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

1.) I Sensor - this is an Infrared Sensor window. We suggest you aim the external remote control
directly at this window to pass commands back to and through the unit.
2.) Source Selector Buttons (1 - 6) - These buttons will select the source you want to listen to.
Individual key caps (supplied with the unit) will allow you to customize the source selections. These
can be: CD, Receiver, Tape, DSS, TV or whatever combination you wish.
3.) Source Selection LEDs (1 -6) - These Light Emitting Diodes (LED) will light up next to the selected
source to let you know the selection was made.
4.) Power Status LED - This LED indicates the power status of the system. Lighted, the system is on
and ready. Off, the system is not engaged.
5.) Mute Button - This button will instantly stop the audio through the system. It is used for temporarily
muting the system such as to take a phone call or listen to someone speaking in another room.
6.) Volume Up - This raises the local zone volume up at a rate of 2-4 db per 1/10 second. Hold down
the control and the volume goes up quickly.
7.) Volume Down - This lowers the local zone volume down at a rate of 2-4 db per 1/10 second. Hold
down the control and the volume goes down quickly.
Page 3
2.) Source Selectors (1 - 6)
TAPE
AMFM
DM2
CD2
DM1
CD1
POWER
VOL
VOL
MUTE
1.) I eceiver
7.) Volume Down
6.) Volume Up
5.) Mute Button
D4.) Power Status LE
3.) Source LED ( 1 - 6)
KHS6S CONT OLLE

KHS6D CONT OLLE
8.) eset - This resets the local zone controller if an IR command locks up the zone. It will not erase
the local zone memory. It will just send a local clear command.
9.) Clear - This button has 3 modes: a.) Device mode - Will clear learned commands from the local
zone memory. If you press clear and then say source selector #1 then the commands associated with
that page of memory will be erased. b.) Storage mode - This will allow any individual key to be erased
and reprogrammed. c.) Macro memory mode - This will allow you to reprogram a individual macro key
(0 -9).
(This is a permanent erase function, so be careful with this command.)
10.) Clone X - This button will place the controller into a ready to receive commands mode. This is
the learning mode. When setting up the system initially, place all but one controller in this mode and
use the one master controller to teach the local zones their commands. The clone/learn LED will light
and stay on. When the data is received correctly, the red LED will go out and the green OK light will
go on. This process takes between 6 and 8 minutes. *See detailed clone description on page 9.
11.) Clone TX - This button will place the controller into a ready to transmit commands mode. This
is the teaching mode. When setting up the system initially, place one controller in this mode and use it
as a master controller to teach the other local zones their commands. The clone/learn LED and OK
LED will stay on. When the data is transmitted correctly, the red LED will go out and the green OK light
will flash then go off. This process takes between 6 and 8 minutes. *See Page 9.
12.) Clone/Learn LED - This LED will let you know the status of transmit and receive during the learning
or teaching processes.
13.) OK - This LED will also let you know the progress of the learning/teaching processes. *See Page
9.
14) Learn Button - This button puts the controller into a learning mode.*See Page 9.
15.) I Sensor - Use this IR window when teaching a controller new IR commands with an external
remote.
The left side of this controller is identical to the KHS6S consult last page.
Page 4
8.) eset
9.) Clear
10.) Clone X
11.) Clone TX
12.) Clone/Learn LED
13.) OK LED
14.) Learn Button
15.) I Sensor LED
16.) Numeric Entry
17.) Enter Button
18.) Macro Button
19.) Skip Backward
20.) Skip Forward
21.) Power On
22.) everse
23.) Forward
24.) Play
25.) Pause
26.) Stop
POWER
TAPE
DM2
AMFM
DM1
CD2
OK
CLO E/
LEAR
VOL
VOL
ERROR
IR SE SOR
LEAR
MUTE
CLO E TX
CLO E RX
PLAY
PWR
0
8
E
7
M
9
CD1
CLEAR
RESET
2
54
1
6
3
KHS6D

