3M C860 User manual

i
Headset Intercom Systems
Model C860/C960/C960SL/C1025
Installation Instructions

i
Table of Contents
Typical Single Lane Installation...................................................................................................................... 1
Battery Charger ............................................................................................................................................... 2
Speaker and Microphone Assemblies.............................................................................................................. 3
Standard Systems...................................................................................................................................... 3
Duplex Systems ........................................................................................................................................ 3
Face–to–Face Type Duplex Systems........................................................................................................ 3
Base Station..................................................................................................................................................... 3
Interconnect Module (Optional)...................................................................................................................... 4
Connecting the Base Station Directly to Components .................................................................................... 5
Connecting the Base Station to Components Using the Optional Interconnect Module................................. 6
Connecting the Auxiliary Intercom (Optional) ............................................................................................... 8
Dual Lane System Installation......................................................................................................................... 9
Cross Lane System Installation ....................................................................................................................... 10
System Configurations and Function Jumper Settings.................................................................................... 14
Standard Operation – Single Lane System (One Base Station)................................................................ 14
Standard Operation – Dual Lane System (Two Base Stations) ................................................................ 14
Duplex Operation – Single Lane System (One Base Station)................................................................... 15
Duplex Operation – Dual Lane System (Two Base Stations)................................................................... 15
Channel Selection............................................................................................................................................ 16
Setting Audio Levels....................................................................................................................................... 17
Duplex Systems Only ............................................................................................................................... 18
Duplex and Standard Systems .................................................................................................................. 18
Alert Tone Level....................................................................................................................................... 18
Monitor Speaker Volume Levels........................................................................................................ 19
Standard Systems Only............................................................................................................................. 19
Listen Level (Menu Sign Microphone Sensitivity)............................................................................ 19
Menu Sign Talk Volume Level.......................................................................................................... 19
Circuit Board Jumpers, Adjustment Controls, Indicators and Switches.......................................................... 21
Jumpers..................................................................................................................................................... 21
Adjustment Controls................................................................................................................................. 22
Indicators................................................................................................................................................... 22
Switches (etc.)........................................................................................................................................... 22
Connectors ................................................................................................................................................ 23
Finishing Up.................................................................................................................................................... 24
Troubleshooting Audio Feedback ................................................................................................................... 24
Technical Assistance ....................................................................................................................................... 24

ii
Illustrations
Figure 1. Typical Installation......................................................................................................................... 1
Figure 2. Battery Chargers (3–Slot and 6–Slot Versions).............................................................................. 2
Figure 3. Base Station Mounting Holes......................................................................................................... 3
Figure 4. Interconnect Module....................................................................................................................... 4
Figure 5. Direct Base Station–to–Component Connections........................................................................... 5
Figure 6. Base Station – Interconnect Module Connections.......................................................................... 6
Figure 7. Connecting Components to the Interconnect Module .................................................................... 7
Figure 8. D–15D (M478 DA) Connections.................................................................................................... 8
Figure 9. D–15B and D–15C (M478 BA and CA) Connections.................................................................... 8
Figure 10. D–30 Connections ........................................................................................................................ 9
Figure 11. Cross–Lane Wiring Diagram........................................................................................................ 11
Figure 12. Removing the Half–Cover from the Base Station........................................................................ 16
Figure 13. Base Station Circuit Board ........................................................................................................... 17
Figure 14. Base Station Circuit Board ........................................................................................................... 21

1
Typical Single Lane Installation
Figure 1. Typical Installation
Material Required (not supplied)
• 3/4–inch conduit (metal or plastic) – 2 pieces 4–5 feet in length
• conduit clamps
• assortment of sheet metal screws
• two sets of 18–gauge, twisted–pair (two wires each set) audio cable, sufficient in length to connect the speaker
and microphone assembly (in the menu sign) to the interconnect module or base station.
!Important
The twisted–pair of wires for the microphone connection must be shielded for
proper operation. In duplex systems, microphone and speaker cannot be in the
same jacket unless specially designed for duplex such as 3M 78–8095–0180–8.
• sufficient twisted–pair sets of audio cable to connect other components such as monitor speaker, vehicle
detection device, etc.

