3M c960 Service Information
Model C960
Headset Intercom System
Service Information
Food Services Trade Department
3M Center
St. Paul,MN 55144-1000
PrintedinU.S.A.
Copyright E 3M IPC. All Rights Reserved.
78-6912-0673-0 Rev C
Model C960 Headset Intercom System
This manual was published in September, 1997 at revision level A.
Someportionsofthismanualarealsopublishedseparately. Thepublishingdatesforthefrontmatter,individual
sections, and separately-published documents are as follows:
Front Matter
Cover 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History Page 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ableof Contents 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1
Operation and Diagrams 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
C960/860 Installation Instructions (78-6912-0672-2) 2000 May. . . . . . . . . . . . . . . . .
Section 3
Replacement Parts and Service 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision History
Section 4
T roubleshootingGuide (78-6912-0680-5) 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . .
Analyzing Batteries 1997 September. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5
Operating Instructions (78-6912-0671-4) 2000 May. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Procedures:
Noise Reduction Module, Model A121 (78-6912-0699--5) 1999 November. . . . . . . . . . . . .
Noise Reduction Module, Model A125 (78--6912--0723--3) 2000 March. . . . . . . . . . . . .
Loop Detector, Models A200 and A201 (78--6912--0712--6) 2000 April. . . . . . . . . . . .
Audio Greeter, Model A300 (78--6912--0717--5) 2000 February. . . . . . . . . . . . . . . . . . . . .
Duplex Microphone/Speaker Assembly (78-6912-0490-9) 1995 August. . . . . . . . . . . . . .
Cross-Lane Module (78-6912-0487-5) 1995 March. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headset Storage Rack Kit (78-6912-0508-8) 1995 March. . . . . . . . . . . . . . . . . . . . . . . .
Duplex Menu Cable (78-6912-0509-6) 1995 March. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3M Communications Bar (78-6912-0581-5) 1996 July. . . . . . . . . . . . . . . . . . . . . . . .
Five-Inch Speaker and Mic Assembly (78--8050--8497--3) 1996 April. . . . . . . . . . . . . .
3.5-Inch Duplex Microphone (78--6912--0596--3) 1996 June. . . . . . . . . . . . . . . . . . . .
5-Inch Duplex Speaker Asembly (78--6912--0530--2) 1999 April. . . . . . . . . . . . . . . . . .
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Model C960Headset Intercom SystemRevision History
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Model C960 Headset Intercom System
Table of Contents
Section 1. Operation and Diagrams
Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Station 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headset 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speaker and Microphone Assemblies 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect Module 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-Lane Module 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Alert System 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Configurations 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-Lane Standard Communication System 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual-Lane Standard Communication System 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single-Lane Duplex Communication System 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual-Lane Duplex Communication System 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual-Lane Duplex Cross-Lane Communication System 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Theory 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Processing Vehicle Alert Signals 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ransmittingand Receiving 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T alk/ListenCommunication 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T alkLock Mode 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Mode 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page Monitor Mode 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross-Lane Talk/Listen Mode 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Amplifier and Speaker 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headset Components 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rechargeable Battery 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headband 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Microphone Boom Assembly 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speaker Assembly 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Station 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T alk/PageInput 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Detector Input 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Mic Input 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Model C960 Headset Intercom SystemTable of Contents
Base Station Configuration Jumpers and Switches 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base Station and External Components Diagram 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect Module 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On/Off DC 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Microphone Signal Control 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Speaker Audio Control 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitor Speaker Audio Control 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Detector Signal DC 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect Module Diagram 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2. Installation Instructions
