Headset Intercom System
Model C1060
Installation Instructions
Table of Contents
Typical Single Lane Installation...................................................................................................................... 1
Battery Charger ............................................................................................................................................... 2
Speaker and Microphone Assemblies.............................................................................................................. 3
Standard Systems ...................................................................................................................................... 3
Duplex Systems ........................................................................................................................................ 3
Base Station ..................................................................................................................................................... 3
Programming Station....................................................................................................................................... 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
Installation................................................................................................................................................. 11
Wiring the System .............................................................................................................................. 11
Programming the Headsets for Cross-Lane Operation....................................................................... 11
Operation................................................................................................................................................... 12
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
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Table of Contents (continued)
Circuit Board Jumpers, Adjustment Controls, Indicators and Switches ......................................................... 21
Jumpers..................................................................................................................................................... 21
Adjustment Controls................................................................................................................................. 22
Indicators .................................................................................................................................................. 22
Switches (etc.) .......................................................................................................................................... 23
Connectors................................................................................................................................................ 23
Finishing Up.................................................................................................................................................... 24
Troubleshooting Audio Feedback ................................................................................................................... 24
Technical Assistance....................................................................................................................................... 24
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. Programming Station Mounting Holes........................................................................................... 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
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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.
1
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.
9 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)
2
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.
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
Programming Station
1. For proper system operation, locate the programming station module 18 inches or less from the base station.
An 18 inch cable is provided to connect between the base station and the programming station.
!
Important
Allow enough room below the programming station to allow insertion of the
headset while it is being programmed. