GAI-Tronics DHF-101 User manual

Pub.: 42004-383D
GAI-Tronics Corporation 400 E. Wyomissing Ave. Mohnton, PA 19540 USA
610-777-1374 800-492-1212 Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
GAI-TRONICS® CORPORATION
A HUBBELL COMPANY
Model DHS/DHF Series
Digital Intercom Stations
TABLE OF CONTENTS
Confidentiality Notice.....................................................................................................................1
General Information.......................................................................................................................1
Product Overview ...................................................................................................................................1
System Requirements and Limitations.................................................................................................1
Features and Functions ..........................................................................................................................2
Available Models.....................................................................................................................................3
Wall-Mount Handset Intercoms (Indoor/Outdoor) ...............................................................................................3
Wall-Mount Hands-free Intercoms (Indoor/Outdoor)...........................................................................................3
Flush-Mount Hands-free Intercoms ......................................................................................................................3
Description of Major Components........................................................................................................4
Installation ......................................................................................................................................5
General Information...............................................................................................................................5
Station Placement .................................................................................................................................................5
Mounting..................................................................................................................................................6
Models DHS-101, DHF-101, and DHF-102 .........................................................................................................6
Models DHF-103 and DHF-104 ...........................................................................................................................7
Conduit Installation................................................................................................................................8
Metallic Conduit Installation Details ....................................................................................................................8
Field Wire Installation............................................................................................................................9
Power ....................................................................................................................................................................9
System.................................................................................................................................................................11
Audio ..................................................................................................................................................................11
Audio Level Adjustments ...................................................................................................................................12
Switch Configuration..........................................................................................................................................15
Inputs ..................................................................................................................................................................16
Outputs................................................................................................................................................................16
Operation.......................................................................................................................................18
Hands-free Operation...........................................................................................................................18
Handset Operation................................................................................................................................18
Headset Operation................................................................................................................................19
Paging.....................................................................................................................................................19
Alarms and Music.................................................................................................................................19
Status Indication...................................................................................................................................20
Call Status ...........................................................................................................................................................20

Table of Contents Pub.: 42004-383D
MODEL DHS/DHF SERIES DIGITAL INTERCOM STATIONS
GAI-Tronics Corporation 400 E. Wyomissing Ave. Mohnton, PA 19540 USA
610-777-1374 800-492-1212 Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
ii
Controls..................................................................................................................................................20
Keypad................................................................................................................................................................20
Single Button Dialing .........................................................................................................................................20
Talk/Listen Control.............................................................................................................................................20
Call Cancel..........................................................................................................................................................20
Master Volume ...................................................................................................................................................20
Maintenance..................................................................................................................................21
General Information.............................................................................................................................21
Troubleshooting....................................................................................................................................21
Service ................................................................................................................................................................22
Replacement Parts................................................................................................................................22
Specifications ................................................................................................................................23

Pub. 42004-383D
GAI-Tronics Corporation 400 E. Wyomissing Ave. Mohnton, PA 19540 USA
610-777-1374 800-492-1212 Fax: [phone]
VISIT WWW.GAI-TRONICS.COM FOR PRODUCT LITERATURE AND MANUALS
GAI-TRONICS® CORPORATION
A HUBBELL COMPANY
Model DHS/DHF Series
Digital Intercom Stations
Confidentiality Notice
This manual is provided solely as an operational, installation, 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
Product Overview
The GAI-Tronics DHS/DHF Series Digital Intercom
Stations are designed for use in hazardous and non-
hazardous area communications, both indoors and
outdoors, and in high noise areas.
The DHS/DHF Series Intercom Stations are ideal for
both large and small intercom systems. Communication
and security systems can be networked to include up to
120 intercom servers with the capability to support a
corresponding maximum of 5,760 stations. The
systems can be upgraded to include alarms, radio
interface, telephone interface, music, etc. All
communication to the stations is via a two-wire digital
communication line.
These intercom stations provide all-call, group call,
hands-free, handset and headset communication,
input/output controls, and a variety of other functions.
These stations also contain integrated functions such as
door and gate control, and video integration, and control
desk functions, etc.
System Requirements and Limitations
As a minimum, the DHS/DHF Series Stations require a central cabinet to supply power for operation with
its basic functions. A local 24 V ac or dc power source is required for full functionality (external speaker,
audio line driver and headset operation). Remote amplifiers can be installed with these stations to
broadcast additional audio.
Figure 1. Digital Intercom Station

