inter-tel phone does not power up on 100+ phone cord

I work in a large warehouse and need to move a phone across the room, about 120 ft.  I made a cable using CAT 5 and used a 6 conductor phone connector, but cannot get phone to power up.  The phone is an inter-tel multi line phone system.  I tested the line I made with a data cable tester, all 6 wires give signal, and the phone only needs two working wires to work. When I plug in the wall jack, the tester shows Volts! so I don't think there is anything wrong with the line.  However, When I plug in a shorter phone line about 25' the phone works.  I tried using a data coupler for phones and extend the line that way and it stops working.  

So is the problem the distance of the cable?  There is probably about 300ft of line leading up to the wall jack.  So the line I made would make it 400+ ft.  But to my knowledge phones can handle great distances.  So I am not sure what the deal is.  Would changing the connector to a 4 conductor make a difference?
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JohnBusiness Consultant (Owner)Commented:
There is probably about 300ft of line leading up to the wall jack.  <-- So then there is your issue (amplified by the fact that a short cord from the wall works).

I suggest getting a phone company in to put in a repeater to give you more distance.

A small switch works for Ethernet extension but I do not know about phone repeaters.

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icecom4Author Commented:
I am ware of the 300ft signal limitation on CAT5 but thought phone signals could go great distances?
JohnBusiness Consultant (Owner)Commented:
Everywhere I am, phone lines come from a phone system box usually near by. For DSL, you need to be somewhere less than 4 Km from a Phone Communication Office (CO) but as you go along, I think there must be some repeaters somewhere.

Even if you can go longer distances, you need a phone company technician to test the lines.
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JohnBusiness Consultant (Owner)Commented:
but thought phone signals could go great distances?  <--- Is your phone a POTS land line phone? Such a phone does not need power and does not need to "power up". Is it VOIP?  If so, it needs to power up and is subject to the lower length limit. I am confused a bit by "power up"
Dave BaldwinFixer of ProblemsCommented:
I can't find an installation manual for that phone so I can't tell whether it is an analog (2-wire) phone or a digital phone that requires special cabling.  Analog phone typically have 48 volts between the 2 wires while digital cables may have just about anything depending on what the PBX manufacturer decided to do.  The analog and digital phones are not interchangeable.  

On this page it says...
PLEASE NOTE: All business telephones listed on this web site will operate only if connected to the appropriate phone system. They will not function as a stand-alone telephone.
This pretty much says that you do not have an analog phone that will work on just two wires.
icecom4Author Commented:
ah yes, I did not mention that, this is not an analog phone system

@ John
for lack of better wording, by "power up", I mean when I plug in the phone cord, the digital display turns on (which also means I get a dial tone)

@ Dave
Perhaps you are right, maybe not just 2 wires, but I know it does not require more than 4 that because 90% of the phone cords only have 4 wires.  That being said, not sure why a 6-wire phone cord that tests fine would not do the job.
JohnBusiness Consultant (Owner)Commented:
Either check your own connections that you made, or call in a phone technician. I am not sure of the length of a digital phone. You may need some installation assistance.
Dave BaldwinFixer of ProblemsCommented:
You might check to see if your 120 ft cord is wired the same as the shorter ones.  I've had a couple of products where we had to supply 6-wire 'phone' cords because we couldn't count on the ones at the store being wired correctly.  For ordinary analog phones, all you need is the center pair and the phone takes care of polarity.  That isn't necessarily so on other devices.
icecom4Author Commented:
Well, I just arranged the cables in same order 1-6 like I would a CAT5 cable, just dropping the last two (brown-white, brown).  All 6 wires test out correct with my hand-held data tester (same order on both ends).  That being said, the line will continue the same order as the jack I am plugging it into.
Dave BaldwinFixer of ProblemsCommented:
That's what I would do.  What's the "data coupler"?  Is that an inline double female jack?  Have you checked it for having all six wires in the correct order?  Consumer versions often don't have all six wires.
icecom4Author Commented:
well at the moment, not using a coupler, just a 120' line I made plugged directly in the wall jack.  I am going to try and shave that last 20' off and put on some different connectors and see what happens
icecom4Author Commented:
I have not done this yet, I will in next couple days then update this thread
JohnBusiness Consultant (Owner)Commented:
@icecom4  - Thanks and I was happy to help.
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