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PS-232
2-CHANNEL POWER SUPPLY
INSTRUCTION MANUAL
2002 Clear-Com Intercom Systems
All Rights Reserved
Part Number 810277 Rev. A
Clear-Com Intercom Systems
4065 Hollis Street
Emeryville, CA 94608-3505
U.S.A
Clear-Com is a registered trademark of Clear-Com Intercom Systems.
The Clear-Com Logo is a registered trademark of Clear-Com Intercom Systems.
Clear-Com PS-232 Power Supply
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 produce heat.
9
Do not defeat the safety purpose of the grounding-type plug. A grounding type plug has two
blades and a third grounding prong. The third prong is provided for your safety. If the provided
plug does not fit into your outlet, 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 Unplug this apparatus during lightning storms or when unused for long periods of time.
13 Refer all servicing to qualified service personnel. Servicing is required when the apparatus has
been damaged in any way, such as if the power-supply cord or plug is damaged, liquid had
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.
14 Do not expose the apparatus to to dripping or splashing and do not place opjects filled with liquids, such as vases, on the apparatus.
WARNING: To reduce the risk of electric shock, do not expose this apparatus to rain
or moisture .
1
Clear-Com PS-232 Power Supply
QUICK START
1
Unpack the unit and inspect for any damage that may have occurred in shipping. Connect the
proper AC Mains cable to the outlet on the rear panel.
2
Install the PS-232.
3
Connect the intercom lines and Program Input as required. Connect the AC cord to the Mains
circuit.
4
Set the two termination switches on the rear panel to ON.
5
Switch the Power ON. The green power light should be ON and the two red overload lights
should be OFF.
6
Switch the Test Tone and A+B Link switches OFF. The yellow A+B Link light should be off.
7
Select program sends and set program levels as required using Program Trim and Program
Send Level controls.
8
Set levels and sidetone nulls at remote stations.
9
The intercom system should now be operating properly.
10 Read the rest of this manual for further information.
OPERATION
Congratulations on choosing this Clear-Com product.
The PS-232 Power Supply is a powerful, yet user friendly unit that can serve as the heart of a ClearCom system.
We recommend that you read through this manual completely to better understand the functions of the
PS-232 and how to optimize your system setup. Please pay particular 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 ready to help.
Description
The Clear-Com PS-232 is a single rack space, one- or two-channel intercom power supply which can
provide 1 amp (2 amps peak during call signals and other temporary events) at 30 Volts DC to operate
Clear-Com beltpacks and remote stations. This power is supplied to either or both channels, and will
support up to 40 headset stations or 15 speaker stations. Clear-Com's advanced fail-safe design can
sense the difference between a short or an overload to optimally protect itself. Power is restored in as
quickly as 1/2 second, depending upon whether there was a single or multiple short or overload. The
other channel continues to operate normally. The PS-232's advanced fail-safe circuit will bring the
power back up even under full load conditions. LED indicators signal a fault on either channel. A linelevel program input offers a master input level. Individual program selects, each with its own send level,
are provided for each channel. Use of a switching power supply allows the PS-232 to operate with
any AC line voltage from 90 to 240 Volts AC at 50 or 60 Hz. The unitized aluminum chassis and extrathick front panel with integral rack ears result in reduced size and a lighter weight package that maintains legendary Clear-Com ruggedness.
Advanced Fail Safe Power Scheme
As the heart of an intercom system, the power supply has special needs which are not met by traditional
designs. It must work in adverse conditions such as low AC line voltage, momentary or continuous
2
Clear-Com PS-232 Power Supply
shorts on the DC power lines to the stations, and excessive peak loads during power-on and sometimes
during use. The mission of an intercom power supply is torn between giving its all to provide power in
the face of these adverse conditions and protecting itself from them. This mission finds an intelligent
balance in the PS-232. The following features are incorporated into the PS-232 power supply to make it
quickly react to shorts and overloads yet provide a long, reliable product life:
AUTOMATIC SHORT CIRCUIT PROTECTION: The microprocessor in the PS-232 checks each
channel for a short or current overload 100 times per second. If a short lasting longer than 700 mS
is detected, the microprocessor will shut down that channel. An short lasting less than 700 mS will
not cause the PS-232 to interrupt power. However, during this 700 mS, the output current will be
limited to 2 amperes.
AUTOMATIC OVERLOAD PROTECTION: The PS-232 senses the difference between shorts and
overloads. If an overload lasting longer than 2.5 seconds is detected, the microprocessor will shut
down that channel. An overload lasting less than 2.5 seconds will not cause the PS-232 to interrupt
power. During this 2.5 seconds, the output voltage will be reduced to limit the current to 2 amperes.