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Features and Functions
•Central power (limited functionality) or
local power operation (full functionality)
•Direct dial, auto-dial, group call, and all-call
capability
•Two-wire digital communication •Suitable for high noise areas
•24 V ac or dc power •Optional footswitch
•Footswitch input •Optional headset
•12-watt Class-D speaker amplifier •Optional noise-canceling gooseneck microphone
•0 dBm, 600-ohm audio line driver •Protection against feedback
•Volume control •Simplex, switched duplex, and full-duplex capable
•16-button keypad •Call transfer
•Optional Talk/Listen control •Conference calling
•Configurable buttons •Two configurable outputs
•Call status indicator •Suitable for Div. 2 Hazardous Areas
•Noise-canceling handsets •UL Listed
•Hands-free operation •CE Mark
•Two configurable inputs

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Available Models
Wall-Mount Handset Intercoms (Indoor/Outdoor)
The Model DHS-101 Wall-mount Handset Intercom has a built-in speaker amplifier and external audio
output with an optional headset jack.
Wall-Mount Hands-free Intercoms (Indoor/Outdoor)
The wall-mount hands-free intercoms include a built-in speaker amplifier and external audio output.
They are available with an optional gooseneck mic or a headset jack.
Models DHF-101 (NEC Div. 2) Single Button Wall-mount Hands-free Intercom includes a single
programmable push button for call-in only.
Models DHF-102 (NEC Div. 2) Wall-mount Hands-free Intercom with 16-Button Keypad includes
two programmable push buttons.
Flush-Mount Hands-free Intercoms
The flush-mount hands-free models include a
built-in speaker amplifier and external audio
output, and are available with an optional
gooseneck microphone.
Model DHF-103 Single Button Flush-Mount
Hands-free Intercom includes a single
programmable push button for call-in only.
Model DHF-104 Flush-Mount Hands-free
Intercom with 16-Button Keypad includes two
programmable push buttons.
Figure 2. Model DHS-101
Figure 3. Models DHF-101 and DHF-102
Figure 4. Models DHF-103 and DHF-104

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Description of Major Components
The Digital Intercom Stations are made up of a front panel assembly and a rear enclosure.
The following assemblies are mounted on the interior side of the front panel:
•69539-00X Audio/Interface PCB Assembly.
•69547-00X Intercom PCB Assembly
Refer to Figure 5 below. The front panel contains the user interface components (microphone, speaker,
status LED, keypad, and handset) in addition to the 69539-00x Audio/Interface PCBA that provides all
terminations except earth ground. This PCBA also contains controls for volume, gain, and switch
configuration.
The 69547-00x Intercom PCBA connects to the Audio Interface PCBA from below to transmit/receive
audio, data, and control information to and from the central control cabinet. The rear enclosure protects
the electronics from the harsh environment, and also contains the termination for earth ground.
Figure 5. Front Panel Assembly with Intercom and Audio Interface PCBAs

