Part Number 810229Z Rev. 4
Vitec Group Communications LLC
850 Marina Village Parkway
Alameda, CA 94501
U.S.A
Vitec Group Communications Ltd
7400 Beach Drive
IQ Cambridge
Cambridgeshire
United Kingdom
CB25 9TP
The Vitec Group plc
Beijing Representative Office
Room 706, Tower B
Derun Building, YongAn Dongli A No.3
Jianwai Ave., Chaoyang District
Beijing, P.R.China 100022
® Clear-Com, CellCom/FreeSpeak and the Clear-Com Communications Systems logo are registered trademarks of
The Vitec Group plc.
Please read and follow
these instructions
before operating this
product.
IMPORTANT SAFETY
INSTRUCTIONS
1. Read these instructions.
2. Keep these instructions.
3. Heed all warnings.
4. Follow all instructions.
5. Do not use this apparatus near water.
6. Clean only with dry cloth.
7. Do not block any ventilation openings. Install in accordance with the
manufacturer’s instructions.
8. Do not install near any heat sources such as radiators, heat
registers, stoves, or other apparatus (including amplifiers) that
produces heat.
9. Do not defeat the safety purpose of the polarized or grounding-type
plug. A polarized plug has two blades, with one blade wider than
the other. A grounding-type plug has two blades and a third
grounding prong. The wide blade or the third prong are provided for
your safety . If the provided plug d oes not fit into your o utlet, consult
an electrician for replacement of the obsolete outlet.
10. Protect the power cord from being walked on or pinched
particularly at plugs, convenience receptacles, and the point where
they exit from the apparatus.
11. Only use attachments/accessories specified by the manufacturer.
12. Use only with the cart, stand, tripod, bracket, or table specified by
the manufacturer , or sold with the app aratus. When a cart is used,
use caution when moving the cart/apparatus combination to avoid
injury from tip-over.
13. Unplug this apparatus during lightning storms or when unused for
long periods of time.
14. Refer all servicing to qualified service personnel. Servicing is
required when the apparatus has been damaged in any way, such
as power-supply cord or plug is damaged, liquid has been spilled
or objects have fallen into the apparatus, the apparatus has been
exposed to rain or moisture, does not operate normally, or has
been dropped.
15. WARNING: To reduce the risk of fire or electric shock, do not
expose this product to rain or moisture.
Clear-Com Communication Systems
Encore System Installation Instruction Manual
Please familiarize yourself with the safety symbols in Figure 1. When
you see these symbols on this product, they warn you of the potential
danger of electric shock if the speaker station is used improperly. They
also refer you to important operating and maintenance instructions in
the manual.
i
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
This symbol alerts you to the presence of uninsulated dangerous
voltage within the product's enclosure that might be of sufficient
magnitude to constitute a risk of electric shock. Do not open
the product's case.
This symbol informs you that important operating and maintenance instructions are included in the literature accompanying
this product.
Figure 1: Safety Symbols
EMC AND SAFETY
The Clear-Com Encore product line meets all relevant CE, FCC, UL,
and CSA specifications set out below:
EN55103-1 Electromagnetic compatibility. Product family standard for
audio, video, audio-visual, and entertainment lighting control app aratus
for professional use. Part 1: Emissions.
EN55103-2 Electromagnetic compatibility. Product family standard for
audio, video, audio-visual, and entertainment lighting control app aratus
for professional use. Part 2: Immunity.
UL 60065-7, CAN/CSA-C22.2 No.60065-3, IEC 60065-7 Safety
requirements.
And thereby compliance with the requirement of Electromagnetic
Compatibility Directive 2004/108/EC and Low Voltage Directive
2006/95/EC
This device complies with Part 15 of the FCC Rules. Operation is
subject to the following two conditions: (1) this device may not cause
harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.
ii
Encore System Installation Instruction Manual
Clear-Com Communication Systems
1
INTRODUCTION
Congratulations on choosing Clear-Com products. Clear-Com was
established in 1968 and remains the market leader in providing
intercom for entertainment, educational, broadcast and industrial
applications. The ruggedness and high build-quality of Clear-Com
products is the industry standard. In fact, many of our original
beltpacks and Main Stations are still in daily use around the world.