KHS6D CONT OLLE (contd)
16.) Numeric Entry Keys (0 - 9) - Depending on the mode you are in these keys will allow direct track
access on a CD, an individual station on TV or DSS, or a station on a tuner, etc. If you are in the macro
mode, these will allow direct access to your stored macros.
17.) Enter button - Working in conjunction with the numeric keys above, this button will allow you to
address larger numbers quicker. For instance, if you are looking for track # 23 on a CD, you press this
2 and then 3 and enter. This will allow access to DSS and multi-disc changers.
The following buttons are completely programmable. They may be reprogrammed to any function you
want depending on the source. In fact, they can be A Y IR related command. It does not even have
to pertain to the source units.
18.) Macro Button - This button has its own section. Please refer to the MAC O P OG AMMING
section in this manual.
19.) Skip Backward - This button skips or searches backward. For instance if your source is a CD, it
will skip back to the beginning of the track that is playing, then if pushed again, it will skip back to next
track previous to the one you are on. Repeat as necessary. This is a programmable button. It may be
reprogrammed to any function you want depending on the source. .
20.) Skip Forward - This button skips or searches forward. For instance if your source is a CD, it will
skip forward to the beginning of the next track, then if pushed again, it will skip forward to the next track
beyond that one. Repeat as necessary. This is a programmable button. It may be reprogrammed to any
function you want depending on the source.
21.) Power On - this button will turn on the source power switch from whatever zone you are in. It can
be programmed to cycle between on and off. When you program this button, press it once and transmit
the code for power on, then press it again for the command to power off. When pressed it will toggle
between on and off positions.
22.) everse - This button will scan backward within a track if you are in the CD source mode, or move
down the dial in a tuner source mode. This is a programmable button. It may be reprogrammed to any
function you want depending on the source. .
23.) Forward - This button will scan forward within a track if you are in the CD source mode, or move
up the dial in a tuner source mode. This is a programmable button. It may be reprogrammed to any
function you want. Pressing and holding it down will move
it quicker. This is a programmable button. It may be reprogrammed to any function you want depending
on the source.
24.) Play - This button in the CD or tape mode will start playing the appropriate device. This is a
programmable button. It may be reprogrammed to any function you want depending on the source.
25.) Pause - Primarily for tape or CD modes, this button will stop the music and wait in the same place
until the play button (or other function), is engaged. This is a programmable button. It may be
reprogrammed to any function you want depending on the source. .
26.) Stop - This button will stop the CD or tape player in those modes. This is a programmable button.
It may be reprogrammed to any function you want depending on the source.
Page 5

The KHS6D controller is designed to learn and store IR codes for virtually any piece of audio/video
equipment. This enables the individual programming and use of multiple functions for all of your source
components.
Programming Individual Functions
1) Press the learn button on the controller. The left, red Clone/Learn LED will begin flashing.
2) Press the source device button to be programmed.
3) Press the numeric or function key you wish to program on the right side of the controller. The red
Clone/Learn LED will stop flashing and glow continuously.
4) Hold the source remote control IR emitter 1 to 2 from the IR Sensor on the controller and press
the corresponding function key on the source remote. After a short period of time, the right, green OK
LED will glow indicating the acceptance of that command. At this point the controller will return to a
flashing red LED. It is now ready to be taught the next command for that source. (A solid red and green
LED simultaneously indicates an error with that command. Should this occur, clear it and try reentering
that function.)
5) Repeat steps 2-4 for the next desired function.
6) When all the desired functions for a particular source have been programmed, we suggest you reset
the keypad.
7) Repeat steps 1-6 for the remaining functions.
(All of the numeric and function keys will learn any ir code. Functions programmed into the controller
are solely at the discretion of the installer.)
Cloning
The has a cloning feature that will allow you to down load the information stored in one controller to
up to five additional controllers within an installation.
Once one of the controllers is programmed, go to the other controllers and press the Clone RX button.
Then return to the programmed controller and press the Clone/TX button. The green LED will remain
lit while the cloning process is in progress. When the process is complete, the green LED will turn off.
This should take about 8 minutes. It is a good idea to then reset all of the controllers.
ow all the controllers share identical information. The nonvolatile memory will remain regardless of
whether the controllers are plugged into the system. Using the Clear button will clear the controller
memory. To erase an entire page of memory, simply press the Clear button and then a Source Device
button. By pressing a source device button, the Clear button and one of the programmed function
buttons will erase a single function. Once cleared, a controller or individual function can be reprogrammed.
NOTE:
It is important to avoid issuing any IR commands or allowing any external IR interference during the
cloning process. This will result in corrupted information being sent to the receiving controllers.
Should a controllers programming be corrupted, it may be necessary to completely clear a controller
to factory condition. This is done by cloning an unprogrammed controller to the corrupted controller.
Once this is done, that controller can then be re-cloned.
Page 6
P OG AMMING THE KHS6D CONT OLLE S

