Clear-Com 4000 series II User manual

4000 Series II
Technical Manual
Issue 2.1
June 2006

4000 Digital Series II Issue 2.1 Technical Manual
STA0381 Page i
4000 Series II
Thank you for purchasing this product; we hope it will provide many years of reliable and rewarding
service.
We would be pleased to hear from you if you have any difficulties, comments or suggestions related to
this product, the user documentation or the support service which we offer. Please feel free to contact
us by e-mail, postal mail or telephone.
Please also visit our website whic is continually being enhanced to offer increased levels of information.
You can find us at http://www.vitecgroupcomms.com/
Vitec Group Communications Limited
7400 Beach Drive
Cambridge Research Park
Cambridgeshire
United Kingdom
CB5 9TP

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STA0381 Page iii
General Enquiries: Tel: [phone]
Fax: [phone]
email: [email protected]
EMEA Sales: New
Orders: Tel: [phone] Fax: [phone]
email: customerservices[email protected]
Support: Tel: [phone] (day)
Tel: [phone] (night)
Fax: [phone] (repairs)
[email protected] (repairs)
[email protected] (support)
http://www.avc.de/if/vitec (repairs booking)
Asia Pacific and
South/Central
America Sales:
New Orders: Maria Gonzalez
International Export Coordination
Tel: [phone]
Fax: [phone]
email: [e-mail]
Amado Bautista
International Export Coordination
Tel [phone]
Fax: [phone]
email: [e-mail]
Jon Ernst
Manager
Tel: [phone]
Fax: [phone]
email: [email protected]
Support Richard Spicer
Product Technical Support
Tel: [phone] (office)
Tel: [phone] (mobile)
Fax: [phone]
email: [email protected]

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Policy Statement
Vitec Group Communications has a policy of continuous improvement of both products and
documentation and reserves the right modify product specifications and characteristics without notice,
at any time.
Vitec Group Communications has endeavoured to ensure that information, details and descriptions set
out in this document are correct at the time of publication. Where alterations have been made to the
product, we will endeavour to produce appropriate additional information such as supplementary
documents, changes to the website or re-issued copies of a CDROM.
Vitec Group Communications is, however, unable to guarantee that no changes have taken place to the
specification or characteristics of this product after the publication of this document. Vitec Group
Communications shall not be liable for any loss or damage whatsoever arising from the use of any
information, errors or omissions in this document or any use of the product.
Vitec Group Communications declares that the electronic equipment has been manufactured in
conformity with the following standards:
Trademarks
MS-DOS and Windows are registered trademarks of Microsoft Corporation.
Ethernet is a registered trademark of Xerox Corporation.
© 2006 All rights reserved. Neither the whole, nor any part of the information contained herein, nor in
the products described in this guide, may be adapted or reproduced in any material form except with the
prior written approval of Vitec Group Communications.
European Union Declaration of
Conformity
BS EN 50081-1:1992 Electromagnetic compatibility. Generic
emission standard.
Residential, commercial and light industry.
BS EN 50082-1:1998 Electromagnetic compatibility. Generic
immunity standard.
Residential, commercial and light industry.
BS EN 60950:1992 Safety of information technology equipment.

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Revision History
Issue Date Notes
2.0 April 2000 Initial Issue
2.1 June 2006 Updates

