Firecom 4100 User manual

4100 Portable Intercom System
Operation Manual
Revision A

TABLE OF CONTENTS
Safety Information
Intrinsic Safety and Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Confined Space
Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Setup and Operation
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Setup and Connections
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ground Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The Intercom Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting Headsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation and System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parts & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
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SAFETY INFORMATION
Intrinsic Safety and Certification
What is Intrinsic Safety?
Intrinsic safety is a type of protection in which a portion of the electrical system (apparatus, circuits, and wiring) contains
only equipment that is incapable of causing ignition in the surrounding atmosphere. No single device or wiring is
intrinsically safe by itself (except for battery operated, self-contained apparatus such as portable pagers, transceivers,
gas detectors, etc., which are specifically designed as intrinsically safe, self-contained devices). Devices are intrinsi-
cally safe only when employed in a properly designed intrinsically safe system.
Certification
The Firecom 4100 Portable Intercom System is listed by SGS / United States Testing Company (USTC) as Intrinsically
Safe for use in certain hazardous atmospheres. Hazardous atmospheres can range from gas vapor to dust to flying
fibers. The listing by USTC indicates that Firecom’s 4100 Portable Intercom System has undergone a series of tests
that demonstrate it is incapable of releasing a level of energy, either thermal or electrical, under normal or abnormal
conditions, that may cause ignition in a specific hazardous atmosphere.
The Firecom 4100 Portable Intercom System has been listed as Intrinsically Safe for use in Class I, II, and III,
Division 1, Groups A, B, C, D, E, F, G hazardous locations.
The following accessories can be used with the Firecom 4100 Portable Intercom System while maintaining full
compliance with the Intrinsically Safe listing:
Headset Description Part No.
Model CH-U Under-the-helmet headset 105-0110-00
Model CH-FS Single-ear headset 105-0115-00
Model CH-LW Lightweight headset 105-0120-00
Extension Cables Description Part No.
Cable, 50 ft. Abrasion resistant polyurethane 108-0070-05
Cable, 100 ft. Abrasion resistant polyurethane 108-0070-10
Warning
Battery chargers sold with this unit are not Intrinsically Safe. Do not charge or change batteries in intrinsically safe
zones or hazardous environments.
Warning
Do not charge or change batteries in intrinsically safe zones or hazardous environments.
Warning
Substitution of components or unqualified service or maintenance will impair intrinsic safety. Contact Firecom for
intrinsically safe repair services.

CONFINED SPACE
Definition
A confined space has all of the following characteristics:
•A restricted opening that makes entry and exit difficult
•Large enough for an adult to enter completely
•Not designed to be occupied
Most confined spaces are designed to hold substances such as liquids, gases, and loose materials, or to house equip-
ment. Though they come in many sizes and shapes, most can be classified in two ways: those with depth and open
tops, and those with narrow openings.
Examples
Open top and deep spaces include pits, wells, vats, hoppers, bins, degreasers, and kettles. Spaces with narrow open-
ings include ship compartments, silos, pipes, tunnels, utility vaults, casings, and sewers.
Permit Space
A permit space is a confined space that may contain life-threatening hazards. No one can enter a permit space
without first completing a written entry permit and having it signed and posted by an entry supervisor. For more
information, see the OSHA web site.
For a quick reference to the required Confined Space Standard permit, see www.orosha.org -or- osha.org
3

SETUP AND OPERATION
Features
Firecom’s 4100 Portable Intercom System features six independent, full-duplex audio channels designed for
continuous hands-free voice communications in confined space and high-noise environments. The six stations
include four entrants, an attendant, and an additional monitoring station or accessory port. The system provides
constant, real-time communications between all interfaced personnel. Each entrant is equipped with an individual
alarm and local volume on each headset. In addition, each team has its own volume control at the main unit
while the standby team has a built-in mute switch, that when pressed, prevents them from being heard by the
entry team, attendant, and accessory ports.
ON
Figure 1.
Figure 2.
Grease Marking Pencil
Power Switch
Power On Indicator
Low Battery Indicator
Team Volume Controls
Standby Team
Mic. Mute
Audible Alarm
(Internal)
Alarm Test
and Reset Buttons
Alarm Indicator (4) Places
Erasable
Identification Area
(4) Places
Headset Port
(4) Places
Accessory Port
Attendant Headset Port
and Volume Control
Intrinsic Safety Label
Pressure Release Valve
Control Panel
4

SETUP AND CONNECTIONS
Charging the Battery
The Firecom 4100 Portable Intercom System is powered by a sealed lead-acid rechargeable battery housed in the
base unit. Before you can put the 4100 Portable Intercom System to work, you must charge the battery with a full
charge.
Connect the battery charger to the back of the main unit and plug the battery charger into an indoor 120-volt AC
outlet as shown in figure 3. Initial battery charge time is 24 hours. After the initial battery charge, charge time will
decrease according to usage. The battery charger unit comes with an indicator light. The light will illuminate red if a
fault condition exists, yellow when the unit is charging, and green when the charger is in float (slow charge) mode.
The 4100 Portable Intercom System will operate up to 80 hours on a full charge. Do not drain the battery completely.
Warning
Battery chargers sold with this unit are not Intrinsically Safe.
Warning
Do not charge or change batteries in intrinsically safe zones or hazardous environments.
Warning
Use the battery charger indoors only.
Ground Connection
A grounding connection is provided on the back of the intercom unit (see figure 3). The intercom unit should be
grounded according to local safety practices and those outlined by the National Electric Code.
Figure 3.
5
Ground Connection