AUTOMATIC POWER RESTORE: The PS-232 microprocessor senses the difference between
short-term and long-term shorts and overload conditions. After the first few times a short or overload
occurs the PS-232 will try to restore power after only 0.5 seconds. If the short or overload persists
or repeatedly happens, the microprocessor will take progressively longer (to a maximum of 20
seconds) to try to restore power. This protects the PS-232 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
20
15
14
Number of
Seconds to 10
Restore
5
0
7
4
0.5
2
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Number of Recent
Shorts or Overloads
INDIVIDUAL CHANNEL SHORT CIRCUIT PROTECTION: Each individual channel is separately
overload and short circuit protected and may draw as much as 2 Amps, though the total to both
channels is limited to 2.25 Amps. A short on any one intercom line will not bring the whole system
down.1
FRONT PANEL INDICATIONS: There are two Overload indicators on the front panel (one for each
channel) and a Power indicator for the power supply. The Overload indicators light steady when an
overload or short condition is detected. They blink if power to a channel has been shut off as a
result of an overload or short. There is also an indicator to show when channels A and B are linked.
PARALLELING MULTIPLE POWER SUPPLIES: Multiple power supplies can be paralleled to
increase system capacity. The PS-232 microprocessor will automatically detect the actions of other
power supplies during overloads and shorts circuits to restore power as quickly as possible.
1
Power supply lines connected together at remote stations will disable the individual channel s h o r t
circuit protection feature.
3
Clear-Com PS-232 Power Supply
MULTI-CHANNEL REMOTE STATIONS MAINTAIN THE POWER LINE ISOLATION: The RM-220,
KB-211, and MR-202 as well as any two-channel remote stations or beltpacks are designed to use
the isolated power provided by the PS-232. Refer to the INSTALLATION section.
LOW NOISE CIRCUITRY: The direct current outputs of the PS-232 contain very little hum and
noise. The PS-232 does not contribute to audible noise in the remote stations and beltpacks.
FRONT AND REAR PANELS
A description of the connectors and controls follows. Refer to Figure 1.
7
12
4
3
2
5
8
6
9
1
10
11
Figure 1
Front Panel
1
POWER SWITCH: Turns the AC power to the PS-232 on and off. The green Power light will
illuminate when the power is ON.
2
OVERLOAD INDICATORS: If a short circuit or overload condition appears on either of the
intercom channel outputs, the red Overload light for that channel will illuminate. If this
condition persists, the microprocessor will disconnect power to that channel and the red
Overload light will blink. If a red Overload light is blinking, the fault on that channel must be
located and removed. When the fault is removed, the PS-232 will restore power to that
channel and the Overload light will go out . If there are no shorts, but the Overload light blinks,
an overload exists, possibly due to too many intercom stations connected on that intercom line.
If the failure continues, unplug the intercom line connected to the affected channel. Its red
Overload light should go out. This indicates a short in that line. Follow that intercom line
connecting and disconnecting cables along the line until the fault is isolated.
3
PROGRAM SEND ON/OFF: These toggle switches, one for each channel, connect program
audio to each channel. Both channels receive the same signal from the rear panel PROGRAM
INPUT. The number of active sends will not affect the overall send level to any channel.
4
PROGRAM SEND LEVEL: These controls (one for each channel) adjust the level of program
heard in that channel. The PROGRAM switch must be ON for the control to function on that
channel. (The level controls work in conjunction with the PROGRAM TRIM (8) level control on
the rear panel.) For a higher program level, turn the control clockwise. For less program level
turn the control counter-clockwise. If the control is all the way up on a channel and the program
4
Clear-Com PS-232 Power Supply
level in the line is not loud enough, increase the input level with the PROGRAM TRIM control
on the rear panel. Conversely, if there is still program heard on a channel when the its level is
all the way down, decrease the PROGRAM TRIM level. Any change in the PROGRAM TRIM
level control on the rear panel to adjust for one channel will necessitate adjustments on the
other channel to compensate.
NOTE: Do not force the controls past their stop points as this will damage them.
5
TEST TONE: This toggle switch turns on a 440 Hz test tone which can be heard on either or
both channels when the PROGRAM SEND switch for that channel is in the OFF position. It
can be handy for identifying which intercom channel is which or for other test purposes. The
PROGRAM SEND LEVEL controls adjust the level of the test tone on each channel.
6
A+B LINK SWITCH and INDICATOR: This toggle switch links the audio for channels A and B
together. A yellow light indicates when the channels are linked. It can be useful to have both
channels linked for rehersals, but separated for performances.
7
INTERCOM LINE CONNECTOR and SWITCH: A single intercom line connector is located on
the front panel for convenience. It can be switched between channels A and B with the
associated toggle switch.
Rear Panel
8
PROGRAM INPUT: This 1/4 inch TRS jack accepts a balanced or unbalanced line-level
signal. This is typically a feed from a mixing console, an air feed from a studio to remote site
over a phone line, or an audio cue track. The input accepts levels up to +10 dBV. Send levels
to the individual channels are controlled with a combination of the PROGRAM TRIM level and
the PROGRAM SEND levels on the channels. This feed can be fed to either or both intercom
lines.
