Description of the equipment

PAGE PHONE SYSTEM

The Page Phone is a loud announcement receiver which can reciprocate a loud reply to
another such phone or a set of such phones. These phones are normally used in
industries and big commercial complexes for generating loud announcements and call
back. The Kaizen Page Phone Model KS/PP-01 is one such paging system for use in
hazardous environment of inflammable gases. A number of these phones are
connected through a system cable (Normally 1.5 or 2.5 sqmm, 3 Core) in a common
bus system for loud calls and private conversation over its handsets. The applicable
gas groups are Gr. I (for mines), Gr. IIA & Gr. IIB (for petroleum sector).

COMPONENTS

The Page Phone system consists of the following:

1. An FLP/IS power supply unit for charging every set of five page phones
2. Two or more page phones
3. Interconnecting cable (1.5 or 2.5 Sqmm x 3 Core)
4. FLP JB for distribution of Mains to FLP Power supplies
5. Non-FLP JB for distribution of Paging signal & 18VDC I.S. Charging voltage

1. FLP POWER SUPPLY

The FLP power supply unit has a transformer and a PCB. The rating of the transformer
is 230VAC – 18VAC, 750 mA. The short circuit current of the unit is as per
intrinsic safety requirements. The PCB has terminals for AC input and DC output.
A caution nameplate is used to tell the user to isolate mains supply elsewhere
before opening the enclosure in the Hazardous area. The FLP enclosure is
designed as per IS-2148 (Ref. Drawing no. KS/MECH/PSU/01-FAB).

Current Limit: The Value of Resistance R1 is so chosen to keep the output current to a
maximum of 300 mA. If excess of 300 mA is drawn because of any reason, the voltage
folds back, keeping the energy at output with intrinsic safety requirements.
Additionally a wire wound resistor of value 25 Ohms, 25 Watts (R3) is connected in
series at output to limit the current. This satisfies the requirement of infallible
component. The maximum current drawn when output terminals are short-circuited is
350 mA because of R1 & 720 mA because of R3. The value of R3 for Group I application
can be as low as 15 Ohms there by the short ckt. current will be 1200 mA. An output
fuse of 500 mA, works as third order protection after R1 & R3.

Voltage Limit: The out voltage is adjusted by the Potentiometer P1 & is set at 17.5 to
17.9 Volts for the system requirement. The output is protected by use of 2 nos. 18V
Zener Diodes. Once the output value goes beyond 18 V DC, the clamping action starts
& the voltage is not allowed to go beyond 18VDC.

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

2. I.S. PAGE PHONE

Each page phone has one PCB, one intrinsically safe Battery Box, one handset, one
speaker and associated terminals. All these components are arranged in one enclosure.
The connection is made as per wiring Scheme no. KS/PPH/BOX-WD/01 .

I.S. BATTERY

The intrinsically safe battery is a 12 V Ni-Cd battery with a series fuse and a 15 ohms
current limiting resistor. The charging is achieved through a set (2 nos) of diodes
whose anodes are connected to the output of power supply unit & cathodes are
connected to battery leads. The rating of each cell is 1.2 V, 700 mAH with 10 such cells
forming the battery in a sealed box as per drawing no. KS/PWB/PPH/01-CS.

PAGE PHONE PCB

The Page Phone PCB as per drawing no. KS/PWB/PPH/01 – CS is a single sided glass
epoxy PCB designed following the norms of intrinsic safety. It has different operational
blocks, viz. The handset amplifier (HSA), the Page circuit, and the power amplifier. The
common 12 VDC supply bus positive line is connected to all the circuits. The
negatives / outputs are taken out to the PCB connector separately.

The HSA takes input from TX capsule of the handset as shown in the drawing. The
capsule generates audio signal in millivolts which is amplified by the HSA in the
audio frequency range. The signal output from the PCB is known as PAGE LINE with
respect to the SYSTEM –VE BUS. The HSA gets the supply negative (pin no. 7)
through the handset pressel switch. The handset pressel switch also disconnects
the supply negative to the power amplifier to avoid self-paging and acoustic
feedback through Q5.

The Page signal comes out through the Page switch and gets superimposed with the
Handset Amplifier Output onto the PAGE LINE, when the PAGE button is pressed.
This PAGE LINE when comes to the input of any idle Page Phone, the power
amplifier switches on and the accompanying voice gets amplified at its output. The
speaker produces a 2-watt peak audio signal. Bridge Amplifier configuration is used
to avoid the requirement of large capacitor for load coupling and generate the class
B output. The short circuit current for any charged capacitor is within the intrinsic
safety standard.

An 8 Ohms Mylar Cone Speaker is used as the announcing device.

