CC2001/IND2 INDUSTRIAL CONTEL

APPLICATION

The INDUSTRIAL CONTEL system has been developed to provide a reliable, robust and effective industrial communication system.

It has been used successfully in a variety of applications including Can Manufacturing, Card and Furniture Manufacturing, Under-Bridge “Cherry-Pickers”, Food Processing Plants and Research Laboratories. The tailored frequency response of the unit reduces transmission of machine noise whilst relaying the communication spectrum and a feedback circuit reduces sidetone to a minimum which enables received signals to be boosted to a high level, audible over the local ambient noise, even with ear-plugs if necessary! The system may be installed with a mixture of industrial type and office type ConTel Stations. ConTel Stations are usually positioned at or near all major workstations. The common speech channel on a standard system provides point to point communication and permits conferencing with more than two stations.

The system normally operates in conjunction with a 100v line PA system. Loudspeaker positioning can provide coverage in any operational area, and particular emphasis is given to the coverage of strategic positions, not necessarily adjacent to a ConTel, for either calling particular personnel to an adjacent ConTel for a discussion or for direct instructions to be relayed. Normally, loudspeakers should be distributed to give even coverage of production areas, taking account of the noise sources. Localised muting should be considered. See CC2001/MR Data Sheet.

Many options are available to suit special applications. These include dual speech path (CC2001/IND/DCCT), selective calling (CC2001/IND/SEL+C2001/MR), zoned calling (CC2001/IND/SEL+CC2001/MR), interfacing to audio/visual systems (CC2001/IND+T1), IP rated enclosures (CC2001/IP55), and auto-call, point-to-point applications (CC2001/PP).
The manufacturer would be pleased to advise on any application not listed above.

SPECIFICATIONS

Speech Paths:                     a)         Intercom Line
                                          b)         Paging Line

Auto Power Off:                 Selectable 12-60 seconds (set at installation Lk3)

Indicators:                          a)         Unit Active
                                          b)         System Busy (set at installation Lk2) or
                                                      Paging Active (set at installation Lk2)

Aux. Switched 24VDC       Maximum load 400mA resistive. (eg. CC2001/MR)
Power Requirements:          Supplied by the ConTel Power Supply CC2001/PSU
                                          Nominal 24VDC @ 100mA (200mA when paging)
Connections:                       Screw Terminals (with cable protectors)
                                          Maximum cable size 1.5mm2CSA
Size:                                   132mm (W) x 256mm (H) x 166mm (D) (excluding cable glands).

CONNECTION DETAILS
 

ConTel Terminal


 

CW1308 Colour

Pair No

TS1-1

Line A

Blue

]1

TS1-2

Line B

White

TS1-3

Page A

Orange

]2

TS1-4

Page B

White

TS1-5

Muting Relay Module 0V Sw

 


 

TS1-6

Muting Relay Module +24V


 


 

TS1-7

Supply 0V

Green

]3

TS1-8

Supply +24VDC

White

TS1-9

Page/Busy line

Brown (White)

4

TS1-10

Special Function


 


 


 

NC

White (Brown)

4


 

NC

Grey

]5


 

NC

White


 


 

TYPICAL LAYOUT OF SYSTEM


 

The parallel design of the system enables additional ConTel Stations to be added without wiring back to a central exchange. Because of this the ConTel Stations may be connected anywhere on the circuit. Consideration should be given to avoidance of volt-drop problems. Please refer to the Data Sheet on the Power Supply Modules, CC2001/PSU. ConTel systems should always have a minimum of two Power Supplies and additional Power Supplies fitted in a ratio of one for every twenty ConTel stations.


 

Ideally, the system should be based around a ring circuit. Spurs are permitted, subject to the above mentioned considerations.

Fig 1 shows an example of a typical installation using two Power Supply Modules.


 


 


 

If operating with a 100v line PA system localised muting of loudspeakers adjacent to ConTel Stations must be considered. Please refer to the CC2001/MR Data Sheet.

Fig 2 shows how up to three ConTel Stations may be wired to mute one bank of loud-speakers.

Each ConTel Station can control up to three CC2001/MR Modules, although in practice this degree of complication should not be necessary.

Installation instructions are detailed in the CC2001/MR Data Sheet.
 

INSTALLATION

The ConTel Stations may be mounted (using the three holes in the rear of the unit) directly to a wall, a panel of a machine, or utilising 'U' bolts (available to special order) to safety rails or similar structures.

The ConTel Stations must be wired in a minimum of 6-wire (3pr) twisted pair cables to CW1308 (or similar). 12-wire (6pr) is preferable to allow for spares and connection of busy circuits, remote muting relays, etc. The conductor size of this cable is 0.5mm diameter. If selecting an alternative cable the important considerations are the twisted pairs, >50 volt rating and small size, allowing daisy-chain connection and spurs from each ConTel Station. The standard terminal strips are able to accept a maximum cable size 1.5mm2 CSA.


 

Fig. 3 shows the internal view of a ConTel Station.

The interconnecting cables (and necessary muting cables) should be routed through the 20mm Nylon gland provided or through Flexible Conduit.

Provide sufficient cable (after termination) inside the box for the ends to reach the top (for possible additions, eg. CC2001-T2 Timer Board Dual Circuit, or alterations.)

Terminal Strip TS1 is located at the bottom of the lower printed circuit board.

