GAI-Tronics TP4512SYN-6 Betriebsanleitung

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

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

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