GAI-Tronics TP4512SYN-6 Operating manual

Pub.: 42004-325A
GAI-Tronics Corporation P.O. Box 1060, Reading, PA 19607-1060 USA
610-777-1374 n800-492-1212 nFax: 610-775-6540
GAI-TRONICS CORPORATION
6-Channel Radio
User and Installation Manual
TABLE OF CONTENTS
Confidentiality Notice................................................................................................................1
General Information..................................................................................................................1
Scope of Manual.................................................................................................................................1
Features and Functions......................................................................................................................1
Description.................................................................................................................................1
Connectors .........................................................................................................................................2
Power Connector ........................................................................................................................................... 3
Speaker Connector......................................................................................................................................... 3
Microphone Connector .................................................................................................................................. 3
Antenna Connector........................................................................................................................................ 3
Channel Selector Switch....................................................................................................................3
Radio Transceiver Module ................................................................................................................3
Interface PCBA..................................................................................................................................4
Jumper Table................................................................................................................................................. 4
Pot 1.............................................................................................................................................................. 4
Wide Range (110/220 V AC/270 V DC) Power Supply PCBA..........................................................4
Pot 2.............................................................................................................................................................. 4
Surge Filter PCBA.............................................................................................................................4
Optional Standby/Emergency Battery ..............................................................................................4
Installation.................................................................................................................................6
Mounting............................................................................................................................................6
FCC Interference Warning................................................................................................................6
Safe Handling of CMOS Integrated Circuit Devices........................................................................6
Equipment Required..........................................................................................................................7
Test Equipment.............................................................................................................................................. 7
Documentation .............................................................................................................................................. 7
Cable Installation Safety Considerations..........................................................................................8
Surge Protection.................................................................................................................................8
Antenna Connection ..........................................................................................................................9
Power Connections.............................................................................................................................9
Battery Connections.........................................................................................................................10
Microphone Connection...................................................................................................................10

Table of Contents
Pub.: 42004-325A
GAI-TRONICS 6-CHANNEL RADIO
ii
Speaker Connection.........................................................................................................................10
Programming...................................................................................................................................10
Power Supply Adjustment...............................................................................................................10
Speaker Output Adjustment............................................................................................................11
Operation.................................................................................................................................11
Initiating Calls............................................................................................................................................. 11
Receiving Calls............................................................................................................................................ 11
Controls....................................................................................................................................................... 11
Maintenance ............................................................................................................................12
Ordering Replacement Parts...........................................................................................................12
Service and Repair...........................................................................................................................12
Troubleshooting the 6-Channel Radio ............................................................................................12
Fuse Replacement............................................................................................................................13
Battery Replacement........................................................................................................................13
Performance Specifications .....................................................................................................13
Accessories .......................................................................................................................................14
Field Replacement Items..................................................................................................................14

Pub.: 42004-325A
GAI-Tronics Corporation P.O. Box 1060, Reading, PA 19607-1060 USA
610-777-1374 n800-492-1212 nFax: 610-775-6540
6-Channel Radio
User and Installation
Confidentiality Notice
This manual is provided solely as an operational, installation, and maintenance guide and contains
sensitive business and technical information which 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 models of the
GAI-Tronics 6-Channel Radio:
•TP4512SYN-6 110/220 V ac, 270 V dc
Frequencies programmed by customer
•TP4514SYN-6 120 V ac
Frequencies programmed by customer
•TP4512SYN-6FR 110/220 V ac, 270 V dc
Frequencies programmed at factory
•TP4514SYN-6FR 120 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
•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
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 2-
watt RF output and CTCSS for private communications is selectable.
Figure 1. GAI-Tronics 6-Channel Radio

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The radio measures 11.25 W x 14.125 H x 3.00 D. The housing is also a mounting bracket, and includes
and 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 the outline drawings 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.
Connectors
Refer to the figure below for the location of the connectors and channel selector switch.
Figure 2. Outline of 6-Channel Radio
Figure 3. Top View of the 6-Channel Radio

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Power Connector
Refer to the Figure 3for the locations of the connectors. The pinout for the power connector is as
follows:
Pin No. Function
ASpare
BLine hot (positive)
CLine neutral (negative)
Speaker Connector
The speaker connector pinout is as follows:
Pin No. Function
ACommon
B8-ohm speaker
C16-ohm speaker
Microphone Connector
The microphone pinout is as follows:
Pin No. Function
AMic high
BPTT (Transmit key)
CMic Lo
D15 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 provides the capability to easily select among the six
labeled channels. In addition, a lighted LED provides indication of the state of the radio.
Radio Transceiver Module
The radio transceiver module is 450 MHz and the six channel frequencies may be factory-programmed to
the customer’s specifications. The frequencies can be programmed in steps of 12.5 kHz. The radio
transceiver can also be programmed for CTCSS.
Note: 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.