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

 Specification of the equipment
FLP POWER SUPPLY

Enclosure MS Welded with CI Terminal Box (Flame Proof)

Mounting Wall / Column mounting type
Paint / Finish Light Gray ( or Customer’s Specs)
Ingress Protection IP 55
Input Voltage 110 / 230 V / 550 VAC, 50 Hz, 1 Ph.
Output Voltage 18VDC , Intrinsically Safe
Weight 30 Kg ( Approx)
Dimension 380(H) X 265 (W) X 190 (D) mm
Environmental Char. Meets IS:13109 (PT.1) / 1991
Intrinsic Safety Char. Meets IS:5780-1980 for Gas Group – I, IIA, IIB
Flame Proof Char. Meets IS:2148-1981 for Gas Group – I, IIA, IIB

I.S. PAGE PHONE

Enclosure MS/FRP
Mounting Wall / Column mounting type
Paint / Finish Light Gray ( or Customer’s Specs)
Ingress Protection IP 65
Input Voltage 18 VDC from FLP Power Supply.
Operating Voltage 12VDC, From IS Battery Pack, In-built
Freq Response 300 Hz- 3.4 Khz
SPL of Handset Receiver 116.5 dB(A) @ 1.5 KHz
SPL of Loudspeaker 104 dB(A) @ 1.5 KHz at 1 Meter Distance
Volume Control Site Adjustable (Internal Volume potentiometer)
Speaker 8 Ohms
System Area Coverage 5 KM
Weight 4 Kg ( Approx)
Dimension 380(H) X 250 (W) X 150 (D) mm
Environmental Char. Meets IS:13109 (PT.1) / 1991
Intrinsic Safety Char. Meets IS:5780-1980 for Gas Group – I, IIA, IIB

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

 Operating Instructions

Making a Page Call:

Press the Handset Pressel Switch & Page Switch on the Phone & speak into the
mouthpiece of the handset. Your announcement will be heard all over the system.
When some body responds to your call, leave the Page Switch & talk with the handset
switch pressed. This conversation is in private mode & shall not be announced. After
conversation is over, release the pressel switch & hang up the handset.

Responding to a Page call:

Upon hearing the announcement, press the handset pressel switch & speak into the
mouthpiece of the handset. After conversation hang up.

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

 Instruction for Maintenance
The Field Call stations & power supply units are to be located in such a place where
there is very little possibility of direct water seepage. They should be fixed at a suitable
height so that attending a phone is not inconvenient. In case the station has to be
located in an area where it might come in direct contact with rainwater or with water
from fire fighting sprinkler etc. suitable canopy has to be installed.

The equipments are (The stations, Power Supply & junction boxes) to be mounted on a
flat wall or column, keeping a clearance of minimum one inch from the wall. Suitable
iron brackets should be used for this purpose. The stations and the junction boxes are
to be firmly fixed on these brackets with the help of screws and nuts.

The 110/230/550 VAC, 50 Hz. input supply to the power supply units is to be connected
to terminals inside the flame proof terminal box meant for the purpose & identified by
suitable rating nameplates. All screws are M6 Allen head type. The bolts are to be
tightened with spring washer (provided) so that surface gap of less than 0.2 mm is
maintained. The I.S. output is available in the terminal box labeled as “ DC OUTPUT”.
This should be taken out to the J.B. meant for the purpose.

Each Phone will be installed with a Non-FLP Junction Box (6 terminal). All the JBs are
connected in Omni Bus Pattern.

In Case FLP Power Supply does not give 18VDC Output –

Remove the cable from Output terminals & check for Open. In case short is found, the
cable has to be replaced.

Check for presence of AC mains in the input Terminal. Check for 18VAC at Transformer
Secondary. In case 18VAC is absent the transformer might be defective & has to be
replaced.

Check for approx. 24 V DC on IC1 Pin #1. In case this is not present, check the Input
Fuse (F2). If found bad it may be replaced.

Now check the Output on terminals T3 & T4. It should be 18VDC. In case it is not
present check whether Output Fuse (F1) is open, Whether Zener Diodes Z1 & Z2 are
short, whether wire Wound Resistor R3 is Open. If any of these is faulty it may be
replaced.

If all the above are in order & still the Output Voltage is not present, the power supply
PCB may be returned to factory for repair.

In Case the Page Phone’s performance is unsatisfactory:

First remove the outgoing cables from terminals SYSBUS/PG & GN. Check whether the
cable is shorted. If so this cable short has to be removed before proceeding further. If
Cable is O.K. proceed further.

