Toa EXES-5000 Installation Handbook
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Toa EXES-5000 Installation Handbook

Toa EXES-5000 Installation Handbook

Toa exes-5000 intercom system: user guide
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INTERCOM SYSTEM

TOA EXES-5000
INTERCOM SYSTEM
INSTALLATION HAND BOOK
&
TROUBLE SHOOTING
TOA ELECTRIC CO., LTD.
KOBE, JAPAN

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  • Page 1: Intercom System

    INTERCOM SYSTEM TOA EXES-5000 INTERCOM SYSTEM INSTALLATION HAND BOOK & TROUBLE SHOOTING TOA ELECTRIC CO., LTD. KOBE, JAPAN...

  • Page 2: Table Of Contents

    CONTENTS Introduction Introduction of the EXES-5000 System 2-1. Exchange 2-1-1. Features 2-1-2. Specifications 2-1-3. Further Details 2-2. Stations 2-2-1. Features 2-2-2. Specifications 2-3. Accessories 2-3-1. Terminal Board BOX-064 2-3-2. Junction Cable YR-801 Installation of the EXES-5000 System 3-1. Exchange 3-2.
  • Page 3 CONTENTS Trouble Shooting Guide 8-1. Fault in Exchange 8-2. How to Find Short between T-Line and R-Line 8-3. Fault in Specific Station only 8-4. Speech and Function Test...

  • Page 4: Introduction

    Introduction This is the installation manual for the exchange, stations, and other components of TOA Intercom System EXES-5000. It includes an outline of the system, an explanation of installation, cable connection, and inspection proce- dures, and a trouble-shooting guide. this manual is recommended prior to installation of the system.

  • Page 5: Introduction Of The Exes-5000 System

    Introduction of the EXES-5000 System Because the EXES-5000 System is a fully electronic intercom system, it has the following features that surpass conventional mechanical systems. All components of the exchange are designed accord- ing to the modular concept. sizable reduction in the number of procedures re- quired to install the system.

  • Page 6: Specifications

    This, in turn, means greater freedom in selec- tion of installation site. Since the system is completely electronic, power consumption is kept to a minimum, and incorporation of a built-in batteries is also possible. 2-1-2. Specifications The exchange of the system is available in the following two models.
  • Page 7 function is incorporated. available, on the other hand, is reduced by 8 when the paging function is adopted. Exchange Specifications Ambient Temperature Range : 32°~122°F. ( 0°~50°C.) Audio Input Level: +10dBm (10mW)max. Audio Output Level : +30dBm (1W) max. Bandwidth : 50 - 5,000Hz Noise Level : -75dBm...