Section 3. Replacement Parts and Service
Ordering Replacement Parts 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T echnicalService 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 - Base Station Assembly and Interconnect Module 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 - Headset Assembly 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 - 3-Slot Battery Charger Assembly 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 - 6-Slot Battery Charger Assembly 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Headset Speaker 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Mic Boom Assembly 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Battery T erminals 3-12.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Battery Release Button Spring 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4. Troubleshooting
T roubleshootingGuide
Analyzing Batteries 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISCHARGE Test 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYCLE 1 Test 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYCLE 2, CYCLE 3, and CYCLE 4 Tests 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Procedures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initiating a Test 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interpreting Test Readings 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Codes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii E 3M 2000 May
Model C960 Headset Intercom System
Section 5. Operating and Installation Instructions
Model A121 Noise Reduction Module, 78-6912-0699--5
Model A125 Noise Reduction Module, 78--6912--0723--3
Models A200 and A201 Loop Detector , 78--6912--0712--6
Model A300 Audio Greeter, 78--6912--0717--5
Model C960 Operating Instructions
Cross-Lane Module Installation Instructions, 78--6912--0487-5
Headset Storage Rack Installation Instructions, 78--6912--0508-8
Duplex Menu Cable Installation Instructions, 78--6912--0509-6
3M Communications Bar Installation Instructions, 78--6912--0581-5
Five Inch Speaker and Mic Assembly Installation Instructions, 78--8050--8497-3
3.5-Inch Duplex Microphone Installation Instructions, 78--6912--0596-3
5--Inch Duplex Speaker Assembly, 78--6912--0530-2
Table of Contents
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Model C960 Headset Intercom SystemTable of Contents
iv E 3M 2000 May
Model C960 Headset Intercom System Operation andDiagrams
Introduction
The 3M Model C960 Headset Intercom System is a
wirelessintercomsystemdesigned forhigh reliability,
compactness, and ease of service. It is designed to
provide two-way, radio-frequency audio
communication in quick service drive-through
restaurants and convenience stores.
Thesystemcanbeprogrammedtooperateonanyone
of16differentchannelstoprovidehigh-qualityaudio
performance andreducethepossibilityofinterference
between neighboring wireless systems.
System Components
The number of components in a system varies
dependingonthesystemconfiguration.However,the
basestation,headset,andbattery chargerare common
to all system configurations.
Base Station
The wall-mounted base station contains logic and
analogcircuitsandrelatedsystemcontrols, areceiver
toreceivesignals transmittedfrom theheadsets,anda
transmitter to transmit signals to the headsets.
Headset
Theheadset is a wireless, battery-powered, two-way
radiousedbytheoperatortocommunicatewithmenu
signcustomersandwithotherstorepersonnelwho are
wearing headsets. The microphone and earpiece
enable the operator to transmit and receive spoken
communication and alert tones.
Theheadsetcanbeprogrammed tooperate onanyone
of16differentchannelstoprovidehigh-qualityaudio
performance andreducethepossibilityofinterference
between neighboring wireless systems.
The headset assembly has several field-replaceable
components. These components are detailed in
Section 3 of this manual (Replacement Parts and
Service).
Battery Charger
The battery charger charges headset batteries in
approximately 1.5 to 2 hours. The charger is
available in 3-slot and 6-slot versions.
Each battery charger has two field-replaceable
components:
S Charger Assembly
S T ransformerAssembly
Speaker and Microphone Assemblies
Standard Systems
The 5-Inch Speaker and Mic Assembly is
recommended for use in standard communication
systems. It consists of a 5-inch, water-resistant,
eight-ohm cone speaker plus a special
weather-resistant dynamic microphone. It also
includes a mounting bracket for easy mounting in
menu signs, speaker posts and other applications.
Usingthis separatespeaker and microphone ensures
maximum sound quality.
Duplex Systems
The3.5-InchDuplexMicrophoneand5-InchDuplex
SpeakerAssembly arerecommendedforusein duplex
communication systems. The microphoneismounted
on a foam housing,which canbe cut to the required
size. The speaker is mounted in a metal housing.
Interconnect Module
This optional module provides a convenient
connection point for equipment such as speakers,
microphones, vehicle detectors, and auxiliary
intercoms.
Cross-Lane Module
This module is a required component for dual-lane
duplexcross-lanecommunicationsystems.Itenables
a single headset to operate two base stations.
