CLEAR-COM INSTRUCTION MANUAL

INTRODUCTION

1. 1 GENERAL
The Clear-Com system is a closed circuit intercommunication system
designed for clear- two-way communication in high noise environments.
Low impedance lines (200 ohms) and specially designed circuitry make the
system virtually immune to RF and dimmer noise. The basic system consists
of a main station and from one to 40 remote stations, joined by inter­
connecting cable. Main stations are available in portable cases (single
channel CS-100 and dual-channel CS-200), as well as rack-mountable enclosures
(CS-100K and CS-200K). There are several interchangeable remote stations:
the RS-100A "belt pack", the KB-100 liKing Biscuit" mic/speaker unit, the
MR-102 wall-mount unit, the KB-lll wall mount unit with speaker, and the
KB-lllP portable remote unit with speaker. The master gain control, located
on the main station rear panel, allows the operator to set the overall gain
in accordance with the number of remote stations being used.
All remote stations, except the MR-102, have adjustable side tone
which enables the user to vary the amount of his or her own voice in the
headset, handset or speaker for maximum intelligibility with minimum chance
of feedback. All remote stations have their own volume control for ad­
justing the level in the earpiece (s), call switches and call lights for
signaling from other stations.
Clear-Com is a distributed amplifier system, with each remote station
housing its own mic preamplifier and headset power amplifier (+20dBm max
output). The main station supplies 28V dc necessary for operating all
circuits, and power is carried to remote stations via the same interconnecting
cable which carries the audio signals. The main stations also have an
auxiliary, line-level input with its own volume control which allows mixing
of an external program with the intercom line. This is useful for program
monitoring.
A power-supply only main station is available, the model PS-3000.
Standard microphone cables (XLR-3 type connectors) are used for inter­
connection in most cases; the WP-l and WP-2 wall-mount connector plates
may be used in some permanent installations. Interconnect cables, and a
4-way splitter (the Quadropuss) are available from Clear-Com.

78 - 1 ­
 SECTION II

INSTALLATI ON
2.1 EQUIPMENT SELECTION
2.1.1 FIXED SYSTEM MAIN STATIONS
For permanent intercom systems, main station equipment is usually
mounted in a standard 19" rack fo ,r security and convenience. For this
reason, we recommend either the CS-100K single-channel main station or
the CS-200K dual-channel main station. However, if an intercom station
is not needed at the area where the equipment rack is located, then the
PS-3000 power supply (without intercom station) should be s~bstituted.

2.1.2 FIXED SYSTEM REMOTE STATIONS

In permanent installations, it is usually desireable to run inter­
connecting cables through conduits, and to bring them to wall-mounted
remote stations, or to wall plates for connection to portable remote
stations. We recommend the MR-102 wall-mount remote station, or the
KB-lll wal l mount remote station with paging speaker. If you don't
wish to have the remote station built into the wall, then use our
WP-l or WP-2 wall plates with any of our portable remote stations;
the RS-100A IIbelt pack", the KB-100 liKing Biscuit mic/speaker station,
ll

or the KB-lllP headset/handset station with paging speaker.

2. 1 .3 PORTABLE SYSTEM MAIN STATIONS

For portable intercom systems, main station equipment must be
compact, lightweight, and easily moved for storage. The CS-100 single­
channel main station and CS-200 dual-channel main station fulfill these
requirements.

2. 1.4 PORTABLE SYSTEM REMOTE STATIONS

The RS-100A "belt pack" is the key to our truly flexible portable
intercom system. Because each RS-100A has a pair of input and extension
connectors, many stations may be "daisy chained" together along one
interconnect path. This saves cable and simplifies installation and
break down.
The KB-'lOO liKing Biscuit mic/speaker remote station is ideal for
ll

use in remote trucks and in studio control rooms, as well as on stage

during setup of live shows. It can be used either in push-to-talk mode,
or in an optional IIhands-free mode where the speaker and microphone both
ll

function simu H aneousl'y. In the latter mode, 2-way cOrrTTlunication is possible

at distances up to three or four feet, depending on ambient noise levels.