2
Battery Charger
Install the battery charger and begin charging the batteries before you install any other components.
Install the battery charger in a clean, dry environment. An office location is best.
The battery charger may be placed on a flat surface such as a table, desk, etc., or it can be fastened to a wall using
the optional wall–mount kit.
Plug the power supply transformer into a 120–Volt wall outlet and then plug the transformer cord into the
connector in the end of the battery charger. The three green lights on the battery charger will turn on.
To charge a battery, plug it into the charger as shown in Figure 2. Observe the charging status indicator next to the
battery:
• The indicator lights RED to indicate the battery is charging.
• The indicator lights GREEN to indicate the battery is fully charged.
• The indicator lights ORANGE to indicate the battery is defective.
9Note
Discharged batteries require 1–1/2 to 2 hours to charge.
When the battery voltage becomes too low, a short, low volume tone, occurring at seven–second intervals is heard
in the headset. This repeating tone continues for two minutes. After the two–minute interval, the headset
automatically turns off to prevent battery damage.
Figure 2. Battery Chargers (3–Slot and 6–Slot Versions)

3
Speaker and Microphone Assemblies
Standard Systems
For standard systems, install the Deluxe 5–Inch Speaker and Microphone Assembly, Part Number 78–6911–1545–
1. Refer to the installation instructions packaged with the assembly.
Duplex Systems
For duplex systems, install the 3.5–Inch Duplex Microphone (with foam housing), Part Number 78–6911–4476–6
and the 5–Inch Metal Speaker Assembly, Part Number 78–6911–4411–3. Refer to the installation instructions
packaged with the assemblies.
Face–to–Face Type Duplex Systems
The 3M Communications Bar, Part Number 78–6911–4451–9 contains the Duplex Speaker and Microphone listed
above. Refer to the installation instructions that are packaged with the assembly.
Base Station
1. For proper system operation, locate the base station module:
• 5 to 6 feet above the floor
• at least 10 feet from the cashier/drive–thru window
• At least 3 feet from large metal objects such as refrigerators, ranges, coolers, etc., and other metal or
electrical devices.
!Important
Do not mount base station under steel countertops, within 3 feet of
coolers/refrigerators/ranges or in areas where it will be obscured by steel
doors, walls, etc. as this will cause operational problems.
2. Mount the base station using the included screws and anchors. (See Figure 3.)
Figure 3. Base Station Mounting Holes
3. Install conduit and cable clamps as necessary.
4. Feed the cables for speaker, microphone, vehicle detect and monitor speaker (if used) through the conduit
down to the interconnect module or base station. (See Figure 1.)
5. Feed the transformer cable from the outlet to the base station. (See Figure 1.)
Keep the transformer cable at least 6 inches from the left half of the base station. This half contains sensitive
radio components which will be affected if the cable is too close.

4
Interconnect Module (Optional)
1. Install the interconnect module in an “out of the way” location, near the wiring for the auxiliary intercom,
vehicle detector, etc. (Under a counter is desirable.)
2. To fasten the interconnect module in position:
a. Remove the backing from the adhesive hook and loop fastener material on the rear of the module.
b. Orient the module to provide the most convenient wire connection arrangement.
c. Press the adhesive surface of the hook and loop fastener material against a flat, smooth surface.
The module is now removable for wiring and if needed, future servicing.
Figure 4. Interconnect Module