9
PROGRAM TRIM: This control adjusts the overall input level of the external program coming
into the PS-232. It is used with the PROGRAM SEND LEVEL controls to achieve desired
system program levels. Turn the control clockwise to increase the gain and counter-clockwise
to reduce it.
NOTE: Do not force this control past its stop points as this will damage it.
10
TERM. ON/OFF: These switches (one per channel) select whether the PS-232 will provide the
required 200 Ohm termination for each channel. These should always be on unless there are
other power supplies or terminated main stations in the system. If there are other possible
terminations in the system, all but one must be turned off.
11
INTERCOM LINE CONNECTORS: There are three 3-Pin male XLR jacks per channel, wired
in parallel, or looped through. All the stations in the system are ultimately connected to the
PS-232 through these jacks. Because intercom audio is bidirectional, they are neither inputs
nor outputs, but may be thought of as "ports." Pin 1 is connected to the shield and carries the
signal ground. Pin 2 carries the DC voltage that runs the remote stations. Pin 3 carries two
way audio and call signals.
12
AC POWER SUPPLY INPUT: Connects to AC with an IEC cable. The PS-232 will accept any
line voltage between 90 and 240 Volts AC @ 50-60 Hz. It will automatically adjust to the line
voltage. There is no need for a selector switch or an external fuse.
Power Distribution and Short Circuit Protection
The PS-232 is capable of delivering up to 2 amps peak of 30 Volt DC current to Clear-Com stations.
The 2 amps peak is available on channel A and 2 amps is available on channel B. Since the total capacity of the PS-232 is 2 amps peak, the combined current of both of the channels at once may not exceed this maximum. Short circuits and overloads on any channel will not damage the PS-232. It will
simply cut power off to either or both channels which exceed their maximum current or which cause the
5
Clear-Com PS-232 Power Supply
system maximum to be exceeded. A channels which is within its maximum current rating will not be affected by the other channel being automatically cutoff.
Depending upon how many shorts or overloads a channel has experienced recently, the PS-232 will attempt to turn power on again within 500 mS to 20 seconds of automatically cutting off power to an overloaded channel. This allows momentary short or overload conditions to clear automatically. If the
PS-232 cuts power off to one or both channels, it will indicate which channel is affected by blinking the
red overload LEDs corresponding to these channel(s). This indication will assist in locating the shorted
or overloaded channel. Shorts are generally caused by miswiring or damaged cables. Overloads are
generally caused by connecting too many beltpacks and stations to a channel.
The current requirements of Clear-Com remote stations and beltpacks vary with model and use. A station that is simply '"on" and idling in the circuit may draw only a small amount of current. The PS-232
15
Number of
Speaker 10
Stations
5
Overload
Acceptable
5
10
15
20
25
30
35
40
Number of Beltpacks
will power up to 50 Beltpacks, 15 Speaker Stations, or a mix of the two. Refer to the following chart to
determine how many of each can be powered in varying combinations. Contact your dealer or ClearCom if you require further assistance in determining the overall current requirements of your system.
INSTALLATION
Intercom Line Connection
The PS-232 provides three rear panel 3-pin male XLR connectors for each intercom line. These connectors are wired in parallel and intended for loop-through connection. Any single-channel station or
channel of a multi-channel station connected on a line plugged into Channel A of the PS-232 will be
"party-lined" with all the other stations on that same channel. In a multi-channel system, the goal is to
assign specific people to the correct group, i.e. the other people whom 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 (+30 VDC)
Pin 3 --- Audio
Line Termination (Rear Panel)
Switching of the channels' terminations ON and OFF are done with the rear-panel toggle switches. In
most systems, all terminations on the PS-232 should be in the ON position (default setting). The fundamental concept of Clear-Com Party-Line intercom is that all channels are terminated in one location,
preferably at the power supply.
6
Clear-Com PS-232 Power Supply
CAUTION: All intercom lines must be terminated. Care must be taken not to
'"double-terminate" a line. All unused intercom lines must also be terminated.
The PS-232 provides terminations for each of its two channels. Clear-Com main stations and power
supplies provide switch-selectable termination networks on all intercom lines. It is up to the user to insure that the terminations are set correctly. An unterminated line will cause excessive levels, possible
oscillation of line drivers, and severe unbalance of hybrid null networks. A line with double or multiple
terminations will cause low levels and severe unbalance of hybrid null circuits.
If the PS-232 is the only power supply in the system (no other power supplies or powered main stations
are in the system) the termination switch on each channel of the PS-232 should be switched to ON.
Simply toggle the rear-panel switch labeled TERM to the ON position. The termination switch should be
set to the OFF position only if the channel is terminated at another station.
