Ampcontrol VCA User manual

VoiceCom System
User Manual
USER MANUAL E06397 ISSUE 4 15/8/08
VCA_Manual_Issue_4_E06397_15/8/08.pdf
Designed and Manufactured in Australia by
Ampcontrol Pty Limited ACN 000 915 542
Phone: [phone] Fax: [phone]
www.ampcontrol.com.au
No copies of the information or drawings
within this manual shall be made without the
prior consent of Ampcontrol.

VOICECOM USER MANUAL ISSUE 4
Copyright Notice
No part of this publication may be
reproduced, transmitted or transcribed into
any language by any means without the
express written permission of Ampcontrol
Pty Ltd, 250 Macquarie Road Warners Bay,
NSW 2282, Australia.
Disclaimer
Ampcontrol Pty Ltd will make no warranties
as to the contents of this documentation
and specifically disclaims any implied
warranties or fitness for any particular
purpose.
Ampcontrol further reserves the right to alter
the specification of the system and/or
manual without obligation to notify any
person or organisation of these changes.
Before You Begin
We would like to take a moment to thank
you for purchasing the VoiceCom
Communication System. To become
completely familiar with this equipment and
to ensure correct operation, we recommend
that you take the time to read this user
manual thoroughly.
CRN: 4820
Software Version 4.0

VOICECOM USER MANUAL ISSUE 4
CONTENTS
CHAPTER 1 –OVERVIEW OF THE VOICECOM SYSTEM................................................................................... 4
System highlights......................................................................................................................................... 4
VCA features................................................................................................................................................ 4
VAA features................................................................................................................................................ 4
Applications.................................................................................................................................................. 4
The VoiceCom Controller –VCA.................................................................................................................. 5
Key Functions .............................................................................................................................................. 5
Controller Terminals..................................................................................................................................... 5
PC Software................................................................................................................................................. 6
Modbus ........................................................................................................................................................ 6
The VoiceCom Amplifier –VAA Overview.................................................................................................... 6
Key Functions .............................................................................................................................................. 6
Keypad......................................................................................................................................................... 6
Display ......................................................................................................................................................... 6
Local Configuration ...................................................................................................................................... 6
Advanced Battery Management................................................................................................................... 6
CHAPTER 2 –INSTALLATION.............................................................................................................................. 7
VCA Physical installation.............................................................................................................................. 7
VCA Connections and Wiring....................................................................................................................... 7
Digital Inputs ................................................................................................................................................ 8
Digital Outputs............................................................................................................................................ 10
110VAC Power Inlet and Relay Outputs.................................................................................................... 10
Case Earth ................................................................................................................................................. 10
Data Communication Ports ........................................................................................................................ 11
Communication Line 1 and 2 I.S. Interfaces .............................................................................................. 11
I.S. Keypad Interface.................................................................................................................................. 13
I.S. Audio Interface..................................................................................................................................... 14
I.S. Earth .................................................................................................................................................... 14
VAA Physical Installation............................................................................................................................ 15
VAA Connections and Wiring..................................................................................................................... 16
CHAPTER 3 - VCA OPERATION......................................................................................................................... 17
HMI Features ............................................................................................................................................. 17
Front Panel................................................................................................................................................. 17
Display and Main Menu Page .................................................................................................................... 18
Menu System ............................................................................................................................................. 19
Navigation .................................................................................................................................................. 19
Voice Message Information Page –Level 1............................................................................................... 19
VCA Message Bank Download Page –Level 1 ......................................................................................... 20
Line Status, VAA Status and Programming Pages –Level 2 and 3........................................................... 20
Line Status Page........................................................................................................................................ 20
VAA Address Setup Page.......................................................................................................................... 21
VAA Status Pages...................................................................................................................................... 23
VAA Operational Status Values ................................................................................................................. 24
VAA User Programmable Settings............................................................................................................. 24
Setting VAA parameters:............................................................................................................................ 25
Modbus Communication Status –Level 4.................................................................................................. 26
Relay Outputs and Digital I/O –Level 5 ..................................................................................................... 27
Relay Outputs Page................................................................................................................................... 27
Digital Output Page.................................................................................................................................... 27
Digital Inputs Page..................................................................................................................................... 28
VCA Configuration –Level 6...................................................................................................................... 29
Changing VCA Settings.............................................................................................................................. 32
CHAPTER 4 –VAA OPERATION ........................................................................................................................ 33
VAA Amplifier Module ................................................................................................................................ 33
VAA Features............................................................................................................................................. 33
The LCD..................................................................................................................................................... 34

