ISO 9001:2000

INSTALLATION MANUAL
(COX-408HB/816HB/824HB)

Thank you for purchasing this Copper Connections Product.

It has been manufactured to stringent quality standards, which makes it highly reliable. Since the
technology used is 100% indigenous, the product is expected to work efficiently in Indian conditions
and is, ideally suited for application in the country. Its specifications are subject to an on-going
process of in-house research and development, a good part of the inputs coming from actual users
like you.
While we do not expect the product to malfunction in any manner, it nevertheless carries a 12months limited warranty against all manufacturing defects, as per the terms and conditions given in
this manual.
We welcome your feedback and suggestions in our continuous improvement initiative to help us
serve you better.
------------------------- Cut from here ---------------------------------------Your Name: _____________________________________
Address: _______________________________________
________________________________________
________________________________________
Tel.No.:________________________________________Fax: __________________________
Date of Purchase: _____________________________________________
Item: ____________________________________ Model: ____________________________
Dealers Name: _____________________________ Invoice No.:
FEEDBACK AND COMMENTS:
____________________________________________________________________________
______________________________________________________________________________
_____________________________________________________________________________
Copper Connections,
195-196 DSIDC Complex, Okhla Industrial Area, Phase-I,
New Delhi-110020 (India)
Phone: 91-11-40625555 (30 lines), Fax: 91-11-40625577
Email: sales@copperconnections.com
www.copperconnections.com

Table of Contents

Page No.

Installation
408 HB Internal Connections
816 HB Internal Connections
824 HB Internal Connections
CLI Card Installation
Technical Specifications
Terms of Warranty
NOTE-Copper Connections reserves the right to alter equipment specifications
and descriptions contained herein and makes no commitment to update
or keep current the information herein. All information herein is subject
to change at any time without notice. No part of this publication shall be
deemed to be part of any contract or commitment whatsoever.
- Product specifications and features are subject to changes without prior
notice due to our constant endeavour to improve the product.
- All features mentioned in this manual are not part of standard systems. Some features need optional
hardware/software upgradation.
- Not every feature in this manual is likely to have been installed in your system or extension.

INSTALLATION

Cabling
a) All cables of the EPABX should be at least 6 away from the electrical cables.
b) They should be away by at least 12 from the area of high frequencies like tube light chokes etc. If
it is not possible to avoid, then use shielded cables and earth the shield.
c) No cables should hang across the walls to form a radio antenna. This will avoid radio reception
during conversation
Earthing : Earth connected to the EPABX should not have more than 5 volts on it.
Spike Busters (OPTIONAL)
It is recommended to use Spike buster of rating 1 Amp in the main supply to the 824HB system where
inductive switching such as Air conditioners, Xerox machine, Fax machine, Motors or such similar gadgets
are used in the premises.
The location at which system is placed should be ventilated. It should be ensured that no liquid should
ever spill over the system especially near the ventilation slots.
One or two separate 3 pin (5 Amp) sockets should be provided near the system for 220v AC supply.

NOTE: The companys warrantee voids if the above points are not followed.

4 0 8 H B I N T E R N AL C O N N E C T I O N S

408HB Exchange consists of 1 CPU, 1 TKB, 1 UPS and Extension card as per the
configuration of the system. Configuration of different extension cards is
explained below:

S.No
1
2
3
4

Card Name
STB-HSN
STB-HN
STB-K
STB-NN

No. of KTS Extn.

1
2
8
-

No. of SLT Extn.

7
6
8

Various cards of the system are interconnected as mentioned below:

UPS
UPS
CPU
CPU
CPU

FROM
M AR K I NG O N
CONNECTOR
CN1
STU1
STU1
TKU1
CTB

CPU
TKB
CPU
CPU

CLI
CN2
RE VE R S AL
VSC

C AR D

C AR D

TO
M AR K ING O N
CONNECTOR
POWER
POWER
CN1
CN1
CTB

CPU
STB
STB
TKB
408HBSENSOR
CLI
CLI
RE V ER S AL
408 VSC

CLI
CN1
REV
VSC

LEAD USED
6 PIN WIRE
4 PIN WIRE
40 PIN FRC
40 PIN FRC
8 PIN WIRE
16 PIN FRC
8 PIN WIRE
10 PIN WIRE
40 PIN FRC

Reversal Card: This card is installed for sensing of Polarity Reversal on

Junction lines at the time of outgoing calls being matured. The connection
details of this card are given in the table above.