- 2 ­
1/78
 2.1.5. CLEAR-COM HEADSETS AND HANDSETS
Clear-Com has three standard headsets available, all with boom­
mounted, noise-cancelling microphones. The CC-240 is a double-muff
headset, ,and the CC-75 is a single-muff headset, both with boom-activated
mics. The PH-7 is a double muff headset which has wider frequency response,
greater isolation from ambient noise, and sturdier physical construction
than the CC-240, and no mic switch in the boom. All units have fie1d­
replaceable cords. The HS-6 telephone-style handset is interchangeable
with the above headsets.
All remote stations can drive 2 headsets with only a slight reduction
in level. A V-cord can be made up using the diagram below and the specified
wire. Extension cords for the headset can also be made out of this same cable
or other separately shielded cable such as Belden 8734, 8416 or 9454.
Extensions should be limited to approximately 15' due to the possibility of
capacity coupling between the microphone signal and the headset signal which
would cause a loss of high frequency response or oscillation.
CAUTION: DO NOT connect microphone ground and earphone ground together
at any poi nt.

A/.{F Cdble:
Be{ c{ en - g 7 31.(
.. -I - - - - - - -- - - -- - - - - - -- - -- -8Jflb
-9~S1
Y-Cord

2.1.6 . OTHER HEADSETS

Non-C1ear-Com headsets are available from Clear-Com or local dealers.
These are recommended for special applications:
Beyer DT-108 Single-muff, high-fidelity earpiece with boom mic;
may be used for monitoring and intercom.
Shure SM-12 Miniature, lightweight type with boom mic and
hearing-aid type earpiece.

, '78 - 3 ­
 2.1.6 INTERFACE TO OTHER COMMUNICATION SYSTEMS
The AC-10 Adapt-a-Com is a universal adapter which enables Clear-Com
to be interfaced with any other intercom or communications link. When
existing non-Clear-Com installations are being upgraded to Clear-Com
equipment, portions of the older system can be retained. Since Adapt-a-Com
works in 2-, 3- and 4-wire systems, it virtually guarantees compatibility
with any house intercom equipment.
Because it will simulate a carbon mic, Adapt-a-Com can be plugged
into the headset jack on a TV camera, control unit, or other 2-wire systems.
Adapt-a-Com operates with telephone company and competitive model 3-wire
intercoms, facilitates on-line intercom via standard telephone systems, and
aids in direct communication between the studio and remote locations via
2 or 4 wire dedicated TEL.CO. pairs.
2.1.7 AUDIO ISOLATION OF PARTS OF THE INTERCOM SYSTEM
In certain applications, it may be desireable to isolate conversations
in one section of the system. In these instances, the BA-l in-line isolator
may be used to block audio while allowing power to flow to the isolated leg
of the system. This inexpensive, passive device creates a quasi-dual channel
system from a single channel, except that the main station cannot contact or
be called by the isolated leg of the system. The BA-l enables you to have
private local conversations along a common interconnect cable without need
for multiple cabling or several main stations. Any number of BA-lls may be
used, so long as the power capacity of the main station is not exceeded.

2.2 MAXIMUM NUMBER OF STATIONS AND CABLE CONSIDERATIONS

2.2.1 MAIN STATION CURRENT AND IMPEDANCE LIMITS
All Clear-Com main stations, induding the PS-3000 power supply, have
the same maximum output current capacity, 2 amps. For dual channel main
stations, the total current draw on both channels cannot exceed 2 amps.
Due to impedance considerations, regardless of the cable lengths or mix
of remote stations, 40 stations are the maximum that can be driven from one
main station. (In certain circumstances, it may be possible to use more than
40 stations; contact the factory for details.)

2.2.2 CALCULATING THE MAXIMUM NUMBER OF REMOTE STATIONS

In installations with less than 500 feet total interconnecting cable,
only the remote station current requirements need be considered. One main
station will support up to 40 RS-100A or MR-102 remote stations, or up to
15 KB-100 or KB-lll remote stations.

1/78 - 4 ­
 When calculating the maximum current drain, only two figures need
be considered; a maximum current drain of 40 ma in the RS-100A or MR-102,
and an average current drain of 130ma in the KB-100 or KB-lll. Thus, an
equation for maximum stations would be as follows:
x= Number Of RS-100A's + MR-102 1 s < 40.
Y = Number of KB-l 00 I s + KB- 111 IS < 15.
Therefore,