We recommend that you read through this manual completely t o better
understand how to install your intercom system. Please p ay p art icular
attention to the section on system wiring, as improper wiring detracts
from the performance of the system or causes system failure. If you
encounter a situation or have a question that this manual does not
address, contact your dealer or call Clear-Com direct at the factory.
Our applications support and service people are standing by to assist
you. Thank you for selecting Clear-Com for your communications
needs.
THE CLEAR-COM CONCEPT
Clear-Com is a closed-circuit intercom system that consistently
provides high-clarity communication in both high-noise and low-noise
environments. A basic system consists of a single- or multi-channel
Power Supply or Main Station connected to various single- or
multi-channel Remote Stations, such as beltpacks and loudspeaker
stations.
Clear-Com is a distributed amplifier system; each Main or Remote
Station houses its own microphone preamplifier, headset or speaker
power amplifier, and signaling circuitry. Stations bridge the intercom
line at a very high impedance and place a minimum load on the line.
The audio level always remains constant, and does not fluctuate as
stations leave and join the system. Low-impedance mic input lines
and specially designed circuitry make Clear-Com channels virtually
immune to RFI and dimmer noise.
Clear-Com stations are interconnected with two-conductor, shielded
microphone cable (or individually shielded multi-pair cable as
required). Portable stations are connected with 2 conductor cables
with 3-pin XLR connectors. One wire, connected to pin 2, carries the
DC power from a Main S tation or Power Supply to all Remote S tations.
The other wire, connected to pin 3, carries the 2-way (duplex) audio
information. The shield, connected to pin 1, acts as a common ground.
One termination per channel is needed throughout the intercom
network, and is usually located in the Main Station or Power Supply.
Clear-Com Main Stations, Power Supplies and certain Remote
Stations each have an auxiliary program input with its own volume
control, which allows an external audio source to be fed to the intercom
system.
Clear-Com Communication Systems
Encore System Installation Instruction Manual
1-1
Visual Signal Circuitry (Call Lights), a st anda rd feature on all Main and
Remote Stations, allows the user to attract the attention of operators
who have removed their headsets. Certain stations also have an
audible Tone Alert feature which can be useful for this purpose.
Clear-Com manufactures a wide variety of both portable and
fixed-installation units. All are compatible with each other. Clear-Com
intercom systems can also interface with other communication
systems and devices.
POWER DISTRIBUTION AND SHORT CIRCUIT PROTECTION
A Main Station or Power Supply is the heart of an intercom system. It
has special features which are not found in traditional designs. It must
supply low-noise DC current to multiple intercom lines. It must
continue to operate in adverse conditions such as low AC line volt age,
momentary shorts on the DC power lines to the stations, and
excessive peak loads during power-on conditions.
Use the chart on this page to determine how many Speaker Stations
and Beltpacks can be powered in varying combinations by a Main
St ation or Po wer Supply. Additional power supplies can be connected
for additional power capability if required by the application. The
current requirements of Clear-Com Remote Stations and Beltpacks
vary with model and use. A station which is simply '"on" and not being
used may draw only a small amount of current. Contact your dealer or
Clear-Com if you require further assistance in determining the overall
current requirements of your system.
1-2
Figure 1-1: Power Supply Loading
For example, the MS-702 provides DC power to operate Clear-Com
beltpacks and remote stations. The power is distributed between the
two channels and will support up to 40 RS-601 beltpacks or 10
speaker stations or 12 headset stations.
Encore System Installation Instruction Manual
Clear-Com Communication Systems
Clear-Com’s fail-safe design automatically shuts down the power to a
channel when a short circuit or electronic overload is sensed on that
channel. The other channel will continue to operate normally. Once the
fault condition is removed, the MS-702’s fail-safe circuit will restore
power, eve n under full load conditions. LED indicators sign al a short or
overload on either channel.