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Warnings and Cautions
Where appropriate, warnings and cautions appear in the text with the following meanings:
WARNING. Given where carrying out an instruction can cause risk of injury or death.
CAUTION. Given where carrying out an instruction can cause risk of damage to the equipment.
WARNING - EARTHING OF EQUIPMENT
This equipment must be properly earthed.
The mains plug must be connected in accordance with the following code:
• BLUE - Neutral (N)
• BROWN - Live (L)
• GREEN/YELLOW - Earth (E)
As the colours of the wires in the mains lead of this equipment may not correspond with the coloured
markings identifying the terminals in your plug, proceed as follows:
• The wire which is coloured BLUE must be connected to the terminal which is
marked with the letter N or is BLACK.
• The write which is coloured BROWN must be connected to the terminal which is
marked with the letter L or is RED.
• The wire which is coloured GREEN and YELLOW must be connected to the ter-
minal which is marked with the letter E or the symbol
CAUTION - ELECTROSTATIC PROTECTION
When carrying out any maintenance or repair taks on this equipment all personnel should ensure that
appropriate grounding equipment is used and checked before commencing work on the equipment.
Electrostatic sensitive devices are marked with the symbol
GENERAL WARNING
Electrical shock can cause severe personal injury or death. All major units of
this equipment are powered by mains voltage. Unless specifically advised
otherwise, DISCONNECT mains supply before carrying out any maintenance
or repair tasks.
This equipment contains electrostatic sensitive devices. Observe
precautions for handling electrostatic sensitive devices when carrying out
any maintenance or repair tasks.

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Glossary of Terms
ADC Analogue to Digital Converter
ADM Assignment, Diagnostics and Monitoring
BNC Standard co-axial video connector
CAT5 Cable standard for high speed data communica-
tions (e.g. 100Base-TX)
CODEC Coder/Decoder
CMAPSi Configuration and Master Assignment Program-
ming System integrated
CSU Central Switching Unit
DAC Digital to Analogue Converter
DAK Direct Access Key
dB Decibel
DPDT Double-Pole-Double-Throw
EPROM Erasable Programmable Read-Only Memory
FLASH RAM Low voltage electrically erasable and program-
mable read-only memory.
GPI General Purpose Interface
GPSF General Purpose Special Function
Howlround Distorted audio - due to feedback of original sig-
nal in close proximity.
I/O Input / Output
I/P Input
IFB Interruptible Foldback
Local Programming Modifying the DAK assignments via the Intelli-
gent Control Panel SOFT Mode
LCD Liquid Crystal Display
LED Light Emitting Diode
Listen Route An audio route to the Control Panel from a
source. The audio is normally heard on the Con-
trol Panel's Loudspeaker or Headset.
LS Loudspeaker
Mb Megabyte
MHz Megahertz
N/C Normally Closed
N/O Normally Open

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NID Non Intrusive Download
NVRAM Non-Volatile Random Access Memory
O/P Output
PCB Printed Circuit Board
Pot. Potentiometer
PSU Power Supply Unit
RAM Random Access Memory
RCU Rear Connector Unit
RJ45 Standard connector for data communications
(used with CAT5 cabling for comms. between
the matrix and control panels)
RMS Root Mean Square
RU Standard Rack Unit (19 inches wide x 1.75
inches high or 482.6mm x 44.45mm)
Side Tone Side tone is the audio, which is heard in the
Headset's earpiece, which is generated by the
headset microphone. This allows the operators
to hear themselves when using headsets.
SPDT Single-Pole-Double-Throw (switch / relay action)
SPST Single-Pole-Single-Throw (switch / relay action)
TA Terminal Adaptor
Talkback A Broadcast term referring to intercom systems
in which 4-wire comms. are used.
Talk Route An audio route fromthe Control Panel to another
destination. The audio is normally generated
from the Control Panel's main microphone or
Headset microphone.
TBU Telephone Balance Unit
VOX Voice Operated Switch
XLR Audio industry standard connector

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Consult the named Vitec Group Communications document for further details.
Contact Vitec Group Communications for suitable options.
Tips given.

