Clear-Com KB-111A Instruction And Service Manual

KB-111A

Speaker Station

INSTRUCTION

and

SERVICE MANUAL

III~I~

Clear-Co.

~I'

Intercom Systems

945 Camelia St. Berkeley, California 94710 510-527-6666

Clear-Com 810026 8/15/88

REV.

C

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DOCUMENTATION

ADDENDUM

KB-ll1A

MANUAL

• . f

REV. A

.•

.j

..

..

November

17,

1987

I .1

r •

MIC

TO

LINE

GAIN

LEVEL

INCREASE

In

effecting

a

4dB

Mic

to

Line

Increase

In

gaIn

level,

the

following

changes

have

been

made:

Change:

270K

OHM

R18, 36 390K

OHM

27pf

C9

lSpf

180pf

CI0

100pf

CLEAR-COM

KB-IIIA

SPEAKER

STATION

INSTRUCTION & SERVICE

MANUAL

TABLE

OF

CONTENTS

Section

Page

II

I

Introduction

to

the

KB-IIIA

•.•....•..••...•.•

1

II

Headsets

and

Mics

•..•...•.........••..•••.•••

l

III

Installation

.•.....••.•••••.•••••••..••••••••

3

IV

Operating

Controls.·

•••..••.•.••.••..•••••••.

7

V

Parts

Listing

••..•.•..•.•••••.•.•.....•••••.•

8

VI

Specifications

•...•.•.........••••.•.••.•••••

8

VII

Call

Signalling

Modification.·

••••••....•••••

9

Illustrations

:

Headset

Y-Cable

.•.•.•••••••.••.•.•.••••

2

Figure

1

Figure

2:

Headset

Extension

Cord.··

•••••.•.••••••

2

Figure

3:

KB-IIIA

Mounting

Dimensions

••..•••.••••

4

Figure

4:

KB-IIIA

Block

Diagram

•.••.••••••••.••••

4

Figure

5:

Two-Channel

Interconnect

Wiring

•.••••••

5

Figure

6:

Portable

Unit

Connections

•.•.•••.••••••

6

Figure

7:

Alternative

Signalling

•..•••.••••••••••

9

Figure

8:

KB-IIIA

Schematic

••••.•••••••••••••••.

10

NOTICE:

-lihiltt

Clttar-CDIII

.a1c.tt.s

"very

attlt.pt

CD

.a/nt.ln

Ch"

.ccur.cl/

III

thlt

In/ormation

contained

In

It.s

product ••nua/a. chit

inlor.atlon

Is

.ubJllct

CD

change

Nithout

notice:"

•

I.

INTRODUCTION

TO

THE

KB-IIIA

REMOTE

STATION

The

Clear-Com

KB-lllA

is a Remote

Speaker

Station

that

provides

talk/

listen

communications

on

one

of

two

channels

within

our

closed-circuit

intercom

system.

It

features

a

wide

frequency

response,

high

out-

put

speaker

and

the

ability

to

operate

with a carbon

headset

OR

a

dynamic

headset,

handset,

or

push-

to-talk

mic.

The

KB-IllA

features

the

Clear-Com

contoured

frequency

response

for

consistently

excellent

speech

in-

telligibility

in

all

surroundings.

The

speaker

delivers

crisp

sound

pressure

levels,

clearly

audible

in

high-

or

low-noise

environments.

The

Remote

Station

features

Automa-

tic

Headset

Detection;

its

built-in

mic

preamp

automatically

shuts

off

when

the

headset

is

disconnected,

eliminating

noise

pick-up

on

the

intercom

line.

The

intercom

cir-

cuitry

incorporates

a

mic

limiter,

which

assures

constant

talk

levels

~nd

prevents

overload.

The

KB-lllA's

speaker

can

remain

on

at

all

times,

or

you

can

turn

it

off

so

that

private

conversations

may

be

carried

out

with a headset

or

telephone

handset . The

three-

position

mic

switch

allows

you

to:

1)

keep

the

mic

on

at

all

times;

2)

activate

the

mic

momentarily;

3)

switch

off

the

mic

so

the

KB-

lIlA

can

function

as a "listen-

only"

station.

II.

