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

VOICECOM USER MANUAL ISSUE 4
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

VOICECOM USER MANUAL ISSUE 4
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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
-8-
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