GAI-Tronics 263 User manual

Pub. 42004-178D
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
GAI-TRONICS®
AHUB BE L LC OM P ANY
Model 263
Isolation Barrier Unit
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
GAI-Tronics Corporation offers intrinsically-safe (I.S.) telephones and isolation barrier units (IBU),
which conform to all pertinent requirements in the USA and Canada. For convenience, a telephone and
an IBU can be purchased together under a single model number: Model 261-001 for indoor use, and
Model 271-001 for outdoors.
However, for rack-mount configurations or special applications, the telephones and IBUs can be
purchased separately:
•Model 262-001 Indoor I.S. Phone
•Model 272-001 Outdoor I.S. Phone
•Model 263 Isolation Barrier Unit
The I.S. telephones are designed to be installed in all hazardous areas. The IBU or rack-mount card unit
is placed in a non-hazardous area up to one mile from the phone, limiting the energy levels going to the
hazardous area to conform to intrinsically-safe requirements.
The Model 263 Isolation Barrier Unit is constructed of durable glass-reinforced polyester, which is highly
resistant to chemicals and weather, and is rated Type 3R (rainproof).

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Installation
Installation Guidelines
When installing any GAI-Tronics telephone equipment, please adhere to the following guidelines to
ensure the safety of all personnel:
•NEVER install telephone wiring during a lightning storm.
•Install a UL Listed lightning arrestor on any phone installed where the phone or phone cable is at
risk of being exposed to lightning strikes. The lightning arrestor must be installed as close to the
phone as possible to maximize the protection. The lightning arrestor must not be installed within the
enclosure supplied with the phone.
•NEVER install telephone jacks in wet locations unless the jack is specifically designed for wet
locations.
•NEVER touch uninsulated telephone wires or terminals unless the telephone line has been
disconnected at the network interface.
•USE CAUTION when installing or modifying telephone lines.
•Install UL Listed telephone line suppressor (customer-supplied) on the telephone line.
•Use silicone sealant or equivalent around and inside all conduit entries
Installation of the IBU
The Model 263 Isolation Barrier Unit provides an intrinsically-safe circuit when connected in accordance
with GAI-Tronics Pub. 42004-380, Control Drawing 73242. It must be installed in a non-hazardous
location. See Figure 1 for a typical installation.
The Model 263 Isolation Barrier Unit interior includes a power switch selector, a ring pitch adjustment,
and four troubleshooting LEDs. The IBU housing is composed of two modular subassemblies, the front
panel and the rear enclosure assembly, for easy installation and wiring.
Figure 1. Typical intrinsically-safe installation

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Wiring Requirements
Design Limits
In order to be intrinsically safe, energy and energy storage must be constrained to “safe” levels in
hazardous area apparatus. Wiring inherently has capacitance formed by a dielectric material between two
conductors. A buildup of this capacitance can form a surge of electricity, a dangerous situation in a
hazardous area.
Intrinsically-safe telephones require cabling that will limit the amount of capacitance formed. The
limitation on cable length was set by Underwriter’s Laboratory (UL) based on test results. This “worst
case” cable available was found to have a capacitance of 60 picofarads/foot. Therefore, UL set the cable
limitation at one mile, the length at which this worst-case cable capacitance level was still within
acceptable bounds. Cable types with less capacitance have been specified to allow connection distances
over one mile.
For example: GAI-Tronics Model 60059-001 and 60021-301 cables allow connection distances of up to
1.5 miles.
Shielded Cable
Where multiple I.S. telephone wires are routed together, shielded cable should be used. The use of
shielded cable prevents cross-talk from occurring between multiple I.S. telephone circuits. The shield
must be grounded to an I.S. ground and connected only at the IBU.
Wiring Guidelines/ControlDrawing
The Model 263 provides an intrinsically-safe circuit when installed in accordance with GAI-Tronics Pub.
42004-380, Control Drawing 73242. In addition, the NEC and the CEC provide additional installation
details that are recommended for safe installation.
General Wire Types
24 AWG 22 AWG 20 AWG 19 AWG 18 AWG
Maximum capacitance,
C (picofarads/mile) 316,800 pF/mile
Maximum resistance,
R (ohms/mile) 271 171 107 85 67
*Ring signal loss,
decibels (dB/mile) -16 -12 -8 -6 -4
*Nominal ring signal is 98 dB @ 10 feet.