VOICECOM USER MANUAL ISSUE 4
CONTENTS
Display Messages...................................................................................................................................... 35
The Keypad................................................................................................................................................ 35
VAA Setup Mode........................................................................................................................................ 36
Enter Setup Mode...................................................................................................................................... 37
Changing the Settings................................................................................................................................ 37
VAA Battery Pack....................................................................................................................................... 38
Battery Pack Features:............................................................................................................................... 38
Removing and Connecting Battery Pack from Amplifier Module................................................................ 39
VAA Battery States –Voltage and Charge................................................................................................. 39
Auto-shutoff................................................................................................................................................ 40
Sleep Mode................................................................................................................................................ 40
Waking the VAA......................................................................................................................................... 40
Power Supplies .......................................................................................................................................... 40
CHAPTER 5 –PRE-START ALARM OPERATION ............................................................................................. 41
Pre-start Alarm Configuration..................................................................................................................... 41
Initiating a Pre-start Alarm.......................................................................................................................... 41
Verifying the Pre-start Alarm Request Input............................................................................................... 42
VAA Pre-start Alarm Sounding and Confirmation....................................................................................... 42
Pre-Start Alarm Confirmation..................................................................................................................... 43
Verifying the Pre-start Alarm While Active ................................................................................................. 43
Verifying the Pre-start Alarm Later............................................................................................................. 44
Pre-start Alarm Operation Examples.......................................................................................................... 45
Example 1 –a successful pre-start alarm .................................................................................................. 45
Example 2 –a failed pre-start alarm .......................................................................................................... 45
Example 3 .................................................................................................................................................. 46
CHAPTER 6 –CREATING AND DOWNLOADING VOICE MESSAGES ............................................................ 47
Recording and Editing Voice Messages..................................................................................................... 47
VCA Message Bank Editor......................................................................................................................... 47
Voice Message Bank Editor Installation..................................................................................................... 47
Creating a Message Bank.......................................................................................................................... 48
Downloading and Uploading the Message Bank........................................................................................ 52
Downloading .............................................................................................................................................. 52
Uploading................................................................................................................................................... 54
CHAPTER 7 –TROUBLESHOOTING.................................................................................................................. 55
APPENDIX A –COMMISSIONING....................................................................................................................... 57
VAA Configuration...................................................................................................................................... 57
Address Setup............................................................................................................................................ 57
Volume, Microphone Gain and Audio Threshold........................................................................................ 58
Charging Current........................................................................................................................................ 58
VCA Line Configuration.............................................................................................................................. 59
Pre-start Alarm Configuration..................................................................................................................... 59
Service Factor............................................................................................................................................ 59
Pre-Start Warning Tone ............................................................................................................................. 60
Pre-Start OK Current Threshold................................................................................................................. 60
VCA Configuration Record......................................................................................................................... 61
APPENDIX B –MODBUS..................................................................................................................................... 63
Configuration.............................................................................................................................................. 63
VCA Modbus Read and Write Functions.................................................................................................... 63
Initiating Voice Messages and Voice Message Control.............................................................................. 63
To initiate a voice message:....................................................................................................................... 64
Stopping a voice message:........................................................................................................................ 64
Message Queuing...................................................................................................................................... 64
Joining messages together: ....................................................................................................................... 64
Reading VAA Parameters.......................................................................................................................... 64
Modbus Tables............................................................................................................................................64
APPENDIX C –APPLICATION NOTES............................................................................................................... 72

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CONTENTS
Communication Line Configurations .......................................................................................................... 72
Longwall..................................................................................................................................................... 72
Conveyor.................................................................................................................................................... 72
VAA Only (eg vehicle road, drift, etc)......................................................................................................... 72
Audio Interface/Audio Barrier..................................................................................................................... 72
SCADA Displays ........................................................................................................................................ 72
Voice Messages......................................................................................................................................... 72
Loading Voice Messages........................................................................................................................... 72
APPENDIX D –MENU MAP ................................................................................................................................. 73
APPENDIX E–PARTS LIST................................................................................................................................. 74
APPENDIX F –SPECIFICATIONS....................................................................................................................... 75
VCA............................................................................................................................................................ 75
Tones......................................................................................................................................................... 75
APPENDIX G –I.S. APPROVALS........................................................................................................................ 77