Vehicle Alert System
The Model C960 is compatible with all 3M vehicle
detectors and those of most other manufacturers.
Thereare twotypes ofvehicledetectors, classifiedas
presence detectors or pulse detectors. Presence
detectors(suchasmagneticloopsorSODAR)provide
a signal for as long as a vehicle is present at the
detector. Pulse detectors, such as air hoses,provide
only a momentarysignal—signalling vehicle arrival
with no indication of whether or not the vehicle
remains at the detector station.
System Configurations
The system can be configured in one of five ways
dependingonthenumberofmenu signsatthefacility
and the type of communication desired.
1-1E 3M 2000 May
ModelC960Headset IntercomSystemOperation and Diagrams
Single-Lane Standard Communication System
This system provides standard communication
(talk/listen) for facilitiesthat have one menu sign. It
consistsof onebase stationandoneormoreheadsets
and battery chargers.
Dual-Lane Standard Communication System
This system provides standard communication
(talk/listen)for facilitiesthat havetwo menu signs. It
consistsof twoindependent systems-- onededicated
tomenu sign 1 and the other dedicated to menusign
2. The headsets are programmed to work with one
systemor theother andare labeled accordingly (1or
2).
Single-Lane Duplex Communication System
This system provides duplex communication
(simultaneous talk/listen) for facilities that have one
menusign. Itconsists ofone base station and one or
more headsets and battery chargers.
Dual-Lane Duplex Communication System
This system provides duplex communication
(simultaneous talk/listen) for facilities that have two
menu signs. Itconsists oftwo base stations and two
or more headsets and battery chargers.
Cross-Lane Communication System
This system provides duplex communication
(simultaneous talk/listen) for facilities that have two
menusigns. Itconsistsoftwoduplexsystemsthatare
connected to a cross-lanemodule. The headsets are
programmed for either lane 1 or lane 2.
During off-peak hours, the cross-lane module is
turned on to link the two systems and enable one
operatorto talkto customersat menu sign 1 or menu
sign 2 or with other headset operators.
Duringpeakhours,the cross-lanemoduleisturnedoff
to separate the systems. Withthe cross-lane module
off, one system is dedicated to menu sign 1 and the
otherto menusign 2. Menusign 1 operators cantalk
to customers at menu sign 1 or with other headset
operators. Menu sign 2 operators can talk to
customers at menu sign 2 or with other headset
operators.
Operating Theory
The 3M Model C960 Headset Intercom System has
two basic functions. First, it processes vehicle alert
signals that are supplied by a hard-wired vehicle
detection system. Second, it transmits and receives
radiosignals toprovide oneor more of the following
types of audio communication:
S T alk/listencommunication
S T alklock communication
S Page communication
S Page monitor communication
S Cross-lane talk/listen communication
Processing Vehicle Alert Signals
The Model C960 is compatible with all 3M vehicle
detectorsandthoseofmostothermanufacturers. The
vehicle alert system provides a signal to the base
station to indicate a customer is present at the menu
sign.
There are two types of vehicle detectors. Presence
detectors (such as magnetic loops or SODAR)
provide a signal for as long as a vehicle is presentat
the detector. Pulse detectors, such as air hoses,
provideonlyamomentarysignal—signallingvehicle
arrival with no indication of whether or not the
vehicle remains at the detector station.
S Ifa presencedetector isused, menu sign audio is
turnedoffautomaticallywhenthevehicleleaves.
S If a pulse detector is used, menu sign audio is
silencedbypressingandreleasinga headsetpage
switch.
When a vehicle detection signal is presented to the
base station, the base station broadcasts a repeating
alert tone to all headsets. The alert tone continues
untilthe talkswitch [onan active headset] ispressed.
Transmitting and Receiving
The transmitting and receiving functions are
accomplished by two separate sets of radio
transmitters and receivers. One set is located in the
headset and the other in the base station.