5
Connecting the Base Station Directly to Components
If an interconnect module is not used, connect the components (vehicle detector, speaker/microphone and optional
monitor speaker) directly to the base station as shown in Figure 5. Use 18–20 gauge twisted pair audio wire for all
connections except the microphone. Use an 18–20 gauge shielded twisted–pair of audio wire for the connection to
the microphone.
!Important
The twisted–pair of wires for the microphone connection must be shielded for
proper operation. In duplex systems, microphone and speaker cannot be in the
same jacket unless specially designed for duplex such as 3M 78–8095–0180–8.
Figure 5. Direct Base Station–to–Component Connections

6
Connecting the Base Station to Components Using the Optional Interconnect Module
Connect the base station to the interconnect module as shown in Figure 6. Note that the connections are made to
the “TO CONTROL MODULE” terminals on the interconnect module.
Figure 6. Base Station – Interconnect Module Connections
Connect the components (vehicle detector, speaker/microphone, and optional monitor speaker) to the interconnect
module as shown in Figure 7. Note that the connections are made to the “TO OUTSIDE” terminals on the
interconnect module.
*Note
If an optional back–up (auxiliary) intercom is connected to the “TO AUXILIARY INTERCOM”
on the interconnect module, the base station must be turned off to enable operation/usage of the
back–up intercom.
Use 18–20 gauge twisted–pair audio wire for all connections except the microphone. Use an 18–20 gauge
shielded twisted–pair audio wire for the connection to the microphone.

7
Figure 7. Connecting Components to the Interconnect Module
2 EA. 1500 OHM Resistors
Supplied MYH Duplex Mic

8
Connecting the Auxiliary Intercom (Optional)
*Note
The base station must be turned off to enable operation/use of the auxiliary intercom.
1. Connect the auxiliary intercom to the “TO AUXILIARY INTERCOM” terminals on the interconnect module
as shown in Figure 8 through Figure 10 (depending on the model of intercom used).
The presence alert shown is wired to operate only when the Wireless Base Station is turned off.
If a separate outside microphone is used, the auxiliary intercom must be configured for OUTSIDE MIC. Refer
to the Auxiliary Intercom Installation Instructions for information about moving any internal jumpers.
Figure 8. D–15D (M478 DA) Connections
Figure 9. D–15B and D–15C (M478 BA and CA) Connections

9
!Important
If you use a D–30 as the auxiliary intercom, a separate monitor speaker must
be provided for the Wireless Base Station. (Both the Wireless Base Station
and D–30 intercoms require separate monitor speakers.)
Figure 10. D–30 Connections
Dual Lane System Installation
A dual lane system consists of two separate single lane systems that operate independently of each other. Each
single lane system has its own dedicated base station and headset(s).
To install a dual lane system:
1. Install two single lane systems as outlined in these installation instructions.
!Important
Base station models C921 and earlier must be mounted at least 25 feet apart.
Base station models C922 may be mounted as close as 2 feet apart.
2. With the base stations turned off, set jumper J3 on one of the base stations so that it jumpers pins 1 and 2. This
designates the base station as a lane 1 system.
3. Set jumper J3 on the other base station so that it jumpers pins 2 and 3. This designates the base station as a
lane 2 system.
!Important
Do not set both base stations to the same lane number as this will cause
operational problems.
4. Turn on both base stations and press the RESET SWITCH on each of the base station circuit boards to “read”
the jumper setting into the microprocessor.

