STAGE INTERCOM KIT 1.1 SPECIFICATION. General: The lower section is a small power amplifier designed to drive headphones or a small 8ohm speaker.
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1 STAGE INTERCOM KIT Version March EduTek Ltd 1.0 DESCRIPTION This intercom module comprises of two separate circuits sharing the same supply. The upper section is a pre-amplifier designed to connect to a standard headset microphone or electret microphone. The output of the pre-amplifier can be adjusted from 0 to 100% output using the onboard preset The lower section is a small power amplifier designed to drive headphones or a small 8ohm speaker. The two circuits combine to provide the functions needed to create an intercom module that can be connected up to other modules all sharing the same "Comm. Link" connection. Extra components are needed which are connected away from the PCB. All connections are made via terminal blocks. 1.1 SPECIFICATION General: Power supply: Standby current: Max. current: 6 to 9v 9v 60mA approx. Pre-amp section: Microphone input: 5 to 25mV (max) AC gain: 45 Input impedance: 22Kohms Power amplifier section Quiescent current: 6mA Voltage gain: 26 Harmonic distortion: 0.2% Input impedance: 50Kohms Output impedance: 8ohms Fig1.1 - Block diagram of intercom
2 1.2 CIRCUIT DIAGRAM The components marked with * are not mounted on the PCB. They are the extra optional components to tailor the module to function as an intercom. The extra components are: D1-1N4001 diode D2 - Green LED D3 - Red LED R7-330 ohm resistor R8-330 ohm resistor R9-220 ohm resistor C5-4.7uF capacitor VR1-47K potentiometer SW1 - SPST toggle switch SW2 - DPDT toggle switch BC1 - PP3 Battery clip Skt1,3-3.5mm mono jack socket Skt2-3.5mm stereo jack socket Skt4 - DC 2.1mm power socket The circuit drawn within the grey box contains all the components that are mounted onto the PCB. The LED indicators are optional and if preferred can be omitted by removing D2,D3, R7 and R8. There are 3 extra components: Rubber control knob for VR1. Mono jack plug to use for connecting intercoms to the Comm. link. Screened cable for internal wiring The circuit has the option to use and recharge a 7.2v NiMH battery if desired. See section power options Fig Stage Intercom Circuit Diagram
3 1.3 EXTRA COMPONENTS The extra components are listed below with their values, images and methods of mounting since they are not included on the PCB. Table Extra component details Label Component Image Method of mounting D1 Diode 1N4001 The anode of D1 is soldered to one of the tabs of Skt4, the DC power input socket. Silver band denotes cathode. D2 D3 LED green 5mm LED amber 5mm The LEDs D2 and D3 are fixed onto the case lid with 5mm holes. LED mounting clips can also be used. R7 R8 Resistor 330 ohm Resistor 330 ohm Resistors R7 and R8 solder between the cathodes (short wire) of D2 and D3 respectively, and the "online" switch SW2. R9 Resistor 220 ohm, 0.5w Resistor R9 solders to one of the tabs of Skt4. C5 Capacitor 4.7uF electrolytic The capacitor is connected with the anode (long wire) to one of the tabs of SW2, and cathode (short wire) to one of the tabs of VR1, the volume control. VR1 Potentiometer 47Kohm Mounted in case - 6.5mm hole required for mounting. SW1 SPST rocker switch S1 is the power switch and a round rocker type - 20mm hole required for mounting. SW2 DPDT toggle switch Mounted in case - 6.5mm hole required for mounting. BC1 Battery clip PP3 Left lose in case, connected to DC power socket. Skt1-3 Jack socket 3.5mm stereo Mounted in case - 6mm hole required for mounting. Skt4 DC power socket 2.1mm Mounted in case - 8mm hole required for mounting.
4 2.0 INTERCOM WIRING Fig 2.1 shows a recommended method of wiring up the intercom. It is advised to use screened cable for low signal connections. Components can be placed in a case with little restrictions. If using a metal case, it is a good idea to connect the case to ground and thus also take care that no bare tab connectors or leads can touch the casing. The jack sockets are stereo types but the module is a mono system so the left and right channel connection tabs can be joined together to ensure contact to both channels of a headset. Fig 2.2 shows how the connection tabs on the jack sockets can be shaped. Fig Bending legs of stereo jack sockets. The power socket shown in Fig 2.3 is wired so that the centre pin is zero volts. This is so the insertion of a mains adapter disconnects the battery supply from the circuit and powers it instead. The mains adapter used should have the following polarity symbol. Fig Polarity symbol The DC socket is shown with the middle tab in front of the socket. For power connection clarity and options please refer to section Power options. It is advised to use sleeving over bare wires from component leads such as the capacitor and resistors. Insulation from standard 7/0.2 stranded wire can be striped and used to cover the leads. The gold colour wires in the diagram denote the shielding in the screened cable. Note the screens on the two comm. link connection wires are joined together. Fig Stage intercom wiring diagram.