  • Page 8: Further Details

    Regular Power Source Batteries 2-1-3. Further Details The component modules of the exchange are grouped according to function as follows: Common Control Section (Central Processing Unit) (Output Control Unit) (Highway Control Unit) Speech Path Section (Signal Generating and Distributing Unit) (Duplex Link Unit) (Conference Link Unit) (Line Modem Unit)
  • Page 9 in the event of a power failure. composed of a cabinet and a frame with connec- tors . The cabinet is not needed when the exchange is mounted on a 19" rack. The connectors and the frame are completely wired at the factory. - 7 - The case is...
  • Page 10 (Central Processing Unit) Function: Reads out the exchange procedure written into the memory and collates the data from the stations for pro- cessing in succession. PROGRAM Switch When functions such as secretary transfer, master/substation and executive priority are employed, the registration, cancellation and changing of these functions are taken care of through Station No.200.
  • Page 11 (Output Control Unit) Function: temporary storage before usage of the output data from CPU classified by lines. SCN SELECT Lamp These lamps display the scanning conditions of both the station "Privacy ON/OFF" conditions and the dial data from the station in each LMU. - 9 -...
  • Page 12 (HIGHWAY CONTROL UNIT) Function: For turning on and off the time- sharing switches at LMU, DLU and SGD according to instructions received from the CPU. LINE ADDRESS Lamp These lamps dispaly the numbers of the stations using the selected link (T: Transmitting station, R: Receiving station) SIGNAL CODE Lamp These lamps display the code of signal tone...
  • Page 13 LINK SELECT Switch The switch position is to be selected in accor- dance with the number of links in use. address and the signal code of the link in use are then displayed by the lamps. Note: These select switches are to be manipu- lated using the binary notation.
  • Page 14 (DUPLEX LINK UNIT) Function: This unit operates under HCU control to connect or disconnect the in- dividual links for hands free con- versation between two stations. One DLU is provided with 4 links. Up to 3 DLUs can be installed with the EX-510, and up to 4 DLUs with the EX-520.
  • Page 15 (SIGNAL GENERATING AND DISTRIBUTING UNIT) Function: Composed of 8 kinds of signal generators (calling, privacy/dis- connected, busy dialing/no-regist- ration, group paging/zone paging, all call, priority/execution priority, registration/call holding/mic-off) and distributors. This unit distributes under HCU control the required signal tones to the individual links.
  • Page 16 0.28 sec 0.54 sec 1.1 sec Calling tone 235Hz Privacy tone 235Hz 470Hz Busy tone Dialing tone Zone/Group 783Hz Paging All-Call Paging 783Hz Priority tone 940Hz Holding tone 783Hz SGD-52 SIGNAL TIMING DIAGRAM 7.3 Hz 235Hz 235Hz 235Hz 470Hz 783Hz 627Hz 783Hz 783Hz...
  • Page 17 (CONFERENCE LINK UNIT) Function: This unit operates under HCU control to connect or disconnect the links for hands-free conference among up to 4 parties and hands-free speech between two parties. One CLU is provided with 1 conference link and 2 hands-free speech links. The CLU is optionally available.
  • Page 18 (LINE MODEM UNIT) This unit is composed of a modulator to receive signals from the station, a demodulator to send out signals to the station and a scanning circuit that scans the station "Privacy ON/OFF" condi- tions and the dial data. Up to 8 stations can be connected to 1 LMU.
  • Page 19 : Exchange and station are not con- nected. Arrangement of the LMUs with individual ranges for the station numbers covered (from left to right) is shown here. - 17 -...
  • Page 20 (PAGING INTERFACE UNIT) Function: This unit is provided for zone pag- ing and group paging. ed to send out over the lines both zone and group paging signals. The zone paging signal goes out through the assigned YR-801 cable to terminal J8 or J16 of the Terminal board (BOX-064), while the group paging signal is distributed to the connec-...

  • Page 21: Stations

    2-2. Stations 2-2-1. Features The stations of the Toa Intercom EXES-5000 have the following features: Each station is provided with a 4-Pin plug (YC-102) for easy connection to cables. Wiring from the exchange to each station is the independent 4-wire system.
  • Page 22 Master Station: Capable of calling any master/sub-station in the system, and also of using all available functions. Sub-Station Capable of calling only its Master Station, and also of using the privacy, single digit dialing and press-to-talk functions. Station Specifications Ambient Temperature +32°~+140°F.

  • Page 23: Accessories

    Accessories 2-3-1. Terminal Board BOX-064 The terminal board BOX-064 provided with the Toa Intercom System EXES-5000 connects the ex- change with the station lines Compact and easy to connect, this terminal board saves space and ensures simple disconnec- tion of any station line from the exchange when inspection is necessary.

  • Page 24: Junction Cable Yr-801

    2-3-2. Junction Cable YR-801 Toa Intercom System EXES-5000 Junction Cable YR-801 connects the exchange to the terminal BOX-064. A single line of this junction cable provides sufficient wires to connect the ex- change to 8 stations (8 x 4 = 32) through the terminal board BOX-064.

  • Page 25: Installation Of The Exes-5000 System

    Installation of the EXES-5000 System 3-1. Exchange Pay particular attention to the following points during installation of the exchange: The layout should allow easy servicing and in- spection. The exchange is compact and lightweight; however it is important to ascertain the strength of the floor or wall on which it will be placed.