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CHAPTER 1 –Overview of the VoiceCom System
The Ampcontrol designed VoiceCom system is a multi-station audio communication system suitable for long wall and
conveyor message applications. The system’s three principal functions include generating pre-start alarms, playing
pre-recorded voice messages and one to many station communications. The system is comprised of two main
components, the VCA VoiceCom Controller and VAA VoiceCom Amplifier field units.
System highlights
2 Intrinsically Safe communication lines
Connection of up to 31 VAA field units per line
User selectable pre-start alarm tones for each line
Pre-start confirmation from all VAA units
User recordable voice messages –up to 255 messages can be stored
PC software to create voice message banks
High quality audio output
Advanced diagnostic and preventative maintenance features
“Call Exchange” functionality
VCA features
One compact unit controls pre-start alarms and voice messages
4 line backlit LCD display
Tactile seven button integrated keypad (optional external keypad available)
Easy to use menu system allowing access to system status and configuration pages
16MB flash memory for up to 25 minutes of voice message storage
Monitor and configure VAA field units from VCA
RS-232 interface for downloading voice messages from a PC
RS-485 Modbus interface, allows control of voice messages and reading to system status by a PLC
110VAC operation
Telephone exchange interface
External I.S. keypad interface
VAA features
Intrinsically Safe
IP66 ingress protection rating when enclosed in an Ampcontrol stainless steel housing
Powered using a sealed lead acid battery for high capacity and longer life
LCD display showing operational status values such as line voltage, battery voltage and battery current
Durable 4 button membrane keypad
Dust and moisture protected microphone
Connection for two external speakers
Address, volume, microphone gain and charging current configurable at the VAA as well as at the VCA
Compatible with most existing voice communication systems
Applications
Long wall operations
Conveyors
Hazardous area communication

VOICECOM USER MANUAL ISSUE 4
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The VoiceCom Controller –VCA
Key Functions
The Controller’s primary functions are to initiate and confirm pre-start alarms and play pre-recorded voice messages.
The system’s operation can be configured and monitored via the Controller’s easy to navigate menu system. Users
already familiar with Ampcontrol’s Motor Protection and Integrated Protection Relay products may recognise the
menu structure.
Controller Terminals
The Controller has a number of input/output and communication interfaces to suit most applications
12 edge triggered digital inputs for voice message control
2 pre-start alarm initiation digital inputs, one for each communication line
4 digital outputs providing system status indication
4 relay contacts providing pre-start alarm confirmation outputs and system status indication
RS-232 3-wire port for downloading of voice messages
RS-485 3-wire port for Modbus connection to a PLC
2 4-wire communication line terminals (Line 1 and Line 2) including a separate I.S. power supply connection for each
line
2-wire audio interface connection to connect the VoiceCom System to a telephone exchange via an approved barrier
8 inputs for the connection external keypad control buttons and a lock switch (or the VCA Remote Keypad Module)
Figure 1 –VoiceCom system connection diagram

VOICECOM USER MANUAL ISSUE 4
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PC Software
The Controller is supplied with the VCA Message Bank Editor Windows PC software. The software enables the user
to create, edit and download voice message banks to the Controller. A separate PC program is required for the
recording of individual voice message audio files before the voice message bank can be created.
Modbus
Most of the Controller’s functionality can be controlled and monitored via a Modbus protocol connection. This
includes playing voice messages and reading VAA operational parameters of all connected VAA units. This Modbus
data can be used for trending via a PLC, allowing for preventative maintenance by giving early indication of cable
failures or VAA batteries that may be ready replacement.
The VoiceCom Amplifier –VAA Overview
Key Functions
The VAA sounds pre-start alarms and amplifies audio signals like voice messages and station-to-station
communication. Unlike other communication systems where pre-start alarm and signalling tones are transmitted via
the audio line, the VAA generates all pre-start alarm tones locally. The VAA has four volume levels and two
microphone gain levels that can be configured, depending on the level of background noise. The VAA also has a
seven level threshold setting that prevents unwanted noise from being amplified.
Keypad
Each of the four VAA keypad buttons also generates a different tone when pressed. The SPEAK button generates a
brief tone when pressed and then a higher pitch tone when released to get the attention of other users. Pressing the
CALL LOCAL button also generates a tone that can also be used to get the attention of other users. The CALL
EXCHANGE button generates a low frequency tone for a short duration that can be used to open telephone circuits.
The FUNC button, when pressed, closes one of the Controller’s digital outputs. This output can be used to trigger an
external event, such as prompting the PLC to initiate certain voice messages.
Display
The LCD display cycles through the VAA’s key operating parameters such as the communication line voltage, battery
voltage, battery current and a system digital communication “heart beat”.
Local Configuration
As well as being configurable from the Controller, the VAA’s programmable settings can also be changed at the VAA
using the unit’s programming mode.
Advanced Battery Management
The VAA’s battery management facility allows the battery’s charging current to be set by the user. The setting of the
battery charging current depends on factors such as the output of the I.S. power supply and the number of VAA units
connected to the communication line. The VAA can effectively disconnect the battery if its voltage falls below a pre-
set level to prevent permanent battery cell damage.