1-2 E 3M 2000 May
Model C960 Headset Intercom System Operation andDiagrams
Theheadset receivesmicrophoneaudiosignalsfrom
the base station on frequency B and transmits both
audiosignals andcontrol toneson frequencyA. The
control tones are above the audible range, and
functiontoturnthebasestation receiverONtoenable
reception of the audio signal from the headset
microphone. Because thecontroltonesareabovethe
audible range, audible tones from devices such as
telephones, pagers, and radios will not interfere.
The base station transmits on frequency B and
receives on frequency A. The receiver in the base
station operates above the audible frequency range.
While it receives the high-frequency control tones
from the headset, it is not affected by audible tones
from devices such as telephones, pages, and radios.
The transmitter in the base station is always
transmitting a “no signal” transmitter carrier, even
when there is no microphone audio from the menu
sign or headset operator being broadcast. This “no
signal“ carrieriscontinuallybroadcasttoand received
by all headset receivers. It serves to block out other
radio-frequency signals or noises from headset
receivers.
Similarly,theheadset receiverisalwaysONtoenable
the listen mode. The headset transmitter turns ON
only when a talk or page switch is pressed.
S Personnel wearing headsets that are operating in
the talk/listen mode.
S People near the optional monitor speaker.
Talk/Listen Communication
Headset to Menu Sign
After the vehicle detection signal is presented to the
base station, the base station broadcasts a repeating
alert tone to all active headsets.
Theheadsetoperatorpressesandholdsthetalkbutton
to acknowledge the customer at the menu sign and
cancel the alert tone. When the headset operator
speaks into the microphone, the headset generates a
talkcontrol toneandaddsittothemicrophoneaudio.
Themicrophone audioand talkcontrol tone are then
transmittedto thebase station. Thetalk controltone
turns the base station receiver ON , enabling it to
receive the microphone audio.
n Note
The talk control tone is above the audible
frequency range, and is used to prevent the base
station receiver from receivingsignals fromother
devices(telephones, pagers,etc.) thatmight be on
the same frequency.
Instandard communicationsystems, theoutputfrom
the headset receiver is muted when the headset
transmitter is ON. This provides standard
communication (talk or listen).
In duplex communication systems, the outputfrom
theheadset receiveris enabled(not muted) when the
headset transmitter is ON. This provides duplex
communication (simultaneous talk and listen).
The two sets of transmitters and receivers work
togetherto provideaudio communicationbetween the
customerat the menu sign and the headset operators
insidethedrive-throughrestaurantorbetween twoor
more headset operators.
All audio transmitted by a headset during talk
operation is heard by:
S Menu sign customers.
S Personnel wearing active headsets.
S People near the optional monitor speaker.
All audio from the menu sign is heard by:
Whenthebasestationreceivesthemicrophoneaudio
signal, it re-transmits it to all headset receivers. The
same microphone audio signal is also routed to the
menu speaker amplifier and the monitor speaker
amplifier.
The menu speaker amplifier routes the amplified
microphoneaudio throughwire tothe menuspeaker
where it can beheard bythe customer. The monitor
speaker amplifier routes the amplified microphone
audio through wire to an optional monitor speaker
(typicallylocated inthe kitchenarea) where it can be
heard by anyone in close proximity to the speaker.
n Note
The menu sign audiois not turned ON unlessthe
base station receives a talk control tone from the
headset. However, the the monitor amplifier is
always turned ON.
1-3E 3M 2000 May
ModelC960Headset IntercomSystemOperation and Diagrams
Menu Sign to Headset
Whenthe customerat themenu sign speaks, audio is
detectedbyamicrophoneandsentthroughwiretothe
transmitter and the monitor amplifier in the base
station.
Thetransmitter transmitsthe microphoneaudio toall
headset receivers. The monitor amplifier routes the
samemicrophone audiothrough wireto theoptional
monitor speaker.
n Note
Personnelwearing headsetsthat areset tomonitor
only page communications will not hear talk
communications. If the headsets is in the Page
Monitor Mode, the “talk” audio output to the
headset speaker is muted.
