GAI-Tronics RigCom 400-001 User manual

Pub. 42004-376D
GAI-TRONICS®
A H U B B E L L C O M P A N Y
Models 400-001 and 400-002NS
RigCom Stations
TA B L E O F CO N T E N T S
GAI-TRONICS 3030 KUTZTOWN RD. READING, PA 19605 USA
610-777-1374 800-492-1212 Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
Confidentiality Notice.....................................................................................................................1
General Information.......................................................................................................................1
Important Safety Instructions.........................................................................................................2
Installation ......................................................................................................................................3
Speaker Horn Assembly (Model 400-001 Only)...................................................................................3
Mounting..................................................................................................................................................4
Hardware Configuration........................................................................................................................5
External.................................................................................................................................................5
Internal..................................................................................................................................................5
Wiring......................................................................................................................................................6
Station Wiring.......................................................................................................................................6
System Line Balance.............................................................................................................................7
System Wiring ......................................................................................................................................9
Field Installation Interface.....................................................................................................................9
TB1—Speaker Terminal Block ............................................................................................................9
TB2—AC Voltage Terminal Block....................................................................................................10
TB3—DC Voltage Terminal Block....................................................................................................10
TB4—Audio and Low Voltage Control Terminal Block ...................................................................10
P1—Front Cover Wire Harness Connections.....................................................................................11
P3—Balanced / Unbalanced Jumper...................................................................................................11
SW1—Master/Slave Switch ...............................................................................................................11
Operation.......................................................................................................................................11
Common Line System...........................................................................................................................12
Master/Slave System.............................................................................................................................12
Maintenance..................................................................................................................................13
F1/F2 Fuses............................................................................................................................................14
Troubleshooting....................................................................................................................................14
Replacement Parts and Accessories.............................................................................................14
Specifications ................................................................................................................................15
AC Power...............................................................................................................................................15
DC Power...............................................................................................................................................15
Amplifier PCBA....................................................................................................................................15

Table of Contents Pub. 42004-376D
GAI-TRONICS 3030 KUTZTOWN RD. READING, PA 19605 USA
610-777-1374 800-492-1212 Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
Speaker (Model 400-001 Only) ............................................................................................................15
Station....................................................................................................................................................15
Environmental.......................................................................................................................................15
Approvals.......................................................................................................................................16
Appendix A—InterfacingaModel400-001RigComStationtoaMS39xxRigComStationSystem.................16
Appendix B—InterfacingaModel400-001RigComStationtoEZPageStations........................................17

Pub. 42004-376D
GAI-TRONICS®
A HUBBELL COMPANY
Models 400-001 and 400-002NS
RigCom Stations
GAI-TRONICS 3030 KUTZTOWN RD. READING, PA 19605 USA
610-777-1374  800-492-1212  Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
Confidentiality Notice
This manual is provided solely as an installation, operation, and maintenance guide and contains sensitive
business and technical information that is confidential and proprietary to GAI-Tronics. GAI-Tronics
retains all intellectual property and other rights in or to the information contained herein, and such
information may only be used in connection with the operation of your GAI-Tronics product or system.
This manual may not be disclosed in any form, in whole or in part, directly or indirectly, to any third
party.
General Information
The GAI-Tronics Model 400-001 and 400-002NS RigCom Stations are designed for a common-talk, or
master/slave communication system for the following hazardous locations: Model 400-001: Class I,
Div. 1, Groups C and D; Model 400-002NS: Class I, Div. 1, Groups B, C, and D, when installed in
accordance with GAI-Tronics Pub. 42004-381, Control Drawing No. 73214. The system provides push-
to-talk, release-to-listen operation, and has a local on/off volume control switch to activate and control the
volume level for each station independently.
The Model 400-001 includes an attached speaker and
driver unit. The Model 400-002NS does not include
the speaker and driver unit, but does have a 1/2-inch
NPT hole to remotely mount and connect the speaker
driver unit to the station.
The RigCom stations have connections for an
auxiliary microphone and footswitch connection for
remote operation from the station itself.
In this operation, the auxiliary microphone replaces
the speaker as the microphone and the auxiliary
footswitch provides the same functionality as the
push-to-talk switch. With the use of auxiliary items,
the approved hazardous locations are reduced to
Class I, Div. 1, Group D.
Figure 1. Model 400-001 RigCom Station

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The Model 400-001 and 400-002NS RigCom Stations are designed to be field replacements for the
previous MS39xx Series RigCom stations. The Model 400 Series must be configured as an unbalanced
station when used as a field replacement for the MS39xx Series.
Along with operation with the MS39xx Series RigCom stations, the Model 400 Series are designed to
operate with the EZ Page Series of GAI-Tronics equipment.
Important Safety Instructions
1. Read, follow, and retain instructions—All safety and operating instructions should be read and
followed before operating the unit. Retain instructions for future reference.
2. Heed warnings—adhere to all warnings on the unit and in the operating instructions.
3. Attachments—Attachments not recommended by the product manufacturer should not be used, as
they may cause hazards.
This permanently connected apparatus must have an ALL-POLE MAINS switch with a contact separation
of at least 3 mm in each pole incorporated in the electrical installation of the building.
WARNING
—To reduce the risk of fire or electrical shock, do not expose this apparatus to rain
or moisture.