VOICECOM USER MANUAL ISSUE 4
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CHAPTER 2 –Installation
This section overs the installation of the VCA and VAA. The various system wiring options are explained as well as
the functions of the VCA and VAA connections. Appendix E lists drawings relevant to the installation and operation of
the VoiceCom system.
VCA Physical installation
The controller can only be installed in the safe area. The required panel cut out is 135mm x 135mm. See drawing
VCOM-A-040 for a panel cut out template with dimensions. To ensure that the installation meets the required IP65
rating, the gasket must be fitted between the controller’s escutcheon and the panel. The controller is supplied with
five mounting brackets each with a M5 x 40mm Phillips head screw. These brackets fitted as shown in Figure 2
below. The fifth bracket is supplied as a spare.
VCA Connections and Wiring
This section covers VCA terminal functions and wiring. All VCA connections are made at the rear of the VCA unit.
VAA unit wiring can be found later in this manual. The VCA has eight terminal headers and is supplied with seven
terminal plugs. The I.S. Earth terminal is the eighth header and is fixed to the rear of the VCA. There is also a mains
earth connection point, which should not be confused with the I.S. Earth.
The eight terminal headers and case earth are shown in Figure 3. These are:
1
Digital Inputs and Output
6
Line 2 I.S. Communication Line Interface
2
Data Communication (RS-232 and RS-485)
7
I.S. External Keypad Interface
3
110VAC Supply Power and Relay Outputs
8
I.S. Earth
4
Line 1 I.S. Communication Line Interface
9
Case Earth
5
I.S. Audio Interface (for telephone exchange circuit
connection)
Figure 2 –VCA VoiceCom Controller (E08588) Front, Side and Rear
+24V
DO4
DO3
DO2
DO1
PSR2
PSR1
DI12
DI11
DI10
DI9
DI8
DI7
DI6
DI5
DI4
DI3
DI2
DI1
DI 0V
485 -
0V 485
485 +
232 TX
0V 232
232 RX
PSC2
PSC1
NO2
COM2
NC2
NO1
NC1
COM1
110Vac
110Vac
AUDIO +
AUDIO -
COM
KP8
KP7
KP6
KP5
KP4
KP3
KP2
KP1
0V 1
Audio 1
Call 1
-V Line 1
0V 1
-V PS1
I.S. EARTH
EARTH
0V 2
Audio 2
Call 2
-V Line 2
0V 2
-V PS2
LINE 2
IS EXT KPD IS LINE I/F COMMS DIGITAL I/O
RELAY/PWR
LINE 1

VOICECOM USER MANUAL ISSUE 4
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Digital Inputs
The controller has 14 digital inputs labelled DI1 to 12, PSR1 and PSR2. A 24VDC supply is required to assert these
inputs. The negative side of this supply is connected to the 0V DI terminal. The positive side of the supply is applied
to the digital input as required.
Inputs 1 to 12 are used for message initiation and are edge triggered. The voice message will not stop when the
24VDC is removed, nor will the message repeat if the 24VDC is held. These inputs will remain active for the duration
of the voice message. Inputs PSR1 and PSR2 are used for pre-start alarm initiation and are active for as long as the
input is asserted. The digital inputs can be wired in several configurations depending on the voice message initiation
mode chosen. The connection options are listed in Table 1, Table 2 and Table 3. The three modes are as follows:
1. Digital Inputs/Modbus
In this mode, asserting digital inputs 1 to 12 plays messages 1 to 12 respectively. Messages 13 to 255 are
initiated via the Modbus communication link.
2. Strobe
In this mode all messages, 1 to 255, can be played by setting up the voice message address as an eight bit
binary number using digital inputs 1 to 8 and then using digital input 9 as a strobe to initiate that message.
This allows relay logic to initiate voice messages if no Modbus communication facility is available.
3. Modbus
In this mode all messages, 1 to 255, are played via Modbus. Asserting digital inputs 1 to 12 will not initiate
voice messages.
Figure 3 - VCA Connections
1
2
3
4
5
6
7
8
9
+24V
DO4
DO3
DO2
DO1
PSR2
PSR1
DI12
DI11
DI10
DI9
DI8
DI7
DI6
DI5
DI4
DI3
DI2
DI1
DI 0V
485 -
0V 485
485 +
232 TX
0V 232
232 RX
PSC2
PSC1
NO2
COM2
NC2
NO1
NC1
COM1
110Vac
110Vac
AUDIO +
AUDIO -
COM
KP8
KP7
KP6
KP5
KP4
KP3
KP2
KP1
0V 1
Audio 1
Call 1
-V Line 1
0V 1
-V PS1
I.S. EARTH
EARTH
0V 2
Audio 2
Call 2
-V Line 2
0V 2
-V PS2
LINE 2
IS EXT KPD IS LINE I/F COMMS DIGITAL I/O
RELAY/PWR
LINE 1