Talk Lock Mode
Thetalklockmodeisusedtooperate“handsfree.” In
this mode, the headset automatically switches from
standby to talk/listen when a customeris detected at
the menu sign. The headset automatically switches
back to standby when the customer leaves the menu
sign. Thismode isonlyavailablewithduplexsystem
configurations.
Page Mode
When the headset page button is pressed, system
operationis identicalto talkoperation except for two
things:
S The talk control tone is not broadcast, so the
menu sign amplifier is not turned on, muting
menu sign audio.
headsettransmitteristurnedONonlywhenitreceives
a page control tone. T alktransmissions from other
headsets or audio from the menu sign are not heard.
Cross-Lane Talk/Listen Mode
Thecross-lane talk/listen mode is available only in a
dual-lane duplex cross-lane system. The cross-lane
moduleinthis systemenablesthemenusignoperator
to selectively communicate (talk and listen) to
customers in either lane 1 or lane 2.
W iththeT1 (TalkLane1)switchpressed,theheadset
transmitter/receiver switches to the lane 1 channel
frequencies,enabling thelane1basestation andlane
1 communications.
W iththeT2 (TalkLane2)switchpressed,theheadset
transmitter/receiver switches to the lane 2 channel
frequencies,enabling thelane2basestation andlane
2 communications.
Monitor Amplifier and Speaker
A one-watt, single-ended monitor amplifier in the
base station powers [an optional] speaker which is
capable of reproducing the following signals:
S T alk audio(communicationsto themenu speaker)
S Listen audio (communication from the menu
speaker)
S Page audio (internal store communications)
S Vehicle alert tone
Separate volume controls adjust the level of each
signal to achieve the desired signal balance. In
addition, there is a master volume control which
adjusts the overall volume of the monitor speaker.
S A page control tone is sent from the headset,
turning on the base station transmitter. The
transmitterrebroadcasts thistone toturn ON any
headsetsthat arein thepage monitor mode. Any
audio detected by the headset microphone is
transmitted to the base station where it is
received,transmittedtootherheadsetsand sentto
the monitor speaker amplifier.
Page Monitor Mode
The page monitor mode allows headset operators to
hearonly pagecommunication. Inthe pagemonitor
mode,talk audiooutputtotheheadsetismuted.Only
internal page communication is heard because the
1-4 E 3M 2000 May
Headset Components
n Note
The receiver/transmitter and logic circuitry
contained in the C960 headset housing is both
proprietary and non-field repairable.
The headset assembly has several field-replaceable
components. These components are detailed in
Section 3 of this manual (Replacement Parts and
Service).
The major components are as follows:
Model C960 Headset Intercom System Operation andDiagrams
S Rechargeable Battery
S Headband
S Microphone Boom Assembly
S Speaker Assembly
Rechargeable Battery
Thenickel metalhydride batteryprovides DC power
for the headset circuitry.
Headband
Theheadbandconsistsoftwointerlockingassemblies
that provide adjustments for headband width and
headband size. Both assemblies are replaceable.
Microphone Boom Assembly
The boom/earpiece assembly includes an electret
microphone and a speaker-driven earpiece. It is
replaceable as a separate unit.
Speaker Assembly
The speaker assembly is housed between the inner
andouter casesand is replaceable as a separate unit.
1-5E 3M 2000 May
ModelC960Headset IntercomSystemOperation and Diagrams
Base Station
n Note
Receiver/transmitter and logic circuitry contained
in the C960 headset intercom base station is both
proprietary and non-field repairable. For this
reason, the accompanying base station diagram
provides no circuitcomponent detail. Onlythose
details that assist fault isolation (such as
connections,configurationjumpers,audiocontrol
circuits,replaceable componentsandinput/output
functions) are shown.
DC Power
DC power for the base station circuits and external
components is provided as follows:
Aself-containedDCpowertransformer,connectedto
120VAC, provides unregulated +12VDC to the base
station power input jack. The +12VDCis turned on
oroffby aslideswitchlocatedonthefrontofthebase
station. The unregulated +DC is routed through a
protective polyswitch (circuit breaker) to circuit
components and a voltage regulator (called power
supply in the diagram). If an overcurrent condition
causesthe polyswitchto open,it automaticallyresets
after power is removed.