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

Check whether the battery output is available. The Voltage between + & - terminals
should be 12 V (Nominal). In case it is less, check the Charge voltage on the Battery
terminal CH. & the Charge current. The voltage should be 14-15VDC Nominal & current
20-30 mA DC (Typical). In case this is not so, check for presence of Charging voltage
(14 to 18VDC) between terminal SYSBUS/CH (Charge Input) & SYSBUS/GN (System
Ground). If absent check the charging line to FLP PSU & the FLP PSU it self as
mentioned earlier. If Voltage is available on CH but not Battery CH terminal then the
Charging Potentiometer may be open or the wiring between CH & potentiometer & CH
terminal may have been snapped. Rectification may be carried out as deemed fit. If
every thing is O.K. but the battery output is below 8 VDC, the charging current may be
adjusted to 50-70 mA by turning the Charging Pot & kept so for 14 hours. After 14
hours if the battery output reaches 12 VDC then the battery is O.K. & charging current
must be reduced to 20-30 mA for normal charging. If the battery does not attain 12VDC
after 14 Hours of Quick Charging as explained earlier then the battery pack is to be
replaced.

If battery is found healthy & charging circuitry in order, then press the handset switch
and speak into the microphone. A part of handset amplifier output is fed back into the
receiver & you will hear what you speak. In case this does not happen, Check the
Handset TX capsule (Terminals HANDSET/TX & TX = 70-80 Ohms), RX Capsule
(Terminals HANDSET RX & RXS=70-80 Ohms) & Handset PTT switch (HANDSET/SW &
RXS= Normally open, short when switch is pressed). If any of them is not in order TX
capsule, RX Capsule, Pressel Switch or the Handset Cord may have to be replaced. If
handset & associated connections are found O.K up to 15 Pin D connector of PCB &
feedback is still not available on the Receiver, then the PCB may be defective. It has to
be replaced.

If Battery & Handset amplifier is O.K. but paging does not take place, check for
presence of Page voltage (8-11 VDC) on terminal SYSBUS/PG while keeping another
page phone’s Page Switch Pressed. In case this is not present, isolate the PCB from its
D connector to check whether it is a line fault or the PCB is causing it. In case it is a line
fault the same has to be investigated. In case the page voltage is present on the
terminal PG without the PCB in Circuit but drops when PCB is inserted then the PCB is
faulty & has to be replaced.

If Page Voltage received from far end is fine then check the Page switch contacts & the
Speaker. If switch or speaker is found defective they have to be replaced.

If cable, battery, handset, handset amp circuitry, Page switch & speaker are found to
be in order but the paging does not take place or page volume is low, try adjusting the
volume control potentiometer R18 on the PCB. If still no improvement is found, the
Page PCB may have to be replaced.

In case incoming paging is O.K., out going handset to handset communication is O.K.
but paging call initiated from a page phone is not announced on other page phones,
then check for presence of page voltage (8 to 11 VDC) on PG when the page phone’s
Page switch is pressed. If it is not present check the same on PAGESW/NO(left) & D
connector pin 3. If present on PAGESW/NO(left) but not on PG then Page Switch is
defective. If present on D Conn. Pin 3 but not on PAGESW/NO(left) then the wiring from
D conn. Pin3 to PAGESW/NO(left) may be snapped. This may be repaired. If Page
Voltage is not available even on D Connector Pin 3, then the Page PCB is defective and
is to be replaced.
Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone
 Wiring scheme for page phone

External connections

Term. Term. Ext. Conn. Colour “D” conn /

group name others
name
SW HANDSET CORD - WHITE WHITE 7
RX HANDSET CORD - GRAY GRAY 14
HANDSET TX HANDSET CORD – BLUE BLUE 12
TX HANDSET CORD – RED RED 13
RXS HANDSET CORD - GREEN GREEN BATT “-VE”
PG PAGE LINE RED 8
(SYSTEM
CBL)
GN GROUND LINE i.e. –VE OF BLACK GROUND
SYS BUS PSU (SYSTEM
CBL)
CH CHARGING LINE FROM YELLOW CH. POT IN
PSU (SYSTEM
CBL)

Internal connections

Term. Term. Ext. Conn. Colour “D” conn /

group name others
name
CH BATTERY TERMINAL “CH” YELLOW CH. POT OUT
BATT GN BATTERY TERMINAL “-VE” BLACK GROUND
B+ BATTERY TERMINAL “+VE” RED 11
SPEAKER TERMINAL RED 9
SPKR
SPEAKER TERMINAL RED 10
NO (LEFT) PAGE SWITCH NO YELLOW 3
TERMINAL
NC (LEFT) PAGE SWITCH NC BLACK 4
TERMINAL
PAGE SW
NC PAGE SWITCH NC BLACK GROUND
(RIGHT) TERMINAL
NO PAGE SWITCH NO YELLOW SYS BUS “PG”
(RIGHT) TERMINAL

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone

Document Number : KS/PPH/BOX-WD/01

Kaizen Services Pvt Ltd Instruction Manual of IS Page Phone