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System Setup
GAI-Tronics recommends taking the following steps to ensure a safe and trouble-free installation:
1. Install the Model 263 Isolation Barrier Unit (IBU) and wire it completely, except for the hazardous
area signal wires.
WARNING The unit must be wired in accordance with Pub. 42004-380, Control
Drawing 73242, to ensure intrinsic safety.
2. Next, temporarily connect the I.S. telephone to the IBU with a short pair of conductors, and operate
the unit by making a test phone call. If any problems are detected, see the Troubleshooting section.
3. Call the I.S. telephone from another telephone, and adjust the RING PITCH (located on the IBU) to
the desired pitch. See Figure 2 for location.
4. Disconnect the I.S. telephone and install it in the intended permanent location.
WARNING The unit must be wired in accordance with Pub. 42004-380, Control
Drawing 73242, to ensure intrinsic safety.
5. Make a call from the I.S. telephone. If any problems are detected, see the Troubleshooting section.

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Figure 2. Rear of IBU enclosure with cover removed

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Mounting
1. Remove the front panel by loosening the four front captive screws.
2. Refer to Figure 3. Determine which of the conduit locations is to be used. Drill spots have been
provided for use with a chassis punch or hole saw. Using a hole saw is recommended.
3. One 0.280-inch diameter hole is located in each corner of the rear enclosure. Install the rear
enclosure to a wall of an appropriate surface through the supplied mounting holes.
4. Refer to Pub. 42004-380, Control Drawing 73242, for wiring details.
NOTE:Telephone system wire must be connected to the Isolation Barrier Unit only and not directly
to the I.S. telephone. Battery backup connection is not required for operation of the Model 262-001
and 272-001 I.S. Phones. If battery backup is desired, please consult the factory for specifications.
5. Apply power and test telephone operation.
6. Refer to the Troubleshooting section of problems are detected.
When proper operation has been verified, replace the cover and secure it by tightening the four captive
screws.

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Figure 3. Model 263 Isolation Barrier Unit dimensions
Operation
The Model 263 Isolation Barrier Unit requires no operator intervention for routine functions.

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Maintenance
This section includes two troubleshooting charts designed to quickly pinpoint the source of problems.
Troubleshooting
NOTE:It may be advantageous to temporarily connect an I.S. telephone panel directly to the output
terminals of the Model 263 IBU when troubleshooting. Then, using the charts below, the cause of the
problem should be more easily determined.
Non-EquipmentRelated Problems
Problem Solution
The I.S. phone is inactive with
no lights on the IBU when the
phone is off-hook.
1. Check the ac power to the Model 263 IBU.
2. Check the ac fuse F4 at the Model 263 IBU.
3. Ensure there is no wiring open at the I.S. phone.
1. If the I.S. phone has a wiring short, the IBU lights will be lit in
the following pattern: O= On, P= Off
ISLOOP
OLOCK P
HOOK
PTELCO P
2. If the TELCO line has an open, the IBU lights will be lit in the
following pattern: : O= On, P= Off
ISLOOP
OLOCK O
The I.S. phone has no dial tone.
HOOK
OTELCO P
The lights on the IBU flash
randomly. The I.S. phone has an intermittent wiring short. The short may be between the conductors or either/both conductor(s) to ground/shield.

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Equipment-Related Problems
Problem Solution
There is no incoming ring tone. 1. Check the I.S. telephone panel.
2. Check the Model 263 IBU.
No receiver audio, no sidetone,
and cannot hear touch tones
when pressed.
1. Check the I.S. telephone panel.
2. Check the Model 263 IBU.
3. There may be a wiring open or a short in the connecting cable.
Cannot dial out, but can hear
touch tones when pressed. 1. Check the Model 263 IBU.
2. There is no TELCO connection or it is faulty.
I.S. phone appears inactive. 1. Check the I.S. telephone panel.
2. Check the ac fuse F4 at the Model 263 IBU.
3. Ensure there is no wiring open in the connecting cable or at the I.S.
telephone.
CAUTION
Any field repairs on the intrinsically-safe design of the phone are strictly prohibited. Any such
change will void ALL hazardous approvals. Please contact the GAI-Tronics Field Service Department at
800-492-1212 inside the USA or 610-777-1374 outside the USA for the Regional Service Center closest
to you.

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Lightning Protection
Telephone lines are susceptible to lightning strikes and must be properly protected and maintained. On-
premise line protection is usually provided at the building entrance by the responsible telephone company
when it is installed. This protection is often neglected after installation.
Degradation of conventional protection, such as carbon blocks or gas discharge types, will occur with
each lightning strike. To ensure safe operation, protective elements should be replaced frequently and
checked for proper connection and grounding. Gas discharge types are by far the most robust, cost-
effective means of protection.
The registered I.S. equipment meets all isolation and safety requirements of FCC, Part 68, DOC CS-03,
UL 913, and CSA C22.2-No. 157. However, lightning strikes are not predictable or considered to be a
condition of fault likely to occur in practice as defined by the guidelines for intrinsic safety. Therefore, it
is imperative that the user employ and maintain a proper lightning protection scheme. This is true for all
hazardous area equipment and all telecommunications equipment subject to lightning.
Figure 4. Example of a lightning protection design