The unregulated +12VDC is used by the vehicle
detectorto providea +DCvehicle detect signal tothe
basestationvehicledetectcircuits. Ifaninterconnect
module is used in the system, unregulated +DC is
providedto energizethe interconnectmodulerelays.
Talk/Page Input
T alkand pagevoicecommunicationstransmittedfrom
the headset are received along with their
accompanying “talk” or “page” control tones.
Received talk communications are routed by the
RCVR & RCVR LOGIC as follows:
S Through the transmit amplifier to the TXMT &
TXMT LOGIC for transmission to all headset
receiversand tooutput connectorpin 9 for usein
cross-lane applications
Received page communications are routed by the
RCVR & RCVR LOGIC as follows:
S T othe monitor speaker amplifier via the MON
P AGEvolumecontrol, throughthe amplifierand
theMasterMonitorVolumecontrolto themonitor
speaker
S Through the transmit amplifier to the TXMT &
TXMT LOGIC for transmission to all headset
receivers,andtooutputconnectorpin9forusein
cross-lane applications
Vehicle Detector Input
Upon detection of a vehicle, the vehicle detector
signal will be a steady DC or a short-duration DC
pulsedepending onwhether the vehicle detector is a
“presence”or “pulse”type detector. Uponreceiptof
the vehicle detect signal, the VEHICLE DETECT
LOGICcircuit emitsalert tones. Thesealerttonesare
routed as follows:
S T othe monitor speaker amplifier via the MON
ALERT volume control, through the monitor
speakeramplifierandtheMasterMonitorvolume
control to the monitor speaker
S T othe transmit amplifier via the Headset Alert
Levelcontrol, throughtheamplifiertotheTXMT
& TXMT LOGIC for transmission to all headset
receivers
S T ooutput connector pin 12 foruse in cross-lane
applications
S T othe menu sign speaker amplifier via the
DAY/NIGHTvolume controlsand DAY/NIGHT
switch, through the amplifier to the menu sign
S T othe monitor speaker amplifier via the MON
T ALKvolumecontrol, through the amplifierand
theMasterMonitorVolumecontrolto themonitor
speaker
1-6 E 3M 2000 May
Model C960 Headset Intercom System Operation andDiagrams
n Note
The vehicle detect PULSE/PRESENCE jumper J4
must be set appropriately and its setting
programmedinto thebase stationlogic forcorrect
vehicle detection and alert tones to occur.For
further explanation of vehicle detect alert tones,
refer to the Vehicle Alert System, The vehicle
detect PULSE/PRESENCE jumper J4 must be set
appropriately and its settingprogrammed intothe
basestation logicfor correctvehicle detectionand
alert tones to occur.For further explanation of
vehicle detect alert tones, refer to the paragraphs
titled Vehicle Alert System and Vehicle Detector
Input in this section.
Menu Mic Input
Audiofromthemenusignmaycomefromoneoftwo
sources: a combination speaker/microphone (the
MENU SIGN SPEAKER) or a separate dynamic
microphone (the MENU MIC). The MIC/SPKR
jumpersJ1 andJ2mustbesetaccordingly;bothmust
beset tothe MICposition ifa separate outside mic is
used, to the SPKR position if a combination outside
speaker/mic (OSM) is used. Depending on jumper
positions, mic input is routed to the mic amplifier,
through the amplifier and its Menu Mic Sensitivity
control and then:
S T othemonitor speakeramplifier viathe MONIN
volume control, through the monitor speaker
amplifierand theMaster Monitorvolumecontrol
to the monitor speaker
S Through the transmit amplifier to the TXMT
&TXMT LOGIC for transmission to all headset
receivers,andtooutputconnectorpin9forusein
cross-lane applications
Base Station Configuration Jumpers and
Switches
Configuration Jumpers
Jumpers J1 and J2 are used to configure the base
station for use with either a separate outside
microphone or a combination outside speaker/mic
(OSM). Unlike jumpers J3, J4 and J5 which affect
logic input levels, jumpers J1 and J2 simply switch
the microphone amplifier inputs to either the
microphoneorOSM. Setbothjumperstojumperpins
2 and 3 for use with a separate outside mic, or to
jumper pins 1 and 2 for a combination speaker/mic
(OSM).