Program Input (Rear Panel)
A TRS connector provides the main program input to the station. This input level is controlled by the
rear panel PROGRAM TRIM control adjacent to the PROGRAM INPUT connector. This control sets the
overall level for all the channels. The input accepts a balanced or unbalanced line-level audio signal
from -20 dBv to +10 dBv. The program can be fed to either or both of the intercom lines by using the
front panel toggle switches labeled PROGRAM ON/OFF. There is one of these switches for each
channel.
The pinout of the Program Input Connector is as follows:
Shield --- Ground (Shield)
Tip --- + Signal
Ring --- - Signal
Rack Mounting
The unit requires 1.75 inches (44 mm) (1RU) of rack space. It requires no additional free rack space
above or below it for ventilation. The station is 5.25 inches (133 mm) in depth and requires at least 2
1/2 inches clearance in the rear for connectors and cables. The single-piece front panel has integral
"rack ears". This adds stability and strength. Take care not to over tighten the rack mounting screws as
this can mar the front panel.
7
Clear-Com PS-232 Power Supply
System Checkout
Before you turn on the power:
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:
1
Using a multimeter, measure the resistance between pins 1 and 3 on one of the Channel A XLR
connectors at the rear of the unit.
2
If the channel is terminated properly, then the resistance should measure approximately 4,000
Ohms. A very high channel resistance means the channel is not terminated. Channel resistance of 2,000 Ohms indicates a double-termination. If a double-termination is indicated, Locate the other power supply or mainstation and set its termination to OFF.
NOTE: The location of the termination switch varies with model. On some products,
the termination switches are on the rear panel; on others they are inside the unit.
Consult the unit's manual for the location.
1
Repeat for the other channels.
2
Check resistance between Chassis Ground and pin 1. Using an Ohmmeter, measure the resistance from pin 1 on the main station or power supply to chassis ground. The measurement
should read 10 Ohms. A high reading (over 100 Ohms) indicates that the 10 Ohm resistor in
the unit has failed and requires replacement. Failure to perform the replacement will result in an
audible "buzz" in the system. A reading of less than 10 Ohms (or a short) typically indicates
that the shell and pin 1 of one of the interconnect cables are shorted together. Test the individual cables until the culprit is located and repair or replace the cable.
NOTE: PIN 1 and the shell of the XLR plug on the interconnect cables should NOT be
connected together.
Check Intercom Cable Resistance
For minimal crosstalk, the ground resistance of the intercom cables should be as low as possible, preferably less than 2 Ohms. Disconnect an intercom line from the main station or power supply. At the
point in the intercom line furthest from the unit, connect a clip lead jumper between pins 1 and 2. Back
at the "powered" end, use an Ohmmeter to measure the resistance between pins 1 and 2. A value of
less than 4 Ohms is ideal.
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 belt pack or station. The call lights on all other stations on that channel should illuminate and then go out when
the call button is released.
3
Adjust the sidetone null on all stations. (Refer to the manual for each specific unit for
instructions.)
8
Clear-Com PS-232 Power Supply
MAINTENANCE
Troubleshooting Tips
Problem:
Cause 1:
Solution 1:
System does not operate. No power to the PS-232. Green POWER light is
not illuminated and no OVERLOAD lights are illuminated
No AC power to the PS-232.
Check AC connection and cable. Plug into dependable AC source.
Cause 2:
Solution 2:
PS-232 has an internal power supply failure.
Unit requires servicing.
Problem:
Cause 1:
Solution 1:
Red Overload Light illuminated
Short or overload on that channel due to a shorted or miswired cable.
Remove cables, one at a time from system until the faulty line is located. Check for
shorts between pins 1 and 2. Once the short is removed, the PS-232 will reset
automatically and the power will come back up within several seconds, depending
upon how long the short has been present.
Cause 2:
Solution 2:
Defective remote station.
Check remote station and replace if necessary.
Problem:
Cause 1:
Solution 1:
Both red Overload Lights are illuminated
System is overloaded.
Remove cables, one at a time from system to help determine where the excess
current requirements lie. Re-evaluate system current needs.
Cause 2:
Solution 2:
Short in multipair cable.
Remove cables, one at a time from system until the faulty line is located. Check for
shorts between pins 1 and 2.
Problem:
Cause 1:
Hum or buzz in system
Inductive pickup caused by close proximity of main or remote stations to power
lines or transformers.
Relocate offending unit.
Solution 1:
Cause 2:
Solution 2:
10 Ohm chassis ground resistor is open.
Check the DC resistance for 10 Ohms between the chassis and Pin 1 of any
intercom connector.
If this condition happens, it is because the system ground came into contact with something
that was "HOT" with respect to the power supply earth ground. If this occurs, carefully check
the system ground and AC distribution in the area.
