Kustom KHS6440 User manual

Six-Source, Four-Zone
Audio Distribution System
KHS6440 OWNE S MANUAL
Congratulations on choosing the KHS6440 audio distribution system. The
Kustom Home Sound products offer unparalleled quality and performance at a
very affordable price. o other products in the industry offer as much flexibility,
ease of installation, and features to meet your needs.
The KHS6440 has 6 individual audio source inputs with a corresponding audio
out for linking with another 6440 or the KHS6640 amplifier. Each zone amplifier
is equipped with active line outputs for utilizing an additional amplifier for zones
that require additional power, as well as speaker outputs for clear, undistorted
audio to your in-wall speakers. A built-in IR routing system allows you to operate
CD players, satellite receivers, or any other equipment independently even
though the same manufacturer makes them and they respond to the same IR
codes. Your 6440 system may be controlled by the KHS6S, single gang controller,
or the KHS6D dual gang, programmable Controller for complete IR control of
your audio equipment from any room of your house.
Whether you are enjoying a movie on TV, relaxing to music at the end of the
day in your bedroom, listening to the evening news as you prepare dinner in the
kitchen, or entertaining friends on your deck, the Kustom Audio Distribution
Systems will enhance your lifestyle for years to come.
SIX-ZO E AMPLIFICATIO SYSTEM
MODEL KHS6440
O
POWER
STA DBY

THIS APPARATUS SHALL NOT BE EXPOSED TO
DRIPPING OR SPLASHING. NO OBJECTS FILLED
WITH LIQUIDS SUCH AS VASES SHALL BE PLACED
ON THE APPARATUS.
TO AVOID ELECTRICAL SHOCK, DO NOT
DISASSEMBLE. REFER SERVICING TO QUALIFIED
PERSONAL ONLY!
Kustom Inc., 4940 Delhi Pike, Cincinnati, OH  USA
( 00) 999-555 Fax: [phone] / www.kustom.com
SOUND LEVEL db FLOW RESPONSE
0
3
5
7
100
103
110
CAUTION
THIS AMPLIFIER HAS BEEN DESIGNED AND CONSTRUCTED TO PROVIDE
ADEQUATE POWER RESERVE FOR PLAYING MODERN MUSIC WHICH MAY
REQUIRE OCCASIONAL PEAK POWER. EXTENDED OPERATION AT
ABSOLUTE MAXIMUM POWER IS NOT RECOMMENDED SINCE THIS
COULD DAMAGE THE ASSOCIATED LOUDSPEAKER SYSTEM. PLEASE BE
AWARE THAT MAXIMUM POWER CAN BE OBTAINED WITH VERY LOW
SETTINGS OF THE MASTER VOLUME CONTROLS IF THE INPUT SIGNAL
IS VERY STRONG.
IMPORTANT
1. Read all safety and operating instructions before using this product.
2. All safety and operating instructions should be kept for future reference.
3. Obey all cautions in the operating instructions and on the back of the unit.
4. All operating instructions should be followed.
5. This product should not be used near water i.e. bathtub, sink, swimming
pool, wet basement, etc.
6. This product should be located so that its position does not interfere
with proper ventilation. It should not be placed flat against a wall or
placed in a built-in enclosure that will impede the flow of cooling air.
7. This product should not be placed near a source of heat, such as a
stove, radiator, or another heat producing amplifier.
8. Connect only to a power supply of the type indicated on the back of the
amplifier near the power supply cord.
. Do not break off the ground pin of the power supply cord.
10. Power supply cords should always handled carefully. Never walk or place
equipment on power supply cords. Periodically check cords for cuts or
signs of stress, especially at the point where the cord exits the unit.
11. The power supply cord should be unplugged when the unit is unused
for long periods of time.
12. If this product is to be mounted in an equipment rack, rear support
should be provided.
13. Metal parts and vinyl covering may be cleaned with a damp rag.
14. Care should be taken so that objects do not fall and liquids are not spilled
into the unit through the ventilation ports or any other openings.
15.This unit should be checked by a qualified service technician if:
A. The power supply cord or plug has been damaged.
B. Anything has fallen or been spilled into the unit.
C. The unit does not operate correctly.
D. The unit has been dropped or the enclosure damaged.
16. The user should not attempt to service this equipment. All service work
must be done by a qualified service technician for warranty repairs.
DANGER
EXPOSURE TO EXTREMELY HIGH NOISE LEVELS MAY CAUSE A PERMANENT
HEARING LOSS. INDIVIDUALS VARY CONSIDERABLY TO NOISE INDUCED HEARING
LOSS BUT NEARLY EVERYONE WILL LOSE SOME HEARING IF EXPOSED TO
SUFFICIENTLY INTENSE NOISE FOR A SUFFICIENT TIME.
THE U.S. GOVERNMENT'S OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) HAS SPECIFIED THE FOLLOWING PERMISSIBLE NOISE LEVEL EXPOSURES:
ACCORDING TO OSHA, ANY EXPOSURE IN THE ABOVE PERMISSIBLE LIMITS COULD
RESULT IN SOME HEARING LOSS. EAR PLUGS OR PROTECTORS IN THE EAR CANAL
OR OVER THE EARS MUST BE WORN WHEN OPERATING THIS AMPLIFICATION
SYSTEM IN ORDER TO PREVENT A PERMANENT HEARING LOSS. IF EXPOSURE IN
EXCESS OF THE LIMITS AS PUT FORTH ABOVE, TO INSURE AGAINST POTENTIALLY
HARMFUL EXPOSURE TO HIGH SOUND PRESSURE LEVELS. IT IS RECOMMENDED
THAT ALL PERSONS EXPOSED TO EQUIPMENT CAPABLE OF INDUCING HIGH SOUND
PRESSURE LEVELS, SUCH AS THIS AMPLIFICATION SYSTEM, BE PROTECTED BY
HEARING PROTECTORS WHILE THIS UNIT IS IN OPERATION.
DURATION PER DAY IN HOURS
8
6
4
3
2
1
1/2 HR. or LESS
THIS SYMBOL IS INTENDED TO ALERT THE USER TO THE PRESENCE OF IMPORTANT
OPERATING AND MAINTENANCE (SERVICING) INSTRUCTIONS IN THE LITERATURE
ACCOMPANYING THE UNIT.
THIS SYMBOL IS INTENDED TO ALERT THE USER TO THE PRESENCE OF
UNINSULATED DANGEROUS VOLTAGE WITHIN THE PRODUCTS ENCLOSURE THAT
MAY BE OF SUFFICIENT MAGNITUDE TO CONSITUTE A RISK OF ELECTRIC SHOCK
TO PERSONS.
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK, DO NOT
REMOVE CHASSIS. NO USER-SERVICEABLE PARTS
INSIDE. REFER SERVICING TO QUALIFIED SERVICE
PERSONNEL.
AVIS: RISQUE DE CHOC ELECTRIQUE-NE PAS OUVRIR.