0.04X + 0.13Y ~ 2.0

2.2.3 CABLES
Where cable lengths greater than 500 feet are involved, the maximum
number of remote stations, depends on four factors; the current requirements
of each remote station, the length of the wire, the wire gauge, and the cable
capacitance. In all instances, 2-conductor, shielded interconnecting cable
should be used.
A. PORTABLE INSTALLATIONS: rubber-insulated and jacketed cable should
be used due to its superior strength and durability. Belden 8413 mini­
ature cable (24 gao stranded conductors) is usable up to 500 feet.
Belden 8412 (20 gao stranded conductors) is usable up to 5,000 feet.
B. PERMANENT INSTALLATIONS: Vinyl-insulated and jacketed cable may
be used; it costs less and is easier to pull through conduit than
rubber insulated types. However, low capacitance cable must be used.
Belden 8762 (20 gao stranded conductors) is usable up to 500 feet.
Belden S'1rA (18 gao stranded conductors) is usable up to 5,000 feet.
NOTE: In systems where conduit is not used, and where equipment may
not -share a common ground, it may be necessary to run an additional
ground wire to tie chassis together. This may be accomplished with
Belden 8770 3-conductor shielded cable.
C. 2-CHANNEL PERMANENT INSTALLATIONS: Permanent systems can be
wired in one of two ways. First, Channel A and Channel B may be
routed to two distinct areas, for use by different people. Second,
both channels may be routed together and brought to WP-2 wall plates
so the user can select either channel A or B. The second method can
be wired with two 2-conductor shielded cables or one multi-pair shielded
cable.
Cables equivalent to the Belden types may be used, so long as their
capacitance and wire gauge are comparable. Particularly in longer runs, it
is desirable to use cable which has low resistance (large diameter conductors)
and low inter-conductor capacitance.

- 5 ­
1/78
 2.3 LAYING OUT THE SYSTEM
2.3.1 PORTABLE INSTALLATIONS
Having determined the number and type of remote stations you wish
to use, decide on a location for the main station. It should be near a
source of 115V AC (power consumption is approximately 80 watts.) There
are six parallel outputs available on the rear panel of the CS-100, and
two sets of 3 parallel outputs on the CS-200. Any remote sta t ions can be
connected directly to the 6 outputs. Additionally, remote stat ions can be
added by "daisy chaining" them to one another and/or by using the QP-100
Quadrapuss splitter. Cables should be routed away from heavy AC power
sources, such as lighting panels, electric motors, etc.

2.3.2 PERM'ANENT INSTALLATIONS

The same general considerations apply here as for portable systems,
as described in the preceding paragraph. Additionally, cables should be
installed in accordance with approved local building codes. Class II
wiring may be used. Connections to wall-plates or wall-mount remote
stations are shown in the di agrams.

2.3.3 ISOLATED CHANNELS

The BA-l In-Line Isolator can be installed anywhere in the system.
For example, plug it into one output connector on the rear panel of the
main station to create an entire isolated channel. Alternately, plug it
into a remote station at the end of a cable run to isolate further remote
stations while using a minimum of additional interconnect cable.

Typical Coliseum Intercom System

1/78 - 6 ­
 OPERATION OF THE SYSTEM
OPERATION OF THE CLEAR-COM SYSTEM IS QUITE SIMPLE, AS FOLLOWS:
1. CONNECT MAIN STATION to all remote stations with interconnecting cable.
NOTE: Before connecting rear panel interconnecting cables, shut power
off and hold call button depressed until call light(s} go out.
2. PLUG IN HEADPHONES at main station and remote stations into HEADSET CONNECTORS
at front panel. (To locate connectors and controls, see Figure l.)
Headset connectors in main station are wired in parrallel. Use one or both.
3. SE T I~ASTER GAIN SET at rear panel of main station for overall system level to
compensate for number of remote stations in system. (CS-200 has one gain control
for each channel.) Under high noise conditions, turn master gain DOWN and speak
with microphone very close to the mouth.
4. SET HEADSET VOLUME CONTROLS at main station and remote stations for individual
volume level. Volume controls are located on front panel.
5. TO SIGNAL stations where headphones may have been removed, press CALL BUTTON
on front panel and CALL LIGHT will go on. Call lights light up at all stations
simultaneously.
6. THE AUXILIARY INPUT CONNECTOR on front panel of the main station provides for
external program feeding into the entire system. (See schematics for connecting
details). The AUXILIARY VOLUME CONTROL is located directly on top of the
auxiliary input connector and controls the auxiliary input volume to the system.
7. THE CS-200 MAIN STATION can communicate with two separate channels, A and B.
THE CHANNEL SELECT SWITCH which is located on the front panel of the main
station, can be switched to positions A, B or A + B. The A or B position
enables the main station to communicate with either channel A or B, respectively,
while the A + B position enables the main station to communicate with both
simultaneously. Regardless of the position of the switch, remote stations on
channel A can always talk to other remote stations on A, but A cannot communicate
with remote stations on channel B, and vice-versa. Also, note that the call
lights are always operative from main station to both channels A and B, regardless
of the switch position.
8. CAUTION:
A} DO NOT allow belt packs to come into contact with other pieces
of electrical equipment. An improper ground or short in a piece
of electrical equipment touching a Clear-Com remote station can
cause a hum or a buzz in the system. When connecting remote
stations to electrical equipment, make sure the equipment is
properly grounded.
B} DO NOT wear the remote stations in wet weather without ensuring
that the station is properly grounded.

