Hubbell GAI-TRONICS 400-005 User manual

Pub. 42004-561A
G A I - T R O N I C S ®
A H U B B E L L C O M P A N Y
400-005 and 400-006 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 ......................................................................................................................................2
Speaker Horn Assembly.........................................................................................................................3
Mounting..................................................................................................................................................3
Hardware Configuration........................................................................................................................3
Internal..................................................................................................................................................3
External.................................................................................................................................................3
Wiring ......................................................................................................................................................5
System Wiring ......................................................................................................................................5
Station Wiring....................................................................................................................................... 5
System Line Balance.............................................................................................................................6
Field Connections .................................................................................................................................8
Cover Installation..................................................................................................................................10
Operation.......................................................................................................................................10
Common Line System...........................................................................................................................11
Master/Slave System.............................................................................................................................11
Maintenance..................................................................................................................................12
F1/F2 Fuses............................................................................................................................................12
Troubleshooting ....................................................................................................................................12
Replacement Parts and Accessories ....................................................................................................13
Specifications ................................................................................................................................13
AC Power...............................................................................................................................................13
DC Power...............................................................................................................................................13
Amplifier PCBA....................................................................................................................................13
Speaker (Model 400-005 Only) ............................................................................................................13
Mechanical.............................................................................................................................................14
Environmental.......................................................................................................................................14
Approvals.......................................................................................................................................14
Appendix A—InterfacingaModel400-005RigComStationtoEZPageStations......................................14

Pub. 42004-561A
GAI-TRONICS®
A HUBBELL COMPANY
400-005 and 400-006 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 installation, operation, and maintenance manual 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. Use this information only in
connection with the operation of your GAI-Tronics product or system. Do not disclose this manual in any
form, in whole or in part, directly or indirectly, to any third party.
General Information
The GAI-Tronics Model 400-005 and 400-006 RigCom
Stations are for use in a common-talk or a master/slave
communication system. The stations’ approvals are for the
following hazardous locations when the installation is in
accordance with GAI-Tronics Pub. 42004-562, RigCom
UL Control Drawing No. 75614:
• Model 400-005: Class I, Div. 1, Groups C and D
• Model 400-006: Class I, Div. 1, Groups B, C, and D
The system provides push-to-talk, release-to-listen
operation. Each station has a local on/off/volume control
switch to activate and control the volume level at each
station.
The Model 400-005 includes an attached speaker and
driver unit. The Model 400-006 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 for remote operation
from the station. The auxiliary microphone replaces the speaker as the microphone and the auxiliary
footswitch provides the same functionality as the push-to-talk switch.
NOTE: Using the auxiliary microphone and/or footswitch reduces the hazardous location approval to
Class I, Div. 1, Group D.
The Model 400 Series RigCom stations operate with the EZ Page Series of GAI-Tronics equipment.
Figure 1. Model 400-005 RigCom Station

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Important Safety Instructions
•Read, follow, and retain instructions—Read and follow all safety and operating instructions before
installing or operating this unit. Retain instructions for future reference.
•Heed warnings—Adhere to all warnings on the unit and in the operating instructions.
•Attachments—Do not use attachments not recommended by the product manufacturer 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.
Installation
Only trained, qualified, and competent personnel shall install these enclosures. Installation must comply
with state and national regulations, as well as safety practices for this type of equipment.
Install the Models 400-005 and 400-006 RigCom stations in accordance with GAI-Tronics Pub.42004-
562, RigCom UL Control Drawing No. 75614.

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CAUTION
—Do not install this equipment in hazardous areas other than those indicated 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
—Ensure proper grounding to protective earthing.
Do not disconnect equipment while energized.
Speaker Horn Assembly (Model 400-005 Only)
Assemble the Model 400-005 Speaker Horn Assembly 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.
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.
Securely fasten the enclosure with 7/16-inch diameter steel mounting bolts located on all four mounting
feet (see Figure 2 for mounting dimensions).
Recommended: Use stainless steel hardware in corrosive environments.
Hardware Configuration
Internal
The enclosure contains a single PCBA, mounted in the rear of the enclosure. Make all customer
connections to this PCBA. The front cover controls plug into the PCBA with a single wiring harness.
External
The enclosure contains a push-to-call button, an on-off/volume control switch, and applicable approval
labeling. The enclosure has ten cover mounting bolts, located around the perimeter of the enclosure.