  • Page 26: Stations

    An area where it will obstruct traffic, for example, an indoor hallway or near the entrance or exit of a room. An area where it will be exposed to fire, heat or direct sunlight (suitable ambient temperature is 32°~+122°F., 0°~+50°C.). A dusty area (where there is metal dust or dirt).

  • Page 27: Accessories

    possible. Stations are compact for easy installation almost anywhere. However, areas described below should be strictly avoided. An area where it can be exposed to fire, heat or direct sunlight (suitable ambient temperature is 32°~+140°F., 0°~+60°C.). A dusty area (where there is metal dust or dirt). Near a storage place for chemicals, oil, etc.

  • Page 28: Cable Installation And Connection

    Cable Installation and Connection 4-1. Cable Installation 4-1-1. Wire type, number of wire pairs and number of individual wires are to be determined for in- dividual sections of the wiring system accord- ing to the guidelines set down below. 4-wire telephone cables unshielded 2 twisted pair cables are to be used for wiring between stations and the intermediate or indoor boards.
  • Page 29 The following chart is provided to give an actual example of the wiring plan within an installed system. Exchange Terminal (EX-510/ Board (BOX-064) 520) Amplifier(s) for Paging Junction Cable (YR-801) Private Branch Cable 4-Wire Telephone Cable Note: Main Intermediate Terminal Terminal Board Board...

  • Page 30: Core Diameter Vs Transmission Distance

    4-2. Core Diameter versus Transmission Distance The diameter of the cable to be used should be deter- mined so that the set limits for speech attenuation (3dB maximum for transmission from the exchange to the station) and the DC resistance (DC loop resis- tance: Less than 300 ohms) are met.

  • Page 31: Wiring

    4-3. Wiring General Information Wiring should be done independent of public tele- phone lines. Wiring conduit is often installed underground or embedded in building structures such as walls and floors, so care must be taken to draw up a wiring plan that has ample reserve for future extension of the system and that can be adapted to future remodelling or expansion of the building it is...

  • Page 32: Piping

    The following chart lists spacing standards to be followed in respect to typical causes of inter- ference. Cause of Interference Heating Pipe Water Pipe Radio transmitting coaxial cables (CB and other). Telephone wire. Radio/TV Antenna coaxial cables & twin lead. Ground cable.
  • Page 33 If the number of connecting wires between an in- door terminal board and a station is small and the station's site is fixed so that it will not be moved frequently, install a box at that site and pull wiring through a metal or hard PVC tube as required by job or ordinance.

  • Page 34: Exchange And Terminal Board Connection

    4-5. Exchange and Terminal Board (BOX-064) Connection The EXES-5000 system includes terminal board BOX- 064, which is connected to the exchange by junction cable YR-801. As seen from the Fig. 11, the numbering plan begins with Jl, the connector on the back of the exchange.
  • Page 35 Cable Diagram when Exchange EX-510 is used: Exchange EX-510 with the rear panel removed. Fasten with clamps Cable Diagram when Exchange EX-520 is used: Exchange EX-520 with the rear panel removed. Terminal Board (BOX-064) with the cover removed. Fig. 11 Junction Cable (YR-801) Fig.
  • Page 37 Connection of the Terminal Board (BOX-064) to the Main Terminal Board Route cables from the main terminal board to the termi- nal board (BOX-064) and connect to the individual clip terminals using clipping tool C (Standard accessory). See Fig. 14 for the diagram of the interior of the ter- minal board (BOX-064).
  • Page 39 Connect cables to the clip terminals according to the following procedure: Remove the cable outside insulation tubing so that the wires are showing. (Cutting through insulation of individual cable wires should be avoided) The length of cable insulation to be removed should be 1.5 times the length of the clip terminal.
  • Page 40 Connection of the Station Line to the Clip Terminal of the Terminal Board (BOX-064) Note: Connect the individual cables in order, starting with the top terminal. When using the clipping tool, be sure that the cutting edge is on the down side.

