David Clark 9500 SERIES Installation Manual Download Page 20 | Manualshive

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19532P-76 (09-15)

of 22

16

Cable

Type

Connector(s)

on Master

Station

Connector

Type

Correct

AMP

Tool

Connector Wiring Diagram

System

Cables

Main Board:

J1-J2-J3-J4

Blue

Connector

59803-1

09271P-35HA000

SYSTEM CABLE

CONDUCTORS

BLUE HEADER

Radio

Cables

Cover Board:

J1-J4-J5

Blue

Connector

59803-1

09271P-35HA000

RADIO CABLE

CONDUCTORS

BLUE HEADER

PTT

Cables

Main Board:

J6-J7

Small White

Connector

59803-1

SMALL WHITE HEADER

REMOTE PTT CABLE

CONDUCTORS

Power

Cable

Main Board:

J5

Large Yellow

Connector

59804-1

09815P-20HA000

POWER CABLE

CONDUCTORS

LARGE YELLOW HEADER

Table 2: Affixing Amp Connectors

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Summary of Contents for 9500 SERIES

Page 1: ...19532P 76 09 15 2015 David Clark Company Incorporated INSTALLATION MANUAL SERIES 9500 MARINE INTERCOM SYSTEM ...

Page 2: ......

Page 3: ...Figure 1 Typical 4 Person Layout 4 Figure 2 Mounting the Master Station 6 Figure 3 C95 XXLN System Cable 10 Figure 4 Correct use of Cable Labels 10 Figure 5 C95 20RD Radio Cable 11 Figure 6 C95 15RS Remote PTT Cable 12 Figure 7 C95 20PW Power Cable 13 Figure 8 Power Cable 14 Figure 9 Master Station Internal Connections 17 Figure 10 Belt Station Connections 18 Figure 11 Master Station Controls 19 F...

Page 4: ......

Page 5: ... THAT APPEARS DAMAGED Upon unpacking your David Clark product inspect the contents for shipping damage If damage is apparent immediately file a claim with the carrier and notify your David Clark product supplier ELECTRICAL HAZARD Disconnect electrical power when making any internal adjustments or repairs All repairs should be performed by a representative or authorized agent of the David Clark Com...

Page 6: ... Headset 40797G 02 Customer Specified Qty C9500PR Portable Radio Cord 40799G 01 1 Req d for each Portable Radio Master Station Mounting Kit 40688G 62 Qty 1 Cable Fittings Nuts As Required Blue 8 pin AMP connectors 1 per Belt Station and Radio Yellow 3 pin AMP connector Qty 1 White 3 pin AMP connectors 1 per Remote PTT AMP tool 59803 1 for blue white connectors Qty 1 AMP tool 59804 1 for yellow con...

Page 7: ...r Station Master Station Model Number U9500 Headsets up to 6 Over the Head Style Model Number H9530 Behind the Head Style Model Number H9540 Cables In Line System Cable 1 per headset 10 ft length Model Number C95 10LN 20 ft length Model Number C95 20LN 30 ft length Model Number C95 30LN Belt Station Cable 1 per Belt Station Straight Cable Model Number C95 12BS Coiled Cable Model Number C95 15BS Po...

Page 8: ...5 20RD 40919G 02 Radio Cable 3 Ea Shown C95 12BS 40798G 01 Cable or C95 15BS 40872G 01 Coil Cord 4 Ea Shown U9510BS 40795G 03 Belt Station 4 Ea Shown 3 4 Dia Cable Fitting 3 Req D 40794G 03 Belt Station Co Captain Belt Station Captain Belt Station Crew 1 Radio 1 Radio 2 Radio 3 Belt Station Holster U9510BH 40796G 01 Belt Station H9540 40797G 02 BTH or H9530 40864G 02 OTH Headset 4 Shown Crew 2 Han...

Page 9: ...ure entering the enclosure The Master Station is weather tight however the mounting location should chosen to minimize direct water exposure Mounting Using a Philips screwdriver remove the 4 screws on the cover of the Master Station and lift off the cover Observe the 4 mounting holes in each corner as shown in Figure 2 Position the Master Station Drilling Template on the mounting surface and mark ...

