Appendix B.
Keypad and Plastic Enclosure

B.1 Keypad Insert

The keypad is designed to accept paper inserts prepared on regular paper. The templates shown below in Figure B-1 can be used to create custom inserts. The numbers shown on the upper template correspond to the codes returned by Dynamic C when that key is pressed.

Figure B-1. Intellicom 2 × 6 Keypad Template

These instructions describe how to change the keypad insert.

1. Set the outer plastic casing aside and lay the front panel face down on a soft cloth so that the Intellicom board is facing up.

2. Unplug the speaker and the keypad as shown in Figure B-2.

3. Remove the four screws shown in Figure B-2 that hold the Intellicom board to the front panel.

4. Lift the Intellicom board up front the front panel and set it aside. Note that the LCD is attached permanently to the Intellicom board.

5. Remove the four screws shown in Figure B-3 that hold the keypad to the front panel.

6. Remove the old insert and place the new insert in between the keypad and the mylar front. You may tape down the portion of the insert that extends beyond the keypad.

7. Line up the keypad over the front panel and replace the four 2-56 screws as shown in Figure B-3. Line up the Intellicom board/LCD and replace the four screws as shown in Figure B-2. Reconnect the keypad and the speaker to the Intellicom board.

Figure B-2. Removing Intellicom Board from Front Panel

Figure B-3. Removing Keypad from Front Panel

B.2 Plastic Enclosure

Figure B-4 shows the dimensions of the Intellicom front panel bezel.

Figure B-4. Intellicom Front Panel Bezel Dimensions

Figure B-5 shows the dimensions of the outer casing, including the attached front panel.

Figure B-5. Intellicom Outer Casing Dimensions

B.2.1 Assembling Intellicom Enclosure

There are two recommended assemblies possible for the Intellicom:

1. Mount the front panel bezel in an opening you have created. This option allows you to have a water-resistant unit by using the gasket supplied with the Intellicom to form a water-resistant seal between the front panel bezel and your opening.

2. Mount the front panel bezel using the outer casing supplied with the Intellicom.

B.2.1.1 Custom Mounting In An Opening

Prepare an opening to accommodate the Intellicom front panel bezel shown in Figure B-4. The thickness of the surface the Intellicom front bezel is mounted on should be either 0.0625 inches (1.6 mm) or 0.125 inches (3.2 mm). Use the brackets on the plastic tree included with the Intellicom (see Figure B-6) to attach the front panel bezel to the surface.

Figure B-6. Mounting Brackets and Speaker Plug

A watertight mounting is also possible.

First, remove the speaker from the front panel bezel, and insert the speaker plug to close the holes in the speaker grille. Apply some hot glue around the edges of the plug to form a watertight seal. Replace the speaker--a dab of glue around the edge of the speaker will hold it in place.

Place the rubber gasket supplied with the Intellicom between the front panel bezel and the surface the Intellicom will be mounted. A watertight seal will result when the brackets are attached.

Figure B-7. Watertight Mounting of Intellicom

B.2.1.2 Supplied Outer Casing

Once the desired wires have been connected to header J7 on the Intellicom board, the Intellicom may be mounted in the plastic outer casing as shown in Figure B-8. Secure the plastic casing with the six screws supplied with the Intellicom

Figure B-8. Mounting Intellicom in Plastic Outer Casing

If you are using the RJ-45 jack at J6 for an Ethernet connection with the Intellicom installed in the plastic outer casing, remove the protective rubber boot around the Ethernet cable RJ-45 jack that plugs into the Intellicom board. This will ensure that the Ethernet cable can bend back within the depth of the plastic outer casing.

The outer casing has a knockout for a conduit on one side. The casing is symmetric, and so the conduit knockout can face up or down. Use a small hacksaw to remove the knockout if you are using a conduit. The conduit opening has an O.D. of 0.826 inches (21.0 mm), which accommodates standard trade size ½ or 17 mm diameter conduit.

When routing cables through the conduit, Z-World has found that an Ethernet cable (minus the rubber boot on the RJ-45 plug) should be routed first, followed by the RS-485 cable with the RJ-12 plug, followed by other wire.

Figure B-9. Remove Rubber Boot from RJ-45 Connection to Intellicom

Figure B-10 shows an Intellicom wired through a conduit.

Figure B-10. Rear View of Intellicom with Outer Casing
Showing Wiring from Conduit