GAI-Tronics 4512-001 Operating manual

Pub. 42004-387G
GAI - TRONI CS
®
AHUBBELL COMPANY
Model 4512-001, 4512-001FR, 4514-001
and 4514-001FR 6-Channel Radios
User and Installation Manual
TABLE OF CONTENTS
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
Scope of Manual......................................................................................................................................1
Features and Functions ..........................................................................................................................1
Description ......................................................................................................................................2
Connectors...............................................................................................................................................3
Power Connector...................................................................................................................................................3
Speaker Connector ................................................................................................................................................4
Microphone Connector .........................................................................................................................................4
Antenna Connector ...............................................................................................................................................4
Channel Selector Switch.........................................................................................................................4
Radio Transceiver Module.....................................................................................................................5
Interface PCBA.......................................................................................................................................5
Pot R7 ...................................................................................................................................................................5
Wide Range (110/220 V AC/270 V DC) Power Supply PCBA............................................................6
Pot 2......................................................................................................................................................................6
Surge Filter PCBA..................................................................................................................................6
Optional Standby/Emergency Battery..................................................................................................7
Installation ......................................................................................................................................8
Mounting..................................................................................................................................................8
FCC Interference Warning....................................................................................................................8
Safe Handling of CMOS Integrated Circuit Devices...........................................................................9
Equipment Required ............................................................................................................................10
Test Equipment ...................................................................................................................................................10
Cable Installation Safety Considerations............................................................................................10
Surge Protection....................................................................................................................................10
Antenna Connection .............................................................................................................................11
Power Connections................................................................................................................................13
Models 4514-001 and 4514-001FR ....................................................................................................................13
Models 4512-001 and 4512-001FR ....................................................................................................................13

TABLE OF CONTENTS PUB.42004-387G
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
Battery Connections..............................................................................................................................13
Microphone Connection.......................................................................................................................13
Speaker Connection..............................................................................................................................13
Programming.........................................................................................................................................14
Power Supply Adjustment ...................................................................................................................14
Speaker Output Adjustment................................................................................................................14
Operation.......................................................................................................................................15
Initiating Calls.......................................................................................................................................15
Receiving Calls......................................................................................................................................15
Controls..................................................................................................................................................15
Maintenance..................................................................................................................................16
Ordering Replacement Parts...............................................................................................................16
Service and Repair................................................................................................................................16
Troubleshooting....................................................................................................................................16
Fuse Replacement .................................................................................................................................17
Battery Replacement ............................................................................................................................17
Performance Specifications..........................................................................................................18
Accessories.............................................................................................................................................19
Field Replacement Items......................................................................................................................19

Pub. 42004-387G
GAI - TRONI CS
®
AHUBBELL COMPANY
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
Model 4512-001, 4512-001FR, 4514-001
and 4514-001FR 6-Channel Radios
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
Scope of Manual
This manual provides descriptive data and service
information for the following GAI-Tronics 6-Channel
Radios:
Model 4512-001 - 270 V dc
Frequencies programmed by customer
Model 4514-001 - 110/220 V ac
Frequencies programmed by customer
Model 4512-001FR - 270 V dc
Frequencies programmed at the factory
Model 4514-001FR - 110/220 V ac
Frequencies programmed at the factory
Features and Functions
Easy installation and maintenance
Portability with integral handle
Programmable CTCSS and DPL provided as standard
Heavy-duty industrial power supply and power line filter eliminates the need for external filtering
Selection of power sources, speakers, and antennas provides system configuration flexibility
Selectable 2-watt or 5-watt RF transmit power
High power receive audio and noise-canceling microphone for noisy environments
Standby/emergency battery option (integral to the chassis) providing continuous operation during
temporary power interruptions
Figure 1. GAI-Tronics 6-Channel Radio

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Description
The GAI-Tronics 6-Channel Radio is a stationary-mounted UHF transceiver suited for industrial
complexes, especially in cranes or other mobile equipment. It has a heavy-duty housing and includes a
choice of power sources (270 V dc or 110/220 V ac), microphones, speakers, and antennas. It has a
choice of 2-watt or 5-watt RF output, and CTCSS for private communications is selectable.
The radio measures 11.25 W 14.14 H 3.00 D inches. The housing is also a mounting bracket, and
includes an integral handle. The mounting bolts double as support feet when the unit is placed
horizontally on a flat surface such as on a desktop.
The channel selector switch and the power, speaker, and microphone connectors are located on the top of
the unit. The antenna connection is on the underside of the unit and remains easily accessible when the
unit is mounted. Refer to Figure 2 and Figure 3 below.
The standard power supply is nominal 120 V ac. There are 110/220 V ac or 270 V dc power supply
options available. Added filtering is standard for the 270 V dc option. The Radio Transceiver Module is
easily replaceable in the field, but must be reprogrammed by a qualified technician.
Figure 2. Outline of 6-Channel Radio