The DC power output details are:
• 1.2A continuous output
• 2A peak output (not exceeding the 1.2A rating for more than 2
seconds per 1 minute period)
The station internal power supply senses the difference between
short-term and long-term shorts and overload conditions. Af ter the first
few times a short or overload occurs, the power supply will try to
restore power after only 0.5 seconds. If the short or overload persists
or occurs repeatedly, the power supply will take progressively longer
(to a maximum of 20 seconds) to try to restore power. This protects the
power supply from damage due to overheating. Once the short is
removed, the channel will recover, even under a full load condition.
The automatic power restore times are shown in the following chart:
20
19
18
17
16
20
Number of
seconds to
restore
20
10
14
121314 15
11
15
10
7
5
0.5
0
2
0
1
4
2
67
4
3
5
Number of recent shorts or overloads
9
8
Figure 1-2: Automatic Power Restore Times
Shorts are generally caused by miswiring or damaged cables.
Overloads are generally caused by connecting too many beltpacks
and stations to a channel.
INSTALLING AN INTERCOM SYSTEM
Clear-Com Communication Systems
Encore System Installation Instruction Manual
When considering how to install and wire an intercom system, several
factors must be taken into account. These include the number of
stations, the length of the cable runs and whether single or multiple
1-3
channels are required. If multi-channel stations are connected with
multi-pair cables, then crosstalk becomes an important issue.
Crosstalk is not a factor with single-channel systems or multi-channel
systems where each channel is run on its own individual cable to
single-channel Remote Stations. While the physical considerations
include ease of installation, type of cabling, station location, etc., the
electrical considerations are concerned primarily with the capacitance
between conductors on the intercom line, and the DC resistance in th e
ground return of the intercom line.
Note: PIN 1 and the shell of the XLR plug on the interconnect
cables should NOT be connected together.
Excessive resistance in the conductors of the cable results in a loss o f
sidetone null at Remote Stations, and some overall loss of level.
Excessive resistance in the ground conductor or shield greatly
increases crosstalk between channels. This can significantly affect the
performance of multi-channel systems.
SINGLE-CHANNEL SYSTEM
In a single-channel system, there are two general methods of wiring
Remote Stations to the Power Supply. Any one method may be used
exclusively in a small system, and both may used in various
combinations for a larger system.
1. Daisy Chain: Remote stations are wired from one station to the
next and so on along each line connected to a Main Station. This
requires the least amount of cable, but may be impractical due to the
system layout. Also, if a break occurs in the line, all stations down
line of the break will be disconnected from the party line.
1-4
Figure 1-3: Party Line Daisy Chain
2. Hub or Star: Each Remote Station is wired directly back to a Main
Station or to a split of a line wired directly to a Main Station.
Encore System Installation Instruction Manual
Clear-Com Communication Systems
Figure 1-4: Party Line Hub Configuration
MULTI-CHANNEL SYSTEM
In a multi-channel system where each channel is run on its own cable
and connected only to single channel Remote Stations as in the
following diagram, there are no crosstalk issues because the channels
do not share a common ground. Consult the table in the next section
for cable recommendations.
Clear-Com Communication Systems
Encore System Installation Instruction Manual
Figure 1-5: Multi-Channel Party Line
It is also important to centrally locate the multi-channel Main Station or
Power Supply containing the termination. Crosstalk does not exist at
the termination point, but can increase in proportion to the length of the
wiring to multi-channel stations. If the termination is centrally located
and the wiring length guidelines in the following section are adhered to,
then crosstalk will be at a minimum.
1-5
CROSSTALK CONSIDERATIONS IN A MULTI-CHANNEL SYSTEM
In a multi-channel system where multiple channels are run from a Main
Station to a Remote Station as in the following diagram, crosstalk can
be an issue. This is because the channels will share a common
ground at both ends of the cable run.