VOICECOM USER MANUAL ISSUE 4
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NOTE: Pre-start alarms cannot be initiated via Modbus. The PSR1 and PSR2 inputs must be used to initiate pre
start alarms on Lines 1 and 2.
Table 1 - Connections for Digital Input/Modbus Mode
Terminal
Function
DI1 to DI12
Momentarily apply +24VDC (edge triggered inputs) to play voice messages 1 to 12
respectively
PSR1
Apply +24VDC to input and hold to play pre-start alarm down line 1
PSR2
Apply +24VDC to input and hold to play pre-start alarm down line 2
0V DI
0V common for all digital inputs (from negative side of 24VDC supply)
Table 2 - Connections for Strobe Mode
Terminal
Function
DI1 to DI8
Set up message address in binary where DI1 is the least significant bit. Apply and
hold +24VDC to the inputs until strobe input has been asserted.
DI9
Momentarily apply +24VDC (edge triggered input) to play the message once the
message address has been set up using inputs DI1 to 8.
DI10 to 12
Not used –no connection
PSR1
Apply +24VDC to input and hold to play pre-start alarm down line 1
PSR2
Apply +24VDC to input and hold to play pre-start alarm down line 2
0V DI
0V common for all digital inputs (from negative side of 24VDC supply)
Table 3 - Connections for Modbus Mode
Terminal
Function
DI1 to DI12
Not used –no connection
PSR1
Apply +24VDC to input and hold to play pre-start alarm down line 1
PSR2
Apply +24VDC to input and hold to play pre-start alarm down line 2
0V DI
0V common for all digital inputs (from negative side of 24VDC supply)

VOICECOM USER MANUAL ISSUE 4
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Digital Outputs
The four digital outputs, labelled DO1 to 4, provide indication of system status. These are transistor outputs. The
positive side of a 24VDC supply must be connected to the terminal marked +24V. The negative side of the 24VDC
supply is connected to the input or device to complete the circuit when the output turns on. See the figure below. The
indication provided by these digital outputs can also be read via Modbus. Refer to the Modbus data table in Appendix
B for the location of these digital output flags. However, they can be wired if Modbus communication is not available
or for redundancy. The function of each digital output is as follows:
DO1 –asserted when a “Line Fault” occurs. Line Faults include faults such as the number of VAA communicating
with the VCA being less than or greater than the number of VAAs online setting (VAA # Reply Alarm) or two or more
VAA have the same address (VAA Address Clash). Refer to the VCA Operation and Troubleshooting chapters for
more information on Line Faults.
DO2 –asserted when the “FUNC” button on a VAA is pressed. This output remains on for 5 seconds after the button
is pressed. This could be used to trigger a function such as re-playing are the currently active voice messages.
DO3 –asserted while a voice message is playing. This output can assist the message control device, such as a
PLC, with voice message queuing.
DO4 –this output current has no function.
110VAC Power Inlet and Relay Outputs
The RELAY/PWR header contains the terminations for VCA power supply connection and relay outputs. The
following table describes the functions of the input/output terminals.
CAUTION –ELECTRICAL SHOCK HAZARD
Isolate the 110Vac supply before connecting or disconnecting.
Terminal
Function
110Vac
Mains supply connection 110VAC 50Hz
110Vac
COM1
Relay 1 common
Energises while the controller is healthy –normally open and normal
closed contacts. De-energises if a VCA or message bank memory fault
occurs. See the Troubleshooting section.
NC1
Relay 1 N/C
NO1
Relay 1 N/O
COM2
Relay 2 common
Reserved for future use.
NC2
Relay 2 N/C
NO2
Relay N/O
PSC1
Relay 3 common
Normally open contact energises when Line 1 pre-start alarm has
successfully sounded –pre-start alarm Line 1 confirmation output
PSC1
Relay 3 N/O
PSC2
Relay 4 common
Normally open contact energises when Line 2 pre-start alarm has
successfully sounded –pre-start alarm Line 2 confirmation output
PSC2
Relay 4 N/O
See the Specifications section of this manual for detailed information on the specifications of digital inputs, digital
outputs and relay outputs.
Case Earth
An EARTH connection point is provided adjacent to the 110Vac terminals for the connection of the mains supply
earth.

