David Clark 9800 Series User manual

19532P-62 (03-11) 

2011 David Clark Company Incorporated
INSTALLATION MANUAL
SERIES 9800
MARINE INTERCOM SYSTEM

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Table of Contents
Cautions and Warnings...................................................................................................1
Parts/Tools List...............................................................................................................2
System Overview............................................................................................................3
1. Mounting the Master Station....................................................................................5
2. Mounting the Panel Display ...................................................................................10
3. System Cables.......................................................................................................15
4. Radio Cables.........................................................................................................19
5. Remote PTT (Optional)..........................................................................................20
6. Power Cable..........................................................................................................22
7. Captain's Priority Switch (Optional)........................................................................24
8. Auxiliary Audio Connection (Optional)....................................................................25
9. Connecting Headsets and PTT Switches...............................................................27
10. Operation...............................................................................................................28
11. Testing and Troubleshooting..................................................................................31
Appendix A....................................................................................................................A1
C98-50LN – 50-foot System Cable
Appendix B....................................................................................................................B1
P/N 40688G-47 Waterproof Fuse Kit Installation Instructions
Appendix C .................................................................................................................. C1
Master Station Adjustments
Appendix D .................................................................................................................. D1
Environmental Specifications
List of Figures
Figure Page
1 Typical 4- Person Layout...............................................................................4
2 Master Station Mounting Diagram..................................................................6
3 Master Station Mounting Template ................................................................7
4 Master Station Connections...........................................................................9
5 Panel Display Control ..................................................................................10
6 C98-20PD Panel Display Cable...................................................................10
7 Panel Display Mounting Diagram.................................................................11
8 Panel Display Mounting Template................................................................13
9 C98-XXLN In-Line Style System Cable........................................................15
10 C98-XXPN Panel Mount System Cable.......................................................15
11 40894G-XX Panel Mounting Template.........................................................17
12 C98-20RD Radio Cable...............................................................................19

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List of Figures (continued)
Figure Page
13 C98-15RS Remote PTT Cable.....................................................................20
14 C98-20PW Cable w/40688G-47 2-Amp Fuse Kit .........................................22
15 C98-20PW Power Cable..............................................................................23
16 C98-20AX Auxiliary Audio Cable..................................................................25
17 Audio Isolation Transformer Circuit..............................................................26
18 Headset with Body PTT Switch....................................................................27
19 Panel Display Control ..................................................................................28
A1 C98-50LN Connector Pin Diagram...............................................................A2
A2 C98-50LN Proper use of Compression Ring................................................A2
A3 C98-50LN Proper Assembly of Connector onto Cable.................................A2
B1 Proper Assembly of Fuse Holder Kit (40688G-47).......................................B1
C1 Adjustment Potentiometer Locations (U9800S)........................................... C2
C2 Jumper Locations (U9800S) ....................................................................... C3
List of Tables
Table Page
1 System Components......................................................................................3
2 Radio Cable Wire Color Functions...............................................................19
3 C98-20AX Wire Color Chart.........................................................................26
4 Panel Display Menu Options........................................................................28
5 Behavior when Captain's Priority is Disabled...............................................30
6 Behavior when Captain's Priority is Enabled................................................30
7 Troubleshooting...........................................................................................32
A1 Connector Kit Parts and Tools Required C98-50LN.....................................A1
A2 Connector Pins and Wire Colors C98-50LN.................................................A2
D1 Environmental Specifications...................................................................... D1

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Cautions and Warnings
READ AND SAVE THESE INSTRUCTIONS. Follow the instructions in this installation
manual. These instructions must be followed to avoid damage to this product and
associated equipment. Product operation and reliability depends on proper installation.
DO NOT INSTALL ANY DAVID CLARK COMPANY PRODUCT 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 Company.
STATIC HAZARD - Static electricity can damage components.
Therefore, be sure to ground yourself before opening or installing
components.

