch, SPDT On-On| 2
625-020-0005| Knob, Black 1/2” shaft| 2
475-002-0002| Thumbscrews| 2
Equipment installation procedures
- Using the template, drill six holes in the instrument panel in a location convenient to the pilot position(s). The intercom can be mounted horizontally or vertically with supplied face plate.
- Insert the PM1200 from behind the instrument panel, aligning the holes for the knobs, LED, and switch.
- Place the aluminum face-plate over the knob shafts and secure, using the two # 4-40 round head screws provided.
- Install the knobs over the volume and squelch control shafts (except in the case of the 11961).
NOTE: See Page 9 for PM1200 Remote (11961R) installation diagram
Cable harness wiring
To complete the installation, a wire harness must be made as shown in the
appropriate diagram. 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 (865-988- 9800) for more information. If the aircraft already has
pilot and copilot headset jacks installed, you may re-use them. Remove and
discard all wires from the copilot headset jacks. You may use the existing
pilot headset jacks as the Auxiliary Aircraft Radio Headset Jacks, but they
should be moved to a new location to avoid confusion with the pilot’s
headphone jacks. In the event the intercom has to be removed for any reason,
these jacks provide access to the aircraft radio system. To connect intercom
into the aircraft audio system, parallel the appropriate set of cables from
the intercom to the Auxiliary Aircraft Radio Headset Jacks. Finally, install
new headset jacks into the aircraft and connect them directly to the
appropriate pins of the PM1200. See the wiring diagram for all details of the
wire harness interconnects.
-
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 crosscoupling between the large headphone signal and the small microphone signal. The resulting feedback is a high-pitched squeal that varies with the volume controls.
Due to the variety of the radio equipment found in today’s general aviation aircraft, there is the potential of both radiated and conducted noise interference. The PM1200 has a specially designed power supply to reduce conducted electrical noise on the power bus of the aircraft by at least 50dB. Although this is a very large amount of attenuation, it does not eliminate all noise when the amount is excessive. There must be at least 12 Volts DC present at the PM1200 for the power supply to work within its designed regulation. Otherwise, it will not be able to attenuate noise properly.
Shielding can protect the system from radiated noise (rotating beacon, electric gyros, switching power supplies, etc.). However, installation combinations can occur where minor interference is possible. The PM1200 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. The use of a conductor instead of a shield for ground return eliminates these ground loop paths. -
Power Requirements
The PM1200 was designed to work with either 12 or 28 volt DC negative ground systems. The PM1200 must be externally protected with a one ampere (1A) circuit breaker -
PTT-ICS
The PM1200 is designed for noisy installations, such as open cockpit aircraft. In addition to the Advanced Microphone Processing (AMP) and IntelliVOX® squelch, the unit includes a VOX/PTT-ICS mode, controlled by the pushing the copilot volume knob. In this mode, no pilot mic audio is passed to the intercom unless pin 2 is connected to 16, or copilot mic audio unless pin 15 is connected to pin 2 through a normally-open, momentary switch (not supplied). -
Music Input
Entertainment devices can be connected to thePM1200. Install a 1/8″ jack convenient the pilot to connect the entertainment device into the system. Since the PM1200 is monaural, you may want to connect the left and right channels together at the music jack. Depending on the music source used, 10Ω resistors in series with the left and right channels may be desireable to avoid loading and possibly damaging the source. A “Soft Mute” system is installed in the PM1200 that will mute the music during intercom or radio activity.
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. -
Remote Configuration (11961)
The PM1200-Remote is designed for blind mounting. The unit can be controlled through two remote potentiometers for volume and two SPDT switches. Mount the volume controls in a location accessible to the pilot and copilot, and the VOX and ISO switches convenient to the pilot in command position. The pilot’s volume pot also contains an onoff switch. See page 7 for wiring information.
NOTE: Due to the exposed signal paths for the volume controls, these installations are more prone to electrical noise, and extreme care must be taken in constructing the harness, with wire runs as short as possible. PS Engineering does not guarantee a noise-free installation in this configuration.
This version cannot be expanded. -
Expansion Configuration (11960-EXP)
The PM1200-EXP is configured internally to add expansion capability for more than two positions. Using an IntelliPAX expansion unit, part number 11616, an additional 6 intercom positions can be available. Although not marked, the lower position on the ISO/ ALL switch becomes a “Crew” position.
NOTE: The IntelliPAX includes IntelliVOX intercom, but is not specifically designed for high noise environment. It may be desirable to have an intercom P-T-T, by installing an inline, momentary normally open switch on the mic audio lines, or use a portable intercom P-T-T that have an open mic audio switch contact.
Post installation checkout
After wiring is complete, verify power is ONLY on pin 14 of the connector, and
airframe ground on pin 1. Failure to do so will cause internal damage and void
PS Engineering’s warranty.
- Apply power to the aircraft and avionics.
- Plug headsets into the pilot and copilot positions.
- Verify that the pilot position can transmit and receive. With the PM1200 in the OFF position (press the pilot’s volume control knob to turn off).