HEADSETS

AND

MICS

To

provide

you

with

the

ability

to

talk

on

the

intercom

channel,

the

KB-lllA

contains:

--one

1/4"

phone

jack

for a stan-

dard

carbon

headset,

AND

--one

4-pin,

male,

XLR-type

connec-

tor

(D4M)

for a dynamic

headset,

telephone-style

handset,

or

push-

to-talk

mic

The

KB-lllA

provides

an

adjustable

sidetone

circuit

which

allows

you

to

vary

the

level

of

your

voice

as

you

hear

it

in

your

headset

or

speaker.

The

circuit

also

prevents

feedback

when

using

the

speaker

and

a

mic

simultaneously.

You

need

only

adjust

the

sidetone

once,

even

if

other

Stations

subsequently

join

or

leave

the

intercom

system.

Designed

for

custom-mounting,

the

KB-lllA

is

built

on

a

charcoal-

brown,

aluminum

panel,

5/32"

thick,

that

can

be

installed

in a cut-out

in

any

convenient

surface,

or

moun-

ted

inside

a

6" x 8"

Nema

electri-

cal

enclosure.

The

Station

connects

to

the

intercom

system

via

a

5-

pin

terminal

block

behind

the

front

panel.

Clear-Com

offers

the

"P"

Box,

which

allows

you

to

convert

the

KB-lllA

to a portable

Remote

Station.

The

P-Box

is-a

sturdy,

sloped-front,

steel

enclosure

with

solid

walnut

sides.

When

installed

in a P-Box,

the

KB-lllA

connects

to

the

inter-

com

system

with

3-pin,

XLR

connec-

tors·

~fuen

the

KB-lllA

is

installed

in

the

P-Box,

it

provides

talk/listen

capability

on

one

channel.

Standard

two-conductor

shielded

mic

cable

interconnects

stations

within

the

intercom

system.

The

KB-lllA's

built-in

headset/

speaker

amplifier

can

drive a stan-

dard

headset

to

levels

greater

than

110

dB

SPL.

The

Station's

mic

preamp

automatically

shuts

off

when

the

headset

is

disconnected,

there-

by

eliminating

hum

pick-up.

NOTE:

If

you

use a carbon

headset

and a dynamic

headset

simultaneous-

ly . the

listen-level

in

the

carbon

headset

drops

audibly-

The

carbon

headset

connections

are:

Ring--

Headphone

Tip--

Mic

Sleeve--

Ground

The

D4M

connector

pins

are:

Pin

1:

Mic

Ground

Pin

2:

Mic

Hot

Pin

3:

Headphone

Ground

Pin

4:

Headphone

Hot

To

assure

proper -level

and

perfor-

mance,

the

dynamic

headset

should

have

the

following

characteristics:

Microphone

type:

dynamic

Impedance

~

150-250

ohms

Output

level:

-55

dB

Headphone

type:

dynamic

Output

impedance:

300-2000

ohms

Clear-Com

offers

three

dynamic

headsets,

all

with

boom-mounted,

noise-cancelling

mics.

Model

CC-

240B

is a double-muff

and

Model

CC-

75B

is

Single-muff;

both

have

boom-

activated

mics

with

on/off

swit-

ches.

Model

PH-7

is a very

rugged,

double-muff,

high-fidelity

headset

with

wider

frequency

response

and

greater

isolation

from

ambient

noise.

Clear-Com

also

offers

Model

HS-6,

a

telephone-style

handset

with a dynamic

mic

and

push-to-talk

switch;

it

is

interchangeable

with

the

above

headsets.

All

units

have

field-replaceable

cords.

The

KB-111A

drives

two

dynamic

headsets

with

only a slight

(3

dB)

reduction

in

level.

Clear-Com

can

supply

you

with

Model

YC-100

"y"

Cable,

which

allows

you

to

plug

two

headsets

into

the

one

D4M

connector

on

the

Station's

front

panel.

Alternately,

you

may

construct

your

own

Y-cable;

we

recommend

you

use

Belden

8416

or

the

equivalent

(2-

conductor,

25

gauge)

or

Belden

8734

or

the

eqivalent

(3-conductor,

22

gauge).

See

Figure

1.