Page 10: ...19532P 76 09 15 of 22 6 Figure 2 Mounting the Master Station ...

Page 11: ...19532P 76 09 15 of 22 7 ...

Page 12: ...19532P 76 09 15 blank of 22 8 ...

Page 13: ... feed the end with 2 of insulation removed toward the Master Station The end with the large Nexus jack connects to the Belt Station Use grommets each time the cable is passed through a wall or surface Use wire ties where necessary Determine the function of the position Captain Co Captain Crew1 Crew2 Insert the cable into the correct cable fitting on the Master Station The correct fitting to use is...

Page 14: ... BRN ORG ORG BLUE SHIELD MIC HI 8V EAR HI GND REMOTE PTT PTT HI SHIELD MIC HI 8V EAR HI GND REMOTE PTT PTT HI SHIELD To Master Station Main P C Board J1 J2 J3 and J4 D C C I Cable 09271P 35 HA000 or equivalent Measure and Strip Jacket 2 1 2 from Cable End C95 XXLN System Cable P N 40877G XX Figure 3 Figure 4 Correct use of cable labels ...

Page 15: ...from radio antenna coax cables and anywhere water may collect Measure the length of cable necessary adding 3 ft as a service loop If necessary trim the length of the cable to the length you just determined in the previous step Be sure to trim the un prepared Radio end of the cable See Figure 5 above Route the cable Use grommets each time the cable is passed through a wall or surface Use wire ties ...

Page 16: ... possible from radio antenna coax cables and anywhere water may collect Estimate the length of the cable necessary adding 3 ft as a service loop If necessary trim the length of the cable to the length you just estimated Be sure to trim the end of the cable that does NOT have the PTT switch Route the cable Use grommets each time the cable is passed through a wall or surface Use wire ties where nece...

Page 17: ...amperage circuit breaker is available it may be used but the David Clark 2 Amp Fuse Kit 40688G 47 must also be used Determine the path of the cable between the power source and the Master Station The cable should be routed using under deck conduits and be as far as possible from radio antenna coax cables and anywhere water may collect Measure the length of cable necessary adding 3 ft as a service ...

Page 18: ...the cable as shown in Figure 8 below If using the David Clark 2 Amp Fuse Kit please see Appendix B for assembly instructions Connect the cable to the power source o Connect the RED to the positive terminal o Connect the BLACK and SHIELD to the negative terminal Do not turn on power at this time wait until Section 9 Testing Troubleshooting To 2 amp circuit breaker fuse RED BLACK SHIELD Figure 8 Pow...

Page 19: ... AMP tools Place the connector on a flat surface or suitable support to prevent rocking when inserting the wires Position wire over the contact in the AMP connector Make sure the end of the wire does not extend over the shoulder of the connector Start the wire into contact with finger Place appropriate tool on wire over contact so that the center line of the tool matches the contact The tool must ...

Page 20: ...00 SYSTEM CABLE CONDUCTORS BLUE HEADER Radio Cables Cover Board J1 J4 J5 Blue Connector 59803 1 09271P 35HA000 RADIO CABLE CONDUCTORS BLUE HEADER PTT Cables Main Board J6 J7 Small White Connector 59803 1 SMALL WHITE HEADER REMOTE PTT CABLE CONDUCTORS Power Cable Main Board J5 Large Yellow Connector 59804 1 09815P 20HA000 POWER CABLE CONDUCTORS LARGE YELLOW HEADER Table 2 Affixing Amp Connectors ...

Page 21: ...PTT LO BROWN 5 EAR HI GREEN 6 EAR LO BLACK 7 N C 8 N C SYSTEM CABLE SIGNALS FOR J1 AND J2 1 MIC HI RED 2 EAR HI GREEN 3 PTT HI ORANGE 4 MIC HI RED FOR PARALLED STATION 5 GND BLACK 6 8V WHITE 7 SHIELD JUMPER BLUE 8 REMOTE PTT BROWN SYSTEM CABLE SIGNALS FOR J3 AND J4 1 MIC HI RED 2 EAR HI GREEN 3 PTT HI ORANGE 4 MIC HI RED FOR PARALLED STATION 5 GND BLACK 6 8V WHITE 7 SHIELD JUMPER BLUE 8 NO REMOTE ...