Reversal Generator: If Polarity Reversal is not available on Junction lines then

Reversal Generator unit can be installed for generating Polarity Reversal. This

unit checks for ring back tone in case of outgoing calls. Based on this ring
back tone, it senses when the call is matured and then generates Reversal,

which is then sensed by EPABX. Reversal Generator is installed in series of the

Junction lines before being terminated on the Junction ports of the PBX.

Night Facility: To provide Junction line to SLT extensions follow the procedure
given below:
a) Connect CN2 connector of STB card to night facility card.
b) Connect Junction line direct to Junction port of night facility card.
c) Connect extension wires from STB card to STBN port of night facility card.
d) Connect COs of TKB card to TKB port of night facility card.
e) Connect instrument to instrument port of night facility card.

F AX Ma chi ne: Upto t wo F a x ma ch in es ca n b e co nn ect ed to t he s yst em at

connectors marked as FAX1/2 on TKB cards. If one TKB card is installed then
only one Fax machine can be connected. The Fax machine works for all incoming
calls on the last Junction line of TKB card, which has operation. Once
programmed the last Junction line gets dedicated for incoming Fax. However the
line can be used for making outgoing calls.

Door Phone: Connect 2 wires of Door phone to terminal marked as DP1. In case
of two Door phones, connect the second one at terminal marked as DP2 in CPU
card.

External Music: It can be used in place of in-built music of the system, connect
the external source to the terminal marked as EX-MS of CPU card and change
the shorting plugs (JP1 & JP2) position of CPU card.
External Paging System: Connect the MIC points of PA system to terminal
marked as EX-PG of CPU card.

Sensor Operation: Connect sensor wires to terminal marked as SEN-1 and SEN2 of 408HB-sensor card.

Relay Operations: For applications like Door lock, etc., connect the wires of
D o or lock to t ermina l m ark ed a s SW 1/SW 2 of 408 HB- se ns or c ard.

Voice Service Card: Connect 40 pin FRC of VSC card at VSC port of CPU
CARD.

CLI Card: Various CLI Card are interconnected as mentioned below:

FROM
C AR D
M AR K I NG ON
CONNECTOR
CPU
CLI
TKB

CN2

C AR D
CLI
CLI

TO
M AR K ING O N
CONNECTOR
CLI
CN1

LEAD USED
16 PIN FRC
8 PIN WIRE

Parallel Printer: Connect the lead of parallel port printer to the female
connector on CPU card.

I NS T AL L ATI O N AN D CO NN E C TIO N D E T AI L S FO R
C ON V ER TE R C AR D FO R CO X-4 08 H B/8 16 H B/8 24 H B

S E RI AL

TO

PAR ALLEL

This card is installed for connecting a Parallel Port Printer to COX408HB/816HB/824HB.

Normally, the system gives Serial output through PRN card. This Serial output can
be connected to a Computer Serial Port or a Serial Port Printer directly.

1. The Serial to parallel converter card is to be mounted on TKB card.

2. One of the Power cable from UPS to STB card should be replaced with the
enclosed lead. This lead has an extra lead connected to Serial to Parallel
Converter for providing supply to it.
3. Connect RJ female connector of the Converter card to RJ female connector of
MDF with the lead enclosed.
4. Keep switch No. 3 in OFF position of the DIP switch (SW 1) and rest all in ON
position.
N OT E: If the pr int er d oe sn t work th en pr es s th e res et s witc h (SW 2).

8 16 H B IN TE R N AL CON N EC TION S
816HB Exchange consists of 1 CPU, 2 TKB, 1 UPS and Extension cards as per
the configuration of the system. Configuration of different extension cards is
explained below:

S.No
1
2
3
4

Card Name
STB-HSN
STB-HN
STB-K
STB-NN

No. of KTS Extn.