5 2.1 POWER OPTIONS DC ADAPTER AND RECARGEABLE BATTERY This is the option shown in Fig 2.3. It is important that only a rechargeable battery (NimH) is used in this configuration since the DC socket is wired to charge the battery when an external supply is used. in this configuration, the centre pin of the mains adapter plug is 0v and the outer shell is positive. Do not use a lithium cell battery. If using a standard PP3 battery it is essential that R9 is not connected (see fig. 2.4) to prevent charging occurring when a plug from a mains adapter is inserted. The polarity of the DC plug is the same as fig.2.3. Fig Wiring DC socket without charging option. 2.2 LINKING INTERCOMS The intercoms are connected via the "Comm Link" socket. Each unit is connected in parallel (see fig.2.7). The distance between the units is almost unlimited although quality and loss of signal will be affected with runs over 100m. Ordinary speaker wire can be used for the communication link but for distances greater than 10m, it is recommended to use screened cable to reduce noise and interference. If using screened cable for the communication link, the centre wire should connect to the centre connection of the jack plug and the braiding to the wire grip connection. The maximum number of intercoms that can be linked in parallel is around 10 to 15. More will result in loading of the comm. link and degradation of the communicated signal. Fig Linking intercoms on Comm. link MAINS ADAPTER ONLY With the power coming from a mains adapter connected via SK4, the resistor R9 and the battery clip can be removed (see fig. 2.5). The mains adapter can be from 6 volts to 9 volts. The polarity is the same as fig.2.3 and fig.2.4. Fig Wiring DC socket with no battery. OPPOSITE POLARITY If the battery option is not required and there is difficulty obtaining a mains adapter with the centre pin at 0v and the outer shell at +v, then the DC socket can be wired to accommodate the opposite polarity, as this tends to be more common. Fig Wiring DC socket with opposite polarity. A small block connector can be used to join the link wires. It should be housed in a small potting box or similar small enclosure.
6 Fig Using terminal block to connect to link. 3.0 FUNCTION PR1 sets the level out from the pre-amp connection and thus the line level of the communication link for each intercom. Each intercom should be set around the same level. The units perform best with the level set on the communication link (using PR1) between 750mv - 1v. Turning the preset to the halfway position is approximately correct. The same method can be used to distribute power and the comm. link to all intercoms requiring just one power supply. Fig Combining power and link distribution TESTING Use a headset with microphone. Plug the headset into the jack sockets. Leave the communication link disconnected. Set the level of PR1 halfway. Set the level of VR1 about a third of the way. Turn the power on. Switch the on-line switch on. The amber LED should come on and you should be able to hear your own voice. If it starts to whistle or howl, then reduce the level of VR1 or PR CHARGING If using the recharging option, the charging current is controlled via R9, the 220 ohm resistor. If the DC mains adapter used is 9v, then the charging current will be a minimum of: Icharge = (9v - ( )) / 220 = 5mA Assuming the battery has dropped to half its voltage, the charge current will be: Icharge = (9v - ( ) / 220 = 21mA The values are approximate since most unregulated mains adapters vary in voltage under different loads. A mains adapter with a current capability of approx. 100mA for each intercom should be used. 2.4 USING A SPEAKER Instead of a headset, an 8 ohm speaker can be used. The microphone can be a standard electret type terminated with a 3.5mm jack plug. Care should be taken with the levels, not to create positive feedback resulting in screeching noises. Turn off the on-line switch. Connect the comm. link jack into the socket. Connect another intercom and headset. Turn on the second intercom and on-line switch. Sound from the second intercom should be heard in the headset of the first FAULT FINDING No Power LEDs and no sound on headset. Battery flat. DC plug polarity incorrect. 2.5mm DC power plug instead of 2.1mm. Fault mains adapter. LEDs light up but no sound can be heard. Short circuit in connection to SKT2. Fault with headset. Level turned down. Sound goes quiet when the comm. link jack plug is inserted. Short circuit on comm. link wire/plug/socket Using different power supplies and the jack plug or jack sockets are wired in reverse. Screeching and feedback can be heard. Lower the gain of PR1 and VR1 Move the microphone further from the speakers Disclaimer: Edutek Ltd takes no responsibility or liability for the use of this kit. You accept this by using this kit. All work should be carried out by a competent and experienced engineer. Seek advice if you are unsure about any aspects of this document. Care should be taken when using mains adapters. Always read instructions provided. If you have any questions or concerns, please contact us at sales@edutek.ltd.uk
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