  • Page 41: Connection Of The Station Plug To The Exchange Jack

    4-6. Connection of the Station Plug to the Exchange Jack Station 4-Pin Plug (YC-102) Insert (Cover) 4-Pin Jack (YC-101) (YC-103: 4-Pin Jack for flush-mount) NOTE: use 4" x 2" Switch-Box for YC-103 Receiving Lines (not Polarity Specified) Transmitting Lines Terminal Board (BOX-064) Clip Terminals (not Polarity Specified) (Viewed from the station side) From the exchange...

  • Page 42: 4-7. Zone/Group Paging Connection

    4-7. Zone/Group Paging Connection Connection Instruction when Zone Paging Function is Employed The audio signal line and control line out of PIU module are connected to clip terminal J8 or J16 on the inside of the terminal board. tween the terminal board BOX-064 and external PA amplifier. Specifications of each output line Audio signal line Impedance...
  • Page 43 contact capacity of the line is a very small (30V DC, 0.5A). Refer to Fig. 17 and control power switch indirectly with the control line. Connection Instruction when Group Paging Function is Employed The audio signal lines need to be connected to each group of the LMU modules.
  • Page 44 40 PIN Assignment Socket for Group Paging. Strapping Fig. 18-1 Fig. 18-2 - 42 - (ALL-CALL)
  • Page 45 Example: When #200 ~ #205 are in Group P #206 ~ #220 are in Group P #223 ~ #231 are in Group P #232 ~ #239 are in Group P LMU 1 LMU 2 Station numbers covered by the individual LMU modules are in- dicated in Fig.
  • Page 46 Group Paging Input...
  • Page 47 The input lines (46A and 46B of the connector of LMU) of LMU 1 ~ LMU 7 # 2 0 0 ~ #256) for EX-510 and LMU 1 ~ LMU 15 (#200 ~ #319) for EX-520 are connected to the group paging assignment socket.

  • Page 48: Connection Of Power Supply

    LMU input terminals GROUP PAGING ASSIGNMENT LMU input terminals Fig. 20 Group Paging Assignment and 40-Pin IC Socket 4-8. Connection of Power Supply The connection on the terminals of the power section is illustrated next page Fig. 21. When batteries are to be connected, connect the con- nector after plugging into the AC power source.
  • Page 49 Batteries Put the Power supply unit into the bottom part of the exchange Power Supply Unit (DS-510) Power Set the voltage selector in conformity with Cord the source voltage to be used. Fig. 21 +24V +18V C O M +18V +24V COM +24V COM +24V - 47 - B L U +12V...

  • Page 50: Programming Of Secretary Transfer, Master/Sub-Station And/Or "Executive Priority" Functions

    Programming of "secretary transfer" , "master/sub- station" , and/or "executive priority" functions After confirming that the system is working correctly, register "secretary transfer", "master/substation", and/ or"priority" functions. Use station #200 for the programming. Determine the station numbers before registering. For "secretary transfer" function; Determine the station numbers of the executive and his secretary.
  • Page 51 Flow Chart of Programming at Station No. 200 Make sure that power source of exchange is on Turn on PROGRAM switch of CPU Touch key to ascertain dial tone First installation ? key for more than 10 times to ascertain signal tone Touch Touch key to ascertain dial tone...
  • Page 55 Photo of CPU - 53 -...

  • Page 56: Adjustment Of The Cpu Module

    Adjustment of the CPU modules (Refer to CPU Photo on Page 53) Take out the CPU module for adjustment before use. The picture below shows the mounting side of the CPU module. The numbered sections in the picture require adjustment. The adjustment method is as follows: DIP switch These switches select the CLU and/or DLU modules to be used,...
  • Page 57 time needed to warm up the paging amplifier, so the switch can be in either position when the paging function is not being used. This switch activates "Programming" of the "Secretary transfer", "master/substation", and/or "executive priority" functions at station #200. switch", which fulfills the same function, is provided on the front panel of the CPU model, this switch does not have to be used, and should be kept in the OFF position.
  • Page 58 Battery Specifications Nominal Voltage Nominal Capacity : During delivery, the batteries are connected as il- lustrated above to prevent unnecessary discharge. Insert the jack into the pin A. By so doing, the batteries will be connected and will safeguard the programming of the special functions. Note: Connect the batteries just before turning the exchange power switch on.
  • Page 59 [C] Program Switch This switch makes station #200 a programming station, that is, it directs station #200 to program the "sec- retary transfer", "master/substation" and/or "executive priority" functions. PROGRAM Use a small screw driver to change the switch setting. Fig. 24 Station #200 becomes the programming station.