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TABLE OF CONTENTS
1 Introduction ..........................................................................................................1
1.1 Scope .......................................................................................................................1
1.2 System Overview .....................................................................................................1
2 Control Panel Description ....................................................................................3
2.1 Overview ..................................................................................................................3
2.2 Standard Control Panels ..........................................................................................4
2.2.1 PD4215R/4215 - 16 Key Control Panel (1RU) ..............................................................4
2.2.1.1 PD4215R Front View..............................................................................................4
2.2.1.2 PD4215 Front View ................................................................................................ 5
2.2.1.3 PD4215R/PD4215 Rear View ................................................................................ 5
2.2.1.4 PD4215R/PD4215 Components............................................................................. 6
2.2.2 PD4217 - Intelligent Control Panel (1RU) ...................................................................... 7
2.2.2.1 PD4217 Front View ................................................................................................ 7
2.2.2.2 PD4217 Rear View................................................................................................. 7
2.2.2.3 PD4217 Components .............................................................................................8
2.2.3 PD4211 LCD Key Panel (1RU) ......................................................................................9
2.2.3.1 PD4211 Front View ................................................................................................ 9
2.2.3.2 PD4211 Rear View................................................................................................. 9
2.2.3.3 PD4211 Components ........................................................................................... 10
2.2.4 PD4212R/PD4212 LCD Key Panel and Rotary Encoder ............................................. 11
2.2.4.1 PD4212R (revised) Front View............................................................................. 11
2.2.4.2 PD4212R Front View............................................................................................ 11
2.2.4.3 PD4212 Front View .............................................................................................. 12
2.2.4.4 PD4212R/PD4212 Rear View .............................................................................. 12
2.2.4.5 PD4212R/PD4212 Components........................................................................... 13
2.2.5 PD4216 - Custom Panel Interface (1RU) .................................................................... 14
2.2.5.1 PD4216 Front View .............................................................................................. 14
2.2.5.2 PD4216 Rear View...............................................................................................14
2.2.5.3 PD4216 Components ........................................................................................... 15
2.2.5.4 PD4216 Operation................................................................................................ 15
2.2.5.5 PD4216 Controls and Indicators........................................................................... 15
2.2.5.6 PD4216 Installation Information ........................................................................... 15
2.2.6 PDE3530 - Remote Panel Driver Card ........................................................................16
2.2.7 PDE3531 - Custom Panel Card ...................................................................................16
2.2.7.1 PDE3531 Operation ............................................................................................. 16
2.2.7.2 PDE3531 Installation Information.........................................................................16
2.2.7.3 PDE3531 Assembly Diagram:..............................................................................17
2.2.7.4 PDE3531 Connector Information.......................................................................... 17
2.2.8 PD4224R/PD4224 - Intelligent Control Panel (2RU) ................................................... 19
2.2.8.1 PD4224R (revised) Front View............................................................................. 19
2.2.8.2 PD4224R Front View............................................................................................ 20
2.2.8.3 PD4224 Front View .............................................................................................. 21
2.2.8.4 PD4224R/PD4224 Rear View .............................................................................. 22
2.2.8.5 PD4224R/PD4224 Components........................................................................... 22
2.2.9 PD4225R/PD4225 Router Control Panel (2RU) .......................................................... 24
2.2.9.1 PD4225R Front View............................................................................................ 24
2.2.9.2 PD4225 Front View .............................................................................................. 25
2.2.9.3 PD4225R/PD4225 Rear View .............................................................................. 26
2.2.10 PD4226R/PD 4226 32-key control panel (2RU) ........................................................27
2.2.10.1 PD4226R Front View.......................................................................................... 27
2.2.10.2 PD4226 Front View ............................................................................................ 28

