GAI-Tronics ILC-1117 User manual

Doc. No. 502-20-0132-001 Iss2. Dec 2012. (CN37277-002)
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Installation and User Guide
ILC-1117
Titan Illuminated
Crossing Telephone
GAI-TRONICS

2 ILC-1117 Titan Illuminated Crossing Telephone
CONTENTS
1. Safety and Care Information....................................................................... 3
2. Product Description .................................................................................... 3
2.1. Changes from previous versions..................................................3
2.2. At a Glance .................................................................................. 4
3. Operation / Testing ..................................................................................... 5
3.1. Call timer ...................................................................................... 5
3.2. Handset integrity alert .................................................................. 5
4. Installation .................................................................................................. 6
4.1. General ........................................................................................ 6
4.2. If glands are required ................................................................... 6
4.3. Wall mounting ..............................................................................7
4.4. Pole mounting ..............................................................................8
5. Connections and option settings................................................................. 9
6. Legend Panel. .......................................................................................... 12
6.1. Legend panel dimensions .......................................................... 12
6.2. Fitting the legend panel.............................................................. 13
7. Cleaning ................................................................................................... 13
7.1. Normal Cleaning ........................................................................ 13
7.2. Stainless Steel Push-buttons ..................................................... 13
7.3. Graffiti......................................................................................... 13
8. Aftercare................................................................................................... 14
9. Technical Specifications ........................................................................... 15
10. CE Declaration ......................................................................................... 17

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1. Safety and Care Information
▲
The safety of the user/installer relies on the isolation of the telephone
network and not on the earthing of the case
▲
Please read these instructions thoroughly before starting installation.
These products must be installed by competent personnel familiar with
telephone installation.
▲
Telephone network voltages can be hazardous. Take adequate
precautions when opening the case or installing. If in doubt, disconnect
the telephone line elsewhere before accessing the line connections.
▲
For increased protection against lightning transients, attach a local
earth to the main terminal block (see section 5)
▲
Do not fit a terminating resistor across the telephone terminals. The
system does not require a terminating resistor, fitting a resistor may
prevent the telephone from initiating a call.
2. Product Description
This manual describes the ILC-1117 model Titan telephone, designed for use
on PETS (Public Emergency Telephone System) at automatic half barrier
(AHB) level crossings in the UK. The product was introduced with the design
of PETS3, but is backward compatible with PETS2 and PETS1.
2.1. Changes from previous versions
This manual describes an updated range of products introduced in June 2009.
For those familiar with GAI-Tronics’ products, the list of new or changed
features is as follows:
•Larger illuminated area, with instructions
•Clearer, more even illumination. Backlight colour is now white as
opposed to red. Illumination level does not vary when on or off hook.
•Prominent, vandal resistant pushbutton
•New, simpler terminal layout (section 5). No separate Cap-Shunt link
(ringing is permanently enabled). The pushbutton is permanently in
circuit.
•There is no longer an option to select an illumination current. Illumination
current is fixed at 6mA.
•Increased lightning protection (section 9).
•Compliance with railway EMC standards (section 9)
For the full list of product features, please see the specifications in section 9.

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2.2. At a Glance
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Door
Handset
Pushbutton
Faceplate
Illuminated
panel
Timer Switch Main Terminal Block
Legend
panel
slides in
here

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3. Operation / Testing
When connected to a telephone line, the telephone will draw a constant
current of 6mA on-hook and the illuminated panel will be lit.
Pressing the button with the handset on hook will cause the display to flicker
briefly. This will have no other effect and neither a call nor a fault will be
initiated
Lifting the handset will cause the phone to loop the line – dial tone should be
heard but a call will not be initiated.
Pressing the button will cause a timed loop break (approx 100ms) which
should initiate a call. Refer to the relevant PETS instructions for call
connection timings.
The loop break duration is independent of how long the button is held
pressed. Keeping the button pressed will still only result in a 100ms break.
3.1. Call timer
The phone has a selectable call timer that can limit the maximum call duration
to approximately 7 minutes.
When on, the timer forces the phone back off line after the preset time. This
prevents the line remaining tied if the handset is left off-hook. The timer is
factory-set to OFF by default.
3.2. Handset integrity alert
If the handset integrity loop is broken (most commonly because the handset
has been damaged or torn off), the illumination will not be lit and the on hook
current will be almost zero. This should cause PETS to signal an alarm.
Note that a terminating resistor should not be fitted across the telephone
terminals.

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4. Installation
4.1. General
IMPORTANT
All possible measures must be taken to ensure water, fluid or dust
does not contaminate the internal components of the telephone whilst
unpacking, preparing and installing the telephone in inclement weather
conditions or by negligence.
Failure to do so may invalidate your warranty.
These telephones are supplied without connection leads – cabling to the
telephone network must be supplied and installed by the installer. Because of
this, extra precautions must be observed: installation must be carried out by
trained personnel. Contact GAI-Tronics if installation service is required.
1. To prepare for installation, open the door, then undo the four retaining
screws to remove the faceplate from the rear enclosure. A 3mm Allen
key is required. Take care not to damage the exposed circuit board
when setting the faceplate aside during installation.
Caution – take care to support the spring-loaded door whilst open
to prevent it slamming shut and trapping fingers.
2. All connections and option settings are on the rear of the faceplate
towards the lower edge.
3. The Titan telephone is intended for vertical installation to a wall or pole.
Select the required mounting method (section 4) and mount the rear
enclosure first where applicable.
4. Route the required cables through glands as appropriate, and make
connections and option settings following section 5.
Ensure that both cable entries are sealed with either a gland or a black
blanking plug as described.
5. Re-fit the faceplate ensuring a weatherproof seal is maintained.
6. Test the operation of the telephone (section 3). Installation is now
complete.
4.2. If glands are required
Before mounting the telephone, check the cable routing and requirements. If
glands are required, fit them to the case as follows:
1. Remove the RED blanking plug leaving the other (usually BLACK) in
place.

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2. Select the appropriate sized gland:
Use the smaller gland for cables diameters 4 - 7mm.
Use the larger gland for cable diameters 8 - 13mm.
3. From the outside of the case, insert
the selected gland into the threaded
cable entry hole and tighten, so that its
sealing washer is compressed against
the enclosure surface.
4. Proceed with chosen mounting method
below
As standard, The telephone is supplied with a pole mounting kit 100-02-0208-
001, but no glands.
4.3. Wall mounting
1. Using a suitable tool, punch out 4 holes in the rear enclosure, taking
care not to damage or dislodge the plastic bushes. Only four of the
eight holes are required - the outer ones are recommended. The
inner holes are provided to be compatible with older-style mounting
posts, and should be left intact if not used. If the inner holes are
used they must be fitted with the supplied plastic bushes.

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WARNING:.Your warranty will be invalidated if :-
1. Any fixing hole made in the rear enclosure is left unused.
2. Any additional holes are drilled into the telephone enclosure.
3. Plastic bushes are not used on all fixing holes.
2. Mark the wall with hole centres based on the dimensions shown
(145 x 270mm). If necessary offer the rear enclosure up to the wall
to check alignment. Do not use the enclosure as a template for
drilling.
3. Drill holes in the wall on the marked positions. Select appropriate
screws, wall plugs etc., for the type of wall, bearing in mind that the
weight of the complete phone is around 5kg.
IMPORTANT:Check that screws seat properly in the plastic bushes to
ensure a watertight seal. Do not use excessive tightening force, as
this may crack the case.
4. Ensure that all four plastic flanged bushes are in place and the rear
enclosure is screwed tightly to the surface to prevent any water
ingress through the punched holes.
5. Complete the installation by making the appropriate connections
(section 5) and re-fitting the face plate.
4.4. Pole mounting

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Kit No 100-02-0208-001
This accessory is for mounting GAI-Tronics telephones on to the side of
round poles of 100mm to 200mm diameter, or on to square or
rectangular section uprights of 100mm to 150mm across the mounting
surface.
NOTE:
Banding straps (large scale worm-drive clamps) are not included in this
kit and must be obtained separately. For details of where banding can
be obtained, refer to GAI-Tronics.
1. Using a suitable tool, punch out the 4 outer holes in the rear
enclosure, taking care not to damage or dislodge the plastic
bushes.
2. Attach the pole mounting clamp assemblies to the rear enclosure
using the M6 x 25 screws provided, pushing the screws through
from inside the phone.
3. Tighten nuts to a torque of 4.5Nm max.
IMPORTANT: avoid the use of power tools. Spinning the nuts too
quickly can cause a rapid increase in heat which can cause the nuts
to seize as a result of galling or cold-welding.
Note: only use the outer four holes, and ensure that the screws seat
properly in the plastic bushes to avoid water ingress.
4. Ensuring that the glands are at the bottom, pass a proprietary
banding strap round each of the pole mounting clamps and the
support pole. Tighten securely.
5. Continue the installation by making the appropriate connections
(section 5) and re-fitting the face plate.
6. Re-tighten the straps firmly and trim off any excess band material.
For security the driving head of the band may also be sawn off.
5. Connections and option settings
If glands are used, insert the cable through the gland body and tighten the gland nut
sufficiently to clamp the cable, making a seal. Ensure sufficient cable is left to allow
removal of the faceplate without straining the cable.

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IMPORTANT: If only one cable entry is used, the black blanking plug fitted to the
second position must be left in place.
Connect the telephone line A and B to the main terminal block TB2 as shown.
The centre earth terminal is intended for connection to a local earth to provide
common mode protection from lightning transients. If this terminal is not
earthed there is an increased risk that the telephone could be damaged
by line-born transients.
Note that user safety from the telephone network is provided by isolation and
does not rely on this earth connection.
Do not fit a terminating resistor across the telephone terminals. The
system does not require a terminating resistor, fitting a resistor may
prevent the telephone from initiating a call.
Note: Conductor sizes to be 0.5mm-2.5mm
2
(flexible cable);0.5-4.0mm
2
(solid cable) The terminal block can be disconnected from the circuit board
for easier installation
Cabling must not infringe European Low Voltage Directive (LVD)
2006/95/EC.

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Timer Switch Main Terminal Block
The timer is set by the position of switch SW2. Position the switch to the left to
set the timer ON, and to the right to set it OFF.
This unit is supplied with the switch set to the OFF position.

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6. Legend Panel.
The telephone is designed to accept a legend panel, giving details of the level
crossing. The legend panel slides into a thin slot behind the faceplate and is
held in place when the faceplate is secured in the rear enclosure. The legend
panel is then backlit by the illuminated panel.
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Variable
Information
(Replaceable
Legend Panel)
Fixed
Information
6.1. Legend panel dimensions
The legend panel should be made from clear material (for example laser
printer OHP film), preferably 0.5mm thick (max 1mm), and cut to the template
below.
AREA FOR TEXT
90
66
81 83
2
1
Note that the area for printing is 81mm x 66mm and allows a border and a tab
for ease of fitting.

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6.2. Fitting the legend panel.
To fit the legend panel, first ensure that a panel has been correctly printed and
cut to size according to the template above.
Remove the faceplate from the telephone by removing the 4 retaining screws.
Locate the slot behind the window, at the left hand edge when viewing from
the front. The slot is only approximately 1mm thick, and there is a retaining
guide to keep the legend panel aligned correctly.
Gently slide the legend panel into place. Undue force should not be
necessary. Note that the slot is fairly tight to the dimensions above to ensure
correct alignment.
When fully inserted, the edge of the legend panel will protrude beyond the
circuit board to the edge of the gasket, allowing a tab for ease of removal. It
must not overlap the strip of gasket, otherwise the water seal will be
compromised.
7. Cleaning
Recommended cleaning methods are outlined below:
7.1. Normal Cleaning
For normal cleaning we recommend "Virosol", manufactured by Clover
products.
Carefully follow manufacturer's instructions for storage, handling and use.
7.2. Stainless Steel Push-button
The stainless steel push-button should be cleaned regularly especially if the
telephone is in a marine environment. The stainless steel may show signs of
discolouration or rust – this will not damage the button or impair its
performance but may look unsightly and can be cleaned off using normal
cleaning agents as above. In extreme cases a mild abrasive may be
necessary.
7.3. Graffiti
For graffiti, paint and ink we recommend the use of 3M GR1 graffiti stain
remover.
CAUTION: This is a very aggressive chemical. Pay close attention to the
manufacturer's recommendations for storage, handling and use.

