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 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.
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 . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INSTRUCTIONS Please read and follow these instructions before operating this product. 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.
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.
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.
Visual Signal Circuitry (Call Lights), a standard 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.
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, even under full load conditions. LED indicators signal a short or overload on either channel. The DC power output details are: • 1.2A continuous output • 2A peak output (not exceeding the 1.
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.
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.
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.
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.
BELDEN SHIELDED CABLES Trade # # of Pairs AWG & Stranding Nom. O.D. (inch) Nom. Cap. (pF/ft) 8412.000 1.000 20 (26x34) 0.268 8762.000 1.000 20 (7x28) 8760.000 1.000 1814A Shield Nom. D.C.R. (Ohms) Max.* Cable Run (ft) Recommended Application 30.000 5000.000 Portable 0.196 27.000 5000.000 Permanent (short) 18 (16x30) 0.222 24.000 5000.000 Permanent (long) 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.
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.
• 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.
interrupted by the announcement. Program audio feed to the Announce Output is selected by setting a jumper on the Main board to the ON position. The pinout of the Announce Out connector is as follows: • Pin 1 --- Ground (Shield) • Pin 2 --- - Signal • Pin 3 --- + Signal The audio output is balanced and transformer isolated. It has a 600 ohm impedance and a nominal output level of 0 dBu. A shielded twisted pair cable should be used in the cable wired to this connector.
• AC Power Connection: An IEC type 320 connector is provided on most Main Stations and Power Supplies to interface to the appropriate AC power cord to be used. Refer to the chart on the inside back cover of this manual. Main Stations and Power Supplies can either be switched between 115 or 230 VAC operation or will automatically adjust to voltages from 100 to 240 VAC at 50 or 60 Hz. Consult the User Manual for information on the particular unit.
KB-112/KB-212/KB-701 Speaker Station KB-112, KB-212 and KB-701 stations are all sucessive models of single channel speaker stations with similar functionality. In the following description the current model KB-701 is cited but the functionality is similar or identical on the earlier stations. The KB-701 Speaker Station provides intercom communication capability in places where wearing a headset is not feasible. It can be optioned for several remote control functions.
A Main Station, such as the MS-232 or MS-702can be configured to provide program audio on a channel but allow this audio to be interrupted whenever the Talk button for that channel is pressed. If a Remote Station, such as the RM-220 or RM-702 is used along with the Main Station in this configuration, it can be important to have the program audio interrupted by the operator of either station.
TYPICAL APPLICATIONS CABLE OR SCHOOL TELEVISION STUDIO Figure 1-7: Party Line Studio Application The typical Cable or School Television Studio installation shown in the preceding diagram is centered around a two-channel Main Station, which also powers the system. The Director operates this station and an Assistant Director operates a two-channel Remote Station. A line of single-channel beltpacks is connected to Channel A. The beltpacks are used by camera operators and floor managers.
signal can interrupt the program audio that feeds into the Remote Station. Talent and Announcers use Talent Receivers which are connected to Channel B. The Director and Assistant Director must be able to interrupt this program audio to cue the Talent and Announcers, so Channel B would be programmed as follows: • The Momentary Talk B option switch on the Main and Remote Stations must be set to the ON (down) position. This will cause the Channel B Talk button to have a momentary only action and not latch.
THEATRE 1 Figure 1-8: Party Line Theatre Application Example 1 In the preceding diagram of a typical Theatre installation, the Stage Manager operates a two-channel Main Station, which also powers the system. Several single-channel beltpacks are connected to Channel A. The beltpacks are used by curtain, spot, patch panel, and light board operators. Communication between these people and the Stage Manager is on Channel A. Some Main Stations contain a Tone Alert function.
audio is to be interrupted by communication from the Stage Manager, then the Channel A On-Off-Interrupt switch should be set to the INTERRUPT position. If stage microphone audio should be heard on Channel A at all times, the On-Off-Interrupt switch should be set to the ON position. If it is not desirable to have audio from the stage microphones on this intercom channel, the On-Off-Interrupt switch should be set to the OFF position.
THEATRE 2 Figure 1-9: Party Line Theatre Application Example 2 In this example of another typical Theatre installation, the Stage Manager operates a two-channel Main Station, which also powers the system. Several single-channel beltpacks are connected to Channel A. The beltpacks are used by props and scenery people. Communication between these people and the Stage Manager is on Channel A. Several single-channel beltpacks are also connected to Channel B.
Announce button on the Main Station to communicate with the people in these rooms. When this happens, the audio from the stage is interrupted automatically. As long as the Stage Manager does not have a Talk set, the announcement is heard only by the people in the Green Room, Hallways, and Dressing Rooms, but not by the people on intercom Channels A or B. To adjust the stage announce and program levels, use the following steps: 1.