Terminate all ConTel Stations in parallel. i.e. TS1-1TS1-1, TS1-2TS1-2, etc., as detailed on the Connection Details on Page 2.

The connection of TS1-9 will give global or local indication as desired, see COMMISSIONING NOTES at the end of this Data Sheet.

Do not cut off remaining unused conductors these may be needed later. (e.g. TS1-9).

 

COMMISSIONING

Link Lk1 is set on manufacture to provide for electret/moving coil microphone insert and should only be re-set if replacing a circuit board/microphone insert.

Link Lk2 may be used to pre-set whether the red LED is illuminated on Paging, Paging Busy or System Busy. When deciding this option, consideration should be given to whether your system needs to seize priority from other services for paging. Most installations do not carry music, and so the line input is connected at lowest priority, not needing to do so. Also consider that TS1-9 is used to control local paging amplifiers in desk ConTel stations so use of TS1-9 is desirable if CC3000 Desk Stations are included on the system.

The connection of TS1-9 will give global or local indication as desired. Place Lk2 in position B to illuminate on Paging, position A to illuminate on System Busy. TS1-9 line will be switched low, (seizing priority if this is to be used). Please note, to provide global indication, TS1-9 must be connected throughout the system, and all ConTel stations similarly set-up to illuminate the red LED on the front panel as per the selected option.

Global paging busy indication” Lk2 in position B and TS1-9 connected throughout: In this setting, the red LED on the front of all ConTel stations will illuminate whenever any similarly set ConTel is paging. TS1-9 will be taken low, seizing priority if applicable.

Global intercom busy indication” Lk2 to position A and TS1-9 connected throughout The red LED will indicate “system busy” whenever any ConTel station of ‘off-hook’ (intercom or paging). TS1-9 will be switched low. (NB This will have the effect of seizing priority if used and any CC3000 Desk ConTel Stations on the system will have their paging amplifiers ‘switched on’ whenever the system is busy.)

If global control/indication is not fitted/required (no connection is made to TS1-9), link Lk2 to B (as supplied). The red LED illuminates when ConTel is paging to indicate local paging. (If Desk Stations are included, the Lk1 link on the Mk3000 Interface Unit Interface module labelled should be set to D to permanently ‘switch on’ the internal amplifier.

TS1-10 is switched low whenever a ConTel is in use. Applications include remote switching and silencing of local audio/visual alarms.

Link Lk3 is the automatic power-off pre-settable timer selector. Adjustment of this is largely a matter for site conditions to dictate based on the following guidelines; The on-timer starts on initial activation of the handset trigger and will start timing again every time the trigger is reactivated. Therefore, momentary activation of the handset trigger is recommended during lengthy conversations, avoiding the necessity to be prompted by the green LED extinguishing! From this it could be concluded that the longer the timer, the better. Unfortunately, whenever a unit remains switched on after use, local machine noise is transmitted onto the line, inconveniencing other users, so the timer should be as short as possible! As a rule of thumb, the noisier the environment the ConTel Station is installed into, the shorter the timer should be. Minimum time is 12-15 seconds with the link installed at the top, up to 45-60 seconds with the link at the bottom. The two middle settings are the most common, and the users quickly develop a habit of squeezing the handset after each sentence.

RV1, RV2 & RV3. The ConTel Station pre-sets are all factory set. They should not be touched without an a.c. micro-voltmeter or oscilloscope and full setting-up instructions. If adjustment of RV1 or RV3 presets is carried out without the necessary set-up equipment, system balance will be adversely affected and system efficiency will be reduced.

RVI sets mic gain and directly affects both intercom and paging levels. This potentiometer is pre-set at manufacture and should not need adjusting unless your site uses historically ‘peculiar’ line levels. In this unusual case, adjust this potentiometer to suit existing site levels at installation. Subsequent adjustment will not be necessary. Any suspicion that such adjustment is required should be investigated more thoroughly.

RV2 sets earpiece levels. Rather like the setting of the timer link Lk3 above, this is set to accommodate the locality at installation. A relatively quiet office may need earpiece volume reduced; a noisy machine may need it turned up, particularly if users will usually be wearing ear-plugs. Subsequent adjustment will not be necessary. Any suspicion that such adjustment is required should be investigated more thoroughly.

RV3 sets side-tone to null out local noise in your earpiece when engaged on an intercom conversation. This is pre-set at manufacture and should only need adjustment if it has been inadvertently moved! It must be adjusted to ‘null’ local side tone when one (and only one) other ConTel is switched on to terminate the balanced bridge circuit.

RV1, RV2 & RV3. The ConTel Station pre-sets are all factory set. They should not be touched without an a.c. micro-voltmeter or oscilloscope and full setting-up instructions. If adjustment of RV1 or RV3 presets is carried out without the necessary set-up equipment, system balance will be adversely affected and system efficiency will be reduced.


 

 

 

 

Electromagnetic compatibility (EMC) directive. This equipment has been designed and manufactured to the highest standards. If connected and operated as set out in this manual, there should be no Electromagnetic Compatibility problems. If any aspect of operation gives rise to concern, then please contact the manufacture for advice.

This CONTEL STATION is supplied subject to our Terms & Conditions of Trade, a copy of which is available on request from Porter Electronics, Tel 01726 851120. Because we are the manufacturer of the ConTel system, we are able to offer considerable flexibility to suit specific applications. We would be pleased to advise on any application not listed above.

 

 

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