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8. Aftercare
The purchase of your GAI-Tronics product does not end our commitment to
you.
In addition to our warranty obligations, GAI-Tronics are able to offer various
levels of maintenance packages, installation and commissioning packages and
technical support, from ad-hoc repairs to full maintenance contracts.
By choosing GAI-Tronics as your aftercare provider you are ensured of
manufacturer expertise and ISO 9000-certified quality control standards
throughout the life of the product.
We can also supply a full range of accessories including mounting posts,
beacons and high-volume sounders.
Contact GAI-Tronics for details. www.gai-tronics.co.uk

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9. Technical Specifications
Operational Requirements
Systems. •Public Emergency Telephone System (PETS) only.
Not suitable for
connection to:
•Public networks (PSTN)
•Standard PABXs
Telephone line
parameters
•On-hook current: 6mA ± 10%
•Ring Voltage: 30V to 100V rms, 20Hz to 50Hz
•Line voltage 20 to 70 Vdc
•Loop current ≥15mA
Product features
Power supply 100% line power.
Hookswitch Electronic with no external moving parts
Time Out 7 minutes (±1). Selectable
Ringer loudness 80dBA @ 1m
Handset Suitable for inductive coupling to Hearing Aids having
a `T' switch position.
Tested to ETS 300-381
Environmental limits
Temperature: Operating: -20ºC to +60ºC
Storing: -40ºC to +70ºC
Relative Humidity Up to 95% (non-condensing)
Ingress
Protection
IP65 to EN60529:1992 – Degrees of protection provided by
enclosures.
Physical characteristics
Casing material Die-cast Aluminium
Handset Material Cycoloy (2800) with stainless steel cord.
Weight 5kg approx.
Dimensions 189W x 366H x 130D (mm)

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Compliance to standards
European
Directive
2004/108/EC – EMC Directive
2006/95/EC – Low Volltage Directive (LVD)
2011/65/EC - Restriction of the use of certain
hazardous substances in electrical and electronic
equipment (recast) (RoHS 2) Directive
EMC EN55022 – Information technology equipment. Radio
disturbance characteristics.
EN55024 – Information technology equipment. Immunity
characteristics.
EN 50121-4 - Railway applications, emission and immunity
RT/E/S/30003 iss1 1999 – The performance of
Telecommunications Equipment under Conditions of Electrical
Interference
Safety EN60950-1 – Specification for information technology
equipment, including electrical business equipment.
Telephony BS6305:1992 (with the exception that on-hook leakage
current is 6mA).
BS6317:1992
Lightning and
transients
ITU-T recommendation K.21 - Enhanced surge protection.
Recycling
Information
The symbol shown here and on the product means
that the product is classed as Electrical or Electronic
Equipment and should not be disposed with other
household or commercial waste at the end of its
working life.
The Waste of Electrical and Electronic Equipment
(WEEE) Directive has been put in place to recycle
products using best available recovery and recycling
techniques to minimise the impact on the
environment, treat any hazardous substances and
avoid the increasing landfill.
Business users should contact their suppliers and
check the terms and conditions of the purchase
contract and ensure that this product is not mixed
with other commercial waste for disposal.

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10. CE Declaration

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GAI-TRONICS
A division of Hubbell Ltd.
Brunel Drive
Stretton Park
Burton on Trent
DE13 0BZ
England
Tel: [phone]
Fax: [phone]
www.gai-tronics.co.uk
The policy of GAI-Tronics is one of continuous improvement, therefore the Company
reserves the right to change specifications without notice