A.) Power Switch - Left on, the KHS6440, when not being used, will go into a sleep mode, ready
to turn back on when an input signal is applied from any of the six sources. In the off position, the unit
will not function.
B.) On LED - With the power switch on, this LED indicates that the unit is powered up and awake.
C.) Standby LED - This LED indicates that the unit is plugged into the wall.
D.) Output Section - This section is the output section. It provides the speaker terminals and line
outputs.
E.) Distribution Section - This section is the line level input/output section. It provides the inputs from
your sources and the outputs for stacking additional units.
F.) Controller Section - This section is where the wall controller in each zone connect. This section
includes the party mode master controller input.
G.) Infrared (I ) Section - This is the IR section. It provides outputs for the IR emitters.
H.) AC Power Cord - This is where the AC power cord connects to the unit. It is a detachable 3 prong
I.E.C. plug.
Page 1
G HFED
A B C
SIX-ZO E AMPLIFICATIO SYSTEM
MODEL KHS6440
O
POWER
STA DBY
IR REMOTE OUTPUTS
1
SOURCE OUTPUT
I OUT
SOURCE 1
I OUT
SOURCE 2
I OUT
SOURCE 3
I OUT
SOURCE 4
I OUT
SOURCE 5
I OUT
SOURCE 6
I PUT SOURCES ZO E CO TROLLERS
L
R
SUM OUTPUT
A
2
B
3
C
4
D
120V 50/60Hz 300W
KUSTOM I C. CI CI ATI, OH
USA
MODEL KHS6440A
MULTI-ZO E
CAUTION
RISK OF ELECTRIC SHOCK
DO NOT OPEN
AVIS: RISQUE DE CHOC ELECTRIQUE-NE PAS OUVRIR.
WARNING: SHOCK HAZARD - DO NOT OPEN.
ZO E 1
L R
LEFT
- + RIGHT - +
ZO E 2
LR
LEFT
- + RIGHT - +
ZO E 3
LR
LEFT
- + RIGHT - +
ZO E 4
LR
LEFT
- + RIGHT - +
LI E OUT / SPEAKER OUT
20W/8 OHM X220W/8 OHM X220W/8 OHM X220W/8 OHM X2
LI E OUT LI E OUT LI E OUT LI E OUT
OUT
1 81 81 81 81 81 8
I 1234
MASTER I DIVIDUAL ZO ES