Page 22: ...l they lock To remove turn collar counter clockwise and pull Connect the system end of the Belt Station Cable large black green plug to the mating jack on the System Cable by aligning the keyway and pushing until it locks into place To remove simply pull apart If you are also connecting a hand held radio connect the yellow black end of the hand held radio cable to the yellow black jack on the Belt...

Page 23: ... all three radios on the intercom 2 System Volume adjusts the voice level of all of the users on the intercom 3 The toggle switches control whether the Rx audio from the radios can be heard Each radio has its own Rx Audio On Off switch 4 The Radio Select switch determines which radio is active for transmitting ON RX 3 RADIO RX VOLUME RADIO SELECT 1 2 3 SYSTEM VOLUME ON RX 2 R R Figure 11 Master St...

Page 24: ...to Intercom PTT function Headset Can Hear IC YES PTT enables user to speak over intercom No ship radio transmit Intercom Ship radio Hand held radio if connected RAD YES User has hot mic over intercom PTT enables transmit over ship radio Intercom Ship radio Hand held radio if connected Table 3 Belt Station Operation when connected to 9500 Marine Intercom System Belt Station with Hand Held Radio Att...

Page 25: ...nd transmit capability over each radio in the system o Flip switches for each radio on the Master Station to the ON position up Verify receive audio from each radio o IC RAD switch must be in RAD mode only then does PTT key the radio o At the Master Station switch to each radio with the selector switch and verify PTT Mic This switch controls which radio the Belt Stations have Mic PTT access to o O...

Page 26: ...turned on 2 Radio turned on 3 Radio s volume setting up to an audible level on radio 4 Check radio settings wiring No boat radio transmit 1 Power to system turned on 2 Radio turned on 3 Belt Station IC RAD switch in IC mode Must be in RAD mode 4 Check radio settings wiring No handheld radio transmit 1 Power off and then power on the handheld radio Too low or too high radio transmit audio 2 See App...

Page 27: ...MIC HI RED FOR PARALLED STATION 5 GND BLACK 6 8V WHITE 7 SHIELD JUMPER BLUE 8 NO REMOTE PTT 8 7 6 5 4 3 2 1 J1 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 8 7 6 5 4 3 2 1 10 11 12 13 14 15 16 9 8 7 6 5 4 3 2 1 10 11 12 13 14 15 16 1 2 3 J8 J7 J6 J5 J1 J2 J3 J4 Radio 1 Radio 2 Radio 3 RX1 Level R3 TX1 Level 8 7 6 5 4 3 2 1 J5 8 7 6 5 4 3 2 1 J4 RX3 Level R21 R2 RX2 Level R10 R...

Page 28: ...ce of 1 8 diameter heat shrink tubing over the red wire on the C98 20PW Power Cable 2 Thread red wire of power cord with heat shrink tubing into one end of fuse holder 3 Thread the heat shrink end of the 4 inch red wire into other end of fuse holder 4 Strip insulation on both wires 1 4 inch 5 Crimp fuse clips to both wires Recommended crimp tool Radio Shack No 64 409 or equivalent 6 Insert 2 amp f...

Page 29: ...erting the wire 2 Position wire over the contact in the MTA connector Make sure the end of the wire does not extend over the shoulder of the connector Start the wire into contact with finger 3 Place appropriate tool on wire over contact so that the centerline of the tool matches the contact The tool must be positioned as shown in Figure below 4 Holding the tool handle perpendicular to the contact ...

Page 30: ...egrade the quality of the transmissions If you have the equipment to measure the modulation 4 4 5 KHz is an optimum deviation level Radio Receive Level Adjustments The factory has pre set the receive audio adjustment potentiometers to levels which should be acceptable in most applications Should the need arise to change these settings the installer may do so by the following procedure To increase ...

Page 31: ...ut level of Radio 3 is 1 7 VRMS TX Audio outputs for all three radios are based on a 98 dB SPL 1 4 from the headset microphone Radio RX Audio System has transformer coupled audio input 600 ohms primary and can be adjusted for various input levels depending on Radio Volume Setting Radio Inputs Provides connection for up to three mobile radios Radio Connection MTA 100 Amp Closed End Housing with pin...

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