Figure 1-6: Party Line Multi-Channel Configuration
When multiple channels are fed to Remote Stations, the amount of
crosstalk between channels is proportional to the DC resistance o f the
ground return path back to the channel terminations. To minimize this
crosstalk between channels when running more than one channel in a
multi-pair cable, keep the DC resistance of the ground retu rn as low as
possible. Ideally, this should be less than 2 Ohms. This can be
achieved as follows:
• Keep cable runs under 500 feet. If a longer cable run is
unavoidable and approaches 1000 feet or more, make sure
the appropriate lone line option switches or jumpers are set in
the stations. Refer to the individual station manuals for
further information.
• Use a cable whose common shield has a low DC resistance.
• Connect unused cable wires of a multi-pair cable to the Pin 1
shield.
Note: All multi-pair cables must have individually shielded pairs.
Clear-Com recommends the Belden 1800 Series of multi-pair cables.
They offer a common shield with a low DC resistance in addition to
individual shields on each pair.
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Encore System Installation Instruction Manual
Clear-Com Communication Systems
The performance of a Clear-Com system depends upon the use of
Clear-Com or Clear-Com approved compatible headsets. Use of
headsets other than these can induce crosstalk into a multi-channel
system through the headset cable. Clear-Com also recommends
against the use of headset extension cables or headset "Y" cables, as
they will increase crosstalk into a multi-channel system.
INTERCOM CABLE CONSIDERATIONS
The Clear-Com intercom line is intended to run on one shielded cable
pair per intercom channel. One conductor carries audio, and the other
conductor carries the DC power for Remote Stations. The shield
serves as the ground return for the audio and power conductors.
When choosing interconnect cable, keep the following considerations
in mind:
• Keep cable runs under 500 feet. The DC resistance of the
ground or common conductor affects crosstalk. For
permanent installation runs longer than 500 feet, do not use
wire smaller than 20 gauge. The capacitance of the
interconnect cable affects system frequency response and
sidetone stability. Total capacitance should not be greater
than 0.25 uF.
• Ground Isolation: The Pin 1 ground connection of each
XLR connector must be isolated from the chassis. Pin 1
should not be connected to the shell of the XLR connector.
• Multi-pair Cable: Individually shielded multi-pair cable is
acceptable for use in multi-channel systems. For crosstalk
considerations the shields must be tied together on both ends
of the cable to produce the lowest possible DC resistance
path for the ground return.
• Suggested Cable Types: The following chart lists the
specifications of various BELDEN cables:
Clear-Com Communication Systems
Encore System Installation Instruction Manual
• Portable Installation Cable: Practical cable for portable
system interconnections is flexible, two-conductor, shielded
microphone cable. We suggest using BELDEN #8413 (24
Gauge). For runs longer than 500 feet use a 20 gauge cable
or larger (BELDEN #8412).
• Permanent Installation Cable: Vinyl-jacketed shielded pair
is the cable of choice for permanent installations. Placing the
cable in conduit is recommended but not necessary.
INSTALLING THE STATIONS
First, choose the location for the Main Stat ion or Power Supply. These
units require access to AC power. They should be located away from
other equipment that generates excessive amounts of heat. Also,
choose locations for each Remote Station and Speaker Station.
Choose general locations and areas of use for the beltpacks.
Determine the locations for other Clear-Com equipment which will
connect to the intercom lines. The choice of location will depend upon
and often define the wiring scheme. It is very helpful to create a
drawing showing where each component will be located as well as
where the wiring will run.
CONNECTIONS
The following sections describe the connections provided on the
intercom stations:
• Intercom Line Connection: The rear panel of Main Stations,
Power Supplies, Remote Stations, and other stations contain
between one and three 3-pin male XLR connectors for each
1-8
Encore System Installation Instruction Manual
Clear-Com Communication Systems
intercom line. These connectors are wired in parallel. Any
single-channel station or channel of a multi-channel station
connected on a line plugged into Channel A of the a Main Station
will be "party-lined" with all the other stations on that channel. In
a multi-channel system, the goal is to assign specific people to
the correct group, i.e. the other people they need to be in contact
with the most. This is particularly important when the party line
users are on a single-channel beltpack or station; less so if they
are on multi-channel stations. The pinout of the intercom
connectors is as follows:
• Pin 1 --- Ground (Shield)
• Pin 2 --- Power
• Pin 3 --- Audio
• Line Termination: The fundamental concept of Clear-Com
Party-Line intercom is that all channels are terminated in one
location, preferably at a Main Station or Power Supply.