- 7 ­
1/78

 OPERATION OF SYSTEM

PS-3000 INTERCOM POWER SUPPLY

DESCRIPTION
The PS-3000 is a regulated intercom power unit designed to power all Clear-Com
remote stations. Typically, it can be installed in areas not requiring a headset
function, i.e., isolated rack bays.
The PS-3000 su-plies 30v at 2 amps and is capable of supporting a minimum of
40 Clear-Com remote stations. It is protected against shorts in the cable by
current foldback in the regulator circuit and provides visual indication of such
conditions on the front panel system. The unit has provisions for an auxillary
program input to the intercom system with the level adjustable from the front
panel.
INSTALLATION' AND OPERATION
The PS-3000 can be mounted in a standard 19" rack. Because the PS-3000 can
dissipate a considerable amount of heat, it is ,r ecommended that at least an
inch of space be allowed above the unit to facilitate ventilation.
All interconnections to the unit are made from the rear panel. Four parallel
D3M connectors are provided for system output. As in any Clear-Com system,
the lines to the remote stations may be "home-runs" or t he stations may be
"daisy chained." Once the system has been set up, the overall level may be
adjusted with system level control.
If, at any time, short circuit conditions are encountered, the problem can
usually be isollated by removing the interconnect cables from the unit, one
at a time, until the short circuit indicator goes out. It may be necessary
to shut the unit off for a few seconds to reset the short circuit indicator.
An internal 1-1/2 amp slow-blow fuse protects the PS-3000 in case of internal
power supply failure. If the fuse repeatedly blows, it means the power transistor
or a component on the p.c. board has failed. The cover is held on by "snap on"
fasteners. To remove - pull cover up hard.

- 8 ­
1/78
 TROUBLE SHOOTING
SYMPTOM CAUSE REMEDY
1) System is totally dead, power switch Circuit breaker open. Reset circuit breaker. Check A.C. power
light doesn't come on. A.C. power failure. line.
2) Circuit breaker trips repeatedly or Shorted or mis-wired inter­ Remove cables from main station one
short circuit LED remains lit (PS-3000 only) connect cable. Defective at a time until faulty line is isolated.
remote unit. Check for shorts between pins 1 and 2.
3) Oscillation Feedback caused by unused Turn off mics on all unused headsets.
headset left with mic on
and volume turned up.
4) Call light doesn't work. Bulb burned out. Unscrew lens from lamp holder. Replace
lamp with GE 327.
5) Individual Remote Station malfunction. Faulty remote station, Replace suspect unit with known good
headset or cable. unit. Defective remote stations or
headsets should be returned to factory
for service. There are no user
servicable parts in these units.
6) Hum or Buzz in system. Inductive pickup caused by Relocate offending unit.
close proximity of main or
remote station to power lines
or transformers.
Ground loop caused by Reverse power cord. Lift ground.
improper grounding of system
(See installation instructions)
10-ohm chassis ground resistor Open main station by removing 2 screws
(Rl CS-200) in main station open. in handle and unscrewing 4 feet. Slide
(Note: This is caused by the off cover and check 10 ohm resistor on
system ground coming in contact the bridge rectifier terminal strip.
with something that is "hot" If open, replace
with respect to main station
earth ground. Should this occur,
a careful check of the system
ground and A.C. distribution in
your location is recommended.)
1/78
- 9 ­
SYSTEM INTERCONNECTION DIAGRAM

CS-100
CS-200 ., . /
PS-3cxx)
~ caM D3M

~ D3F
~~
(UOO
(UQ \.U0 D3M D3M D3M
., " ~

GJOQ

PIN CONNECTIONS
FOR CABLE
PIN 1 - SH IELD
PIN 2 - +28VWS
INTERCONNECT CABLE
PIN 3 - AUDIO
BElLEN 8413
TO OTHE~ - 10 ­
STATIONS
 CS-100/CS-100K MAIN STATION (FRONT PANEL)
FIGURE 3
POWER CALL LIGHT HEADSET AUXILIARY