SETUP AND CONNECTIONS
The Intercom Case
The intercom base unit and accessories case are durable, watertight, and airtight with integrated pressure release
valves. To open the base unit or accessory case, press the black button in the middle of the latch and lift as shown
in figure 4. If the case does not open, the pressure release valve may need to be temporarily opened. This should
equalize pressure and allow the case to be opened. After opening, return the pressure release valve to a closed
position to protect internal components.
Note: When the intercom lid is closed, the system automatically switches off.
Connecting Headsets
The 4100 Portable Intercom System headset includes heavy-duty cables with locking connectors and alignment
features to assure correct wiring. To connect a headset to a cable, visually inspect both connectors for a notch in
the female connector and a mating protrusion in the male connector. Align these items, retract the locking ring on
the female connector, and insert. After insertion, push the locking ring forward and rotate clockwise to lock, as
shown in figure 5. To disconnect cables, reverse the process. The identical process is used for connecting two or
more cables together
To connect cables to the intercom, remove the connector port covers on the intercom and repeat the process
above, as shown in figure 6.
See headset manuals, included with each headset purchased, for individual headset adjustments and setup.
Pressure
Release Valve
Figure 4.
Figure 5.
Figure 6.
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OPERATION AND SYSTEM TEST
Once the unit has been charged and the headsets connected, you are ready for operation. Put headsets on and
adjust for good performance and a comfortable fit as indicated in your headset manual. Follow the steps below for
clear hands-free communication between all persons wearing a headset.
Step 1. Power On
The 4100 Portable Intercom System is battery powered. To operate, activate the power switch located on the front
panel (figure 2). The power light indicator on the front panel should illuminate. If the low battery light illuminates, the
battery will need to be charged. See Charging the Battery in this manual. The intercom will automatically turn off
when the case is closed.
Note: The unit must be fully charged before first use. See Charging the Battery in this manual.
Step 2. Volume Controls
Portable Intercom headsets come with individual volume controls for each user. In addition, there are volume
controls for each entrant team and the attendant on the main unit (see figure 2). To adjust the volume, turn the
control knob clockwise to increase volume and counter clockwise to decrease.
Step 3. Identification Area
An erasable identification area is provided for each of the (4) entrants, seen in figure 2. A grease marking pencil is
used for writing in these spaces and can be found on the interior lid of the intercom case (see figure 1). Examples
of notes include entrant’s name and time of entry.
Note: Use a clean dry rag or mild soap and water to erase identification areas.
Step 4. Alarm Buttons
Each Firecom Portable Intercom headset comes with an alarm button. If a headset is plugged into one of the (4)
entrant headset ports and the headset alarm button is depressed, a warning light will illuminate on the front panel
indicating which entrant has activated their alarm and an audible buzzer will sound (reference figure 2). The alarm
is cancelled by depressing the alarm reset button on the front panel.
Note: The accessory and attendant ports do not have alarm function capabilities.
Step 5. Mute Button
The mute button should be checked at the start of operation. When the mute button is depressed, the standby
team will not be heard by other participants or on their own headsets. However, the standby team will hear
communications between all other participants. The mute button will illuminate when activated. To deactivate the
mute feature, depress the mute button (see figure 2).
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OPERATION AND SYSTEM TEST
Step 6. System Test
Headset users should take turns speaking and listening as a group to make sure communication is open between
all participants. If one or more participants can not be heard or hear, adjust volumes, check the mute button, or
refer to the Troubleshooting in this manual.
The alarm circuit and each entrant’s alarm should be tested prior to every use. Test the alarm circuit by depressing
the alarm test button on the front panel. Turn the alarm off by pressing the alarm reset button on the front panel.
Next, each entrant should test their individual alarm buttons located on each headset, one at a time. Both the
audible alarm and entrant’s alarm indicator light should activate. This should be confirmed by the attendant. Turn
off the alarm by pressing the alarm reset button and repeat the procedure for each entrant.
Note: The accessory and attendant ports do not have alarm function capabilities.
ON
Entrant Team Alarm Light
(4) Places
Alarm Reset Button
Alarm Test Button