You

can

also

build

an

extension

cord

for a dynamic

headset,

using

the

cable

specified

above.

Limit

its

length

to

15

feet

or

less;

greater

lengths

lead

to

possible

capacity

coupling

between

the

mic

signal

and

the

headset

Signal,

which

causes

oscillation

or a loss

in

frequency

response.

See

Fig.

2.

FIGURE 1: HEADSET

"Y"

CABLE

CONNECTIONS

SHI'EL

DEO

A4M

PA

IR

PIN

1:

MIC GROUND
PIN 2: MtC HOT
PIN

J : HEADPHONE

GROUND

PI" 4 : HEADPHONE HOT

FIGURE 2: HEADSET EXTENSION CORD

I S'

OR

LES

S

~------~~------~

A4F

>---'T--

----------

---I-

(~

!

A4M

?

SHIELDED P ALA

PIN 1: MIC GROUND

CAUTION:

:x)

NOT

CONNEC"

PIN 2.:

MIC

HOT

,\ l

IC

GROUND &

''':

EADPHo

r~E

PIN 3: HEAOPHONE GROUND

GRO G

NO

~QGETHEA

PI"

4: HEADPHONE

HOT

A4F

SHLELDED

PAIR

A4M

CA UTION: DO

~OT

CONNECT

Mle

GROUND & HEAD

PHONE

GAO

UN

:J

TOGETHER

AT

AN

Y POI

NT

2

•

II.

KB-IIIA

INSTALLATION

The

KB-111A

connects

to

the

inter-

com

system

with a five-screw

termi-

nal

strip,

which

is

located

on

the

PC

Board.

Route

two-pair

(indi-

vidually

shielded)

cable

(i.e.

Bel-

den

8723)

from a Main

Station

or

Power

Supply

output

connector

to

the

location

of

your

Remote

Station

(or

route

two

separate,

two-conduc-

tor

mic

cables,

one

per

channel).

Each

channel

must

be

fed

within

its

own

shield,

although

unshielded

cable

may

be

used

when

run

in

condui

t.

The

KB-lllA

can

be

mounted

in

a

cut-ou~

in

any

surface,

or

it

can

mount

ins~de a

6"

by

8"

Black

(electrical)

Box

(minimum

depth,

3").

See

figure

3

for

dimensions.

After

preparing

a

surface

for

in-

stallation,

bring

wiring

into

the

header

on

the

terminal

strip.

While

making

connections,

refer

to

the

lable

adjacent

to

the

terminal

strip;

it

identifies

each

pin

by

assignment:

Ith

CH .

A

CH

.

8

+30

V

~]

Connect

the

leads

according

to

the

label

shown

above.

IMPORTANT

to

prevent

ground

loops

and

buzzes,

the

common

terminal

(pin

5)

should

NEVER

be

directly

connected

to

chassis

ground

(pin

1).

Use

conduit

or a separate

wire

to

interconnect

two

or

more

KB-111A

Stations

to

pin

1.

If

you

plan

to

use

only

one

channel

on

the

KB-111A,

disable

the

Channel

Select

switch

by

jumping

Channels

A

and

B

together

on

the

connector

block,

and

hook

the

intercom

audio

line

to

either

terminal 2 or

3.

If

you

don't

disable

the

Channel

Select

switch

and

are

only

using

one

channel,

you

must

be

sure

to

keep

the

Channel

Select

switch

set

to

the

active

channel.

If

you

switch

to

the

unconnected

channel,

the

Station

will

exhibit

disturbing

oscillation.

See

Figure 5 (page

5)

for

examples

of

KB-111A

Two-Channel

Wiring.

THE

PORTABLE

KB-111A

The

KB-111A may

be

mounted

inside

the

Clear-Com

Model

"P"

Box,

there-

by

becoming a portable

Remote

Sta-

tion.

The

"P"

Box

is

supplied

wi

th

a

handle,

rubber

feet,

and

screws

for

attaching

the

handle

and

the

intercom

to

the

enclosure.

When

the

KB-111A

is

mounted

in

the

P-Box,

only

one

channel

can

be

used

for

communication.

The

wiring

in

the

P-Box

contains

a

jumper

to

defeat

the

Station's

Channel

Select

switch.