MAC O P OG AMMING
The KHS6D has 16 programmable macro memories. It will automatically transmit a series of 20
commands deep.
To enter the macro mode - press macro and the either the 0 through 9 buttons OR the device source
keys (1-6). You can insert a delay time from 1 to 99 seconds between steps (the default is .5 sec.) to
suit their specialized needs. To program in time delays, press the appropriate button and hold it from
1 to 99 seconds then input the next command.
Here is an example of how to set a macro.
The list of things you want to accomplish are:
1.) Power on CD1
2.) Put CD player in disc change mode.
3.) Select disc 10.
4.) Select play mode for CD player.
Press Learn then the M button to enter the macro learning mode. The Red LED should begin flashing.
Then press the CD1 source device button on the left side of the controller. The following functions will
then be grouped as a macro under the CD1 source button.
The following selections are made on the right side of the KHS6D dual controller. See diagram page
7.
1.) Press PWR button
2.) Press the button programmed for disc select
3.) Enter 1 and 0 on the numeric keypad
4.) Press the button programmed for disc enter
5.) Press the button programmed for play
Press the learn button or wait 15 seconds for it to return to normal. The red LED should turn off.
To utilize the macro mode, press the M button (it will only wait for 2 seconds for a second button to
be pressed) then press either numeric button (0-9) or source button (1-6) to engage a pre-programmed
macro.
To clear a macro out of memory, press the CLEAR then the M buttons and then the key with the
memory you wish to erase. It is a permanent erase, so make sure you are careful. If no key is pressed
within 15 seconds, the unit will exit the clear mode and return to normal operation.
NOTE: All macro commands must come from individual commands already programmed in the KHS6D.
They cannot come from the sources wireless remote.
Page 7

Page 8
1) Remove the Decora cover plate, and controller face plate.
2) Place your wireless remote in learn mode.
3) Select the device bank button to program (i.e. TV, VCR, Tuner, Aux, etc.) on the wireless remote.
4) Select the button to be programmed on the learning remote. (i.e. 1-6, mute, or volume up and down)
5) While holding the wireless remote within 2" from the top, center, clear LED on the KHS6S (this is
the controller IR emitter), press the command button on the KHS6S Controller you wish to program into
the wireless remote.
6) The wireless remote should then accept the KHS6S command.
7) Once you have programmed the source number, volume up and down, and mute functions. You
can then go to the memory bank on your wireless remote chosen for the 6440 system to change volume,
source, or mute the system from any zone in the house.
*Please ote:
When programming, it is best to hold the KHS6S or KHS6D button until the wireless remote has indicated
that it has learned the command.
P OG AMMING A WI ELESS EMOTE
USING THE KHS6S O KHS6D WALL CONT OLLE