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:
System feedback (Acoustical)
Volume control at the remote station is set too high.
Adjust.
Cause 2:
Solution 2:
Channel unterminated.
Set the PS-232 temination switch for that channel to the ON position.
Cause 3:
Solution 3:
A headset extension cord was used.
Headset extension cords are not recommended.
Problem:
Cause 1:
Solution 1:
440 Hz tone is present on either or both channels
Test tone feature is on.
Set the test tone switch to the OFF positon.
Problem:
Excessive crosstalk
9
Clear-Com PS-232 Power Supply
Cause 1:
Solution 1:
High DC resistance in ground return.
Use heavier cable; add additional conductor(s) to ground return.
Cause 2:
Solution 2:
MULTI-CHANNEL cable pairs are not individually shielded.
Replace cable with individually shield pairs.
Cause 3:
Solution 3:
Headset cables are not wired properly or shielded properly.
Correct wiring. Use headsets with properly shielded wiring.
Problem:
Cause:
Solution:
Program signal sounds distorted.
Overload of PROGRAM IN circuit.
Reduce PROGRAM IN level or reduce the gain of the program signal at the source,
such as an audio mixer.
PS-232 Block Diagram
The following is a block diagram of the PS-232:
90 - 240
VAC
Switching
Power Supply
Module
Voltage
Regulator
Channel A
Power
Controller
Channel A
Current
Sensor
Channel B
Power
Controller
Channel A
Voltage
Sensor
Overload Overload
Channel Channel
A
B
Channel B
Current
Sensor
Channel
A
Channel B
Voltage
Sensor
Microprocessor
Power
Test Tone
On / Off
Program
Trim
Program
Input
440 Hz
Send Levels
A
Channel
B
Filter
B
A
B
Program
On / Off
10
Ch A
Term
Ch B
Term
A+B
Link
Clear-Com PS-232 Power Supply
Parts List
Part Description
.01
uF Ceramic Disc
.1
uF Monolithic
10
uF Aluminum
470 uF Aluminum
1000 uF Aluminum
1
uF Tantalum
.47
uF Aluminum NP
47
pF Ceramic Disc SMD
470 pF Ceramic Disc SMD
.01
uF Ceramic Disc SMD
.1
uF Ceramic Disc SMD
.22
uF Ceramic Disc SMD
.33
uF Ceramic Disc SMD
.47
uF Tantalum SMD
22
uF Aluminum SMD
LED GREEN, ROUND LED
LED RED, ROUND LED
LED YELLOW, ROUND LED
10
OHM 1/4W Carbon Film
1K
OHM 1/2W Carbon Film
.18
OHM 1W Carbon Comp
.11
OHM 1W Carbon Comp
0
OHM 1/10
10.0 OHM 1/10
221 OHM 1/10
475 OHM 1/10
1.00K OHM 1/10
3.92K OHM 1/10
4.32K OHM 1/10
4.75K OHM 1/10
10.0K OHM 1/10
20.0K OHM 1/10
47.5K OHM 1/10
100K OHM 1/10
Rating
1.4KV
50V
50V
25V
35V
35V
50V
50V
50V
50V
50V
50V
25V
35V
50V
SMD
SMD
SMD
SMD
SMD
SMD
SMD
SMD
SMD
Part #
20% 150029
10% 150035
150064
150089
150092
20% 150116
150151
5% 151120
5% 151132
10% 151160
10% 151172
10% 151176
10% 151178
10% 151184
20% 151200
390051
480064
480065
5% 410002
5% 410121
5% 410200
5% 410201
1% 411100
1% 411197
1% 411326
1% 411358
1% 411389
1% 411446
1% 411450
1% 411454
1% 411485
SMD
SMD
SMD
1%
1%
1%
411514
411550
411581
Relay SPDT 24V MINI PC RELAY ITT#SZ24
450004
Pot
10K TRIMPOT PIHER#PT110WH-10K
470058
Pot
50K TRIMPOT PIHER#PT10WH-50K470059
Diode 1N5401 RECT 3A 100PIV
480005
IC
7805T POS 5V REGULATOR TO220 PKG 480083
Diode 1N5822 SHTKY 3A 40PIV
480100
IC
LM833N DUAL 8 PIN DIP
480175
TransistorTIP35C NPN 100V 25A TO-218
480228
Diode BAV70 DUAL DIODE COM CATH SMD 481019
IC
833 DUAL OPAMP... SMD
481023
Transistor2222A NPN 40V 600MA... SMD
481026
