PS Engineering IntelliPAX Intercom Expansion Unit User Manual
- June 9, 2024
- PS Engineering
Table of Contents
IntelliPAX Intercom Expansion Unit
9800 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
Rev
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Date
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Change
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0
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Feb 2022
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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 Description Part Number IntelliPAX intercom expansion unit for other intercom/audio systems 11616 IntelliPAX Remote blind-mount intercom expansion unit 11616R IntelliPAX Remote blind- mount intercom expansion unit for PMA8000E 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 Ω typical Audio Distortion: <10% @ 35 mW into 150 Ω load Aircraft Radio Impedance: 1000 Ω 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, 150Ω 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
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Part Number
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Description
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11616
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11616R
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11636R
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4-40 Machine screws, black
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2
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625-003-0001
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Soft Touch Knob “D” shaft
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1
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IntelliPAX Faceplate
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1
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425-025-0009
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25 pin Sub-D connector shell
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1
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1
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1
425-020-5089
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Male Crimp Pins
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25
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25
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25
625-025-0001
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Connector hood
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1
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1
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1
475-002-0002
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Connector Thumbscrews
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2
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2
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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
NOT TO SCALE
For panel mounted installation (11616,)
- Using the template, drill three holes in the instrument panel in a location convenient to the pilot or passengers position(s).
- Insert the IntelliPAX from behind the instrument panel, aligning the holes for the knobs.
- Place the aluminum faceplate over the knob shaft and secure, using the two # 4-40 round head screws provided.
- Install the volume knob over the volume control shafts.
Blind mounting: (11616R, 11636R)
- Install the unit on an avionics shelf or other appropriate structure.
- 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.
- 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.
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
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IntelliPA
X
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PM1200
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PM1000II Series
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PMA8000C &
PMA8000E
Expansion 1
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PMA8000E
Expansion 2
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Expansion
Power
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1
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8
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15
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J2-41
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J2 41
Expansion
Ground
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14
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4
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2
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J2-38
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J2 38
Audio Input
(rt)
Audio Input
(lt)
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2
15
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13
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16
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J1-41
J1-40
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J1 41
J1 40
Audio Output
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3
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3
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3
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J2-37
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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
Section III – OPERATION
3.1 Power
Switching on the intercom or audio panel automatically activates the IntelliPAX unit. The Stand Alone unit is active when power is applied to the Avionics Bus.
3.2 Adjusting the Volume
The 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. 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.
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
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 Instructions for Continued Airworthiness:
Section
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Item
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Information
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1
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Introduction
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Installation of passenger intercommunications system.
2
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Description
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Installation as described in manufacturer’s installation manual referenced on FAA Form 337, including interface with other avionics audio as required.
3
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Controls
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See installation and operator’s guide referenced on FAA Form 337.
4
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Servicing
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None Required
5
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Maintenance Instructions
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On Condition, no special instructions
6
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Troubleshooting
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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.
7
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Removal and replacement
information
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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
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Diagrams
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Not applicable
9
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Special Inspection Requirements
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Not Applicable
10
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Protective Treatments
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Not Applicable
11
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Structural Data
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Not Applicable
12
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Special Tools
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None
13
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Not Applicable
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Not Applicable
14
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Recommended Overhaul Periods
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None
15
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Airworthiness Limitations
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Not Applicable
16
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Revision
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To be determined by installer
200-250-0006 Page A February 2022
Appendix B Installation A
Appendix C Wiring Information
Figure 1 IntelliPAX Wiring (11616, 11616R, 11636R)
Figure 2 – Expansion Interface with PMA8000C or PMA8000E
Documents / Resources
| PS
Engineering IntelliPAX Intercom Expansion
Unit
[pdf] User Manual
IntelliPAX, Intercom Expansion Unit, IntelliPAX Intercom Expansion Unit,
Expansion Unit
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