10
5. Select a channel for each of the base stations. (See page 14 for the channel selection procedure.) After you
select the channel, press the RESET SWITCH on the base station circuit boards to “read” the selection into the
microprocessor.
6. Re–program the headsets as instructed on page 15.
1. Check the operation of each of the systems. Note that the alert tone for the Lane 1 system headsets is a
single repeating “beep” while the alert tone for the Lane 2 system headsets is a double repeating “beep.”
Cross-Lane System Installation
Description
The Cross-Lane System is designed for facilities that have two menu signs. It consists of two Wireless Base Stations that are
connected to a Cross–Lane Module. A Cross–Lane Module is a five–pole switch that allows the two systems to be separated
during hours of peak activity. The Cross-Lane System can be used with C760, C860, C960, C1025, and C1060 headsets. The
C760 headset may require additional equipment.
A Cross–Lane Module can be useful if the manager wishes to operate each lane with a separate crew during
periods of peak activity. This is accomplished by turning the Cross–Lane switch OFF. By pressing the T1 button
on any headset, the operator can communicate with a customer at menu sign 1. By pressing the T2 button on any
headset, another operator can communicate with a customer at menu sign 2. When the Cross–Lane Module is
OFF, the operator will only hear the vehicle detector alert from the menu sign with which he or she last talked.
During periods of lower activity, the Cross–Lane Module is turned ON, allowing one headset order–taker to operate both
lanes. When the Cross–Lane Module is turned ON, the operator will always hear vehicle detector alerts from both menu signs.
A single alert indicates a vehicle is a menu sign 1, while a double alert indicates a vehicle is at menu sign 2.
Additional Material Required
•A sufficient length of two-conductor 20 AWG twisted pair shielded audio cable (not supplied) for connecting the Cross-
Lane Module to the two base stations.
•Applicable screws/fasteners (not supplied) for mounting the Cross-Lane Module.
Installation
Notes: Both base stations must be set to the same channel number and different lane numbers.
Base station models C921 and earlier must be mounted at least 25 feet apart. Base station models C922
may be mounted as close as 2 feet apart. Test the system prior to installation by placing the base stations
in the desired locations. Set Jumpers and program the headsets. Insure that the talk L.E.D. on the proper
base station lights when the appropriate (T1 and T2) button on the headset is pressed.

11
Wiring the System:
1. Use the applicable screws/fasteners and mount the Cross-Lane Module to the wall in a convenient location next to one of
the base stations. Note
To ensure access to the switch on the Cross-Lane Module, locate the module near one of
the base stations.
2. Run a length of two-conductor 20 AWG twisted pair shielded audio cable between the Cross-Lane Module and the
nearest base station.
3. Run a length of two-conductor 20 AWG twisted pair shielded audio cable between the Cross-Lane Module and the other
base station.
4. Connect the cables from the module to the base stations as shown in Figure 1.
Important!
Both Base stations must be set to the same channel number and different
lane numbers.
Important!
For proper operation, the base stations must be at least 25 feet apart.
Figure 11

12
Programming the Headsets for Cross–Lane Operation
Follow the steps below to program the headsets for Cross–Lane operation, and disable the Talk—Lock function. It does not
matter which base station is used to program the headsets. By pressing T1, the headset will communicate with the lane 1 base
station; by pressing T2, the headset will communicate with lane 2 base station.
1. Disable the Talk Lock function:
Talk–Lock is a toggle function that must be checked first to see if it is enabled or disabled. If the Talk LED on the base
station lights when the Lbutton is pressed, Talk–Lock is enabled.
• To disable Talk–Lock, turn the headset OFF, press and hold the L button while pressing ON for 5 seconds. You will
hear a series of beeps indicating that Talk–Lock is off.
• Recheck the Talk–Lock function by pressing the L(talk-lock) button. The Talk LED on the base station should not
light.
2. Programming the headsets for Cross–Lane Operation:
a. Start with the headset OFF. Then, hold down the T1 and T2 buttons while pressing ON for 5 seconds. You will hear
a series of beeps indicating that the headset has been programmed.
b. Verify that the headsets are properly programmed for Cross–Lane operation as follows:
(1) Press T1 and verify that the Talk LED lights on the lane 1 base station and does not light on the lane 2 base
station.
(2) Press T2 and verify that the Talk LED lights on the lane 2 base station and does not light on the lane 1 base
station.
c. To remove the Cross–Lane function and return the headsets to the normal (single lane) operating mode, first turn the
headset OFF, and then do one of the following operations:
– For lane 1 operation only, hold down T1 while pressing ON for 5 seconds. You will hear a series of beeps
indicating that Cross–Lane function is no longer active. Reprogram the headsets from the lane 1 base station
if you want to communicate with lane 1.
– For lane 2 operation only, hold down T2 while pressing ON for 5 seconds. You will hear a series of beeps
indicating that Cross–Lane function is no longer active. Reprogram the headsets from the lane 2 base station
if you want to communicate with lane 2.
Operation
Cross–Lane Module OFF:
Vehicle detector alerts
The operator will only hear the vehicle detector alert from the menu sign with which he or she last talked. Vehicles at
menu sign 1 will be heard as a single repeating alert. Vehicles at menu sign 2 will be heard as a double repeating
alert.
Answering customers
Pressing T1 will only allow communications with the lane 1 customer. Pressing T2 will only allow communication
with the lane 2 customer.
Paging function
Pressing the P (Page) button will communicate using the base station last communicated with (via T1 or T2).
Headsets programmed for the last used base station will receive the page.