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Parts/Tools List
Supplied by David Clark
qU9800S Master Station (P/N 40898G-01)
qU9810PD Panel Display (P/N 40879G-01)
qU9810BS Body Switch PTT (P/N 40895G-03)
qU9811BS Body Switch PTT/Cell Phone (P/N 40895G-02)
qH9832 Headset OTH (P/N 40896G-02)
qH9842 Headset BTH (P/N 40897G-03)
qH9842BK Headset BTH(black) (P/N 40897G-04)
qH9842SK Headset BTH with Momentary (P/N 40897G-06)
Mic Switch (black)
qH9842TM Headset BTH with Throat Mic (P/N 40897G-08)
(black)
qC98-15RS Remote PTT Switch (P/N 40800G-02)
qC98-20PW Cable Assy, Power (P/N 40892G-02)
qC98-20PD Cable Assy, Panel Display (P/N 40892G-03)
qC98-10LN System Cable, In-Line, 10ft (P/N 40893G-07)
qC98-15LN System Cable, In-Line, 15ft (P/N 40893G-08)
qC98-20LN System Cable, In-Line, 20ft (P/N 40893G-09)
qC98-25LN System Cable, In-Line, 25ft (P/N 40893G-10)
qC98-30LN System Cable, In-Line, 30ft (P/N 40893G-11)
qC98-50LN System Cable, In-Line, 50ft (P/N 40893G-12)
qC98-10PN System Cable, Panel, 10ft (P/N 40894G-04)
qC98-20PN System Cable, Panel, 20ft (P/N 40894G-05)
qC98-30PN System Cable, Panel, 30ft (P/N 40894G-06)
qC98-20AX Cable Assy, Auxiliary (P/N 40892G-04)
qC98-20RD Cable Assy, Radio (P/N 40892G-01)
qC98-15CP Cable Assy, Multi Use, 15 ft. (P/N 40892G-05)
qC98-30CP Cable Assy, Multi Use, 30 ft. (P/N 40892G-10)
qMaster Station Mounting Kit (P/N 40688G-63)
qC98-XXPN Mounting Kit (P/N 40688G-64)
qCable Fittings & Nuts are included with System Cables
Customer Supplied
qScrewdriver selection
qPen/Pencil
qDrill
qDrill Bits (5/8”, 5/32”, 27/32”)
q1 1/4” hole-saw
qWire strippers
qWire cutters
qNeedle-Nose pliers
qGrommet assortment
qWire tie assortment
qTape Measure
qX-Acto/Razor knife
qSoldering Iron/Solder
qHeat gun
qRadio adapters (for interfacing to radios—supplied by radio manufacturer)
qPin assignments for each radio adapter (supplied by radio manufacturer)
qHeat Shrink tubing assortment 1/8” to 3/8”