VOICECOM USER MANUAL ISSUE 4
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Data Communication Ports
RS-232 –Message Bank Download
The controller has two data ports. The RS-232 port is used to connect the VCA to a PC for the downloading of the
Voice Message Bank. The Voice Message Bank is a single file that contains all of the pre-recorded voice messages.
This file is compiled and downloaded using the Voice Message Bank Editor PC program provided with the VCA. This
function is normally carried out before the controller is installed and so it is not necessary to wire these terminals.
However, the RS-232 terminals could be wired to a standard female DB9 9-way type socket mounted within the
cubicle for easy connection to a PC via a standard RS-232 9-way serial cable. A ready made serial cable (p/n
E09400) is available from Ampcontrol. A serial cable can also be easily assembled. Figure 4 details the DB 9 pins
that are used for this RS-232 serial cable.
RS-485 –Modbus Communication
The RS-485 port is used to connect the controller to a Modbus capable control or SCADA system. The configuration
of these two ports is described in the Refer to the VCA Operation chapter of this manual for information on how to
configure the communication parameters for this port. Further information on using Modbus can be found in
Appendix B. Table 4, below, lists the data port connections and Figure 4 shows the terminal wiring.
Table 4 - VCA Data Port Connections
Terminal
Function (w.r.t. the VCA)
485 -
RS-485 negative
0V 485
RS-485 common
485 +
RS-485 positive
No connection
Not used
232 TX
RS-232 transmit
0V 232
RS-232 common
232 RX
RS-232 receive
Communication Line 1 and 2 I.S. Interfaces
Note: Refer to VCA Certificate of Conformity AUS Ex 03.3880X and VAA Certificate of Conformity Aus Ex 03.3881X
for the correct installation and wiring of Intrinsically Safe VCA interfaces.
The controller has two intrinsically safe communication line interfaces, labelled LINE 1 and LINE 2. Each interface
has six terminals: four for connection to the VoiceCom communication line and two for connection to an Intrinsically
Safe power supply. Each line can support a maximum of 31 VAA units, depending on the cable length and power
supply used.
Figure 4 - VCA data communication wiring
485 –
0V 485
485 +
232 TX
0V 232
232 RX
VCA COMMS
Terminal
Remote
Device
TxD-/RxD-
GND
TxD+/RxD+
RxD (DB9 Pin 2)
GND
(DB9 Pin 5)
TxD
(DB9 Pin 3)
To Modbus Master
Device (RS-485)
To PC Serial COM
Port (RS-232)

VOICECOM USER MANUAL ISSUE 4
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Note: The output parameters of the I.S supply must match the input parameters of the VCA and the VAA. Refer to
VCA Certificate of Conformity AUS Ex 03.3880X and VAA Certificate of Conformity Aus Ex 03.3881X for input
parameters.
The VoiceCom intrinsically safe communication line consists of four cores commonly referred to as: 0V, Audio, Call
(digital communication signals) and –V Line. The 0V and –V Line cores provide voltage for VAA battery charging.
The Audio line carries the system audio signals. The Call line is the digital communication link between the controller
and VAA units. This digital communication line runs the VoiceCom digital protocol, which allows the VCA to retrieve
VAA operating parameters, such as voltage and current values. Table 5
Table 6 list the I.S. communication line interface terminations and Figure 5 shows the terminal wiring for LINE 1. The
wiring for LINE 2 is identical.
NOTE: Each communication line must be powered by a separate I.S. power supply.
Table 5 - LINE 1 Communication Line Interface Connections
Terminal
Function
0V 1
0V supply line 1
VoiceCom LINE 1
Audio 1
Audio line 1
Call 1
Call/digital line 1
-V Line 1
Negative supply line 1
0V 1
I.S. power supply 1 positive input
-V PS1
I.S. power supply 1 negative input
Table 6 - LINE 2 Communication Line Interface Connections
Terminal
Function
0V 2
0V supply line 2
VoiceCom LINE 2
Audio 2
Audio line 2
Call 2
Call/digital line 2
-V Line 2
Negative supply line 2
0V 2
I.S. power supply 2 positive input
-V PS2
I.S. power supply 2 negative input
CALL
LOCAL
CALL
EXCHANGE FUNC. SPEAK
VAA Field Unit
+ -
CALL
LOCAL
CALL
EXCHANGE FUNC. SPEAK
VAA Field Unit
+ -
CALL
LOCAL
CALL
EXCHANGE FUNC. SPEAK
VAA Field Unit
+ -
CALL
LOCAL
CALL
EXCHANGE FUNC. SPEAK
VAA Field Unit
+ -
0V 1
Audio 1
Call 1
-V Line 1
0V 1
-V PS1
+ –
12VDC –18VDC
I.S. Power Supply
VAA31
VAA2
VAA1
VCA IS LINE I/F
Terminals
VoiceCom communication line
Figure 5 - I.S. communication line interface wiring
(LINE 1 shown)