Note: All intercom lines must be terminated. Care must be taken
not to '"double-terminate" a line. All unused intercom lines
must also be terminated.
Switching of the channel terminations ON and OFF is done with
switches or jumpers on the Main Station. In most systems, the
terminations should be in the ON position (default setting).
Clear-Com Power Supplies also provide switch-selectable
termination networks on all intercom lines. Refer to the User
manual for the specific Main Station or Power Supply for the exact
location. It is up to the user to ensure that the terminations are set
correctly . An unterminated line will cause excessive levels, possible
oscillation of line drivers, and squealing in the headsets. An
intercom line with double or multiple terminations will cause low
levels and the inability to null the headsets.
The termination switches on a Main S tation should be set to the OFF
position only if the channel is terminated by another Main Station or
Power Supply in the system. If there are no other Main Stations
or Power Supplies terminating the line, the termination switch
on each channel of the Main Station should be switched to ON.
Clear-Com Communication Systems
Encore System Installation Instruction Manual
• Headset Connector: The headset connector is located on the
front panel of all stations. Clear-Com headsets are
recommended, but others can be used if they meet the following
requirements:
• Mic Type --- Dynamic; 150 to 250 ohms impedance; -55 dB
output level
• Headphone --- Dynamic; 50 to 2000 ohms impedance
The wiring of the headset is to be as follows:
• Pin 1 --- Mic common
1-9
• Pin 2 --- Mic hot
• Pin 3 --- Headphone common
• Pin 4 --- Headphone hot
The mic and headphone wiring in the headset cord must be
individually shielded. Do not connect Pins 1 and 3 together.
Headset extension cords or headset "Y" cables are not
recommended because they will increase crosstalk between
channels.
• Panel Mic Connector: Clear-Com recommends the GM-9 and
GM-18 plug-in panel microphones for use with all stations having
a panel mic connector . The GM-9 is 9 inches long and the GM-18
is 18 inches long. The microphone is an electret type. The 1/4
inch phone jack on the microphone mates with the Panel Mic
receptacle on the front panel.
To install a GM-9 or GM-18 microphone, use the following steps:
1. Check the set screw in the mic mounting flange to make sure it
is clear of the threads in the bushing.
2. Screw the microphone into the bushing hand tight.
3. Set the set screw on top of the bushing to lock the microphone in
place.
• Hot Mic Out / IFB System: Some Main and Remote Stations
have an interface to the External Line In jack on Clear-Com's IFB
System. This connection is a 1/4 inch phone jack on the rear
panel. It provides a 0 dBu output signal from the selected
headset or panel microphone on the station. It connects using a
standard 2-wire and shield stereo 1/4 inch plug-to-plug cable
such as the Clear-Com P/N 73016501 (18 inch) or P/N 73016502
(5 foot). It allows the station's microphone to be used to cue
talent through the IFB System. A control signal sent into this
connector from the IFB System can optionally disconnect the
station's microphone from the intercom line(s). The jack is wired
as follows:
• Ring --- Ext. IFB Control Signal Input
• Tip --- Hot Mic Audio Output
• Sleeve --- Ground (Shield)
• Stage Announce Output: Some Main and Remote Stations
have a 3-pin XLR male connector on the rear panel to feed into a
studio PA. Pressing the Announce button on the front panel
places the audio from the selected headset or panel microphone
on the rear panel connector. Optionally, pressing the Announce
button can also disconnect the selected headset or panel
microphone from the intercom line(s). This option is controlled by
the Interrupt Announce option switch. Simultaneously, if the
program audio feed to the Announce Output is enabled, it is
1-10
Encore System Installation Instruction Manual
Clear-Com Communication Systems
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