JumperJ3is usedtoconfigurethebasestationforuse
inacross-lane,dual-lanecommunicationssystem. In
sucha system,one basestation must be set for lane 1
frequency communications, the other base station
must be set for lane 2 frequency communications.
JumperJ3pins1and2(forcingtherelatedlogicinput
high)forlane1configuration. JumperJ3pins2and3
(forcing the related logic input low) for lane 2
configuration. WheneverjumperJ3 ischanged, you
mustpress thebase stationRESETswitch toprogram
the new jumper setting into the base station
microprocessor.
n Note
It may also be necessary to re-program system
headsets, depending on system configuration.
RefertotheC960InstallationInstructions formore
information.
JumperJ4is usedtoconfigurethebasestationforuse
witheither apresencetypevehicledetectororapulse
typevehicledetector. JumperJ4pins 1and2(forcing
the related logic input high) for a presence type
detector. JumperJ4pins 2and 3 (forcing the related
logicinput low)for apulse typedetector. Whenever
jumperJ4 ischanged,youmustpressthebasestation
RESETswitchtoprogramthenewjumpersettinginto
the base station microprocessor.
JumperJ5 isusedtoconfigurethe basestation sothat
itcan inturn,programtheheadsetsforstandard(talk,
then listen, then talk etc.) communications or for
duplex (simultaneous talk and listen)
communications. Duringstandardcommunications,
headset receiver output is muted during talk
transmissions. During duplex communications,
headset receiver output is not muted during talk
transmissions. The headset receiver mute/not mute
(standard/duplex) command is sent to the headset
logic during headset programming—determined by
the jumper J5 setting. Whenever Jumper J5 is
1-7E 3M 2000 May
changed, you must press the base station RESET
switch to program the new jumper setting into the
base station microprocessor.
n Note
When jumper J5 is changed, you must also
reprogramthe systemheadsets. Referto theC960
Installation Instructions for more information.
Configuration Switches
RESET SWITCH: Very briefly, actuation of the
RESET SWITCH clears logic inputs of their
establishedlevels andlatches thelogic inputs at their
new levels.
CHANNELSELECT SWITCH: TheC960 systemis
capable of operating on eight different channels for
each of two lanes. This provides a total of 16
operating channels since each system may be
designated as a lane 1 or lane 2 system. Each
operating channel is comprised of a “set” of two
frequencies, one for receiving, one for transmitting.
Thechannel frequenciesare preprogrammedin both
the base station and headset microprocessors. Each
actuationof theCHANNELSELECTswitchprompts
thebasestationmicroprocessortoadvancetothenext
available channel. After a new channel is selected,
you must reprogram all system headsets to the new
channel. (Headsetscanoperateonlyonlane1orlane
2 channels unless they are used with an accessory
cross-lanemodule.) Formoreinformationon channel
selection and reprogrammning, refer to the C960
Installation Instructions.
ModelC960Headset IntercomSystemOperation and Diagrams
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Model C960 Headset Intercom System
Operation and Diagrams
1-9
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Base Station and External Components Diagram
Model C960 Headset Intercom System
Operation and Diagrams
1-10
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Model C960 Headset Intercom System
Operation andDiagrams
Interconnect Module
An interconnect module is needed when a C960
Headset Intercom system includes an auxiliary
intercomtoprovidecontinuedcommunicationswhen
the primary intercom needs service.
The auxiliary intercom may be a conventional,
hard-wiredintercom oritmaybeasecondC960base
station.