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Installation
General Information
WARNING This equipment is suitable for use in Class I, Division 2, Groups A, B, C and
D, Class II Division 2, Groups F, and G, Class III OR non-hazardous locations only. Combinations
of equipment in your system are subject to investigation by the local Authority Having Jurisdiction
at the time of installation.
WARNING EXPLOSION HAZARD – Do not disconnect equipment unless power has
been removed or the area is known to be non-hazardous.
WARNING EXPLOSION HAZARD - Substitution of components may impair suitability
for Class I, Division 2.
Averttissement – Risque d’explosion - la substitition de composants peut rendre ce matériel
inacceptable pour les em-placements de Classe 1, Division 2.
Averttissement – Risque d’explosion – avant de déconnector l’equipment, couper le courant ou
s’assurer que l’emplacement est désigné non dandereux.
Install equipment without modification and according to all applicable local and national electrical codes.
USA and Canada Consult the National Electrical Code (NFPA 70), Canadian Standards Association
(CSA 22.1), and local codes for specific requirements regarding your installation. Class 2 circuit wiring
must be performed in accordance with NEC 725.55.
Station Placement
This station contains a high gain amplifier, which enables operation in high noise environments. To
prevent feedback problems in the system, the ambient noise levels, volume settings, and station placement
must be taken into consideration. Unpleasant feedback problems can be reduced by taking the following
measures:
•Pointing the speaker away from nearby Intercom Stations
•Placing the speakers in separate rooms from Intercom Stations
•Reducing volume levels

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Mounting
Models DHS-101, DHF-101, and DHF-102
The mounting and wiring instructions for the model
listed above are as follows:
1. Remove the four tamper-resistant screws from the
front of the intercom station, and separate the
front panel from the rear enclosure. Place the
front panel and screws in a safe location.
2. Secure the rear enclosure to the mounting surface
using the four 0.28-inch (7.11-mm) mounting
holes provided along with four ¼-inch (M6)
diameter bolts of the appropriate length for the
mounting surface.
3. Install the field wiring according to the
instructions provided on page 9.
4. Using the appropriate section of this manual,
make the necessary set-up changes:
•Adjust the audio levels as described in the
“Audio Level Adjustments” section beginning
on page 12.
•Make any necessary hardware configuration
changes as described in the “Switch
Configuration” section on page 15.
•Refer to page 16 for the initial programming
options.
5. Complete the installation by reattaching the front
panel assembly to the rear enclosure using the
four tamper-resistant screws. Use a torque setting
of 30 in-lbs. or 35 cm-kg.
6. Verify that the unit is operating as described in the
“Operation” section beginning on page 18.
NOTE:When using the GAI-Tronics Model 231 Pole
Mounting Kit, follow the mounting instructions
provided in the kit.
Figure 6. Model DHF-102
Figure 7. Model DHS-101

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Models DHF-103 and DHF-104
1. For flush-mount installations, mount the included back box in the desired location using appropriate
hardware. Refer to Figure 10 on page 8 for cutout dimensions.
2. Install the wiring and cable fitting through either the top or bottom cutout. Bottom entry is
recommended.
Figure 8. Model DHF-103
Figure 9. Model DHF-104
3. When the cable has been pulled into the enclosure, complete the field wiring according to the Field
Wire Installation instructions provided on page 9.
4. Using the appropriate section of this manual, make the necessary set-up changes:
•Adjust the audio levels as described in the “Audio Level Adjustments” section beginning on page
12.
•Make any necessary hardware configuration changes as described in the “Switch Configuration”
section on page 15.
•Refer to page 16 for the initial programming options.
5. Complete the installation by attaching the front panel assembly to the rear enclosure using the six
tamper-resistant screws.
6. Verify that the unit is operating as described in the “Operation” section beginning on page 18.
For mounting Models DHF-103 and DHF-104 in GAI-Tronics Model 236 Surface-Mount Enclosure and
Model 234/234WM Stanchions, please refer to the installation manual included with the enclosure or
stanchion. The installation manuals are also available at www.gai-tronics.com.

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Figure 10. Model DHF-103 and DHF-104 Mounting Details
Conduit Installation
Metallic Conduit Installation Details
To prevent moisture from entering the enclosure, we strongly recommend the following:
•Conduit should enter the enclosure from the bottom.
•Silicone sealant or equivalent should be applied around and inside all conduit entries.