1.) Line Outputs (Left & ight) - These are dual RCA line outputs to go to additional amplifiers or
to powered sub-woofers. The white one is for left channel and the red one is for right channel. These
outputs will react to the volume controllers for each zone. Any changes made to these will follow
through to these outputs.
If you need additional speakers, say for a deck or large family room and require more power than
onboard, simply take these outputs and plug into the larger amp.
If you want to run sub-woofers in a zone, you can use powered sub-woofer systems or an additional
amp to power them as in the above explanation.
2.) Speaker Connectors - These connectors are where the speaker connections for each zone are
made. First determine which individual wire is ground (negative) and the other being the signal
(positive) of your speaker wire. The detachable speaker connectors are labeled as L- (left negative);
L+ (left positive); R- (right negative); R+ (right positive). There are small set screws on this connector
to allow solderless connections to be made. We suggest using a straight blade Jewelers screwdriver
to easily make this connection.
These speaker outputs are rated at 20 watts RMS a side into an 8 ohm load. Stay within that ohm
rating. This will be more than adequate power for most of the in-wall speakers on the market.
These connectors are then duplicated for the additional five zones and are identical in nature.
I OUT
SOURCE 1
I OUT
SOURCE 2
I OUT
SOURCE 3
I OUT
SOURCE 4
I OUT
SOURCE 5
I OUT
SOURCE 6
I PUT SOURCES
L
R
3.) Source #1 Left Input (White) - This RCA input will accept any standard line level source such
as CD, Receiver, Tuner, DSS, TV audio and more. It connects the left channel.
4.) Source #1 ight Input ( ed) - This RCA input will accept any standard line level source such
as CD, Receiver, Tuner, DSS, TV audio and more. It connects the right channel.
5.) Source #1 Left Output (White) - This RCA output will send a line level signal out, an exact copy
of that source signal, from the signal plugged into the left channel of source #1 inputs. It is used for
stacking additional KHS6440 units together. This provides an ultra clean audio distribution amplifier
for signal clarity.
6.) Source #1 ight Output ( ed) - This RCA output will send a line level signal out, an exact copy
of that source signal, from the signal plugged into the right channel of source #1 inputs.
These connectors are then duplicated for the additional five sources and are identical in nature.
OUTPUT SECTION
DIST IBUTION SECTION
34 56
Page 2
ZO E 1
L R
LEFT
- + RIGHT - +
ZO E 2
LR
LEFT
- + RIGHT - +
ZO E 3
LR
LEFT
- + RIGHT - +
ZO E 4
LR
LEFT
- + RIGHT - +
LI E OUT / SPEAKER OUT
20W/8 OHM X220W/8 OHM X220W/8 OHM X220W/8 OHM X2
LI E OUT LI E OUT LI E OUT LI E OUT
1 2

CONT OLLE SECTION
7.) Master Output - This connector allows the party mode to apply to multiple units if additional
units are added.
8.) Master Input - This is for the party mode controller. This controller should be located near the
unit and sources. It will override all zone controllers and select a source which will then play in all
zones. This mode is used for playing the same background music in all zones such as during a party.
The individual wall controllers still have the ability to select a different source after the party mode is
engaged. It uses a standard 8 pin RJ-45 connector.
9.) Individual Zone #1 Controller - This connector hooks up the wall controllers used in zone #1.
The signals from this wall controller control all the functions in zone #1. It uses a standard 8-pin RJ-
45 connector.
This connector is duplicated for the remaining 5 zones and function exactly the same.
Page 3
10.) Source Output #1 through 4 - This 1/8 2 conductor jack is for the IR emitters and are locked
source specific. This is useful for instance, if you have 2 or more of the same brand CD player, since
the same IR command will work on both, this O LY sends the IR command to this particular source.
early any brand of emitter will work. There are four source specific IR jacks.
This connector is duplicated for the remaining 3 outputs and function exactly the same as the first
one.
11.) Sum Output #1 through 4 - This 1/8 2 conductor jack is for the IR emitters and are summed
across the IR buss. This will allow normal operation of different components that dont share the same
IR commands. There are four sum ouptut IR jacks.
This connector is duplicated for the remaining 3 outputs and function exactly the same as the first
one..
12.) A.C. Power - This is where the AC power cord connects to the unit. It is a detachable 3 prong
I.E.C. plug. ever remove the ground lug on the plug or electrical shock and damage to the unit
could result.
AVIS: RISQUE DE CHOC ELECTRIQUE-NE PAS OUVRIR.
WARNING: SHOCK HAZARD - DO NOT OPEN.
IR REMOTE OUTPUTS
1
SOURCE OUTPUT
SUM OUTPUT
A
2
B
3
C
4
D
INF A ED (I ) SECTION
10
11
12
789
OUT
1 81 81 81 81 81 8
I 1234
MASTER I DIVIDUAL ZO ES