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Interface PCBA
The Interface 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. It contains three jumper settings, which can be configured in accordance with the table
below.
Jumper Table
Jumper
Name Function Position Default (as shipped)
JU1 Receive Audio Level Select Out = High level
In = Low level attenuated 15 dB Out
JU2 Speaker Power Amp Enable 1-2 = Enabled by Carrier Detect
2-3 = Always enabled 1-2
JU3 Microphone Bias In = Supply bias power to Mic
Out = No bias In
Pot 1
Pot 1 is used to adjust the speaker level. Refer to Figure 4on page 5for the location of the pot. Refer to
the Installation section for instructions for speaker output adjustment.
Wide Range (110/220 V AC/270 V DC) Power Supply PCBA
This switch-mode power supply features high-efficiency operation over an 85 to 300 V ac or dc input
range. The output is adjustable to provide proper float charging voltage to the optional standby battery.
Pot 2
The power supply PCBA contains a pot adjustment, Pot 2. It is used to adjust the charging current into
the optional standby/emergency battery. Refer to Figure 4on page 5for the location of the pot. Refer to
Installation section for instructions for the charging current adjustment.
Surge Filter PCBA
This module provides additional power input filtering for noisy industrial 270 V dc power. It is standard
only on the TP4512SYN-6 and the TP4512SYN-6FR.
Optional Standby/Emergency Battery
Each radio model is designed to operate with a rechargable battery.
When installed, the standby/emergency battery supplies power for up to 15 minutes during maximum
power drain, and longer at the average power drain. The GAI-Tronics 40201-004 battery is sold
separately.

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For locations of internal components, refer to the diagram shown below:
Figure 4. Internal Components of the 6-Channel Radio

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Installation
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.
Safe Handling of CMOS Integrated Circuit Devices
Many of the integrated circuit devices used in communications equipment are of the Complementary
Metal Oxide Semiconductor (CMOS) type. Because of their high open circuit impedance, CMOS
integrated circuits are vulnerable to damage from static charges. Care must be taken handling, shipping,
and servicing them and the assemblies in which they are used.
Even though protection devices are provided in CMOS integrated circuit inputs, the protection is effective
only against overvoltage in the hundreds of volts range such as is encountered in an operating system. In
a system, circuit elements distribute static charges and load the CMOS circuits, decreasing the chance of
damage. However, CMOS circuits can be damaged by improper handling of the modules, even in a
system.
Figure 5. Sample Installation Diagram

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To avoid damage to circuits, observe the following handling, shipping, and servicing precautions:
1. Prior to and while servicing a circuit module, particularly after moving within the service area,
momentarily touch both hands to a bare metal, earth-grounded surface. This will discharge any static
charge which may have accumulated on the person doing the servicing.
Note: Wearing a conductive wrist strap will minimize static build-up during servicing.
2. Whenever possible, avoid touching any electrically conductive parts of the circuit module with your
hands.
3. Power down the unit before installing or removing the circuit module.
4. When servicing a circuit module, avoid carpeted areas, dry environments, and certain types of
clothing (silk, nylon, etc.) because they contribute to static build-up. Similarly, disconnect the test
probe prior to removing the ground lead.
5. All electrically powered test equipment should be grounded. Apply the ground lead from the test
equipment to the circuit module before connecting the test probe.
6. If a circuit module is removed from the system, it is desirable to lay it on a conductive surface (such
as a sheet of aluminum foil) which is connected to ground through 100K of resistance.
7. When soldering, be sure the soldering iron is grounded with a grounded tip.
8. Prior to connecting jumpers, replacing circuit components, or touching CMOS pins (if this becomes
necessary in the replacement of an integrated circuit device), be sure to discharge any static build-up
as described in procedure 1. Since voltage differences can exist across the human body, it is
recommended that only one hand be used if it is necessary to touch pins on the CMOS device and
associated board wiring.
9. When replacing a CMOS integrated circuit device, leave the device in its conductive rail container or
conductive foam until it is to be inserted into the printed circuit module.
10. All low impedance test equipment (such as pulse generators, etc.) should be connected to CMOS
device inputs after power is applied to the CMOS circuitry. Similarly, such low impedance
equipment should be disconnected before power is turned off.
11. Replacement modules shipped separately from the factory will be packaged in a conductive material.
Any modules being transported from one area to another should be wrapped in a similar material
(aluminum foil may be used). Never use non-conductive material for packaging these modules.
Equipment Required
Test Equipment
•RF service monitor
•AC voltmeter with dB ranges for measuring audio levels
•#1 Phillips screwdriver
•1/8-inch flat blade screwdriver
Documentation
•these installation instructions
•the manual for the radio transceiver module, Pub. DTX-MRM

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Cable Installation Safety Considerations
Interconnecting, communications, and Class 2 dc power cables should be separated from electrical light
or other Class I circuits by at least 2 inches. The exception is where Class I wiring or power circuits are
run in a raceway, or are metal-sheathed or metal-clad, or are permanently separated from the conductors
of the other circuitry by a continuous and firmly fixed nonconductor such as porcelain tubes or flexible
tubing in addition to the insulation on the wire. Communications cables and in-building wiring should be
listed and marked for the purpose according to NEC Article 800.
Surge Protection
The Model TP4514SYN-6 6-Channel Radio (120 V ac) incorporates standard agency-approved surge
protection. The power line fuse on the power supply module must be replaced with the same type fuse to
maintain agency approval and safety protection.
Additional surge protection is available on the TP4512SYN-6 module with additional safety fusing.
These fuses must also be replaced with the same type to maintain agency approval and safety protection.
See the Field Replacement Items section.
Figure 6. TP4512SYN-6 Connection Diagram