VOICECOM USER MANUAL ISSUE 4
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Note: The I.S. power supply can either be connected to the controller terminals, as shown in Figure 5, or to
anywhere on the communication line to overcome the voltage drop caused by long lines. Refer to VCA approval
drawing VCOM-Z-036 for I.S. power supply connection options.
I.S. Keypad Interface
The intrinsically safe keypad interface allows an external VCA keypad module (or suitable push buttons) to be
installed in the hazardous area when the VCA is installed in a flameproof enclosure or the VCA keypad is otherwise
inaccessible.
Table 7 shows the I.S. Keypad Interface termination and Figure 6 shows the wiring connections to the VCA Remote
Keypad Module, available from Ampcontrol (p/n E08985). The keypad input functions are self explanatory. Input KP3
is the LOCK input. When the LOCK input is asserted, VCA configuration settings can be changed and Voice
Message Bank files can be downloaded. Opening the LOCK input prevents any settings from being changed. The
LOCK input should be wired to a key lock switch located adjacent to the VCA or behind the panel door.
The keypad inputs are powered from an I.S. power supply. One of the communication line I.S. power supplies can be
used. For further wiring details refer to approval drawing VCOM-Z-036.
Table 7 - I.S. Keypad Interface Connections
Terminal
Function
KP1
UP button
KP2
LEFT button
KP3
Key LOCK (allows access to VCA settings)
KP4
RIGHT button
KP5
DOWN button
KP6
ENTER button
KP7
FUNCTION button
KP8
ESCAPE button
COM
IS power supply common
NOTE: The I.S. power supply connected to LINE 1 or LINE 2 can be used to for the VCA I.S. Keypad Interface.
+ -
+ -
COM
KP8
KP7
KP6
KP5
KP4
KP3
KP2
KP1
12VDC –18VDC
I.S. Power Supply
+ –
+V
KP8
KP7
KP6
KP5
KP4
KP2
KP1
VCA Remote Keypad
Terminals
VCA I.S. Keypad
Interface Terminals

Figure 6 - I.S. keypad interface wiring to VCA Remote Keypad Module (E08985)

VOICECOM USER MANUAL ISSUE 4
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I.S. Audio Interface
The intrinsically safe audio interface allows the VoiceCom System to be connected to a site-wide communication or
telephone network. All audio signals originating from the VoiceCom System such as voice messages and VAA to
VAA communication are output from the audio interface. Likewise, any audio signal input to the interface is broadcast
over the VoiceCom System.
The VoiceCom Audio Barrier (p/n E09441) is required in order to connect the VCA I.S. Audio Interface to an
intrinsically safe communication network. The VoiceCom Audio Barrier provides a number of connection options,
such as allowing two independent VoiceCom communication lines to be connected together. This allows the audio
from one VoiceCom system to be broadcast on the other system and vice versa. Note, however, that this does not
enable a pre-start alarm to sound on the other VoiceCom system or the extension of the digital communication. Refer
to Appendix C for more information on connecting the VoiceCom system to other communication systems.
Table 8 - I.S. Audio Interface Connections
Terminal
Function
AUDIO +
Audio line positive
AUDIO -
Audio line negative
I.S. Earth
The intrinsically safe earth terminals are used to connect the VCA to a local intrinsically safe earth. The I.S. earth
should be a direct connection and should not be shared with other devises. A minimum of two 4mm2cores should be
used.
NOTES:
1. Refer to Certificate of Conformity AUS 03.3880X for the correct installation and wiring of Intrinsically Safe
VCA interfaces.
2. The I.S. Earth should not be confused with the VCA Case Earth. These earths should be kept separate.

VOICECOM USER MANUAL ISSUE 4
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VAA Physical Installation
The VAA comes in its own stainless steel enclosure. The VAA stainless steel IP66 enclosure includes two speakers
and gland entries (p/n E09100). Other entry configurations can be accommodated. The VAA is also available as a
panel mountable module (p/n E08831) for installation into an existing enclosure or panel door, shown in Figure 8.
See drawing VCOM-A-040 for a panel cut out template with dimensions for the VAA and speakers.
Figure 8 - VAA module (p/n E08831)
The VAA module consists of the following items:
1
VAA amplifier sub-assembly (p/n E08831)
4
4-way double headed plug for VoiceCom
communication line connection
2
6V 1.2Ahr battery pack (p/n E08584)
5
4 M6 x 20mm Allen head bolts
3
4-way mini plug for speaker connection
6
4 M6 nylon flat washers
NOTE: Only the approved speakers can be connected to the VoiceCom VAA. Two 12 watt, 8 ohm speakers are available as a
separate item (p/n E08783).
CALL
LOCAL
CALL
EXCHANGE FUNC. SPEAK
VAA Field Unit
+ -
VAA Front
VAA Side
VAA Back
4
3
1
2
5
6
EXCHANGE SPEAKLOCAL
CALL CALL
FUNC.
Figure 7 - VAA Speaker Enclosure (p/n E09100)

