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

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System Wiring
The maximum line length for the complete system, while still maintaining maximum output signal, is
15,000 feet for a system with less than ten stations. This is based on No. 18 AWG wire, the stations
spaced equidistantly, and one station in talk mode at a time. For each station in talk mode, the signal
level reduces by half (see Figure 7 for systems with more than ten stations to determine the maximum line
distance).
Figure 7. Number of Stations vs. Line Length
Field Installation Interface
TB1—Speaker Terminal Block
The following table lists the connections for the speaker output terminal block, TB1:
Name
Pin No.
Description
16
1
16-ohm terminal for external speaker connection
8
2
8-ohm terminal for external speaker connection
COM
3
common terminal for external speaker connection
0
2
4
6
8
10
12
14
16
0 5 10 15 20 25 30
Line Length 18 AWG wire (1000 feet)
Number of Stations
Number of Station per Line Length

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TB2—AC Voltage Terminal Block
The following table lists the connections for the ac voltage terminal block, TB2:
Name
Pin No.
Description
AC POWER H
1
external ac power supply positive terminal
No connection when external ac power supply is not used.
AC POWER N
3
external ac power supply neutral terminal
No connection when external ac power supply is not used.
AC POWER
GND
Ground terminal for the ac power must be electrically connected
to the chassis.
TB3—DC Voltage Terminal Block
The following table lists the connections for the dc voltage terminal block, TB3:
Name
Pin No.
Description
DC POWER
INPUT+
2
external dc power supply positive terminal
No connection when external dc power supply is not used.
DC POWER
INPUT–
1
external dc power supply negative terminal
No connection when external dc power supply is not used.
TB4—Audio and Low Voltage Control Terminal Block
The following table lists the connections for the low voltage control and audio signal terminal block,
TB4:
Name
Pin No.
Description
AUX MIC+
1
Positive terminal for the auxiliary microphone.
AUX MIC–
2
Negative terminal for the auxiliary microphone.
EXT CONT+
3
Talk/listen control signal for Master/Slave operation. No
connection in Common Line mode.
EXT CONT–
4
Ground reference for talk/listen control signal for Master/Slave
operation. No connection in Common Line mode or UNBAL
audio configuration.
SHIELD
5
Ground reference for shield terminations.
AUDIO+
6
Positive side of the audio port line during 600-ohm or 15-kilohm
termination configuration.
AUDIO–
7
Negative side of the audio page port line during 600-ohm or 15-
kilohm termination configuration.
FOOTSWITCH+
8
Positive side of auxiliary footswitch that operates as the local
push-to-talk switch.
FOOTSWITCH–
9
Negative side of auxiliary footswitch that operates as the local
push-to-talk switch.

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P1—Front Cover Wire Harness Connections
Plug in the front cover wire harness connector at P1 (see Figure 4).
P3—Balanced / Unbalanced Jumper
Jumper P3 allows configuration of the unit for balanced or unbalanced audio connections. The assembly
is configured for balanced audio input signals if the header is installed in the BAL position. The assembly
is configured for unbalanced audio input signals if the header is installed in the UNBAL position.
NOTE:The system must be set up as an unbalanced system in systems where the external control signal
is single-ended, such as previous GAI-Tronics Model MS39xx RigCom Stations.
SW1—Master/Slave Switch
Switch SW1 allows configuration of the unit as a master or slave unit. The unit is configured as a master
if the switch is in the MASTER position. The unit is configured as a slave if the switch is in the SLAVE
position. The switch must be in the MASTER position for common line operation.
Operation
The operator has access to an on-off/volume control switch and the push-to-talk switch.
The on-off/volume control switch allows the operator to turn the unit on or off and adjust the volume
level in the listen mode. Turn the unit off by turning the switch completely counterclockwise. Adjust the
switch completely clockwise for maximum volume.
The push-to-talk switch controls the audio communication between stations. The push-to-talk switch
allows the operator to send a message to another station when activated. The station is in listen mode and
the station receives messages from other stations when not activated. The push-to-talk switch has no
function when a station is configured as a slave station.