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2.2.10.3 PD4226 Rear View............................................................................................. 29
2.2.10.4 PD4226R/PD4226 Components.........................................................................29
2.2.11 PD4221 LCD Key Panel (2RU) ..................................................................................31
2.2.11.1 PD4221 Front View ............................................................................................ 31
2.2.11.2 PD4221 Rear View............................................................................................. 31
2.2.11.3 PD4221 Components.........................................................................................32
2.2.12 PD4222R/PD4222 LCD Key Panel and Rotary Encoder (2RU) ................................ 33
2.2.12.1 PD4222R Front View.......................................................................................... 33
2.2.12.2 PD4222 Front View ............................................................................................ 34
2.2.12.3 PD4222R/PD4222 Rear View ............................................................................34
2.2.12.4 PD4222R/PD4222 Components.........................................................................35
2.2.13 PD4222SR/PD4222S Supervisor Key Panel ............................................................. 36
2.2.13.1 PD4222SR Front View ....................................................................................... 36
2.2.13.2 PD4222S Front View.......................................................................................... 37
2.2.13.3 PD4222SR/PD4222S Rear View........................................................................ 37
2.2.13.4 PD4222SR/PD4222S Panel Description............................................................38
2.2.14 PD4232RBL LCD Key Panel and Rotary Encoder (3RU) .......................................... 39
2.2.14.1 PD4232RBL Front View ..................................................................................... 39
2.2.14.2 PD4232RBL Rear View......................................................................................40
2.2.14.3 PD4232RBL Components..................................................................................41
2.2.15 PD4294R/PD4294 - Desktop Control Panel .............................................................. 42
2.2.15.1 PD4294R Front View.......................................................................................... 42
2.2.15.2 PD4294 Front View ............................................................................................ 43
2.2.15.3 PD4294R/PD4294 Rear View ............................................................................44
2.2.15.4 PD4294R/PD4294 Components.........................................................................44
2.2.16 PD4295MCI LCD Desktop Panel ...............................................................................46
2.2.16.1 PD4295MCI Components................................................................................... 47
2.2.17 PD4296MCI LCD Desktop Panel ...............................................................................48
2.2.17.1 PD4296MCI Components................................................................................... 49
2.3 Extension Panels ...................................................................................................51
2.3.1 PD4203R/PD4203 - Level Control Panel (1RU) .......................................................... 51
2.3.1.1 PD4203R Front View............................................................................................ 51
2.3.1.2 PD4203 Front View .............................................................................................. 51
2.3.1.3 PD4203R/PD4203 Rear View .............................................................................. 51
2.3.1.4 PD4203R/PD4203 Control Panel Description...................................................... 52
2.3.1.5 PD4203R/PD4203 Components........................................................................... 52
2.3.1.6 Mechanical Construction......................................................................................52
2.3.2 PD4206R/PD4206 - 20 Key Extension Panel (1RU) ................................................... 53
2.3.2.1 PD4206R Front View............................................................................................ 53
2.3.2.2 PD4206 Front View .............................................................................................. 53
2.3.2.3 PD4206R/PD4206 Rear View .............................................................................. 54
2.3.2.4 PD4206R/PD4206 Extension Panel Description..................................................54
2.3.2.5 PD4206R/PD4206 Components........................................................................... 54
2.3.2.6 PD4206R/PD4206 Mechanical Construction........................................................ 54
2.3.2.7 PD4206R/PD4206 Wiring..................................................................................... 54
2.3.3 PD4230R Half Width LCD Extension Panel (1RU) ...................................................... 55
2.3.4 PD4230RV Half Width Vertical LCD Control Panel (1RU) ........................................... 56
2.3.5 PD4231R Half Width LCD Control Panel (1RU) .......................................................... 57
3 Sub Assembly PCBs ..........................................................................................59