- Turn the unit on and rotate the pilot volume clockwise, about half way. Verify that the Pwr/Xmt light comes on, and shows green. If the LED is red, stop testing and trouble-shoot the microphone PTT installation.
- Verify that the pilot can transmit and receive on the com transceivers.
- Verify that the LED in the intercom changes from green to red when a radio PTT is pressed.
- Verify proper intercom operation for pilot and copilot. For more information, consult Section 3.
- Verify proper transmit and receive operation on the copilot position, noting that the copilot PTT switch allows proper transmission on the selected transceiver.
- Verify proper Intercom system operation in the ALL and ISO modes.
- Verify that the intercom system does not adversely affect any other aircraft system by systematically switching the unit on and off, while monitoring the other avionics and electrical equipment on the aircraft.
- PTT ICS– Push the copilot volume control to activate the PTT-ICS mode. Verify that the mic audio is heard when the intercom push to talk switch is activated.
OPERATION
On/Off and Volume
Press the left hand knob to turn the unit on and off. This is also the fail-
safe position. Whenever the unit is off, or power removed, the pilot’s headset
is connected directly to the aircraft audio system. The pilot’s volume control
knob adjusts the loudness of the intercom and music for the pilot’s headset
only. It has no effect on aircraft radio volume level, allowing an additional
degree of aircraft radio listening flexibility. The copilot’s volume control
adjusts the intercom volume for the copilot.
Squelch
The PM1200 incorporates PS Engineering’s revolutionary Advanced Microphone
Processing (AMP) and IntelliVox™ intercom squelch. No adjustment of the
squelch control is required. Through individual signal processors, the ambient
noise appearing in both microphones is constantly being sampled. Non-voice
signals are blocked. When someone speaks, only their microphone circuit opens,
placing their voice on the intercom.
The system is designed to block continuous tones, therefore people humming or whistling in monotone may be blocked after a few moments. The IntelliVox® is designed to work with normal aircraft cabin noise levels (70 dB and above). Therefore, it may not recognize speech and clip syllables in a quiet cabin, such as in the hangar, or without the engine running. This is normal. 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.
For optimum microphone performance, PS Engineering, Inc. recommends installation of a Microphone Muff Kit (provided). This will not only optimize VOX performance, but will improve the clarity of all your communications In some extremely high noise environments, it may be desirable to have a push to talk (PTT) intercom, instead of relying on voice-activation (VOX). In the PM1200 audio panel the PTT intercom capability is added. To operate the PTT, push the PTT-ICS control switch on the copilot volume control. Using an external ICS PTT switch for pilot and copilot will allow voice on the intercom.
Mode Select
The center switch is a mode control that allows the pilot to tailor the
intercom function to suit flight conditions. Regardless of configuration, the
pilot will always hear the aircraft radio. NOTE: If there is a power failure
to the PM1200, or if the power switch is turned off, the copilot will not hear
the aircraft radio. Only the pilot is connected directly to the aircraft
radio.
- ISO (Up Position): The pilot is isolated from the intercom and is connected only to the aircraft radios. He will hear the aircraft radio reception (and sidetone during radio transmissions). Copilot and passengers will hear themselves and music but not the aircraft radio traffic.
- ALL (Middle position): All parties will hear the aircraft radio, intercom, and music. However, during any ICS or radio communications, the music volume automatically mutes. The music volume increases gradually back to the original level after communications have been completed.
- CREW (with expansion and 11960-EXP ONLY, down position, unlabeled): Pilot and copilot have access to aircraft radios, and hear Music input to PM1200. Passengers do not hear aircraft radio or pilot and copilot, but can talk to each other, and hear Music 2. In non-expanded systems, the down and middle positions operate the same way.
The music input on the expansion unit will only be active in Crew mode, otherwise, music from the PM1200 EXP will be heard by passengers.
DIMENSION
Wiring
200-196-0104 Page 7 April 2020 Rev. 13
PM1200, REMOTE Wiring P/N 11961
PM1200, P/N 11960 Wiring
Warranty and Service
Warranty
In order for the factory warranty to be valid, the installations in aircraft
must be accomplished by an FAA- certified avionics shop and authorized PS
Engineering dealer. If the unit is being installed by a non-certified
individual 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 to the PS Engineering dealer, if the unit should be
determined to be defective after consultation with a factory technician. PS
Engineering will not ship to theend user under warranty, unless authorized by
the dealer. 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 which 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.
Factory Service
The PM1200 is covered by a one-year limited warranty. See warranty
information. Call PS Engineering, Inc. at
865-988-9800 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 to:
PS Engineering, Inc.
Attn: Service Department
9800 Martel Road
Lenoir City, TN 37772
865-988-9800
FAX 865-988-6619.
NOTE: PS Engineering is not responsible for units shipped US Mail. If no method of payment is provided, the units will be returned COD. If no RMA or description of problem is present, the shipment will be refused.
PS ENGINEERING, INCORPORATED
9800 Martel Road
Lenoir City, TN 37772
Phone 865-988-9800
FAX 865-988-6619
www.ps-engineering.com
NOTICE: Warranty is not valid unless this product is installed by an Authorized PS Engineering dealer.
PS Engineering, Inc. 2020© 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