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Common Line System
All stations are on a common talking path and are normally in the listen mode in the common line
configuration. The audio signal is supplied to the audio lines when one of the stations has its push-to-talk
toggle switch activated. All other units receive the audio signal and broadcast the announcement over
their speakers. The push-to-talk switch must be held down as long as the operator talks. Releasing the
switch deactivates the microphone and returns the unit to listen mode.
Figure 8. Common Talk Wiring Detail
Master/Slave System
A Master station controls the talk-listen function of the Slave units through external control wiring in the
master/slave configuration
Slave stations are in talk mode allowing the master to monitor the slave’s audio when the master’s push-
to-talk is not activated. When the master’s push-to-talk is activated, the slaves are in listen mode,
allowing the master to transmit audio to the slave stations. The Slave’s push-to-talk is not operable, and
their operation is hands-free.

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Figure 9. Master/Slave Wiring Detail
Maintenance
CAUTION —These servicing instructions are for use by qualified service personnel only. To
reduce risk of electric shock, do not perform any servicing other than that
contained in the Maintenance section unless you are qualified to do so.
Regular inspection and a good preventive maintenance program will increase the reliability of your
GAI-Tronics station. The GAI-Tronics Field Service Department can formulate a service contract suited
to your facility’s specific need for preventive maintenance.
WARNING —Before performing any of the following preventive maintenance steps, remove
all power from the station.
CAUTION —To reduce the risk of ignition of hazardous atmospheres, disconnect the
equipment from the supply circuit before making any adjustments to the
PCBA’s settings.

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F1/F2 Fuses
WARNING
—Do not remove fuses when energized.
Replace with the same type and size fuse for continued safe operation.
F1 is the fuse on the ac power line: 0.5 A, SLO-BLO, 250 V, 5×20 mm, UL.
F2 is the fuse on the dc power line: 2.0 A, SLO-BLO, 250 V, 5×20 mm, UL.
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.
Install and tighten all cover bolts to 17 ft∙lb, (23 N∙m). Make certain no cover bolts are omitted. Use only
the bolts supplied with the enclosure.
Troubleshooting
Problem
Solution
Any problem with station
performance
Always review all steps of installation, ensuring that you
correctly followed all steps. Check all terminations on the
board.
Speaker volume needs
adjustment
Adjust volume control.
Replace speaker or driver.
Crosstalk
One or more system cable pairs may be improperly terminated.
Visually inspect the system cable for accidental crossing of
cable pairs or grounds.
Replacement Parts and Accessories
Contact GAI-Tronics for replacement part information.
The following accessories are available for the RigCom stations:
Part No.
Description
12801-001
auxiliary microphone
51052-003
auxiliary footswitch
10438-001
microphone I.S. barrier kit (contains 12801-001 auxiliary mic assembly)
12807-001
connector kit
60075-001
audio cable, No. 18 AWG, (two-pair)