ENG/EFP TRUCK Figure 1-10: Party Line Eng/EFT Truck Application In the preceding diagram of a typical ENG/EFP Truck installation, a 2-Channel Main Station powers the intercom system. The Director operates the Main Station, and an Engineer operates the Remote Station. A line of single-channel beltpacks is connected to Channel A and are used by camera operators and floor managers. Communication between these people and the Director is on Channel A.
Program Input jack, the Program Level controls on the Main Station have no effect. Channel B is connected to a Talent Receiver for Talent or an Announcer. Program feed audio from the studio feed can be heard by the Director and Engineer, as well as the Talent or Announcer. The Call on Talk B and Momentary Talk B options switches on the Main and Remote Stations would be set to the ON (down) position .
SYSTEM CHECKOUT Before you turn on the power, perform the following tests: CHECK TERMINATION There should be one and only one termination for each channel in the system. This termination is usually set to ON at the Main Station or Power Supply. To ascertain that only one termination is present on the channel, perform the following test: Note: The location of the termination switch varies with model.
FINAL TESTS After you turn the power ON: 1. Check for proper voltage on pin 2 of any intercom line or jack in a channel. It should read 26-30 Volts. 2. Test for proper operation of Call Signaling. Activate the Call Signal on any beltpack or station. The call light on the Main Station should illuminate and then go out when the call button is released. If enabled, the Tone Alert should sound. Activate the Call Signal on the Main Station.
TROUBLESHOOTING PROBLEM: Cause 1: Solution 1: Cause 2: Solution 2: PROBLEM: Cause 1: Solution 1: Cause 2: Solution 2: PROBLEM: Cause 1: Solution 1: Cause 2: Solution 2: PROBLEM: Cause 1: Solution 1: Cause 2 Solution 2: System does not operate. No power to Main Station or Power Supply. Green POWER LED is not illuminated and no SHORT LED's are illuminated No AC power to the Main Station or Power Supply. Make sure the power switch on the rear panel is turned ON. Check AC connection and cable.
Warning:This is a potentially dangerous situation. A shock hazard may exist between the metal boom of a Remote Station headset and ground. PROBLEM: Cause 1: Solution 1: Cause 2: Solution 2: Cause 3: Solution 3: Cause 4: Solution 4: PROBLEM: Cause 1: Solution 1: Cause 2: Solution 2: Cause 3: Solution 3: Excessive crosstalk High DC resistance in ground return. Use heavier cable; add additional conductor(s) to ground return. MULTI-CHANNEL cable pairs are not individually shielded.
GLOSSARY Some of the terms used when discussing critical communications for television or theatre may be new to you as they are unique to intercom applications. Although many of the terms are common to other audio applications, to be certain you understand their meanings we offer the following definitions: All Call: Ability to push one button from the Main Station and talk to all channels at once on a multiple channel system.
EFP: Electronic Field Production. An EFP truck contains the necessary audio, video, intercom, and other equipment to create these productions. ENG: Electronic News Gathering. An ENG truck contains the necessary audio, video, intercom, communications, and other equipment to effectively support gathering news and transmitting news reports back to a studio. IFB: The term means "Interrupt Fold Back.
to speak privately to any one of the six, add a second channel. You now have a seven-station, two-channel system. Termination: Passive network that is connected in each channel, usually on the Power Supply or Main Station.
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2 CONFIGURATION OPTIONS PARTY LINE PRODUCTS The following table provides information on Party Line products indicating which model numbers have similar functionality to assist in upgrading existing systems where the current products are no longer available. As the functionality of the equivalent products may be slightly different the user should check the product manuals for details.
DESCRIPTION ENCORE PRODUCT PARTY LINE PRODUCT 2-Channel Wall Mount Headset Station HB-702 MR-202 4-Channel Wall Mount Headset Station HB-704 MR-704 2-Channel Power Supply PS-702 PS-232 4-Channel Power Supply PS-704 PS464 Program Interrupt Controller PIC-4704 PIC-4000 System Interface TWC-12C TWC-12B 4-Wire Interface IF4W4 IF4B-2 IF4B-4 2-Channel Intercom Adapter TWC-701 4-Channel Intercom Adapter TWC-704 2-Way Radio Interface TW-47 TW-40 Party Line to 4-Wire Interface EF-701M
PROGRAM AUDIO TO ANNOUNCE OUTPUT OPTION The MS-232, MS-440, RM-440, and SB-440 products include the Program Audio to Stage Announce Output option. This option allows audio from the main Program Audio input to be routed through the Stage Announce output. Pressing the Announce button interrupts this audio and instead routes audio from the selected panel or headset microphone through the Stage Announce output. This facility is also available as standard on the MS-702, MS-704, RM-704 and SB-704 products.