MAINTENANCE
General maintenance is required on your 4100 Portable Intercom System.
•It is recommended that you inspect all cables for damage and wear after every use.
•Clean dirt and debris out of intercom, headset ports, and connectors after working in hazardous areas.
Inspect for damage or corrosion. Intercom port covers should remain closed when cables are not attached to
protect from damage or corrosion.
•Check headset cables, earphones, and microphone boom assemblies for damaged or worn parts. See your
headset manual for individual headset care.
TROUBLESHOOTING
Problem: Intercom will not function
•The battery may not be charged. The unit must be fully charged after purchase. See Charging the Battery in
this manual.
•Confirm that the power switch is on.
Problem: There is no sound on the headset
•Check the volume control on the headset and the front panel of the main unit.
•Disconnect, inspect, and reconnect cable connections on the headset and intercom. Inspect for damaged or
corroded pins.
•Check to see if the mute button is depressed.
Problem: You can hear others on the headset but they can not hear you
•Check to see if the mute button is depressed.
•Check the volume control on all headsets and at the team stations on the front panel of the main unit.
•Disconnect, inspect, and reconnect cable connections on the headset and intercom. Inspect for damaged or
corroded pins.
Problem: The alarm button does not work on a headset
•The alarm button will NOT function on the attendant or accessory ports. Plug the headset into one of the (4)
entrant ports.
•Check and reconnect cable connection ports on the headset and intercom. Inspect for damaged or corroded pins.
Problem: Noise or interference persists on the intercom
•Inspect the surrounding area for sources of radio interference or electromagnetic interference.
•Uncoil attached cables and straighten. Inspect cables for damaged or worn areas.
•Disconnect and inspect all headset and cable connections for damaged or worn pins.
•Disconnect the battery charger and check to see if the problem persists.
Problem: The main unit battery does not charge properly
•If the battery has been completely drained, its ability to recharge will be impaired. If you suspect the battery is
dead, connect the main unit to the charger to see if it will go into a charge mode. If the battery charger does
not go into charge mode in one hour, and then in float mode in 24 hours, the battery is unrecoverable. See
Charging the Battery in this manual for charging details.
•If the problem persists, disconnect the charger and return the unit to Firecom for battery replacement.
9

TROUBLESHOOTING
10
Warning
Battery chargers sold with this unit are not Intrinsically Safe.
Warning
Do not charge or change batteries in intrinsically safe zones or hazardous environments.
Warning
Use the battery charger indoors only.
Warning
Substitution of components, unqualified service or maintenance will impair intrinsic safety. Contact Firecom for
intrinsically safe repair services.
If a problem persists in a headset or intercom unit, contact Firecom for a Return Merchandise Authorization (RMA)
number. Return the headset or intercom for replacement or repair.
CONTACT: Firecom 1-800-527-0555
7340 SW Durham Road
Portland, OR 97224
USA
PARTS & ACCESSORIES
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Part Number
CH-U (under-the-helmet headset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-0110-00
CH-FS (single-ear headset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-0115-00
CH-LW (lightweight headset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105-0120-00
BC-1 (battery charger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0080-00
VC-1 (vehicle power adapter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0082-00
PC-50 (cable, headset extension 50ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0070-05
PC-100 (cable, headset extension 100ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0070-10
AC-1 (accessories carrying case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0078-00
CM-1 (cable management clip) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108-0060-00
See www.firecom.com for additional parts and accessories.
SPECIFICATIONS
Headsets & Microphones
See headset manual for headset specifications.
Battery & Charger
12VDC, 3.4Ah, sealed lead-acid rechargeable battery
Charger requirements: 120 V~, 60 Hz, .2A RMS

WARRANTY
Two-Year Limited Warranty to the Original Purchaser
Sonetics Corporation warrants to the original purchaser of its products, that they will be free from defects in materials and work-
manship, under normal and proper use, for the period of two years from date of purchase. Sonetics Corporation will repair or
replace, at its option, any parts showing factory defects during this warranty period, subject to the following provisions. This warranty
applies only to a new product which has been sold through authorized channels of distribution. All work under warranty must be
performed by Sonetics Corporation. All returned products must be shipped to our address, freight prepaid, accompanied by a
dated proof of purchase. The purchaser voids this warranty if he, she or others attempt to repair, service or alter the product in
any way. This warranty does not apply in the event of accident, abuse, improper installation, unauthorized repair, tampering,
modification, fire, flood, collision, or other damage from external sources, including damage which is caused by user replaceable
parts (leaking batteries, etc.). This warranty does not extend to any other equipment or apparatus to which this product may be
attached or connected. The foregoing is your sole remedy for failure in service or defects. Sonetics Corporation shall not be liable
under this or any implied warranty for incidental or consequential damages, nor for any installation or removal costs or
other service fees. This warranty is in lieu of all other warranties, express or implied, including the warranty of
merchantability or fitness of use, which are hereby excluded. To the extent that this exclusion is not legally enforceable, the
duration of such implied warranties shall be limited to two years from date of purchase. No suit for breach of express or implied
warranty may be brought after two years from date of purchase.
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FIRECOM is a division of Sonetics Corporation
7340 SW Durham Road •Portland, Oregon 97224
800-527-0555 •503-684-6647 •Fax: [phone]
Email: [email protected] •www.firecom.com
Copyright © 2003 Sonetics Corporation - All rights reserved.
The information in this document is subject to change without notice.
No part of this document may be reproduced in any form without prior written consent of Sonetics Corporation.
This document is part number 600-0105-00 Printed in U.S.A.