The

portable

Station

connects

to

the

intercom

system

with

the

3-pin,

XLR

connectors

located

on

the

side

of

the

P-Box.

There

is

one

female

connector

for

input,

and

one

male

connector

for

extending

the

intercom

line

to

other

Remote

Stations.

Inside

the

P-Box,

the

connectors

are

wired

to

a

5-pin

terminal

strip,

which

you

plug

onto

the

header

on

the

KB-111A

PC

Board.

Refer

to

Figure

6,

Portable

Unit

Connections

(page

6).

--continued--

3

,

I~---

---

KB-lllA INMOUN TS

(

8.6"------~1

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Q

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6"x

8"

BACK BOX

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--, _.

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6.5"

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MINIM

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3"

__

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DEPTH

1

FIGURE 3

KB-///A

MOUNTING DIMENSIONS

KB-111A BLOCK DIAGRAM

CARBON

HEADSET

CO'

...

NEC

TO~

I •

..IC~

DYNAM,e I

~

HEADSET

C

ONNECTOR

t

I

M'C

GA!N

(TRWI)

""

-

-401-

--~

I

~

CURRENT

SOURCE

B

UFFER

AMP

I

L<

4

•

KB-111A FIXED INSTALLATION WIRING

(TWO-CHANNEL)

CONNECT

TO

EARTH GROUND

IF

NON-GROUNDED ENCLOSURE

IS

USED

2 2-CONDUCTOR SHIELDED

PAIR

NOTE:

IF

WIRES DO NOT FIT

IN

STATION CONNECTOR BLOCK,

USE SEPARATE TERMINAL STRIP

OR

JUNCTION BLOCK

TO

CONNECT WIRES TOGETHER

KB111P5.

CDR

01

•

To

install

the

KB-lllA

in a P-Box:

1)

Remove

the

plastic

screw

termi-

nal

block

from

the

header

on

the

KB-lllA

PC

Board;

pull

straight

up

to

lift

block

off.

2) A similar

terminal

block

is

wired

to

the

P-Box's

3-pin

con-

nectors;

plug

that

block

onto

the

KB-IllA's

5-pin

header.

The

terminal

block

and

the

PC

Board

are

clearly

labelled

with

the

pin

numbers

to

ensure

proper

connections-

See

Figure

5,

Por-

table

Unit

Connection·

3)

Because

the

P-Box

accepts

one

channel,

the

KB-IllA's "Channel

Select"

toggle

switch

is

inef-

fective.

No

matter

which

posi-

tion

this

switch

is

in,

the

KB-

lIlA

operator

communicates

on

the

one

channel

that's

fed

into

the

P-Box

-

4)

Attach

the

KB-lllA

to

the

front

of

the

P-Box,

using

the

supplied

screws · If

desired,

attach

the

handle

and

the

protective

rubber

feet

onto

the

suitable

sides-

The

enclosure

also

has

cut-outs

on

each

side

for

hanging

it

from

the

wall,

a

console,

or

where

ever-

Use

standard

two-conductor

mic

ca-

ble

(i.e-,

Belden

8413)

with

3-pin

connectors

to

interconnect

the

por-

table

station

within

the

intercom

system.

The

pin-out

assignment

for

each

XLR

connector

is:

Pin

1--

common

Pin

2--

+30

volts

DC

Pin

3--

intercom

audio

Route

cable

from

the

Main

Station,

Power

Supply,

or

another

Remote

Station

to

the

portable

KB-IllA,

and

input

to

the

female

connector·

Use

the

male

output

connector

to

"daisy-chain"

the

intercom

line

between

the

KB-IllA

and

another

portable

Remote

Station.

A

diode

in

the

DC

input

of

the

KB-

lIlA

protects

the

circuitry

against

wiring

in

the

interconnect

cables.

All

Remote

Stations

bridge

the

terminated

audio

line

with

approxi-

ma

tely

15k

ohms.

-Figure 6: Portable Box Connections

o

Remove original
lerminal block.

PC

-}.,. BOA

RD

-+

....

~:\~

Vl

~

Use

pl'n

num

bers
on PC Board and
terminal block lor
proper

al

ignmenl.

