Hubbell GAI-TRONICS 400-001 Configuration guide

Pub. 42004-376E
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
400-001 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 ......................................................................................................................................2
Speaker Horn Assembly (Model 400-001 Only)...................................................................................3
Mounting..................................................................................................................................................3
Hardware Configuration........................................................................................................................4
External.................................................................................................................................................4
Internal..................................................................................................................................................5
Wiring......................................................................................................................................................5
Station Wiring.......................................................................................................................................5
System Line Balance.............................................................................................................................6
System Wiring ......................................................................................................................................7
Field Wiring Terminations.....................................................................................................................7
TB1—Speaker Terminal Block ............................................................................................................7
TB2—AC Power Terminal Block.........................................................................................................8
TB3—DC Power Terminal Block.........................................................................................................8
TB4—Audio and Low Voltage Control Terminal Block .....................................................................8
P1—Front Cover Wire Harness Connections.......................................................................................9
P3—Balanced/Unbalanced Jumper.......................................................................................................9
SW1—Master/Slave Switch .................................................................................................................9
Cover Installation....................................................................................................................................9
Operation.........................................................................................................................................9
Common Line System...........................................................................................................................10
Master/Slave System.............................................................................................................................10
Maintenance..................................................................................................................................11
F1/F2 Fuses............................................................................................................................................11
Cover Installation..................................................................................................................................11
Troubleshooting....................................................................................................................................12
Replacement Parts and Accessories.............................................................................................12
Specifications ................................................................................................................................12
AC Power...............................................................................................................................................12
DC Power...............................................................................................................................................12
Amplifier PCBA....................................................................................................................................13

Table of Contents Pub. 42004-376E
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) ............................................................................................................13
Station....................................................................................................................................................13
Environmental.......................................................................................................................................13
Approvals.......................................................................................................................................13
Appendix A—InterfacingaModel400-001RigComStationtoaMS39xxRigComStationSystem.................14
Appendix B—InterfacingaModel400-001RigComStationtoEZPageStations........................................16

Pub. 42004-376E
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
400-001 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 a master/slave
communication system. The stations are approved for the
following hazardous locations when installed in accordance
with GAI-Tronics Pub. 42004-381, Control Drawing No.
73214:
•Model 400-001: Class I, Div. 1, Groups C and D
•Model 400-002NS: Class I, Div. 1, Groups B, C, and D
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 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:The approved hazardous locations are reduced to Class I, Div. 1, Group D with the use of
auxiliary items.
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.
Figure 1. Model 400-001 RigCom Station

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Important Safety Instructions
•Read, follow, and retain instructions—All safety and operating instructions should be read and
followed before operating the unit. Retain instructions for future reference.
•Heed warnings—adhere to all warnings on the unit and in the operating instructions.
•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.
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.
The Models 400-001 and 400-002NS Rigcom stations must be installed in accordance with GAI-Tronics
Pub. 42004-381, Control Drawing No. 73214.

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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.
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.
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).
NOTE:Stainless steel hardware is recommended for applications in corrosive environments.

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Figure 2. Model 400-001/400-002NS Mounting Details and Conduit Entries
Hardware Configuration
External
The enclosure contains a push-to-call button, an on-off/volume control switch, and applicable approval
labeling. The enclosure has 12 cover mounting bolts located around the perimeter of the enclosure.
NO USER SERVICEABLE PARTSINSIDE.
REFER SERVICING TOQUALIFIED PERSONNELONLY.
OFF-ON VOLUME
PUSH TO CALL
GAI-TRONICS CORPORATION
P.O. BOX 1060 READING, PA 19607
SUITABLE FOR USE IN HAZARDOUS LOCATIO NS
CLASS I, DIV. I, GROUPS C, D
WARNING:EXPLOSION HAZARD - D O NOT DISCONNECTEQUIPMENTUNLESS
TO REDUCE THE RISK OF IGNITION OF HAZARDOUSATMOSPHERES,
CONDUIT SEALS MUSTBE INSTALLED WITHIN 18 INCHESOF ENCLOSURE.
AMBIENT TEMPERATURE: -20°C TO 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 CIRCUITSARE ALIVE.
CAUTION:
POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWNTO BE NON-HAZARDOUS.
12VDC, 1.8 AMP MAX
CAUTION
RISKOF E LECTRIC
SHOCK,DO NOT OPEN! !
SERVICECENTERS: In USA: 1-800-492-1212 Outside USA: 1-610-777-1374
~
Figure 3. Model 400-001 RigCom Station Outline

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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.
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 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. Attach the wires to the terminal blocks located on the PCBA within the enclosure (see Figure 4 and
the Field Wiring Terminations section for connection points and descriptions).
5. 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.
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 a 1-kilohm, 1-watt resistor assembly
included with each unit. The line balance resistor assembly is made for easy installation into a customer-
supplied junction box.
NOTE:Only one line-balance resistor assembly is needed 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 5 and Figure 6).
NOTE:The junction box must be suitable for the applicable hazardous location where it is located.
Figure 5. System cable wiring less than 4000 feet in length
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 Wiring Terminations
TB1—Speaker Terminal Block
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
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 Power Terminal 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 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
ac power ground terminal must be electrically connected to the
chassis
TB3—DC Power Terminal 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 external dc power supply is not used.
TB4—Audio and Low Voltage Control Terminal 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.