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Figure 2. Model 400-005/400-006 Mounting Detail and Conduit Entries
NO USER SER VICE ABLE PART S INSI DE.
REFER SERV ICING TO QU ALIFIED PERSONNEL ONLY.
OFF- ON VOL UME
PUSH TO CALL
GAI-T RONICS C ORPORA TION
3030 KUTZTO WN RD., READI NG, PA 19605
SOUND REPRODU CING EQUIPMENT FOR USE IN
HAZARDOUS LOCATION S CLASS I, DIV. I, GROUPS C, D
WAR NIN G: EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS
TO R EDUCE TH E RISK OF I GNITION OF HAZARDOUS ATM OSPHERES,
CONDUIT SEALS MUST BE INSTALLED WITHIN 18 INCHES OF ENCLOSURE.
AMBIENT TEMPER ATURE: -20°C TO 60°C
No. 400-005 - RIGCOM INTEGRAL SPEAKER
DAT E C OD E:
13R2
WAR NIN G:
120VAC, 50 /60 Hz, 0. 4 AMP MAX. OR
KEEP COV ER TIGH T WHILE C IRCUITS ARE ALIVE.
CAUTION :
POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.
12VDC, 1.8 AMP MAX
CAUTION
RISK OF ELE CTRIC
SHOCK, DO NOT OPEN!
!
In USA: 1-800- 492-121 2 Outs ide USA : 1-610-7 77-1374
GAI-T RON ICS SER VICE C ENTERS: www.g ai-tronic s.com
Figure 3. Model 400-005 RigCom Station Outline

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Wiring
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; based on No. 18 AWG wire, equidistant station
spacing, and one station in talk mode at a time. For each station in talk mode, the signal level reduces by
half (see Figure 4 for systems with more than ten stations to determine the maximum line distance).
Figure 4. Number of Stations vs. Line Length
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 through the conduit or cable gland and into the left-side hole, as viewed
from the front of the station.
3. Feed the power wiring through the conduit or cable gland and into the right-side hole, as viewed from
the front of the station.
4. For ac power supply:
1. Install a #6 ring lug to the ground conductor
2. Connect the ring lug on the ground wire to the ground terminal, located at the lower right corner
of the RigCom station PCBA (see Figure 5).
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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Figure 5. RigCom Station PCBA
5. Attach the wires to the terminal blocks, on the PCBA, within the enclosure (see Figure 5 and the Field
Connections section for connection points and descriptions).
6. If using the 10438-002 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.
7. 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.
System Line Balance
Each system requires termination of the audio pair wires with a 1-kilohm, 1-watt resistor assembly,
included with each unit. Install the line balance resistor assembly in a (customer supplied) junction box.
NOTE: Use only one line-balance resistor assembly per system.
Install the resistor assembly in a (customer supplied) junction box that is close to the center of the system
when cable runs approximately 4000 feet (1219 m) or longer are used (see Figure 6 and Figure 7).

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NOTE: The junction box must be suitable for the applicable hazardous location where it is located.
Figure 6. System Cable (wiring less than 4000 feet long)
Figure 7. Master/Slave System (wiring greater than 4000 feet long)

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Field Connections
TB1—SpeakerTerminalBlock
Table 1. Speaker Output Connection at 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
TB2—ACPowerTerminal Block
Table 2. AC Power Connection at Terminal Block TB2
Name
Pin No.
Description
AC POWER H
1
external ac power supply positive terminal
no connection when using a dc power supply
2
no connection
AC POWER N
3
external ac power supply neutral terminal
no connection when using a dc power supply
AC POWER
GND
ac ground conductor—Connect to the ground stud, located at the
lower right corner of the station’s PCBA.
TB3—DC PowerTerminal Block
Table 3. DC Power Connection at 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 not using an external dc power supply

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TB4—AudioandLow Voltage ControlTerminal Block
Table 4. Audio Signal and Low Voltage Control Connections at 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.
P1—FrontCoverWireHarnessConnections
Plug the front cover wire harness connector in at P1 (see Figure 5).
P3—Balanced/Unbalanced Jumper
Jumper P3 allows configuration of the unit for balanced or unbalanced audio connections. Install the
header in the BAL position for balanced audio input signals. Install the header is in the UNBAL position
to configure the assembly for unbalanced audio input signals.
NOTE:Configure the system as an unbalanced system when 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 switch must be in the
MASTER position for common line operation.
•Master—Place switch SW1 in the MASTER position.
•Slave—Place switch SW1 in the SLAVE position.