Can I control volume and source selection with a wireless remote?
Yes, the KHS6S and the KHS6D controllers have a built-in IR emitter that will teach learning remote
the Kustom IR codes for volume, source selection, and mute.
How do I control I if I am using more than one 6440 amplifier?
The best solution is to use Y cords with two 1/8 male ends going to a 1/8 female end. This works
with the 4 source outputs as well as the 4 summed outputs.
Can I use more than one controller within a single zone?
Yes, the controllers can be tied together via a cat. 5 Y cord or an RJ45-Y adapter. We suggest using
only two controllers within one zone. It is also possible to control two zones with one controller.
Can I use more than one pair of speakers within a single zone?
The 6440 is intended to be used with two 8 ohm speakers per zone. It is equipped with line level preamp
outs for each zone. You can line out to any external amplifier using standard RCA cables. This makes
it possible to power additional speakers, or a powered subwoofer for surround sound systems.
Do I have to have all zones playing music to be able to hear the doorbell and page?
o, the page and doorbell features will work regardless of the status of the zones. You can, however,
use internal switches on each zone to defeat the doorbell and page, or allow the doorbell and page
without muting the system.
Can I program functions into a macro other than my audio equipment?
The 6D controller will learn and store any IR code in its memory. Once an IR command is programmed,
that can then be used as part of a series of macro commands. It is important to note that the 6D can
only do macros on commands that have already been stored into the controller's memory.
Do I need to have a backup for the memory in case of a power outage?
o, the 6D controller has a non-volatile memory that will retain its memory once the controller has been
programmed.
What if none of the lights on the controller come on?
It could be that the POWER button is not depressed on the KHS6440. ext verify that you have a
source plugged in and playing. Remember that the 6440 will go into standby mode after approximately
2 minutes if no incoming signal is detected. If both of these conditions have been met then you probably
have an incorrectly wired Cat-5 cable. The correct pin assignment from end to end is: 1 to 8, 2 to 7,
3 to 6, 4 to 5, 5 to 4, 6 to 3, 7 to 2, and 8 to 1.
What does it mean if the red power LED is lit on the controller, but none of the source LEDs
is lit?
This condition indicates that the controller is muted. Press the mute button to turn off the mute in
that zone at which point one of the source LEDs should light. If this doesnt solve the problem, and
you are using the paging and or doorbell hook-ups on the back of the KHS6440, disconnect these. If
the page audio inputs are causing the muting then try adjusting the page sensitivity pot in the inside
of the 6440 (see the owners manual). Sometimes it is necessary to reset the 6D controller by pressing
the reset button on the controller.
When I am installing the KHS6D controller, do I have to program each one individually?
o. The 6D are equipped with a unique cloning feature. Once you have programmed one controller,
you then go to the other controllers in the house and press the Clone RX button. Then go back to
the programmed controller and press the clone TX button. The process then occurs automatically,
but you need to make sure that you are pressing the clone TX button before the others have timed
out, or reverted back to normal operation. In a large house, it may be necessary to do smaller groups
of controllers at one time. Future runs of the controllers will have an increased time out of 15 minutes.
Standard Installation Questions for the KHS6440
Page 9

Page 10
Once I have programmed my KHS6D controller, why does some of the source equipment not
work?
It is possible that the 6D did not store all the commands properly. Try repeating IR commands with the
source remote through the IR window of the controller. If the commands pass through the system, then
go back to the controller and reenter the desired functions. If the source remote does not work through
the systems IR repeater, then you could have a defective emitter. If a different emitter does not solve
the problem, then possibly the modulation frequency of the sources IR is well above 40kHz or well
below 40kHz. Either scenario is fixable by adjusting the IR frequency trim pot (see the owners manual
p.9).

INSTALLATION NOTES
Date of Purchase: _________ Date of Install: ____________
Serial Number of Unit: __________________________________
Installing Company: ___________________ Name: __________
Installers Address: __________________________________________________
Installers Phone: ___________________________
Source #1: ______________________________________
Source #2: ______________________________________
Source #3: ______________________________________
Source #4: ______________________________________
Source #5: ______________________________________
Source #6: ______________________________________
Additional Notes:
Page 11

SPECIFICATIONS
Power Output: 20 Watts at 6 ohms x 12
Frequency Response: 20 Hz-20 kHz +/- 1 dB)
T.H.D.: 0.2% or less @ rated power
Signal/Noise Ratio: >80 dB A weighted)
Slew Rate: 10V/u sec.
Input Impedance: 10k Ohms
Input Sensitivity: -10 dBv for rated output
Dimensions: 17"W x 3.5"H x 10.5"D
432mm x 90mm x 266mm
Weight: 14 Lb. 6.4 kg)
WA ANTY
Kustom Sound Systems, Inc. warrants this product to be free of defects in workmanship or materials for
a period of three (3) years from the original date of purchase. This warranty applies to the original purchaser
only and is not transferable. This warranty is subject to the following conditions and exclusions:
-Defects caused by wear and tear, misuse or neglect
are not covered by this warranty.
-This warranty will be void if:
a. The unit has been altered or modified.
b. The serial number has been removed or defaced.
c. Original purchase is not from an Authorized Kustom Dealer.
d. The warranty card is not completely filled out and mailed
within 10 days of the original purchase.
either Kustom Sound Systems, Inc., nor authorized Kustom dealers are liable for any incidental or
consequential damages resulting from any defect in or failure of Kustom Sound products. This warranty
gives the original owner of Kustom Sound products specific legal rights, and he may also have other rights
which vary from state to state. This warranty is expressly in lieu of all other agreements and warranties,
expressed or implied, except as may be otherwise required by law.
Kustom, Inc.
4940 Delhi Pike - Cincinnati, OH 45238
Phone [phone] Fax [phone]