Transistor2907A PNP 60V 600MA... SMD
481027
Diode BAV99 DUAL DIODE... SMD
481033
IC
74HC165 CMOS 8-BIT PAR S/R... SMD 481037
Transistor5551 NPN 150V 200MA... SMD
481068
Sw
SPDT 2POS RT ANG PC MTG
510094
Sw
DPDT R/A SLIDE SWITCH
510121
IC
PS-232 FIRMWARE ASSEMBLY
710567
11
Designator
C4
C1 C6
C28 C29
C7 C8
C2
C12 C3
C21 C26
C19 C20 C24
C10 C9
C15
C11 C17 C18
C14
C5 C13 C22 C23
C25
C16
D3
D7 D6
D8
R4
R11 R12 R13 R14
R1
R6 R5
R40
R39 R2
R52 R53
R10 R34 R35 R36
R8 R9
R22 R21
R45 R55
R3 R7 R56 R57
R19 R20 R23 R24 R25 R26 R27 R28
R29 R37
R51
R42 R41
R15 R16 R17 R18 R30 R31 R32 R33
R38 R43 R46 R47 R48 R50
K1
R54 R44
R49
D1 D2
IC1
D4 D5
IC4
Q3 Q4
D9
IC4
Q7 Q8 Q9 Q11
Q2 Q1
D10
IC3
Q5 Q6 Q10 Q12
S6 S3
S1 S2 S4 S5 S7
IC2
Component Layout Drawing
1
2
3
2899
REV ECO#
A
R34
475
Ch. A
Fault
(red)
J1
+5V
D6
R29
10.0K
+5V
1
2
3
4
5
6
P5
R2
10
C2
1000uF
C5
.33uF
RB0
RB1
RB2
RB3
RB4
RB5
A
DESCRIPTION
DATE
1-11-02
Bias
R48
100K
C24
47pF
BY
JKG
7
9
R43
100K
D9
BAV70
+
-
SER
A
B
C
D
E
F
G
H
1
.1uF
C18
R42
47.5K
2
IC3
74HC165
CLK
INH
SH/LD
3
2
15
1
10
11
12
13
14
3
4
5
6
+
6
5
R49
50K
.1uF
C17
+
-
7
Bias
R31
100K
IC4B
LM833
R47
100K
C20
47pF
R41
47.5K
R30
100K
R23
10.0K
2
Bias
Q1
MMBT2907A
Q9
MMBT2222A
1
R19
10.0K
R10
475
D3
Power
(green)
+5V
+5V
R51
20.0K
C16
22uF
GND
C6
.1uF
VCC
+5V
P8
1
2
3
4
5
R38
100K
+30V
1
.22uF
C14
Options
1. ALL RESISTORS ARE 1/10W 1% LISTED IN OHMS
2. RESISTORS 1/4W AND GREATER ARE 5% TOLERANCE
3. ALL CAPACITORS ARE LISTED IN MICROFARADS
B
3
R13
1K 1/2W
R11
1K 1/2W
R37
10.0K
R27
10.0K
R33
100K
C25
.47uF
C13
.33uF
R32
100K
R24
10.0K
C9
470 pF
C7
470uF
+
R5
.11 1W
R8
1.00K
R3
4.75K
R1
.18 1W
NOTES: (UNLESS OTHERWISE SPECIFIED)
Bias
IC4A
CW
LM833 SOIC
QH
QH
7805T
VOut
CHK
R50
100K
3
C23
.33uF
C19
47pF
R39
10
1
3
1
R46
100K
+30V
Ch. B
Fault
(red)
10
9
8
7
6
5
IC2
PIC16C505P
RC0
RC1
RC2
RC3
RC4
RC5
VIn
IC1
2
C22
.33uF
R35
475
D7
+5V
13
12
11
4
3
2
C11
.1uF
+5V
1
2
Release to Manufacturing
Balanced
Program
Input
R4
10 1/4W
+
PROGRAMMING / TEST INTERFACE
1 - Gnd
/ Gnd
2 - Data
/ Strobe
3 - n/a
/ Data Out
4 - Clock
/ Clock
5 - MCLR (not) / Data In
6 - +5V
/ n/a
C4
.01uF 1.4KV
C1
.1uF
GND
2
4
+30V
R40
0
3
1
+5V
D4
1N5822
S3
C27
.22uF
3
1
S6
CW
R54
10K
Ch. B
2
Program Off
/ Test Tone
CW
R44
10K
Ch. A
2
C15
.01uF
6
4
3
1
Tone Off
Tone On
Q7
MMBT2222A
1
R15
100K
D1
1N5401
Program On
Q10
MMBT5551
Q5
MMBT5551
2
Q3
TIP35C
2
3
1
+30V
3
2
+30V
3
2
1
3
2
C
5
2
R45
4.32K
R55
4.32K
Ch. B
Program
Level
2
Ch. A
Program
Level
2
S1
R21
3.92K
R17
100K
+5V
C26
.47uF NP
C21
.47uF NP
R25
10.0K
Q11
MMBT2222A
1
R20
10.0K
Q2
MMBT2907A
R26
10.0K
R28
10.0K
5
2
Link Off
+30V
3
S2
6
4
3
1
1
D
1
R36
475
D8
D10
BAV99
K1
3
4
SCALE
SHEET:
+
C12
1uF TANT
+
C3
1uF TANT
SIZE
3-13-01
C29
10uF
710568SA.DSN
1 OF: 1
-----------------------
ORCAD P/N
DATE
DATE
+
R53
221
S5
APP
C28
10uF
R57
4.75K
Ch. B
Termination
2
5
1
R22
3.92K
R18
100K
DATE
JKG
+
R52
221
S4
2
+30V
Q8
MMBT2222A
1
R16
100K
D2
1N5401
3
CHK
DWN
R56
4.75K
+5V
D5
1N5822
+30V
Ch. A
Termination
+5V
Q12
MMBT5551
Q6
MMBT5551
2
Q4
TIP35C
2
3
Link
(yellow)
R14
1K 1/2W
R12
1K 1/2W
C10
470 pF
C8
470uF
+
Link On
R9
1.00K
R6
R7
.11 1W
4.75K
1
3
2
1
1
2
3
1
VDD
VSS
14
3
2
D
6
C
1
B
3
4
5
3
2
3
2
P1
3
8
4
6
30 VDC
Input from
Switching
Power
Supply
3
1
4
5
A
+
3
1
3
1
1
2
C
DWG No.