1
2
8
-

Various cards of the system are interconnected as mention below:

FROM
C AR D
M AR K I NG ON
CONNECTOR
UPS
CN1
UPS
STU1
UPS

STU2

CPU

STU1

CPU

STU2

CPU

TKU1

CPU

TKU2

CPU

CTB

CPU
TKB
CPU
CPU

CLI
CN2
REVE
VSC

No. of SLT Extn.

7
6
8

C AR D

TO

CPU
STB
1st
STB
2nd
STB
1st
STB
2nd
TKB
1st
TKB
2nd
408HBSENSOR
CLI
CLI
RE V ER S AL
816 VSC

M AR K I NG O N
CONNECTOR
POWER
POWER

LEAD USED
6 PIN WIRE
4 PIN WIRE

POWER

4 PIN WIRE

CN1

40 PIN FRC

CN1

40 PIN FRC

CN1

40 PIN FRC

CN1

40 PIN FRC

CTB
CLI
CN1
REV
VSC

8 PIN WIRE
16 PIN FRC
8 PIN WIRE
10 PIN WIRE
40 PIN FRC

Reversal Card: This card is installed for sensing of Polarity Reversal on

Junction lines at the time of outgoing call being matured. The connection details
of this card are given in the table above.
Reversal Generator: If Polarity Reversal is not available on Junction lines then
Reversal Generator unit can be installed for generating Polarity Reversal. This
unit checks for ring back tone in case of outgoing calls. Based on this ring back

tone, it senses when the call is matured and then generates Reversal, which is
then sensed by EPABX. Reversal Generator is installed in series of the Junction
lines before being terminated on the Junction ports of the PBX.

Night Facility: To provide Junction line to SLT extensions follow theprocedure

given below:
a) Connect CN2 connector of STB card to night facility card.
b) Connect Junction line direct to Junction port of night facility card.
c) Connect extension wires from STB card to STBN port of night facility card.
d) Connect COs of TKB card to TKB port of night facility card.
e) Connect instrument to instrument port of night facility card.

F AX Ma chi ne: Upto t wo F a x ma ch in es ca n b e co nn ect ed to t he s yst em at

connectors marked as FAX1/2 on TKB cards. If one TKB card is installed then
only one Fax machine can be connected. The Fax machine works for all incoming
calls on the last Junction line of TKB card, which has to be programmed for Fax
operation. Once programmed the last Junction line gets dedicated for incoming
Fax. However the line can be used for making outgoing calls.

Door Phone: Connect 2 wires of Door phone to terminal marked as DP1. In case
of two door phones, connect the second one at terminal marked as DP2 in CPU
card.

External Music: It can be used in place of in-built music of the system. Connect
the external source to the terminal marked as EX-MS of CPU card and change
the shorting plugs (JP1 & JP2) position of CPU card.

External Paging System: Connect the MIC points of PA system to terminal

marked as EX-PG of CPU card.

Sensor Operation: Connect sensor wires to terminal marked as SEN-1 and SEN2 of 408HB-sensor card.

Relay Operations: For applications like Door lock, etc. connect the wires of
D o or lock to t ermina l m ark ed a s SW 1/SW 2 of 408 HB- se ns or c ard.

Voice Service Card: Connect 40 pin FRC of VSC card at VSC port of CPU
CARD.

CLI Card: Various CLI Card are interconnected as mentioned below:

C AR D
CPU
TKB 1st
TKB 2nd

FROM
M AR K I NG O N
CONNECTOR
CLI
CN2
CN2

Parallel Printer: Connect

connector on CPU card.

C AR D
CLI
CLI
CLI
the

TO
M AR K I N G ON
CONNECTOR
CLI
CN1
CN2
lead

of

parallel

LEAD USED
16 PIN FRC
8 PIN WIRE
8 PIN WIRE
port

printer

to

the

female

8 24 H B IN TE R N AL CON N EC TION S
824HB exchange consists of 1 CPU, 2 TKB, 1 UPS, extension cards as per
the configuration of the system. Configuration of different extension cards is

explained below:
S.No
1
2
3
4

Card Name
STB-HSN
STB-HN
STB-K
STB-NN

No. of KTS Extn.