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Field Wire Installation
1. Unfasten the front panel assembly.
2. Pull the field wiring through the conduit entrance in the rear of the enclosure. The use of ferrules is
recommended on the ends of stranded wire to create a secure, reliable connection.
3. Install all connections as indicated below. Refer to Figure 11 for wiring details. Refer to Table 1 and
Table 2 on page 11 for the recommended conductor sizes and lengths.
NOTE: USA and Canada Consult the National Electrical Code (NFPA 70), Canadian Standards
Association (CSA 22.1), and local codes for the specific requirements regarding your installation. Install
all equipment without modification and according to the local and national codes. Class 2 circuit wiring
must be performed in accordance with NEC 725.55.
Power
Central Power
This assembly is capable of operating without a 24 V ac or dc power source. When a 24 V dc power
source is not connected to P46, this station is powered by the central cabinet via the system cable. This
will limit the functionality of this station and limit the distance from the central cabinet. The following
functions will not be operational when central power is used:
•External speaker amplifier
•Audio line driver
•Headset operation
•Configurable outputs
The enclosure must be connected to earth ground. Install a ring lug on the ground conductor prior to
connection to the enclosure. Secure the ring lug to the #6 ground screw on the rear enclosure.
Local Power
This assembly requires a 24 V ac or dc power source for the station to be fully functional. The following
functions are enabled when central power is used:
•External speaker amplifier
•Audio line driver
•Headset operation
•Configurable outputs
A separate power feed is recommended for each intercom station. A pluggable terminal block P46 is
provided for connection of power to the station. Power leads can be connected to either L1 or L2 in ac or
dc systems. Also, the enclosure must be connected to earth ground. Install a ring lug on the ground
conductor prior to connection to the enclosure. Secure the ring lug to the #6 ground screw on the rear
enclosure.
Installation of this equipment shall be carried out by suitably-trained personnel in
accordance with the applicable code of practice concerning equipment and protective
systems intended for use in potentially Explosive Atmospheres.

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Figure 11. Typical Station Installation

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System
This station requires a two-conductor twisted pair cable run between the station and the central cabinet.
Cable capacitance is critical to the station performance on long distances. Refer to Table 1 for the
maximum system cable lengths and Table 2 for the recommended cable sizes. Terminate the system
cable on terminal block P44 pins 5 and 6 (Data A and B).
Table 1.
Maximum System Cable Lengths
Cable Capacitance 22 AWG (0.325 mm2) 20 AWG (0.519 mm2)
30.5 nf/1000 feet (304.8 m) 6562 feet (2000 m) 6562 feet (2000 m)
13.7 nf/1000 feet (304.8 m) 6562 feet (2000 m)/
9843 feet (3000 m) with local 24 V power
9843 feet (3000 m)
Table 2.
Recommended Cable Sizes
Cable Use Size
System Two-conductor twisted pair, No. 22 AWG (0.325 mm2) is typical
Power Three-conductor, No. 18 AWG (0.823 mm2) is typical
Footswitch, inputs, audio line Two-conductor, No. 22 AWG (0.325 mm2) is typical
Output contacts Two-conductor twisted pair, No. 18 AWG (0.823 mm2) is typical
Speaker cable Two-conductor twisted pair, No. 18 AWG (0.823 mm2) is typical
Audio
External Speaker
If this station is located in a high noise area, an external speaker or horn can be used to broadcast audio
received by this station. Terminate the external speaker or horn on terminal block TB14.
Audio Output to Remote Amps
Audio received by this station can be transmitted to remote amplifier stations for broadcast into high noise
areas. Terminal block TB1 has been provided to connect audio to the remote amplifiers.

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Audio Level Adjustments
NOTE:The following adjustments should only be performed after the Intercom Level Setting RM has
been set (factory setting) and the Master Volume Adjustment (keypad control) has been set to mid-range.
Refer to Figure 12 for locations.
Figure 12. Setting Locations