SWITCH VOLUME VOLUME

CONTROL CONTROL

Volume Volume

@
Coli

CALL AUXILIARY

BUTTON HEADSET JACKS INPUT

CONNECTOR

* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
CS-100/CS-100K r~AIN STATION (BACK PANEL)
INTERCONNECT
CIRCUIT

CABLE
BREAKER

OUTPUTS

••© 0
~
PUSh~O
reset

••© ©

MASTER GAIN SET

CORD

FIGURE 4
1/78 - 11 ­
 CS-200/CS-200K MAIN STATION (FRONT PANEL)

FIGURE 1

POWER CALL LIGHT HEADSET AUXILIARY

SWITCH CHANNEL A VOLUME VOLUME
CONTROL CONTROL

0 ®

@ 0 :1c"~nel
\/olU!TI& Volume

- -
Call l"l"" '<>eled

® ®

CALL CALL LIGHT HEADSET JACKS AUXILIARY

BUTTON CHANNEL B INPUT
CHANNEL A-B SELECT SWITCH CONNECTOR
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
CS-200/CS-200K MAIN STATION (BACK PANEL)
INTERCONNECT MASTER GAIN SET CIRCUIT
OUTPUTS CHANNEL A BREAKER
CHANNEL A

@Pusl,...tO
re~et

MASTER GAIN SET

OUTPUTS
CHANNEL B POWER-+
CHANNEL B
CORD

FIGURE 2
1/78 - 12 ­
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 CS-I00/CS-200 PARTS LIST

ITEM PART # DESCRIPTION REF. DES. CS-I00 CS-200

\1fY. QTY.

1 1800 Choke, Fi 1 ter Ll 1 1

2 4805 Diode, 3A IN5401 07,8,9,10 4 4

3 1523 2000 mfd 35V Cl, C2 2 2

4 1529 .01 mf/l.4kV Capaci tor C3 3 3

I
5 5202 .5 Amp Circuit Breaker CBl 1 1

6 3900 Call Light Assembly II, 12 1 2

7 3901 #327 Lamp, 28V. 1 2

8 2113 04M Connectors J 1, J2 2 2

9 2102 03F Connector J3 1 1

10 2103 D3r1 Connectors J4 - J9 6 6

11 4701 250K Pot 3/8 " Bushing PI, P2 2 2

12 4702 lK Pot 1/4" Bushing P3, P4 1 2

13 7103 Amplifier Modul e PCl 0 1

14 71 02 Amplifier Modul e PCl 1 0

15 4102 10 ohm 1/4w Re si stor Rl 1 1

16 5100 Push Button Sl 1 1

17 5102 Power Swi tch S2 1 1

18 5602 Power Transformer Tl 1 1

19 6000 Power Cord 1 1

20 7120 3 Position Lever Swi tch/ S3 0 1

Plug Assembly

21 2401 Knob 1 1

22 2402 Feet 4 4
 SPECIFICATIONS
CS-100/CS-200 MAIN STATION

AMPLIFIER: Solid State IC plug in printed circuit amplifier

module including signalling circuit. Current
limited and short circuit protected.
FREQUENCY RESPONSE: 250 Hz - 10 KHz (-3 dB ref. to 1 KHz) with a rising
response to enhance voice intelligibility.
HEADSET MICROPHONE INPUT LEVEL: -55 dBm.

HEADPHONE OUTPUT LEVEL: 9 volts rms into 600 Jl.maximum. (-20dBm)

DISTORTION: Less than 0.5%.

SYSTEM IMPEDANCE AND LEVEL: Approximately -25 dBm into 200 (Level dependent on

master gain control settings)

AUXILIARY INPUT AUDIO LEVEL: 100 mv into 600 Jl. mi nimum.
CHANNEL SEPARATION (CS-200): "> 45 dB.
HEADSET INPUT CONNECTOR: 2 - 4 pin connectors (D4M)
INTERCONNECT OUTPUT CONNECTORS:
CS-100: 6 each in parallel, Switchcraft D3M.
CS-200: Channel A: 3 each in parallel, Switchcraft D3M.
Channel B: 3 each in parallel, Switchcraft D3M.
AUXILIARY INPUT CONNECTOR: Switchcraft D3M.
POWER SUPPLY: 28 volts circuit breaker protected.
CAPACITY: Will support up to 40 RS-100A or MR-102 remote
stations or 15 KB-100 or KB-lll remote stations.
POWER REQUIREMENTS: 115/230 volts 50-60 Hz. 80 watts maximum.
DIMENSIONS:
CS-100/CS-200: 9.5"L X 4"H X 8.5"D.
CS-100K/CS-200K: 19"L X 3.5"H X 9.125"D.
WEIGHT:
CS-100/CS-200: 6 1bs. 14 oz.
CS-100K/CS-200K: 6 1bs. 15 oz.