In the preceding diagram of a typical Theatre installation, the Stage Manager operates a two-channel Main Station, which also powers the system. Several single-channel beltpacks are connected to Channel A. The beltpacks are used by props and scenery people. Communication between these people and the Stage Manager is on Channel A. Several single-channel beltpacks are also connected to Channel B. The beltpacks are used by sound, light board, patch panel, and spot operators.
in all cases. The benefit of this option is that it adds an additional channel of communication from the Stage Manager. SETTING THE OPTION The setting for the Program Audio to Stage Announce option is an internal jumper which may be positioned in either an ON or an OFF position. Products containing this option are shipped from the factory with the option turned OFF.
Figure 2-3: MS-702 Jumpers • In the MS-440, MS-704, RM-440, RM-704, SB-440 and SB-704 stations, the jumper is located near the middle of the main circuit board. J11 should be set to ON to enable the option or OFF to disable it. SYSTEM SETUP After connecting the MS-232, MS-702, MS-440, MS-704, RM-440, RM-704, SB-440 or SB-704 Station, perform the following steps to assure that the audio level will be correct at each listening point: 1.
3 ADDENDUM: POWER CORDS For proper selection of power supply cord, depending upon country of destination, see the figure below.
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LIMITED WARRANTY This document details the Clear-Com Standard Limited Warranty for all new products for sale within all regions with the exception of Military, Aerospace, and Government (MAG). EXCEPT AS SET FORTH HEREIN ("LIMITED WARRANTY"), CLEAR-COM MAKES NO OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF MERCHANTABILITY, NONINFRINGEMENT OF THIRD PARTY RIGHTS, OR FITNESS FOR A PARTICULAR PURPOSE, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. 1.
(5) All software products, including Concert (Client and Server), ECS, Production Maestro and Logic Maestro are warranted for one year and shall substantially conform to published specifications. The media on which the Software is furnished is warranted to be free of defects in material and workmanship (under normal use) for a period of one year. (6) Any Clear-Com products that are listed within the last time buy period have the same Limited Warranty for their type 1.i 1 - 1.i.5 as above.
h) Software Upgrades i) Software Upgrades include new Features and/or Functional Enhancements and are not included as part of the Standard Warranty but may be purchased at the published rates. ii) Note: In the absence of a Software Update containing a program correction and no available workaround to mitigate the problem, at the discretion of Service, Sales, Engineering, or Product Management, the Customer may be provided a Software Upgrade under warranty. 2. Exclusions.
iv Clear-Com Communication Systems Standard Limited Warranty
TECHNICAL SUPPORT & REPAIR POLICY NOVEMBER 1, 2008 In order to ensure that your experience with Clear-Com and our World Class products is as beneficial, effective and efficient as possible, we would like to define the policies and share some "best practices" that can accelerate any problem solving processes which we may find necessary and to enhance your customer service experience. Our Technical Support, Return Material Authorization, and Repair Policies are set forth below.
Days: Tel: Email: iii) Asia-Pacific: Hours: Days: Tel: Email: Monday - Friday +49 40 853 999 700 TechnicalSupportEMEA@vitecgroup.com 0800 - 1700 Pacific Time Monday - Friday +1 510 337 6600 CustomerServicesAPAC@vitecgroup.com d) Email Technical Support is available for all Clear-Com branded products free of charge for the life of the product, or two years after a product has been classified as obsolete, whichever comes first.
d) Damaged equipment will be repaired at the Customer's expense. e) Returns are subject to a 15% restocking fee. f) Advance Warranty Replacements (AWRs); i) During the first 30 days of the Standard Warranty Period: Once the equipment fault has been verified by Clear-Com or its authorized representative, Clear-Com will ship a new replacement product.
vii) Note: Shipping charges, including duties, taxes, and insurance (optional), to Clear-Com's factory is the responsibility of the Customer. Shipping AWRs from Clear-Com is at Clear-Com's expense (normal ground or international economy delivery). Requests for expedited shipping (E.g. "Next-Day Air") and insurance are the responsibility of the Customer.
the cost of repair, the Customer may elect to return the product to the factory for an estimate. The Customer is responsible for shipping costs both to and from the factory in the event they choose not to accept the estimate. v) The Customer must provide either a purchase order for the repair work, or will be required to make an advance payment (as a debit against the Dealer's line of credit, or credit card) prior to the repaired product being returned to the Customer.