INSTALLATION NOTES
# Use Category 5 8-conductor cable. It is not necessary for it to be shielded but be careful with
your cable runs. Avoid running a tight parallel with A.C. wiring. Be careful if stapling the wire to secure
it in place.
# Use high quality RJ-45 connectors and make sure you use a high quality crimp tool. The crimp
of the RJ-45 connectors is crucial in making the system work properly.
# Avoid tight or sharp turns near the ends of the RJ-45 connections to the controller or main
units. This can put excessive strain on already small wires.
# ote when stacking multiple units: Audio sources connect via the distribution outputs. Wall
controllers combine via the Master Controller Out jack. Make a short jumper and connect to the second
units Master Controller In jack to allow the party mode master controller to access all zones. For
the IR Emitters, we strongly suggest using a Y adapter for the emitters that attach directly from the
sources and then to the second units IR outputs. This allows the source specific functionality to be
utilized by the second KHS6440. An additional controller can be run per zone by using a RJ-45 Y
adapter before the main unit.
Page 4
TO KHS6S/6D
DATA LI E C
DATA LI E B
DATA LI E A
+5 VOLT D.C.
GROU D
IR SIG AL
CLO E
STA DBY
TO KHS6440
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
RJ-45
PLUG
RJ-45
PLUG
CLIP
CLIP
WIRI G DIAGRAM FOR REMOTE ROOM CO TROLLERS