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3.1 PDE 4505 Key extension card ...............................................................................59
3.2 PDE 4530 LCD switch driver card .........................................................................59
3.3 PDE 4531 1U LCD Key Card .................................................................................59
3.4 PDE 4532 2U LCD Key Card .................................................................................60
3.5 PDE 4533 Key/Pot. Card .......................................................................................60
3.6 PDE 4534 RJ45 Connector Card ...........................................................................60
3.7 PDE 4535 Panel Electronics Card .........................................................................61
3.7.1 PDE4535 Circuit description ........................................................................................61
3.8 PDE 4536 Coax/Fibre Options Card ......................................................................62
3.8.1 PDE4536 Circuit description ........................................................................................62
3.9 PDE 4537 Panel Audio/GPI Options Card .............................................................63
3.10 PDE 4538 Panel Electronics Card .......................................................................64
3.10.1 PDE4538 Circuit description ......................................................................................64
3.11 PDE 4551 Key/LCD Display Card ........................................................................65
3.12 PDE 4552 Key Card .............................................................................................66
3.13 PDE 4553 Key Card .............................................................................................66
3.14 PDE 4554 Pot. Extension Card ............................................................................66
3.15 PDE 4556 Key/LED Display Card ........................................................................67
3.16 PDE 4557 Drive Card ..........................................................................................67
3.17 PDE 4558 Panel Electronics Card .......................................................................68
3.18 PDE 4566 Key/LCD Display Card ........................................................................68
3.19 PDE4609 8-channel telephone interface control card .........................................68
3.19.1 PDE4609 Circuit description ......................................................................................68
4 Digital Routing Matrix .........................................................................................69
4.1 Racks .....................................................................................................................69
4.1.1 4420 4U rack ...............................................................................................................69
4.1.2 4920 9U rack ...............................................................................................................69
4.1.3 PDE4641 60-way SIMM card ......................................................................................70
4.2 Front Cards ............................................................................................................70
4.2.1 PDE 3601A - Digital Matrix Card (DMC) ...................................................................... 70
4.2.2 PDE 4621A - 16 Channel CODEC Card ...................................................................... 72
4.3 PDE4631 - 16 Channel Audio Input / Output CODEC Card ..................................74
4.3.1 Card Location ..............................................................................................................74
4.3.2 Controls and Indicators ................................................................................................ 75
4.3.3 Description ................................................................................................................... 75
4.3.4 PDE 4606A - Panel Communications Card (PCC) ...................................................... 76
4.4 PDE4606B - 16 Channel Panel Communications Card .........................................78
4.4.1 Card Locations .............................................................................................................78
4.4.2 Controls and Indicators ................................................................................................ 78
4.4.3 PDE4644 - Digital matrix card ..................................................................................... 79
4.4.4 PD 3901 - Beltpack Interface ....................................................................................... 79
4.4.5 PDE 4642 Microprocessor Card (MPC) ....................................................................... 80
4.4.6 Controls and Indicators ................................................................................................ 81
4.5 PDE4662 Central Processor Card .........................................................................81
4.5.1 Card Location ..............................................................................................................81
4.6 PDE Rear Connector Units ....................................................................................82
4.6.1 PDE 4622TX - 16 Channel CODEC RCU ................................................................... 82
4.6.2 PDE 4622 - 16 Channel CODEC RCU ........................................................................ 82
4.6.3 PDE 4643 - Processor I/O RCU (RS232/RS422) ........................................................ 83
4.7 PDE4663 - Central processor RCU Card ..............................................................84
4.7.1 Card location ................................................................................................................84
4.7.2 Links ............................................................................................................................84
4.7.3 Connector details .........................................................................................................85

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4.8 PDE4663B - Central Processor RCU Card ............................................................88
4.8.1 Card location ................................................................................................................89
4.8.2 Links ............................................................................................................................89
4.8.3 Connector details .........................................................................................................89
4.8.4 PDE4645 - Optional GPI card ...................................................................................... 92
4.8.5 PDE 4628 - Serial Communications Rear Connector Unit (SCRCU) .......................... 92
4.8.5.1 Card Location ....................................................................................................... 93
4.8.5.2 Upgrading Firmware............................................................................................. 93
4.8.5.3 Power On Self Test .............................................................................................. 93
4.8.5.4 Data and Audio Connections................................................................................ 95
4.8.6 PDE 4619 - General Purpose Interface (GPI) RCU .....................................................96
4.8.6.1 Card Location ....................................................................................................... 96
4.8.7 Mains Panel (4U and 9U Racks) ................................................................................. 98
4.8.8 AC Supplies ................................................................................................................. 98
4.9 4000 Power Arrangements ....................................................................................98
4.9.1 4420 (4U) Matrix .......................................................................................................... 98
4.9.2 4920 (9U) Matrix .......................................................................................................... 98
4.9.2.1 Supply Protection .................................................................................................99
5 Specifications ...................................................................................................101