  • Page 60: Inspection

    Inspection 7-1. Inspection before Power on Before turning on the switch, check if the power cord is plugged in and the fuse is in place. modules should be placed and secured. that the connection of exchange and stations are completed. Turn on the switch on the back of the exchange.

  • Page 61: Testing

    7-2. Operation and Function Testing Pick out a convenient station and call all the sta- tions connected on the exchange and check the volume and statics. Volume of dialling tone and talking tone can be ad- justed by the volume control on the back of the station.

  • Page 62: Trouble-Shooting Guide

    TROUBLE SHOOTING GUIDE Repairing of the EXES-5000 system is basically done by replacing defective units with good ones. faults in an installation can be divided into the fol- lowing categories. Faults in an exchange Faults in a station Cable faults...
  • Page 63 EXES-5000 SYSTEM CHECK FLOW CHART START DIP switch on CPU correctly set ? Back-up battery on CPU connected ? Program switch on CPU off ? Power switch on Proper voltages at each output power terminal? (tabl 1) No.15 of SCN SELECT on...

  • Page 64: Fault In Exchange

    8-1. FAULT IN EXCHANGE Before power supply check, confirm the following three points to eliminate elementary faults: Is voltage selector set correctly? Is AC power supplied? Is power switch O N ? Start checking after disconnecting all wiring connected to DC output of the power supply unit. SYMPTON Exchange does not operate.

  • Page 65: How To Find Short Between T-Line And R-Line

    8-2. HOW TO FIND SHORT BETWEEN T-LINE AND R-LINE If the shorted condition between T-line and R-line is not corrected for a long time, it may burn out the guard re- sistor (330ft 1/2W) on the LMU board. the shorted line according to the following procedure: Turn off the privacy switch on all stations in the system.
  • Page 66 1. One of transmitting lines (T-Line) is disconnected. Station T-Line R-Line Symptom: can make dialing. can hear can not hear Noise is heard at Noise increases at pressed at LMU Lamps ----- Normal One of receiving lines (R-Line) is disconnected. T-Line R-Line Sympton :...
  • Page 67 T-Line and R-Line are shorted or mixed up. T-Line R-Line Sympton: 3-1 A can not dial. Conversation is impossible between stations. 3-3 When B dials A , noise will be heard at immediately after the calling tone. LMU Lamps ----- Brighter than normal.

  • Page 68: 8-3. Fault In Specific Station Only

    8-3. FAULT IN SPECIFIC STATION ONLY Find the cause according to the following table if the fault lies with a specific station only, not with all stations. Dialing can not be made at privacy off mode. Specific key does not operate. Calling tone can not be heard.
  • Page 69 Same sympton Sound of the other party is broken remains even the station during call. is replaced. Same sympton Immediately after the calling tone, remains even the line switches the station to cancel, busy, is replaced. dial tone, etc. Becomes normal if the station is replaced.

  • Page 70: Speech And Function Test

    8-4. SPEECH AND FUNCTION TEST Speech Test After completing the wiring check and the power supply and exchange test according to the system flow chart, the speech test for each station can then take place. IMPORTANT NOTE Before testing, all programming (Secretary transfer, Master/Substation, Executive Priority Function) must be cleared from station No.200 by turning on the PRO- GRAM switch of the CPU, or the speech test can not...
  • Page 71 Function Test Check all employed functions with a few stations ne the exchange. Check "User Programmable Functions" at stations in - volved after the programming from station 200. + Secretary Transfer: Is transfer made correctly + Master/Substation : Touch dial + Executive Priority: Is this function operated at Use all number keys including To-Talk bar, Vol.
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  • Page 74 TOA ELECTRIC CO., LTD. KOBE, JAPAN Printed in Japan EX5(7)-01R(79...

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