KHS6440 INSTALLATION MANUAL

Page 1
KHS6440 Installation Manual
ecommended Cables:
Category-5 or Category-3 (4 twisted pair stranded), shielded or unshielded.
16-4 or (2) 16-2 speaker cables.
To keep the installation process as simple as possible for first time users, please follow these simple steps. These instructions
are written assuming that you are using the KHS6S controller. If you have the KHS6D controller, there are additional steps
involving teaching the controller IR commands.
Please refer to the KHS6440 Reference Manual for additional steps.
Section 1: Installation of Controller Cables and Speaker Cables.
1. Controllers should be located between wall studs. Locating controllers beside light switches is OK as long as the Cat-5
cable and AC wiring (romex) are not bundled together and in their own box. Each controller cable is home run between
each zone and the KHS6440 unit.
2. The ends of the Cat-5 cable are terminated with RJ-45 crimp on connectors (unkeyed). The proper wiring is the same
as standard phone company wiring: pin 1 to pin 8, pin 2 to pin 7, pin 3 to pin 6, pin 4 to pin 5,...etc. (see diagram below).
Cable testers are available from your local distributor.
3. Each speaker cable is also home run between each speaker and the KHS6440 unit. One pair of 6-8 ohm speakers per
zone is recommended. The speaker wires are attached to the 4-pin terminal blocks located in the back of the 6440 (these
are easily removable for ease of installation). Please observe proper polarity and left-right orientation.
4. All controllers and speakers can then be hooked up to their proper cables but not to the KHS6440 yet.
Section 2: Installation of the 6440 unit.
1. Place the 6440 in its permanent position in a rack or on a shelf. This unit generates large amounts of heat so please
remember to allow for adequate ventilation. The top clearance must be at least 1 inch (25mm).
2. Attach the AC power cord to the unit and plug the cord into the wall.
At this point the Power switch should be off. The Standby LED should be on but the On LED should be off.
3. Select which device will be source 1 and attach the audio outputs from it to the audio in terminals on the KHS6440 using
standard RCA cables. At this point place this source into play so that you will have audio to monitor.
4. ow attach the speaker connector for zone 1 to the KHS6440 (you decide which room will be which zone, and you should
write these assignments down for future reference).
5. ow press the Power button in to activate the KHS6440 (you should now see both the O  and the STA DBY LEDS
lit on the KHS6440).
6. ow attach the zone 1 controller to the zone 1 controller input on the KHS6440.
7. ow go to zone 1 controller. If the source 1 equipment is playing you should see two LEDs lit on the controller. The red
led that indicates the KHS6440 is powered up and 1 of 6 green LEDs that indicate which source is selected (if the green
LEDs are not lit, try pressing the mute button. This button mutes the source audio in this particular zone). Select the proper
source by pressing the corresponding button on the left of the controller. Press the volume up button to adjust the listening
level.
8. If you do not have sound, please review steps 1-7. If you do have audio please attach the remaining sources to the
KHS6440. If all sources are playing, you should now be able to select whichever source you want to listen to. A more detailed
description of controller operation is in the KHS6S operation manual.
9. Once you are comfortable with the operation of one zone you can proceed with wiring the other zones in the same way.
Section 3: Infrared epeater:
The KHS6440 has a built-in IR repeater system. This works by sensing any IR commands issued by an IR remote in any
zone and passing it through the Cat-5 cable and into the KHS6440 unit. From here it goes to the emitter outputs on the back
of the KHS6440. Any IR emitters plugged into the jacks will flash depending on which source is selected and which jack
that emitter is plugged into. The jacks labeled Source Outputs 1-4 will flash only when that particular source is selected.
The jacks labeled Sum Outputs A-D will flash when any source is selected.
1. Plug an emitter into Source 1 emitter out. Attach the flasher end to the face of the source equipment, making sure to
cover the IR sensor window.
2. You should now be able to select Source 1 on the keypad and, using that sources remote, control that source. Make
sure you point the remote at the rectangular IR window located at the top of the KHS6S.
*SPECIAL NOTE*
IR receivers in consumer electronics operate at different modulation frequencies. The most common is 38khz (kilohertz).
However, some satellite receivers operate at 56khz and some equipment operates at 32khz. Still other equipment is not
even compatible with this type of IR system. The KHS6440 will work with the majority of consumer audio/video equipment.
However, some models will not operate. It is up to the installer to determine compatibility.
WIRI G DIAGRAM FOR REMOTE ROOM CO TROLLERS
TO KHS6S/6D
DATA LI E C
DATA LI E B
DATA LI E A
+5 VOLT D.C.
GROU D
IR SIG AL
CLO E
STA DBY
TO KHS6440
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
RJ-45
PLUG
RJ-45
PLUG
CLIP
CLIP

Master In/Out:
The master controller input will accept a seventh KHS6S controller. This controller will then become a master control for
the entire system. If Source 1 is selected on this controller, all zones will switch to Source 1.
If volume up is pressed, all zones will go up and visa versa volume down will lower all zones. If mute is pressed, any zones
active will be muted.
The Master Out jack can be connected to the Master In on a second KHS6440 to allow master control of 2 units (12
zones).
Individual rooms then can override this and return to a local zone mode. This way individual zones can be changed to suit
the listener in a particular zone.
Using Multiple KHS6440 Units:
Up to 3 KHS6440 units may be wired together to provide 18 zones of listening pleasure. First connect all sources into the
first KHS6440 and use the Source Outs to connect to the Source Ins on the second unit. Then use the Source Outs on
the second unit to connect into the Source Ins on the third unit. ext, using Y-adapters (2-1/8 plugs to 1- 1/8 jack), connect
all emitter outputs of the KHS6440 to proper source emitters. Lastly, any connections made to page/doorbell status connectors
must also be made to the other KHS6440s.
Adding More Audio Power to the KHS6440:
If you need more audio power in a zone, simply attach an RCA cable in between the Line Out jacks and the inputs of an
external power amplifier. This allows virtually unlimited volumes to be obtained. (Multiple outdoor speakers are a prime
example).
Page 2
I Emitter Modulation Frequency - these are
factory set to give optimum preformance of the
emitters. Factory setting is 40KHz.
Range is 32 KHz full CCW to 65 KHz full CW.
I OUTPUT PC BOA D (Fig. #1)
( This illustration is for information only - Consult your Installer for Application )
V 1
502
I F EQ