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System Overview
The Series 9800 Marine Intercom System is a weather-resistant communication system designed for the
marine environment. It allows a captain, co-captain, and up to four passengers (six positions total) to
communicate with each other over the intercom, and two of the members (captain and co-captain) to
communicate over two mobile radios. Also available is an option to interface a third audio source such as
a Stereo, CD player, or any other listen-only radio.
Primary components of the system are indicated in Table 1. In addition, a basic layout of a 4-position
system is shown in Figure 1.
Component Part and Model Numbers
Master Station Master Station - Model Number U9800S
Remote Panel Display
Control Panel Display - Model Number U9810PD
Headsets (up to 6)
Over-the-Head Style – Model Number H9832
Behind-the-Head Style – Model Number H9842
Behind-the-Head Style – Model Number H9842BK
Behind-the-Head Style with Momentary Mic Switch – Model Number H9842SK
Note: H9842SK headsets are not recommended for Captain and Co-Captain positions.
Behind-the-Head Style with Throat Mic – Model Number H9842TM
Cables
In-Line System Cable (1 per headset)
10 foot Length – Model C98-10LN
15 foot Length – Model C98-15LN
20 foot Length – Model C98-20LN
25 foot Length – Model C98-25LN
30 foot Length – Model C98-30LN
50 foot Length – Model C98-50LN (connector unassembled for custom length)
Panel Mount System Cable (1 per headset)
10 foot Length – Model C98-10PN
20 foot Length – Model C98-20PN
30 foot Length – Model C98-30PN
Power Cable – Model Number C98-20PW (1 per master station)
Panel Display Cable – Model Number C98-20PD (1 per Panel Display, maximum of 1)
Captain’s Priority Cable – Model Number C98-15CP or C98-30CP (optional, maximum of 1)
Auxiliary Cable – Model Number C98-20AX (1 per Aux input, maximum of 1 )
Radio Cable – Model Number C98-20RD* (1 per Radio Input, maximum of 2)
* Other versions available. Contact factory with radio make and model.
Remote PTT Remote PTT Switch - Model Number C98-15RS (Optional, Maximum of 2)
Remote PTT Cable – Model Number C98-15CP or C98-30CP (Optional, Maximum of 2)
Body Switches Body Switch, PTT, 15’ coil cord - Model Number U9810BS (1 per radio transmit headset,
maximum of 2)
Body Switch, PTT w/cell phone connector, 15’ coil cord - Model Number U9811BS
Table 1: System Components

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Figure 1: Typical 4-Person Layout

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1. Mounting the Master Station
Parts/Tools Required
qU9800S Series 9800 Intercom System Master Station (40898G-01)
qMaster Station Mounting Kit (40688G-63)
o4 neoprene washers
o4 Stainless steel screws
o4 Nylon washers
o4 Stainless steel washers
o4 Stainless steel nuts
qPencil/Pen
qDrill
q7/32-inch Drill Bit
qDrilling Template (Figure 3)
qPhilips-head screwdriver
q11/32-inch nut driver or wrench
Procedure
Location Considerations
Select a location on a flat surface that is out-of-the-way, and provides adequate room to attach all
cables. Be sure to allow for internal access, as adjustments may be necessary. The Master
Station is weather resistant, however the mounting location should be chosen to minimize direct
exposure to the elements.
Mounting
qUsing the mounting template in Figure 3, mark and drill the (4) 7/32-inch holes through the
mounting surface.
qRemove the cover and position the Master Station on the mounting surface and confirm
mounting holes.
qMount the Master Station using the hardware provided. Slide nylon washer over each screw
before using. Place a neoprene washer between the Master Station and the surface where
each screw is located. Use a stainless-steel washer on the back side of the surface under
each nut. Secure tightly with a stainless-steel lock-nut. See Figure 2.
qThe installer may wish to leave the cover removed from the Master Station, as internal
adjustments may be necessary later during the installation. Be sure to replace cover and
tighten the four screws when adjustments are completed.

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Figure 2: Master Station mounting diagram

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Figure 3: Master Station Mounting Template

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Figure 4: Master Station Connections

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2. Mounting the Panel Display
The Panel Display is the control center for the David Clark Series 9800 Marine Intercom System. From
here the user can adjust volume and sensitivity levels, as well as select which radio is active for
transmitting.
See section 10. Operation for complete details.
Parts/Tools Required
qU9810PD Series 9800 Intercom System Panel Display (40879G-01) (Figure 5)
oMounting nut and 3x3-inch gasket included
qC98-20PD Panel Display Cable (40892G-03) (Figure 6)
qDrill
q1 1/4” Hole-saw
qDrilling template (Figure 8)
qPen/Pencil
qWire ties
MODE
TX1 TX2
MARINE INTERCOM
Figure 5: Panel Display Control
Figure 6: C98-20PD Panel Display Cable