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Connectors
Refer to Figure 3 below for the location of the connectors and channel selector switch.
Power Connector
Refer to Figure 3 for the locations of the connectors. The pinout for the power connector is as follows:
Table 1. Model 4512-001 Connector Pinout Table 2. Model 4514-001 Connector Pinout
Pin
No. Function Pin No. Function
A Spare A Line hot
B 270 V dc pos B Line neutral
C 270 V dc neg C Spare
D Spare
Figure 3. Top View of the 6-Channel Radio

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Speaker Connector
The speaker connector pinout is as follows:
Table 3. Speaker Connector Pinout
Pin No. Function
A Common
B Carrier detect output
C 8-ohm speaker
WARNING Do not ground any speaker line as damage may occur to the speaker and/or
radio. Jumper P6 must be in position 2-3 to activate the carrier detect output. Refer to Table 6 on
page 5 and Figure 7 on page 12.
Microphone Connector
The microphone pinout is as follows:
Table 4. Microphone Connector Pinout
Pin No. Function
A Mic high
B PTT (Transmit key)
C Mic Lo
D 15 V dc power
Antenna Connector
The antenna connector is a coax cable connector.
Channel Selector Switch
The channel selector switch on the top of the unit allows easy selection among the six labeled channels.
In addition, a lighted LED provides indication of the state of the radio.

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Radio Transceiver Module
The Radio Transceiver Module’s range is 450–470 MHz, and the six channel frequencies can be
programmed in steps of 12.5 kHz at the factory to the customer’s specifications. The Radio Transceiver
can also be programmed for CTCSS or DPL.
NOTES:
1. When the Radio Transceiver Module is programmed for CTCSS or DPL it can only communicate with
other radios that have the same CTCSS or DPL programming.
2. Certain transmit and receive frequencies within the radio’s range are unavailable. Refer to Table 5
below for these frequencies. Do not attempt to program the radio for these frequencies.
Table 5. UHF (450–470 MHz)
Receive
(MHz) Transmit (MHz)
460.80000 460.78750
461.23750 460.79375
461.24375 460.80625
461.25625 460.81250
461.26250
Interface PCBA
The Interface PCBA contains four jumper settings, which can be configured in accordance with Table 6
below.
Table 6. Jumper Table
Jumper
Name Function Position Default (as shipped)
P1 Receive Audio Level Select 1-2 = High level
2-3 = Low level attenuated 14 dB
1–2
P4 Audio Amp Enable 1-2 = Enable
2-3 = Disable
1–2
P5 Dynamic Mic/Carbon Mic Enable 1-2 = Enable
2-3 = Disable
1–2
P6 Optional Carrier Detect Output 1-2 = Disable
2-3 = Enable*
1–2
P8 RF Output Power Selection 1-2 = Low Power (2-watt)
2-3 = High Power (5-watt)
1–2
Pot R7
R7 is used to adjust the speaker level. Refer to Figure 4 on page 7 for the location of the pot. Refer to the
“Installation” section for instructions for speaker output adjustment.

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Wide Range (110/220 V AC/270 V DC) Power Supply PCBA
This switch-mode power supply features high-efficiency operation over an 85–300 V ac or dc input range.
The output is adjustable to provide proper float charging voltage to the optional standby battery.
The Power Supply PCBA provided as standard equipment maintains regulation per a wide range of input
voltages, and in addition to the internal protection, it is further protected from transients on the external
power source by the optional Surge Filter PCBA. The power supply provides regulated 12.5 V dc to the
radio circuits.
Pot 2
The Power Supply PCBA contains a pot adjustment, Pot 2, which is used to adjust the charging current
into the optional standby/emergency battery. Refer to Figure 4 on page 7 for the location of the pot.
Refer to the “Installation” section for instructions for the charging current adjustment.
Surge Filter PCBA
The Surge Filter PCBA provides additional power input filtering for noisy industrial 270 V dc power. It
is standard on the Models 4512-001 and the 4512-001FR only.

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Optional Standby/Emergency Battery
The GAI-Tronics 6-Channel Radios are designed to operate with a rechargeable battery. When installed,
the standby/ emergency battery supplies power for up to 15 minutes of normal run time with RF set to
low power setting; and less time if RF power is set to high power. The GAI-Tronics 40201-004 Battery is
sold separately. Refer to Figure 4 below for the locations of the internal components.
Figure 4. Internal Components of the 6-Channel Radio

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Installation
Figure 5. Sample Installation Diagram
Mounting
The radio can be placed horizontally on a desk or mounted vertically on a wall. To wall mount the radio,
remove the four bolts/support feet from the back of the housing. Mark the position of the housing, and
reinstall the bolts through the housing to a base plate or other suitable support.
FCC Interference Warning
The FCC requires that manuals pertaining to Class A and Class B computing devices must contain
warnings about possible interference with local residential radio and TV reception. This warning reads as
follows:
NOTE:This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.