1
2
8
-

Various cards of the system are interconnected as mentioned below:

FROM
M AR K I NG ON
C AR D
CONNECTOR
UPS
UPS

POWER
STU1

UPS

STU2

UPS

STU3

CPU

STU1

CPU

STU2

CPU

STU3
3rd
TKU1
1st
TKU2
2nd
CTB
CN2
CLI
CN2
REVE
VSC

CPU
CPU
CPU
STB
CPU
TKB
CPU
CPU

No. of SLT Extn.

7
6
8

C AR D
CPU
STB

1st
STB
2nd
STB
3rd
STB
1st
STB
2nd

TO

M AR K I NG O N
CONNECTOR

LEAD USED

POWER
POWER

5 PIN WIRE
4 PIN WIRE

POWER

4 PIN WIRE

POWER

4 PIN WIRE

CN1

40 PIN FRC

CN1

40 PIN FRC

STB

CN1

40 PIN FRC

TKB

CN1

40 PIN FRC

TKB

CN1

40 PIN FRC

CN1
CN2
CLI
CN1
REV
VSC

20 PIN FRC
02 PIN WIRE
16 PIN FRC
8 PIN WIRE
10 PIN WIRE
40 PIN FRC

UTLITY
UTILITY
CLI
CLI
RE VE R S AL
824 VSC

Reversal card: This card is installed for sensing of Polarity reversal on junction
lines at the time of outgoing calls being matured. The connection details of this
card are given in the table above.
Reversal Generator: If Polarity reversal is not available on Junction lines then
Reversal Generator unit can be installed for generating Polarity reversal. This
unit checks for ring back tone in case of outgoing calls. Based on this ring back
tone, it senses when the call is matured and then generates Reversal, which is
then sensed by EPABX. Reversal Generator is installed in series of the Junction
lines before being terminated on the Junction ports of the PBX.
Night Facility: To provide Junction line to SLT extensions follow the procedure
given below:
a) Connect CN2 connector of STB card to night facility card.
b) Connect Junction line direct to Junction port of night facility card.
c) Connect extension wires from STB card to STBN port of night facility card.
d) Connect COs of TKB card to TKB port of night facility card.
e) Connect instrument to instrument port of night facility card.

F AX Ma chi ne: Upto t wo F a x ma ch in es ca n b e co nn ect ed to t he s yst em at

connectors marked as FAX1/2 on TKB cards. If one TKB card is installed then
only one Fax machine can be connected. The Fax machine works for all incoming
calls on the last Junction line of TKB card, which has to be programmed for Fax
operation. Once programmed, the last Junction line gets dedicated for incoming
Fax. However the line can be used for making outgoing calls.

Door Phone: Connect 2 wires of Door phone to terminal marked as DP1. In case
of two door phones. Connect the second one at terminal marked as DP2 in utility
card.

External Music: It can be used in place of in-built music of the system. Connect
the external source to the terminal mark as EX-MS of utility card and change the
shorting plugs (JP1 & JP2) position of CPU card.

External Paging System: Connect the MIC points of PA system to terminal

marked as EX-PG of utility card.

Sensor Operation: Connect sensor wires to terminal marked as SEN-1 and SEN2 of utility card.

Relay Operations: For applications like Door lock etc. Connect the wires of
D o or lock to t ermina l m ark ed a s SW 1/SW 2 of utilit y c ard.

Voice Service Card: Connect 40 pin FRC of VSC card at VSC port of CPU Card.

CLI Card: Various CLI Card are interconnected as mentioned below:

FROM
M AR K I NG ON
CONNECTOR
CPU
CLI
st
CN2
TKB 1
TKB 2nd
CN2
C AR D

CARD
CLI
CLI
CLI

TO
M AR K I NG O N
CONNECTOR
CLI
CN1
CN2

LE AD US E D
16 PIN FRC
8 PIN WIRE
8 PIN WIRE

Parallel Printer: Connect the lead of parallel port printer to the female
connector on CPU card.

CLI CARD INSTALLATION

(In 408HB/816HB/824HB)
1. Connect FRC cable from CLI connector of CLI card to CLI connector of CPU card
2. Connect 8-wire cable connector from TKB1 to CLI card at connector CN1.
3. Connect another 8 wire cable connector from TK B-2 to CLI card at connector CN2. (In case of 8
line CLI card in 816 HB/824HB)

BLOCK DIAGRAM

CPU CARD

C
L
I
C
A
R
D

P/S
CARD

STB CARD

TKB CARD

EXT.
BAT.