Externalsystemcomponents (speakers,microphone,
vehicle detector) connect to interconnect module
connector J302. Base station inputs and outputs
(power, common, menu mic, menu speaker, vehicle
detector) connect to interconnect module connector
J303. Auxiliary intercom (or second base station)
inputs and outputs connect to interconnect module
connector J301.
On/Off DC
In the interconnect module schematic diagram, the
interconnect module is shown in its “on” state, with
relays energized.
On/Offcontroloftheinterconnectmoduleisprovided
by (the presence or absence of) +12VDC from the
(primary) base station. W ithbase station +12VDC
present (via J303 pins 1 and 2), relays K301, K302
and K303energizetoswitch microphone,speakerand
vehicledetect signalsto/from thebase station. Ifthe
basestation-provided DCis notpresent (basestation
turnedoff),relaysK301,K302andK303 de-energize
to the switch the same signals to/from the auxiliary
intercom.
Menu Microphone Signal Control
Relay contacts K301-A and K301-B control
distribution of the menu mic signal(s). W ith relay
K301 energized, the menu mic is connected to the
base station inputs. W ithRelay K301 de-energized,
themenu micis connected to the auxiliary intercom.
Menu Speaker Audio Control
Relay contacts K302-A and K302-B control
distribution of the menu speaker audio. W ith relay
K302energized,themenuspeakerisconnectedtothe
basestation. W ith relayK302de-energized,themenu
speaker is connected to the auxiliary intercom.
Monitor Speaker Audio Control
Relay contactsK303-Bcontroldistributionofmonitor
speakeraudio. W ithrelayK303 energized, the drive
side of the monitor speaker is connected to the
monitorspeakeroutputofthebase station. With relay
K303 de-energized, the drive side of the monitor
speakerisconnected tothemonitorspeakeroutputof
the auxiliary intercom. Monitorspeaker commonis
not switched.
Vehicle Detector Signal DC
Whilethe vehicledetector ispoweredseparately (ifit
isa “presence”typedetector),vehicledetectorsignal
DC is always provided by both the base station and
the auxiliary intercom. This vehicle detector signal
DC is available at interconnect module connector
J302-9.
Avehicle detectorsignal DCof +12VDC isprovided
by the base station at J303pins 9 and 10. A vehicle
detector signal DC of +18VDC is provided by the
auxiliary intercom at J301 pins 1 and 7.
Ifboth theauxiliary intercomand thebasestationare
ON, the vehicle detector signal will always be
+18VDC because the auxiliary intercom’s +18VDC
will take precedence over the +12VDC supplied by
the base station. (Isolation of the twoDC sourcesis
provided by interconnect module diodes D301 and
D303.) If only the base station is ON, the vehicle
detector signal DC will be +12VDC.
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Model C960 Headset Intercom SystemOperation and Diagrams
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Model C960 Headset Intercom System
Operation and Diagrams
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Interconnect Module Diagram
Model C960 Headset Intercom System
Operation and Diagrams
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Headset Intercom Systems
Model C960/C860
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................................................................................................. 20
Circuit Board Jumpers, Adjustment Controls, Indicators and Switches .................................................... 21
Jumpers......................................................................................................................................... 19
Adjustment Controls...................................................................................................................... 22
Indicators...................................................................................................................................... 22
Switches (etc.)............................................................................................................................... 22
Connectors.................................................................................................................................... 22
Finishing Up........................................................................................................................................ 23
Troubleshooting Audio Feedback.......................................................................................................... 23
Technical Assistance............................................................................................................................ 23
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
Typical Single Lane Installation
!
same jacket unless specially designed for duplex such as 3M 78–8095–0180–8.
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
• sufficient twisted–pair sets of audio cable to connect other components such as monitor speaker, vehicle
detection device, etc.
1
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.
ü Note
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)
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.
3
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
Connecting the Base Station Directly to Components
!
same jacket unless specially designed for duplex such as 3M 78–8095–0180–8.
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
Figure 5. Direct Base Station–to–Component Connections
5
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