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Handset Receiver Volume
Potentiometer R73 has been provided for individual adjustment of the handset receiver volume. To
increase the handset volume, rotate R73 (HNDST VOL) clockwise. To decrease the volume, rotate R73
counterclockwise.
Unit Speaker Level
Potentiometer R75 has been provided for individual adjustment of the unit speaker volume. To increase
the speaker volume, rotate R75 (UNIT SPKR VOL) clockwise. To decrease the volume, rotate R75
counterclockwise.
Headset Receiver Level
Potentiometer R79 has been provided for individual adjustment of the headset receiver volume. To
increase the headset volume, rotate R79 (HDST VOL) clockwise. To decrease the volume, rotate R79
counterclockwise.
AGC (Automatic Gain Control)
This station is equipped with an automatic gain control circuit in order to minimize level changes on the
audio line and the external speaker. The master volume control (keypad) affects the audio level received
by this station. The master volume control enables the handset, headset, and unit speaker levels to be
controlled via the keypad, but it also affects the audio level supplied to the audio line and external
speaker; therefore, an automatic gain control circuit has been added. This adjustment has been factory set
and should only be performed by certified Field Service Personnel.
AGC Bypass
If necessary, the AGC circuitry can be bypassed. To bypass the AGC, move the jumpers on P8 and P9
from IN to the OUT position.
NOTE:The following adjustments should only be performed after the Intercom Level Setting RM has
been set (factory setting), the Master Volume Adjustment (keypad control) has been set to mid-range, and
the AGC has been set.

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External Speaker Volume Control
A speaker amplifier has been provided to enable this station to be used in high noise areas. Potentiometer
R43 has been provided for volume control. To increase the volume to the speaker, rotate R43 clockwise.
To decrease the volume to the speaker, rotate R43 counterclockwise.
NOTE:This station will broadcast received audio over the external speaker or horn only when the station
is powered by 24 V, the station’s handset is on-hook or the (optional) headset is not connected. Received
audio is not broadcast over the external speaker if 24 V power is not supplied, the station’s handset is off-
hook or a headset is installed.
External Speaker Gain
The external speaker amplifier contains four user adjustable gain settings:
•0 dB
•6 dB
•12 dB
•24 dB
These settings enable the user to control the maximum gain of the speaker amplifier. The 24-dB setting
provides the maximum gain from the amplifier and the 0-dB setting enables the minimum gain.
Configuration jumpers P36 (GAIN0) and P37 (GAIN1) have been supplied to set the gain. Refer to Table
3 for the desired gain settings.
Table 3. Gain Setting
Setting
Jumper
P37 Jumper P36
0 dB 0 0
6 dB 0 1
12 dB 1 0
24 dB 1 1
Audio Output to Remote Amps
A 600-ohm audio output driver has been provided to enable audio received by this station to be broadcast
over the speakers connected to Model DSA-101 Remote Speaker Amplifiers. This enables additional
areas close to this station to receive audio sent to this station.
NOTE:This station will broadcast received audio to the remote amplifiers only when the station is
powered by 24 V, the handset is on-hook or the headset is not connected. Received audio is not broadcast
to the remote amplifiers when 24 V power is not supplied, the station’s handset is off-hook or the optional
headset is installed.
Audio Output Level
The nominal level on this output is set to 0.775 Vrms. To increase the audio output level, rotate R47
(Audio Line Level) clockwise. To decrease the audio output level, rotate R47 counterclockwise.

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Switch Configuration
A set of configuration jumpers has been provided for panel switches SW1 and SW2. These configuration
jumpers enable switches SW1 or SW2 to be set as a button on the keypad matrix or one of the
programmable inputs IN1 or IN2.
SW1
Configuration jumpers labeled R1-R4 and C1-C5 (on P14 and P29) enable switch SW1 to be set as a
single button of the keypad matrix. For example: to configure switch SW1 as keypad button 5, install the
jumpers on row R2 and column C2. Two configuration jumpers labeled C_GND and IN1 (on P18 and
P23) enable switch SW1 to be set as programmable input IN1. To set switch SW1 as input IN1, install
the jumpers on C_GND and IN1.
NOTE:The function of input IN1 must be programmed in the central cabinet. Refer to the “Inputs”
section of the central cabinet instruction manual for instructions on how to program this input. Also, the
footswitch input shares the programmable input IN1 with SW1. Either the footswitch can use
programmable input IN1 or SW1, but not both.
SW2
Configuration jumpers labeled R1-R4 and C1-C5 (on P13 and P1) enable switch SW2 to be set as a single
button of the keypad matrix. For example: to configure switch SW2 as keypad button 9, install the
jumpers on row R3 and column C3. Two configuration jumpers labeled C_GND and IN2 (on P7 and
P12) enable switch SW2 to be set as programmable input IN2. To set switch SW2 as input IN2, install
the jumpers on C_GND and IN2.
NOTE:The function of input IN2 must be programmed in the central cabinet. Refer to the “Inputs”
section of the central cabinet instructional manual for instructions on how to program this input.