M.D.F

NOTE: The CLI card to be installed by means of spacers in CPU card in case of 824HB and 408HB
while in 816HB it can be installed in system cabinet by means of screws.

T E C HNI C AL S P E CI FI C AT I O NS

Maximum loop resistance

Key Telephone Set

< 40

Single Line Telephone

< 400

Door Phone

< 40

Music Source

Input impedance < 600

Maximum input 0.775 Vrms

External Paging

Output impedance 600

Cabling
Junction Line

Twisted 1 pair cable

Key Telephone Set

Twisted 2/3 pair cable

Single Line Telephone

Twisted 1 pair cable

Door Phone

Twisted 1 pair cable

Power Consumption

100 W atts max.

(COX-824HB)
80 W atts max.
(COX-816HB)
60 W atts max.
(COX-408HB)

TERMS OF WARRANTY
Copper Connections warrants that this product is manufactured under stringent quality standards, making it free from
defects in material and workmanship, as per the following terms and conditions:
1. The limited warranty for the system is valid for a period of twelve months from the date of purchase or fifteen
months from the date of manufacture which ever is earlier.

2. The limited warranty extends only to the original consumer/ purchaser of the product and is not assignable or
transferable to any subsequent purchaser/ end user.
3. During the limited warranty period, Copper Connections or its authorised service network will repair or replace, at
Copper Connections option, any defective product or parts thereof with a new or factory rebuild replacement items
and return the product to the consumer in working conditions. No charge will be made to the consumer for either
parts or labour in repairing or replacing the product. All replaced parts shall become the property of Copper
Connections.
4. Repaired product will be warranted for a balance of original warranty period.
5. Upon request from Copper Connections or its authorised service centre, the consumer must provide purchase receipt
or other information to prove the date and place of purchase.
6. The consumer shall have no benefit or coverage if any of the following conditions are applicable:
a) The product has been subjected to abnormal use, abnormal condition, improper storage, exposure to moisture or
dampness, exposure to excessive temperature or fire etc., unauthorised modifications, unauthorised connections,
unauthorised repairs including but not limited to use of unauthorised spare parts in repairs, misuse, neglect,
abuse, accident, alteration, improper installation.
b) Copper Connections was not notified by consumer of the alleged defect or malfunction of the product during the
limited warranty period.
c) The product was used with or connected to equipment not fit for use with Copper Connections system or used in
other than its intended use.
d) THE SYSTEM IS NOT CONNECTED TO A PROPER EARTH OR INCASE HIGH VOLTAGES
APPEARS ON EARTH.
e) THE DAMAGE IS CAUSED BY LIGHTENING ON EXTENSIONS/ JUNCTION LINES/ OR SPIKES/
SURGES/ HIGH VOLTAGES FROM AC MAIN SUPPLY.
7. The consumer may contact the local dealer for the location of the nearest authorised service centre or call the
service personnel from the local dealer.
8. The consumer will be billed for parts or labour charges not covered by this limited warranty.
9. If the product is returned to Copper Connections after the warranty period , Copper Connections normal service
policy shall apply and customer shall be charged accordingly.
10. In no event shall Copper Connections or their authorised dealer be liable for special or consequential damages or
any delay in the performance of this warranty due to causes beyond their control. Copper Connections shall not be
liable for incidental or consequential damage or a loss of anticipated benefits or profits, loss or impairment of
privacy of conversation, work stoppage or loss or impairment of data arising out of the use or inability to use the
product.
11. Copper connections neither assumes nor authorises any authorised service centre or any person or entity to assume
for it any other obligation or liability beyond what is expressly provided by this limited warranty. All warranty
information, product features and specifications are subject to change without prior notice.
12. Any dispute arising out of this warranty shall be subjected to jurisdiction of the arbitrator within the city of Delhi.
13. The decision of Copper Connections, on defects, damages etc shall be final and binding on the parties and no dispute
regarding this, could be agitated before any civil court.

9.