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Installation
These enclosures must be installed by trained, qualified, and competent personnel. Installation must
comply with state and national regulations, as well as safety practices for this type of equipment.
Model 400-001 and 400-002NS must be installed in accordance with GAI-Tronics Pub. 42004-381,
Control Drawing No. 73214.
CAUTION
—Do not install this equipment in hazardous areas other than those indicated on
the approval listing in the Approvals section of this manual. Such installation
may cause a safety hazard and consequent injury or property damage.
The mounting location must be flat and provide proper clearance, rigidity, and strength to support the
enclosure and all contained devices.
Securely fasten the enclosure to the mounting location using (customer-supplied) 7/16-inch diameter steel
mounting bolts and washers, or washer head bolts.
WARNING
—Insure proper grounding to protective earthing.
Do not disconnect equipment while energized.
Inspect and clean the machined flange flame joint surfaces of both the cover and box. Surfaces must be
smooth, free of nicks, scratches, dirt, or any foreign particle build-up that would prevent a proper seal.
Surfaces must seat fully against each other to provide a proper explosion-proof joint. Clean surfaces by
wiping with a clean lint-free cloth.
Make certain no cover bolts are omitted. Use only those bolts supplied with the enclosure.
Recommended torque setting of cover bolts = 17 ft∙lb (23 N∙m).
Speaker Horn Assembly (Model 400-001 Only)
The Model 400-001 Speaker Horn Assembly must be assembled prior to installation:
1. Unpack the unit.
2. Locate the speaker horn and driver unit.
3. Place the speaker bell over the driver bushing.
4. Position two large diameter fiber washers with the large diameter steel washer sandwiched between
them on the speaker bushing.
5. Place the small diameter rubber washer into the speaker horn tip, followed by the small diameter fiber
washer.
6. Screw the speaker horn tip to the driver bushing until it is snug.

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Mounting
NOTE: The mounting surface must be able to support the weight of the aluminum enclosure. See the
Specifications section for the weights and dimensions of the unit.
The enclosure must be securely fastened with 7/16-inch diameter steel mounting bolts located on all four
mounting feet. Stainless steel hardware is recommended for applications in corrosive environments (see
Figure 2 for mounting dimensions).
Figure 2. Model 400-001/400-002NS Mounting Details and Conduit Entries

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Hardware Configuration
External
The enclosure contains a push-to-call operator, an on-off/volume control operator, and applicable
approval labeling. The enclosure itself has 12 cover mounting bolts located around the perimeter of the
enclosure.
NO U SER S ERVI CEABL E PART S INSID E.
REFER SERVICING TO QUALIFIED PERSONNEL ONLY.
OFF-ON VOLUME
PUSH TO CALL
GAI-TRONI CS CORPORATION
P.O. BOX 1060 READING, PA 19607
SUITABLE FOR USE IN HAZARD OUS LOCATIONS
CLASS I, DIV. I, GROUPS C, D
WARNING: EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS
TO REDUCE THE RISK OF IGNITION OF HAZARDOUS ATMOSPHERES,
CONDUIT SEALS MUST BE INSTALLED WITHIN 18 INCHES OF ENCLOSURE.
AMBIENT TEMPE RATURE: -20°C T O 60°C
No. 400-001 - RIGCOM MASTER/SLAVE/COMMON
DATE CODE:
17R9
WARNING:
120VAC, 50/60 Hz, .400 AMP MAX. OR
KEEP COVER TIGHT WHILE CIRCUITS ARE ALIVE.
CAUTION:
POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
12VDC, 1.8 AMP MAX
CAUTION
RIS K O F E LE C TRI C
SHOCK, DO NOT OPEN!
!
SERVICE CENTERS: In USA: 1-800-492-1212 Outside USA: 1-610-777-1374
~
Figure 3. Model 400-001 RigCom Station Outline
Internal
The enclosure contains a single PCBA where all customer connections are made. All connections are
made to the front cover by a single wiring harness with a plug.

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Wiring
Station Wiring
1. Attach conduit or cable glands to the ¾-inch NPT holes on the bottom of the enclosure.
2. Feed the low-voltage wiring conduit on the left side hole, from the front view
3. Feed the power wiring through the right side hole, from front view.
4. Attach the wires to the terminal blocks located on the PCBA within the enclosure (see Figure 4 for
connection points and descriptions).
5. If using the 10438-001 Auxiliary Microphone Assembly: Connect the assembly to the station at
terminal block TB4-1 (+) and TB4-2 (–), and the shield to TB4-5, if used.
The maximum distance from the station is 50 feet using No. 18 AWG wire.
6. If using the 51052-003 Auxiliary Footswitch Assembly: Connect the assembly to the station at
terminal block TB4-8 (+) and TB4-9 (–), and the shield to TB4-5, if used.
The maximum distance from the station is 50 feet using No. 18 AWG wire.
Figure 4. RigCom Station PCBA

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System Line Balance
Each system requires termination of the audio pair wires with the 1-kilohm, 1-watt resistor assembly
included with each unit. The line balance resistor assembly is made for easy installation into the
customer-supplied junction box.
NOTE: Only one line balance resistor assembly is needed per system.
The resistor assembly should be installed in a junction box (customer supplied) that is close to the center
of the system when cable runs approximately 4000 feet (1219 m) or longer are used (see Figure 5 and
Figure 6). The junction box must be suitable for the applicable hazardous location in which it is located.
Figure 5. System cable wiring less than 4000 feet in length

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Figure 6. Master/Slave System cable wiring greater than 4000 feet in length