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Inputs
Two programmable inputs (IN1 and IN2) have been provided on this assembly. Inputs IN1 and IN2 can
be programmed to perform a variety of functions such as: initiating dialing, changing button functions,
initiating alarms, etc. Termination of the input contacts have been provided on terminal block P44 pins 1-
4 (IN1 +/-, IN2 +/-).
NOTE:Input IN1 is shared with the footswitch and SW1 inputs; therefore, this input can only be used
when the footswitch and SW1 are not in use. Input IN2 is shared with the SW2 input, therefore, this input
can only be used when SW2 is not in use. Please refer to the “Inputs” section of the central cabinet
instruction manual for instructions on how to program these inputs.
Footswitch
A programmable footswitch input has been provided on this assembly. Termination for the input contact
has been provided on terminal block P45 pins 7-8 (footswitch +/−). The footswitch can be programmed
to perform a variety of functions such as: talk/listen control (T button function), direct dialing, etc. The
footswitch input shares the programmable input IN1 with SW1. Either the footswitch can use
programmable input IN1 or SW1, but not both.
NOTE:The function of input IN1 must be programmed in the central cabinet. Refer to the “Inputs”
section of the central cabinet instruction manual for instructions on how to program this input.
Outputs
Two programmable opto-coupler outputs (OUT1 and OUT2) have been provided on this assembly.
Termination for the output have been provided on terminal block P45 pins 2-3 [OUT2 (−), (+)] and pins
4–5 and [OUT1 (−), (+)]. Outputs OUT1 and OUT2 can be programmed to perform a variety of
functions such as: conversation active, loudspeaker active, PA announcement, pre-defined conference
active, all call or group call received, door opener, etc. Please refer to the “Outputs” section of the central
cabinet instruction manual for instructions on how to program these outputs.
Refer to Figure 13 for a typical system interconnection.
NOTE:The outputs can only be used when the station is powered by 24 V.

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Figure 13. Typical system interconnection diagram

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Operation
Hands-free Operation
1. Press a call button located on the front panel. Optional: Use the 16-button keypad to dial the
extension of the desired station. The front panel LED illuminates to indicate a call is in progress.
2. Speak into the panel microphone to transmit audio. If necessary, talk/listen control can be controlled
using the Tbutton on the keypad or by using the station’s footswitch input.
3. Audio is broadcast over the station’s speaker.
NOTE:Audio will not be broadcast over the external speaker or remote amplifiers if 24 V power
is not supplied.
4. Terminate the call by depressing the Xbutton.
Handset Operation
1. Using the 16-button keypad, dial the extension of the desired station or press a call button located on
the front panel. The front panel LED illuminates to indicate a call is in progress.
2. Speak into the handset microphone. If necessary, talk/listen can be controlled using the Tbutton on
the keypad or by using the station’s footswitch input.
3. Audio will be received over the handset receiver. NOTE:Audio will not be broadcast over the
handset, external speaker, or Remote Amplifiers whenever the optional headset is installed or if 24 V
power is not supplied.
4. Terminate the call by depressing the Xbutton or placing the handset on hook.
5. If an incoming call (or page, alarm, or music) is received while the handset is on hook, the audio is
broadcast over the station’s speaker. The external speaker and the remote amplifiers will also
broadcast the audio if 24 V power is supplied to the unit. If the handset is off hook, then audio is
broadcast over the handset receiver.