Pl

wg PoBo

x termin

al
block onto
he

ade

rTB

1.
POB

ox

o

IN

TE

RCOM

Ma

ch rubber feet

INPUT (F)

10

PoBox: peel oN

----~r------J,

paper backing a

nd

I

& O

UTPU

T

Sl

ick feet onto th e

__

-..-/

(M

)

appropnate Side.

__

o

6

•

IV.

KB-IIIA

OPERATING

CONTROLS

"A/B

Chan.

Select"

This

toggle

switch

selects

the

channel

on

which

the

operator

will

communicate.

(This

switch

is

de-

feated

when

the

KB-I11A

is

mounted

in a P-Box.)

"Volume"

This

knob

adjusts

the

listen-level

for

the

speaker/headset.

"Speaker

On/Off"

This

toggle

switch

determines

the

activity

of

the

speaker.

''Mic

On/Off/

(On)"

This

three-position

toggle

switch

determines

the

activity

of

the

microphone

in

your

headset,

hand-

set,

or

gooseneck.

1>Then

the

swi

tch

is

set

to

the

top

"on"

position,

the

mic

remains

on.

When

it's

in

the

middle

position,

the

mic

is

off.

The

bottom

"(on)"

position

is

a

momentary

setting.

"Sidetone

Adj."

The

sidetone

control

enables

the

KB-111A

operator

to

adjust

the

level

of

his/her

voice

as

heard

in

the

Station's

speaker

or

headset,

allowing

up

to

35

dB

reduction

of

acoustical

pick-up-

You

need

only

adjust

the

sidetone

once

(if

at

all),

even

if

other

stations

subse-

quently

join

or

leave

the

intercom

system.

Adjusting

the

side

tone

does

not

affect

the

level

of

incom-

ing

or

outgoing

signals.

The

side

tone

control

is

inside

a

hole

next

to

the

Volume

knob.

Use

a

small

blade

screwdriver

for

ad-

justment.

At

the

factory

.

Clear-Com

sets

the

sidetone

to

be

approximately

6

dB

lower

than

incoming

signals.

If

you

want

to

change

this

level,

take

these

steps:

1)

plug

in

headset

2)

turn

on

mic

3)

turn

up

volume

all

the

way

4)

insert

screwdriver

into

hole

and

engage

the

slot

on

the

trimpot

inside

5)

begin

talking

into

mic

while

slowly

turning

screwdriver;

the

volume

of

your

voice

will

rise

or

drop.

When

using

both

the

headset

and

the

speaker,

set

the

sidetone

for

maximum

null

(you

can't

hear

yourself).

"Call"

The

black

push-button

activates

the

visual

signal

circuit

that's

stan-

dard

on

Clear-Com

intercoms.

It

allows

the

intercom

user

to

attract

the

attention

of

operators

who

have

removed

their

headsets

or

turned

off

their

speakers.

Call

signalling

follows

the

position

of

the

Channel

Select

switch;

for

instance,

if

you

are

using

Channel

A,

pressing

the

Call

button

activates

the

signal

circuitry

at

all

stations

that

are

assigned

to

Channel

A.

As

long

as

you

keep

the

button

pressed,

the

Call

circuit

will

stay

active.

The

Call

button

also

activates

the

speaker

and/or

mic

at

any

other

Station

(on

the

same

channel)

that

is

set

up

for

remote

control.

The

amber

Call

Lamp

illuminates

when

any

Station,

on

the

same

chan-

nel,

activates

a

Call

signal.

If

you

need

to

receive a Call

sig-

nal

from

the

channel

you're

not

using,

refer

to

the

special

modifi-

cation

diagram

on

page

9.

7

•

V.

KB-lllA

FRONT

PANEL

PARTS

LISTING

Schematic

Reference

Part"

Description

Qty.

210013

Connector,

D4M

1

210050

Connector,

1/4"

phone

jack

1

240015

Knob,

1/2"

with

1/8"

shaft

1

240020

Button

cover,

red

1

(510028-

switch,

snap-action)

250144

Panel,

front,

KB-l11A

1

280067

Nut,

dress

cone

2

280071

Nut,

1/4"

dress

2

390000

Lamp

cover,

amber

1

(390001-

bulb,

11387)

500089

Speaker,

3"

round

1

510006

Switch,

mini

toggle

1

510040

Switch,

mini

toggle

1

510044

Switch,

3-position

1

J2

Jl

P3

Sl

Call,

Channel

Select

Speaker

and

Mic

On/Off

11

SPI

Speaker

On/Off

Channel

Select

Mic

On/Off

IOn

VI.