13
Cross–Lane Module ON:
Vehicle detector alerts
The operator will always hear both vehicle detector alerts. Vehicles at menu sign 1 will be heard as a single repeating
alert. Vehicles at menu sign 2 will be heard as a double repeating alert.
Answering customers
Pressing T1 will only allow communications with the lane 1 customer. Pressing T2 will only allow communication
with the lane 2 customer.
Paging function
Pressing the P (Page) button will communicate using the base station last communicated with (via T1 or T2).
Headsets programmed for the last used base station will receive the page.
Notes:
1. Both vehicle alert tones will be heard at all times with the Cross–Lane Module ON.
The order–taker may object to hearing the vehicle alert from the other lane while taking an order, if so, we suggest you
decrease ALERT TONE LEVEL on each base station so that it is audible in the headsets but not objectionable.
2. Listening and Paging in a Cross–Lane system.
The T1 and T2 buttons control which menu sign to talk or listen to. They also control which headsets to Page to. If a
cook or cashier needs to monitor both lanes follow the suggestions below:
• The cook/cashier can press T1 when they hear a single alert tone or, they can press T2 when they hear a double alert
tone.
• Paging function:
a. When order-taker Pages cook/cashier: If cook/cashier is listening on lane 2, order-taker must press
T2 then Page cook/cashier.
b. When cook/cashier Pages order-taker: If order-taker is listening on lane 2, cook/cashier must press
T2 then Page order-taker.
• A monitor speaker from each base station may be installed in the kitchen.
CAUTION!
Monitor speakers are generally not recommended for duplex systems
using base stations earlier than Model C921BA. The speaker location and
volume are usually too critical to avoid feedback. C921BA and C922 base
stations can usually be configured successfully to allow operation of
monitor speakers.

14
System Configurations and Function Jumper Settings
!Important
Whenever a jumper setting is changed, the RESET SWITCH on the base station circuit board must be pressed
to program the new jumper setting into the microprocessor. Also, each of the headsets in the system must be
reprogrammed when a jumper setting is changed (see Channel Selection on page 14 for the headset
programming procedure).
Determine the system type (standard operation – single lane, etc.) and identify the type of speaker (speaker only or
speaker and microphone) and the type of vehicle detector (air switch or loop/SODAR detector).
Refer to the base station circuit board illustration (Figure 14) and the applicable system configuration below. Set
the function jumpers as noted and per the type of speaker and vehicle detector in the system. (An illustration of the
circuit board also appears on the decal inside of the base station half–cover.)
Standard Operation – Single Lane System (One Base Station)
Function Jumper Settings
Menu Sign with Speaker only (OSM) Jumper pins 1 and 2 on jumpers J1 and J2.
or or
Menu Sign with Separate Speaker and
Microphone Jumper pins 2 and 3 on jumpers J1 and J2.
Lane 1 System Jumper pins 1 and 2 of jumper J3.
Air Switch (Pulse) Detector Jumper pins 1 and 2 of jumper J4.
or or
Loop/Sodar (Presence) Detector Jumper pins 2 and 3 of jumper J4.
Standard Operation Jumper pins 2 and 3 of jumper J5.
Menu Power Selection Jumper must cover the top 2 pins of jumper J6.
Talk Monitor Level Jumper left 2 pins of jumper J9.
SWT Threshold (High) Jumper CRFT 2 pins when using a C1060 headset
in Talk Lock mode.
SWT Threshold (NRML) Jumper right 2 pins for all configurations except
those mentioned in “High.”
Standard Operation – Dual Lane System (Two Base Stations)
Function Jumper Settings
Menu Sign with Speaker only (OSM) Jumper pins 1 and 2 on jumpers J1 and J2.
or or
Menu Sign with Separate Speaker and
Microphone Jumper pins 2 and 3 on jumpers J1 and J2.
Lane 1 System Jumper pins 1 and 2 on base station 1, jumper J3.
Lane 2 System Jumper pins 2 and 3 on base station 2, jumper J3.
Air Switch (Pulse) Detector Jumper pins 1 and 2 of jumper J4.
or or
Loop/Sodar (Presence) Detector Jumper pins 2 and 3 of jumper J4.