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P1—Front Cover Wire Harness Connections
Plug the front cover wire harness connector in 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 when the header is installed in the BAL position. The
assembly is configured for unbalanced audio input signals when 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
when the switch is in the MASTER position. The unit is configured as a slave when the switch is in the
SLAVE position. The switch must be in the MASTER position for common line operation.
Cover Installation
1. 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 may
prevent a proper seal. Surfaces must seat fully against each other to provide a proper explosion-proof
joint.
2. Clean the surfaces by wiping them with a clean lint-free cloth.
3. Install all 12 cover bolts.
Use only the bolts supplied with the enclosure. Do not omit any bolts.
4. Torque the cover bolts to 17 ft∙lb (23 N∙m).
Operation
The station has an on-off/volume control switch and a push-to-talk switch.
1. Turn the unit on or off and adjust the volume level in the listen mode using the on-off/volume control
switch.
2. Turn the unit off by turning the switch completely counterclockwise.
3. Adjust the switch completely clockwise for maximum volume.
The push-to-talk switch controls the audio communication between stations.
1. Press the push-to-talk switch to send a message to another station.
2. Release the push-to talk switch to put the station in listen mode so that the station receives messages
from other stations.
The push-to-talk switch is not functional when the station is configured as a slave station.

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Common Line System
All stations are on a common
audio path and are normally in
listen mode in the common line
configuration. Activation of a
station’s push-to-talk toggle switch
supplies its audio signal to the
common audio path. All other
units receive the audio signal and
broadcast the announcement over
their speakers. The push-to-talk
switch must be held down while
the operator talks. Releasing the
switch deactivates the microphone
and returns the unit to listen mode.
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 station to
monitor the slave’s audio when the
master’s push-to-talk is not
activated. Activation of the
master’s push-to-talk toggle switch
places the slaves 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.
Figure 8. Common Talk Wiring Detail
Figure 9. Master/Slave Wiring Detail

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Maintenance
Contact a regional service center for a return authorization number (RA#) if the equipment requires
service. Equipment must be shipped prepaid to GAI-Tronics with a return authorization number and a
purchase order number. Repairs or a replacement will be made in accordance with GAI-Tronics’
warranty policy if the equipment is under warranty. Please include a written explanation of all defects to
assist our technicians in their troubleshooting efforts.
Call 800-492-1212 inside the USA or 610-777-1374 outside the USA for help identifying the Regional
Service Center closest to you.
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 the
GAI-Tronics station. The GAI-Tronics Field Service Department can formulate a service contract suited
to specific needs 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.
F1/F2 Fuses
WARNING
—Do not remove fuses when energized.
Replace with the same type and size fuse for continued safe operation.
•Fuse F1—ac power line: 0.5 A, SLO-BLO, 250 V, 5×20 mm, UL.
•Fuse F2—dc power line: 2.0 A, SLO-BLO, 250 V, 5×20 mm, UL.
Cover Installation
1. 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 may
prevent a proper seal. Surfaces must seat fully against each other to provide a proper explosion-proof
joint.
2. Clean the surfaces by wiping them with a clean lint-free cloth.
3. Install all 12 cover bolts.
Use only the bolts supplied with the enclosure. Do not omit any bolts.
4. Torque the cover bolts to 17 ft∙lb (23 N∙m).

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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.
Table 5. Available Accessories for RigCom Stations
Part No.
Description
12801-002
auxiliary microphone
51052-003
auxiliary footswitch
10438-002
microphone I.S. barrier kit (contains 12801-002 auxiliary mic assembly)
12807-001
connector kit
60075-001
audio cable, No. 18 AWG, (two-pair)
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)....................................................................................................................................... 0.3 W
Standby.............................................................................................................................................. 3 W
Maximum speaker out..................................................................................................................... 20 W

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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 Hz–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)
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

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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 in
systems containing MS39xx RigCom stations.
The MS39xx stations use an unbalanced system for communication and the negative of the audio pair is
used for the ground reference of the control signal. The Model 400-001 can operate in an unbalanced or
balanced system. In a balanced system, the audio pair is not ground referenced and the control signal
requires a ground signal.
Configure the Model 400-001 for unbalanced operation by placing jumper P3 in the UNBAL position for
interoperability between the Model 400-001 and the MS39xx Series stations. No changes are required to
the MS39xx Series station(s). For Master/Slave operation:
1. Connect the AUDIO−to AUDIO (WH) terminal.
2. Connect the AUDIO+ to AUDIO (BLK) terminal.
3. Connect the EXT CONT+ to the KEY.
Only the audio wires require connection for common line operation.
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

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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 in either balanced or unbalanced
systems. An unbalanced communication system uses the negative of the audio pair as the ground
reference for the control signal. The audio pair is not ground referenced in a balanced system and the
control signal requires a separate ground signal.
Configure the Model 400-001 RigCom stations and the EZ Page stations identically as balanced or
unbalanced using jumper P3 on the Model 400-001 station(s) and jumper P5 on the EZ Page station(s)
for interoperability between the Model 400-001 RigCom and the EZ Page Series stations.
The following are wiring diagrams are for the different configurations of a RigCom/EZ Page system:
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

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Figure 15. Unbalanced Common Line Configuration
Figure 16. Master/Slave Balanced Configuration with Model 400-001 as Master

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Figure 17. Master/Slave Balanced Configuration with Model 400-001 as Slave
Figure 18. Balanced Common Line Configuration