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Procedure
qDetermine the location for the Panel Display. The Panel Display should be mounted on a flat
surface that is visible and accessible to the captain and co-captain. The surface can range in
thickness from 1/32 to 7/8 inches. See Figure 7.
qBe sure there is at least 6-inches of room behind the panel to attach and route the C98-20PD
Panel Display Cable.
qUsing the drilling template in Figure 8, mark the location for the 1 1/4” hole on the mounting
surface.
qDrill the 1-1/4” hole using the hole-saw.
qPlace the provided 3”x3” gasket over the threaded bushing of the Panel Display and mount the
Panel Display as shown in Figure 7.
qDo not over-tighten but make sure that the Panel Display will not rotate and sealing gasket is
compressed tightly.
qAttach the C98-20PD cable to the Panel Display.
qConnect the cable to the Master Station’s connector labeled “Panel Display” (see Figures 1&4).
To connect the cable to the Master Station, align keyways and push. Then firmly turn collar
clockwise until it locks into place. Pull back gently on the cable to ensure connector is properly
locked.
qUse plastic cover to protect the Panel Display when it is not in use.
Figure 7: Panel Display Mounting Diagram

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Figure 8: Panel Display Mounting Template
(Overall Clearance with Cover 4-1/2" Square)

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3. System Cables
System Cables interface David Clark Series H9800 Headsets to the Series 9800 Marine Intercom
System. For convenience, there are two types of System Cables available, In-Line and Panel-Mount.
The Series 9800 Intercom System can accommodate up to six headsets.
Parts/Tools Required
qC98-XXLN In-Line style system cable (XX is length in ft, see Table 1 for available lengths)
oCable fitting & nut included (Figure 9)
qC98-XXPN Panel-Mount style system cable (XX is length in ft, see Table 1 for available lengths)
oTemplate and mounting hardware included (Figure 10)
qDrill & Bit(s) (27/32” for In-Line, 7/8" & 5/32” for Panel-Mount)
qPhilips-head screwdriver
qAdjustable wrench (for In-Line)
q5/16-inch wrench or nut driver (for Panel-Mount)
Figure 9: C98-XXLN In-Line Style System Cable
CustomerPanel
Up to 7/8”
Figure 10: C98-XXPN Panel Mount System Cable

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Procedure
•Special note for C98-50LN: See Appendix A for connector assembly instructions .
•For In-Line installation:
qDetermine the location for the System Cable/Fitting. Maximum panel thickness is 7/32”.
qDrill 27/32” hole in panel where System Cable is to be installed.
qRemove mounting nut from cable fitting and put in a safe place.
qSnake cable through hole from the outside (headset side) in.
qSlide mounting nut back onto cable and snugly tighten the cable fitting, leaving 3-4 inches
of length between cable fitting and headset end of cable
qRoute the cable between each Headset/Station 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. Coil and tie-wrap any excess cable.
qDetermine which position this Headset/Station is (Captain/Co-Captain/Passenger) and
connect System Cable to the Master Station. See Figures 1&4 for connector locations.
qTo connect cable to master station, align keyways and push. Then firmly turn collar
clockwise until it locks into place. Pull back gently on the cable to ensure connector is
properly locked.
qRepeat this procedure for each C98-XXLN cable to be installed.
•For Panel-Mount installation:
qDetermine location for the panel to be mounted.
qUse the template in Figure 11 to mark and drill the five holes in the surface. Use a 7/8”
bit for the center hole and a 5/32” bit for the four corners.
qRoute the cable through the 7/8” center hole all the way to 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. Coil and tie-wrap any excess cable.
qSecure Panel to surface using the screws, washers, and nuts provided. See Figure 10.
qDetermine which position this Headset/Station is (Captain/Co-Captain/Passenger) and
connect System Cable to the Master Station. See Figures 1&4 for connector locations.
qTo connect the cable to the Master Station, align keyways and push. Then firmly turn
collar clockwise until it locks into place. Pull back gently on the cable to ensure
connector is properly locked.
qRepeat this procedure for each C98-XXPN cable to be installed.