TITLE:
CH B
1
3
4
6
CH A
1
1
1
P10
1
INTERCOM SYSTEMS
P9
P7
P6
1
1
1
E
710568 - SCH - C -
REV
A
CLEAR-COM R
2
P4
P3
P2
Schematic
PS-232 Power Supply
2
2
2
S7
2
5
Test
Jack
2
2
2
E
4
3
4
3
4
3
4
3
4
3
4
3
4
3
1
2
3
4
Clear-Com PS-232 Power Supply
CLEAR-COM LIMITED WARRANTY
Clear-Com products are warranted to be free from defects in materials and workmanship for a period of
one year from the date of sale.
This warranty does not cover any defect, malfunction or failure caused beyond the control of ClearCom, including unreasonable or negligent operation, abuse, accident, failure to follow instructions in the
manual, defective or improper associated equipment, attempts at modification and repair not authorized
by Clear-Com, and shipping damage. Products with their serial numbers removed or defaced are not
covered by this warranty.
This warranty is the sole and exclusive express warranty given with respect to Clear-Com products. It is
the responsibility of the user to determine before purchase that this product is suitable for the user's intended purpose.
Any and all implied warranties, including the implied warranty of merchantability are limited to the duration of this express limited warranty. Neither Clear-Com nor the dealer who sells Clear-Com products is
liable for incidental or consequential damages of any kind.
For your own records fill in the information below:
* Model No.________________________________ * Serial No.______________________
Date Purchased_____________________________
Purchased from (dealer)______________________________________________________
Address___________________________________________________________________
City_________________________________State___________________Zip____________
Factory Service
All equipment returned for repair must be accompanied by documentation stating your return address,
telephone number and date of purchase, along with a description of the problem.
Note: Do not return any equipment to the factory without first obtaining a Return
Authorization Number.
After obtaining a return authorization, send equipment to be repaired to:
Customer Service Department
Clear-Com Intercom Systems
4065 Hollis Street
Emeryville, California 94608-3505
Telephone: (510) 496-6666
Telefax: (510) 496-6601
Warranty Repairs - If in warranty, no charge will be made for the repairs. Equipment being returned for
warranty repair must be sent prepaid and will be returned prepaid.
Non-Warranty Repair - Equipment that is not under warranty must be sent prepaid to Clear-Com. If requested, an estimate of repair costs will be issued prior to service. Once your approval for repair, and
repair of equipment is completed, the equipment will be shipped freight collect from the factory to the
customer.