15
Standard Operation Jumper pins 2 and 3 of jumper J5.
Menu Power Selection Jumper must cover the top 2 pins of jumper J6.
Talk Monitor Level Jumper left 2 pins of jumper J9.
Duplex Operation – Single Lane System (One Base Station)
Function Jumper Settings
Menu Sign with Separate Speaker and
Microphone Jumper pins 2 and 3 on jumpers J1 and J2.
Lane 1 System Jumper pins 1 and 2 of jumper J3.
Air Switch (Pulse) Detector Jumper pins 1 and 2 of jumper J4.
or or
Loop/Sodar (Presence) Detector Jumper pins 2 and 3 of jumper J4.
Duplex Operation Jumper pins 1 and 2 of jumper J5.
Menu Power Selection Jumper bottom 2 pins of jumper J6.
Talk Monitor Level Jumper left 2 pins of jumper J9.
or
If feedback occurs, jumper right 2 pins of
jumper J9
Duplex Operation – Dual Lane System (Two Base Stations)
Function Jumper Settings
Menu Sign with Separate Speaker and
Microphone Jumper pins 2 and 3 on jumpers J1 and J2.
Lane 1 System Jumper pins 1 and 2 on base station 1, jumper J3.
Lane 2 System Jumper pins 2 and 3 on base station 2, jumper J3.
Air Switch (Pulse) Detector Jumper pins 1 and 2 of jumper J4.
or or
Loop/Sodar (Presence) Detector Jumper pins 2 and 3 of jumper J4.
Duplex Operation Jumper pins 1 and 2 of jumper J5.
Menu Power Selection Jumper bottom 2 pins of jumper J6.
Talk Monitor Level Jumper left 2 pins of jumper J9.
or
If feedback occurs, jumper right 2 pins of
jumper P9.

16
Channel Selection
The Model C960/C860/C1025 Headset Intercom System can operate on any one of eight different channels.*
Select a channel that neither receives or causes interference and then program the headsets to that channel using the
following procedure:
1. Pull slightly outward on the lower right side of the base station half–cover and then lift and remove the cover
as shown in Figure 12.
Figure 12. Removing the Half–Cover from the Base Station
2. With the base station turned on, press and release the CHANNEL SELECT switch once. This advances the
system to the next channel. One of the red indicators (1–8) will light, indicating the newly selected channel.
!Important
After making any changes to the base station jumper settings, you must press
the RESET SWITCH to “read” the new settings into the microprocessor.
!Important
When two systems are used in a dual lane application, each base station must
be set to the same channel, and one base station must be set to Lane 1 and the
other to Lane 2.
*Note
If you are installing this as a single lane system, 8 channels on the LANE 2 setting are also
available for use.