Clear-Com Encore, TW-40, TW-47, KB-112, KB-212 Instruction Manual

...
CLEAR-COM ENCORE
SYSTEM INSTALLATION
INSTRUCTION MANUAL
Encore System Installation Instruction Manual © 2009 Vitec Group Communications Ltd. All Rights Reserved.
Part Number 810229Z Rev. 4 Vitec Group Communications LLC
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.
Website: www.clearcom.com
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
The Clear-Com Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Power Distribution and Short Circuit Protection . . . . . . . . . . . . . . . .1-2
Installing an Intercom System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Single-Channel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Multi-Channel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Crosstalk Considerations in a Multi-Channel System. . . . . . . . . .1-6
Intercom Cable Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Installing the StatioNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Configuring Clear-Com Products to Work Together . . . . . . . . . .1-12
TW-40/TW-47 Two-Way Radio Interface. . . . . . . . . . . . . . . . .1-12
KB-112/KB-212/KB-701 Speaker Station . . . . . . . . . . . . . . . .1-13
RM-220/RM-702 Remote Station . . . . . . . . . . . . . . . . . . . . . .1-13
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Cable or School Television Studio. . . . . . . . . . . . . . . . . . . . . . . .1-15
TheatrE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Theatre 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19
ENG/EFP Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Check Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Check Intercom Cable Resistance . . . . . . . . . . . . . . . . . . . . . . .1-23
Final Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
After you turn the power ON:. . . . . . . . . . . . . . . . . . . . . . . . . .1-24
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-25
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
Clear-Com Communication Systems Encore System Installation Instruction Manual
CONFIGURATION OPTIONS . . . . . . . . . . . . . . . . . 2-1
Party Line Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
PROGRAM AUDIO TO ANNOUNCE OUTPUT OPTION. . . . . . . . .2-3
Theatre Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Setting the Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
i
ADDENDUM: POWER CORDS. . . . . . . . . . . . . . . . 3-1
LIMITED WARRANTY. . . . . . . . . . . . . . . . . . . . . . . W-I
TECHNICAL SUPPORT & REPAIR POLICY. . . . . W-V
TECHNICAL SUPPORT POLICY. . . . . . . . . . . . . . . . . . . . . . . . . . W-v
RETURN MATERIAL AUTHORIZATION POLICY . . . . . . . . . . . . .W-vi
REPAIR POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W-viii
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Encore System Installation Instruction Manual
Clear-Com Communication Systems
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.
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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.
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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
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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.
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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.
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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
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BELDEN SHIELDED CABLES
Trade
#
8412.000 1.000 20 (26x34) 0.268 30.000 5000.000 Portable
8762.000 1.000 20 (7x28) 0.196 27.000 5000.000 Permanent
8760.000 1.000 18 (16x30) 0.222 24.000 5000.000 Permanent
1814A 2.000 22 (7x30) 0.319 31.000 3.9 Ω/M' 1500.000 Permanent 1815A 4.000 22 (7x30) 0.384 31.000 3.9 Ω/M' 1500.000 Permanent 1817A 8.000 22 (7x30) 0.503 31.000 3.6 Ω/M' 1500.000 Permanent 1818A 12.000 22 (7x30) 0.889 31.000 3.4 Ω/M' 1500.000 Permanent
# of
Pairs
AWG &
Stranding
Nom. O.D.
(inch)
Nom. Cap.
(pF/ft)
Shield
Nom. D.C.R.
(Ohms)
Max.* Cable
Run (ft)
Recommended
Application
(short)
(long)
Table 1-1: Belden Shielded Cables
Note: For better than 50 dB channel crosstalk
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
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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
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• 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
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Encore System Installation Instruction Manual
Clear-Com Communication Systems
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