14
Clear-Com PS-232 Power Supply
TECHNICAL SPECIFICATIONS
POWER SUPPLY
Type: Switching, with post filters and overload reset circuitry
Output Voltage: 30 volts DC
Output Current: Channel A, 1 amp continuous, 2 amps max
Channel B, 1 amp continuous, 2 amps max
Short Circuit Reset Time: 0.5 to 20 sec. depending upon recent overload activity
Hum & Noise: < -70 dBV
Station Capacity: 40 headset stations or 15 speaker stations, distributed over both channels
PROGRAM AMPLIFIER
Type: Transformerless, Balanced Differential Input
Input impedance: > 100 kΩ
Frequency Response: 150 Hz - 18 kHz ± 2 dB
Line Level Input: -20 dBV
SYSTEM SPECIFICATIONS
Termination Impedance: 200 Ω , switchable
Intercom Line Length: 5,000 ft. maximum (single channel)
500 ft. for crosstalk < -50 dB (with multi-channel stations)
REAR PANEL CONNECTORS
Intercom: (6) XLR-3M (3 per channel)
Program: (1) 1/4" TRS
AC Power: (1) IEC 320 connector
REAR PANEL CONTROLS
(2) Termination on/off; (1) program input level
FRONT PANEL CONNECTOR
Intercom: (1) XLR-3M (selectable channel A or B)
FRONT PANEL CONTROLS & INDICATORS
(1) Intercom Select switch; (2) Program On-Off switches; (2) Program Send Level controls; (1) Test
Tone switch; (1) A+B Link switch; (1) Power On switch; (2) "Overload" lights; (1) "A+B Link light; (1)
Power "On" light
POWER REQUIREMENTS
90 - 240 VAC, 50 - 60 Hz, 60 VA
ENVIRONMENTAL
32 - 122o F (0 - 50o C)
DIMENSIONS
19" W x 1.75" H x 5.25" D (483 mm x 44 mm x 133 mm)
WEIGHT
4.5 lbs. (2.05 kg)
NOTICE ABOUT SPECIFICATIONS
While Clear-Com makes every attempt to maintain the accuracy of the information contained in its
product manuals, that information is subject to change without notice. Performance specifications included in this manual are design-center specifications and are included for customer guidance and to
facilitate system installation. Actual operating performance may vary.
15
Clear-Com PS-232 Power Supply
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.
Ambient Noise: Those background sounds which are not part of the specific communication but are
picked up by the microphone. Selection of a good "noise-cancelling" mic will reduce ambient noise.
Beltpack: A portable electronics package worn on the belt or mounted on a wall or other convenient
location. Interconnects to system with mic cable and is powered by a central power supply or main
station.
Bridging, High Impedance (hi-Z): A method of connecting to an audio line (such as Clear-Com) without loading or taking appreciable power from that line. Simply stated, as you add more and more stations to the line, the volume remains constant.
Call Signaling: This feature is included with the majority of Clear-Com products. It is a visual indicator
on a station (lamp or LED) used to attract the attention of an operator who has removed the headset.
Channel: A channel is the line that connects parties together within a party line - it is a two-way talk
path. For example, if you have six people who need to hear one director, you have a seven-station
single-channel need. If the same director needs to speak privately to any one of the six, add a second
channel. You now have a seven-station, two-channel system.
Closed-Circuit: Any intercom which is connected via cable (also called hard-wired). The other type
would be Wireless. . .we make those too. However, if you want privacy and versatility, you probably
want a closed-circuit system or a combination of both.
Cross Talk: Leakage of audio transmissions from one channel to another.
Dry Pair: A telephone term is used to describe a pair of wires (2 conductors) that carry audio but no
DC voltage. Contrast this with a "Wet Pair" that carries both audio and voltage.
Duplex: Duplex refers to bidirectional communications. Normal communication between individual
talking face to face is "full duplex" - in other words you can talk and listen simultaneously. The other alternative is "half-duplex" such as a push-to-talk situation where one station at a time can talk while others listen. A walkie-talkie is a good example of half-duplex communication.
IFB: The term means "Interrupted Fold Back." A Fold-Back is a monitor system that allows, for example, talent to hear their voices or musicians to hear their voices and instruments on stage. IFB (program
interrupt) disconnects the program audio source while the talk button on the main station is pushed.
ISO: A private conversation path. An ISO channel allows one to simply push a button and transfer
themselves and the person they wish to speak with to an isolated channel.
Linking: Linking ties separate channels into one single party line.
Main Station: This is a product that includes both the ability to communicate with multiple channels
without connecting them together, and to power all the stations connected to these channels.
Master Station: A remote station which needs AC power to operate
Multi-Channel: More than one channel
Party Line (P.L.): Intercom system where all people talking on the system can talk or listen to each
other simultaneously. Also called conferencing.
Point to Point: One path to one person.
Program: Audio source that is fed into the intercom channels.
16
Clear-Com PS-232 Power Supply
Program Interrupt: Disconnects the audio source while the talk button on the main station is pushed.
(IFB)
Remote Mic Kill (RMK): The ability for certain main stations to shut off all microphones on beltpacks in
a system.
Remote Station: Like the beltpack, this would be any of the products connected to the intercom line
that allow duplex or half-duplex conversation, but do not contain a power supply.
Sidetone: This is your own voice heard in your earphone as you are speaking.
Stage Announce (SA): Redirects output of the main station's microphone to an external destination
(such as a PA system).
Station: A station is connected to one or more channels. For example, if you have six people who
need to hear one director, you have a seven-station single-channel need. If the same director needs to
speak privately to any one of the six, add a second channel. You now have a seven-station, twochannel system.
Termination: Passive network that is connected in each channel, usually on the power supply or main
station.
PS-232 Manual P/N 810277
(C) 2002 Clear-Com Systems
All Rights Reserved
17
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