KB-lllA

SPECIFICATIONS

AMPLIFIER DESIGN
Solid-state,

integrated

circuit

amplifiers

speaker

power

amp,

and

signalling

circuitry-

and

reverse

polarity

protection.

MIC

PREAMPLIFIER

Freq.

Response:

250-lZk

Hz,

with

mic

limiter;

contoured

to

enhance

intelligibility

Mic

Input:

200

ohms

Hic

Preamp

Gain:

31

dB

Hax

Input

Before

Clipping:

-20

dB

Hic

Limiter

Threshold:

-37

dBm

HEADSET/SPEAKER AMPLIFIER
Freq.

Response:

100-18k

Hz,

=2

dB

Load

Impedance

Range:

8-2000

ohms

(dynamic

headset)

Output

Level:

+20

dBm,

26v

p-p

@

100

ohms

Headset

Level:

>110

dB

SPL

with

standard

Clear~Com

headset

Speaker

Level:

>98

dB

SPL

@3

feet

Speaker

Type:

3"

round,

16

ohms

Power

Output:

4

watts

peak

Distortion:

0.5%

THD

@1kHz

Headphone

Amp

Gain:

40

dB

which

include a mic

preamp,

headset/

Current-limited

with

short

circuit

GENERAL

SPECIFICATIONS

Line

Level:

-20

dB

avg-, 0 dB

max.

Side

tone

Adj.:

35dB

null

to

full

on

Signal

Voltage:

IlVDC

on

audio

line

Call

Light

Sensitivity:

4

volts

Signal-to-Noise:

75

dB

Equivalent

Input

Noise:

-118

dB

Station

Bridging

Impedance:

>12k

ohms

(200-1Ok

Hz)

Voltage

Range:

12-32

volts,

28v

nominal

Power

Required:

25

ma

quiescent,

60

ma

talk,

60

ma

signalling,

200

ma

short

circuit

Dimensions

(front

panel):

8.6" x 6.5" x 3.25"

deep

CONNECTORS

Dynamic

Headset:

Male

D4M

Carbon

Headset:

1/

4"

phone

jack

Line:

5-screw

terminal

block

(portable

unit: 1 Male

D3M,

1

Female

D3F)

8

•

VII.

Special

Modification:

Signalling

Configuration

in

Multi-channel

Systems

In

normal

circumstances.

the

KB-

lllA

Call

Light

illuminates

when

someone

signals

on

the

channel

that

the

KB-lllA

operator

has

selected

for

communication.

This

is

because

the

visual

signal

travels.

in

the

form

of

DC

voltage.

on

that

chan-

nel's

line.

You

can

alter

this

configuration

by

making

the

modification

described

below.

In

our

application

(Figure

7).

a

group

of

two-channel

stations

Remote
Station

Remote

Station

(i.e

.•

KB-lllA)

have

selected

Chan-

nel B for

communication.

Yet

they

want

to

be

capable

of

receiving

a

Call

signal

from

stations

that

are

communicating

on

Channel

A.

This

is

achieved

by

putting

four

diodes

(914

type)

in

series

between

the

two

channels

on

the

intercon-

nect

cable.

Call

signalling

is

now

possible

from

Channel A to

Channel

B.

Since

the

Call

signal

follows

the

direction

of

the

diodes.

this

is

one-way

signalling;

Channel

B

cannot

send a signal

to

Channel

A.

FIGURE

7:

ALTERNATIVE

SIGNALLING

1 1

"-

TWO·CHANNEL

Ch.A

./

MAIN STATION

'.

or

j

POWER SUPPL Y

Ch

.B

..

"-,

./

ByA

B)"

B~f

Remote

Remote

Remote

DIODES (4)

914

Type

Station

2-Ch.

Station

2-Ch.

Station

2-Ch.

9

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