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Specifications
AC Power
Voltage.............................................................................................................................120 V ac, 50/60 Hz
Power consumed (at nominal)
Off (mute).............................................................................................................................6 VA, 1.8 W
Standby..............................................................................................................................7.2 VA, 3.6 W
Maximum speaker out.........................................................................................................30 VA, 27 W
DC Power
Voltage................................................................................................................................................12 V dc
Power consumed (at nominal)
Off (mute)........................................................................................................................................ 0.3W
Standby.............................................................................................................................................. 3 W
Maximum speaker out..................................................................................................................... 20 W
Amplifier PCBA
Frequency response...................................................................................................300 Hz–8 kHz, +/–3 dB
Audio output......................................................................................................................................... 8.0 W
Audio THD distortion...........................................................................................1% maximum, 8 W output
Hum/Noise............................................................................................................1% maximum, 8 W output
Gain—Listen mode................................................................................................................................17 dB
Gain—Talk mode (speaker as the microphone) ....................................................................................42 dB
Gain—Talk mode (auxiliary microphone).............................................................................................48 dB
Speaker (Model 400-001 Only)
Rating.................................................................................................................................... 30 W maximum
Impedance............................................................................................................................................... 16 Ω
Frequency response......................................................................................................400–3.5 kHz, +/–6 dB
Sound pressure level, 1 W @ 1 m, swept sine wave....................................................................104 dB SPL
Station
Construction/finish..........................................................................................cast aluminum/tumblast finish
Mounting.................................................................wall or column, four 7/16-inch mounting feet with slots
Connections....................................................................................................... plug-in style terminal blocks
Conduit entries....................................................................................................bottom: two, 3/4-inch NPT
.........................................................................................top: one, 1/2-inch NPT (Model 400-002NS only)
Dimensions ...................................................20.00 H × 10.31 W × 14.21 D in (508.0 × 261.9 × 360.9 mm)
Shipping weight
Model 400-001.............................................................................................................. 36.0 lb (16.4 kg)
Model 400-002NS......................................................................................................... 23.0 lb (10.5 kg)
Environmental
Temperature range (operating and storage)...........................................–4 ºF to +140 ºF (–20 ºC to +60 ºC)

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Approvals
The models below are approved for the following hazardous areas when installed in accordance with Pub.
42004-381, Control Drawing # 73214.
Model 400-001 RigCom Station:
NRTL listed (USA) ....................................................... Hazardous locations Class I, Div. 1, Groups C & D
when auxiliary microphone and/or footswitch is used:........... Hazardous locations Class I, Div. 1, Group D
Model 400-002NS RigCom Station:
NRTL listed (USA) ................................................... Hazardous locations Class I, Div. 1, Groups B, C & D
when auxiliary microphone and/or footswitch is used:........... Hazardous locations Class I, Div. 1, Group D
Appendix A—Interfacing a Model 400-001 RigCom Station to a
MS39xx RigCom Station System
The Model 400-001 RigCom Station is designed to operate as a field replacement or system addition to
the MS39xx RigCom Stations.
The MS39xx uses an unbalanced system for communication and uses the negative of the audio pair as the
ground reference for the control signal. The Model 400-001 has the ability to operate unbalanced or
balanced. In the balanced system, the audio pair is not ground referenced and the control signal requires a
ground signal.
For interoperability between the Model 400-001 and the MS39xx Series, configure the Model 400-001 for
an unbalanced system by placing jumper P3 in the UNBAL position. No changes are required to the
MS39xx Series station(s). For Master/Slave operation, connect AUDIO– to AUDIO (WH), AUDIO+ to
AUDIO (BLK) and EXT CONT+ to KEY. For common line only the audio wires require connection.
The following wiring diagrams are for the different configurations of a RigCom system:
Figure 10. Master/Slave Configuration with the Model 400-001 as Master

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Figure 11. Master/Slave Configuration with the Model 400-001 as Slave
Figure 12. Common Line Configuration
Appendix B—Interfacing a Model 400-001 RigCom Station to EZ
Page Stations
The Model 400-001 RigCom Station is designed to operate as an addition to a system of EZ Page stations.
The EZ Page Series and Model 400-001 Stations are designed to operate either in balanced or unbalanced
systems. An unbalanced system for communication uses the negative of the audio pair as the ground
reference for the control signal. In the balanced system, the audio pair is not ground referenced and the
control signal requires a ground signal.
For interoperability between the Model 400-001 and the EZ Page Series Stations, configure the 400-001
and the EZ Page stations identically, balanced or unbalanced, using jumper P3 on the Model 400-001 and
Jumper P5 on the EZ Page station.
The following are wiring diagrams are for the different configurations of a RigCom/EZ Page system:

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Figure 13. Master/Slave Unbalanced Configuration with the Model 400-001 as Master
Figure 14. Master/Slave Unbalanced Configuration with the Model 400-001 as Slave