VOICECOM USER MANUAL ISSUE 4
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VAA Connections and Wiring
The VAA module has three connection headers, as shown in Figure 9 below:
1
VoiceCom communication line (4-way)
2
Speakers (4-way)
3
Battery pack (10-way)
The communication line connections are listed in table 9 and speaker connections are listed in table 10 below.
Table 9 - VAA communication line connections
NOTE: The double headed communication line plug provides for separate termination of in and out cables and allows the
communication line plug to be disconnected from the VAA module without breaking the line.
Table 10- VAA speaker connections
Terminal
Function
1 +
Speaker 1 positive
1 -
Speaker 1negative
2 +
Speaker 2 positive
2 -
Speaker 2 negative
NOTE: The 4-way speaker terminal allows for the connection of two speakers. Wire length between the speakers
and the VAA module should not exceed 300mm. The connection wire must be a minimum of 0.1mm in diameter and
the wire insulation thickness must be a minimum of 0.25mm, as specified in the VAA Certificate of Conformity Aus Ex
03.3881X. Take careful note of the speaker polarity when wiring.
Terminal
Function
0V
0V supply line
AUDIO
Audio line
CALL
Call/digital line
-VLINE
Negative supply line
Figure 9 - VAA headers and communication line and speaker wiring
1
2
3
0Volts
Audio
Call
-Vline

VOICECOM USER MANUAL ISSUE 4
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CHAPTER 3 - VCA Operation
The VoiceCom Controller version A, or VCA, as its name suggests, is the master controller of the VoiceCom system.
From the VCA, the VoiceCom system can be easily configured and interrogated. It controls the operation of the pre-
start alarm and it stores and plays pre-recorded audio messages. The VCA also allows for the VoiceCom system to
be interfaced with a control system such as a PLC, which provides remote monitoring. The VCA’s operation is best
explained by looking at the all of the VCA status and configuration display pages.
HMI Features
Front Panel
The front panel of the VCA includes:
4 line, 20 character backlit LCD
7 button keypad
Multicolour indicator LED (green, orange, red)
1
Display –backlit LCD
4
Key (Function) –used to view last pre-start
alarm operation
2
Keys –navigate through menu
pages and toggle settings
5
Key –used for changing and saving
configuration settings and for menu shortcuts
3
Key (Escape) –takes user back to Main
Menu Page and for menu shortcuts
6
Status LED –VCA status indication
FUNC .............................................................................
ENTER
ESC
6
5
4
3
2
1
Figure 10 - VCA Front Panel

VOICECOM USER MANUAL ISSUE 4
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Display and Main Menu Page
When power is applied to the VCA the display defaults to the Main Menu page, shown in Figure 11. The backlight will
turn on and remain active for 5 minutes after the last key press. Pressing any of the 7 keys will turn the backlight on.
If not on the Main Menu page, the display will return back to the Main Menu page if no key is pressed for 5 minutes
and the backlight will turn off.
NOTE: The only exception to this is when downloading Message Bank files. The display does not move off of the
VCA Message Bank page when a connection between the VCA and a PC has been established.
1
Menu level number (on all pages)
4
Name of message currently playing
2
VCA Firmware version
5
Line 1 status messages and alarms
3
Number of audio message currently playing
6
Line 2 status messages and alarms
Below are a list of the status and alarm messages that can be displayed for LINE 1 and LINE 2.
Table 11 - VCA Alarm Messages
Message
Description
VAAs Replying OK
The number of VAAs that the VCA can communicate with matches the “# of
VAAs to be online” parameter.
VAA Reply # Alarm
The number of VAAs that the VCA can communicate with is greater/less
than the “# of VAAs to be online” parameter.
Address Clash
Two or more VAAs have the same address.
No VAAs Enabled
The “# of VAAs to be online” parameter is set to “None”.
PSW Active
A pre-start alarm is active.
PSW Healthy
The pre-start alarm has been successful. All the required VAAs confirmed
sounding the pre-start alarm.
PSW Blocked
The maximum pre-start initiation time has been exceeded (30 seconds).
Remove the pre-start alarm input and reapply to sound the pre-start alarm
again. For every second that the pre-start alarm input is removed three
seconds of pre-start alarm can be sounded if the input is reapplied. See the
Pre-Start Alarm Operation chapter for more information on the operation of
the pre-start alarm.
There are also a couple of VCA fault message that can appear on the second line of the display on the Main Menu
page. Refer to the Troubleshooting chapter for more information on VCA faults.
Table 92 - VCA Hardware Fault Alarms
Message
Description
VCA mem. Error
An error has occurred with the VCA configuration memory.
Msg.Proc. Fail
A fault has occurred with the VCA Message Bank hardware.
1 VCA4V02 2003 Msg#
Iso at sta 1 13
L1:VAAs Replying OK
L2:No VAAs Enabled
1
2
3
4
5
6
Figure 11 - Main Menu Page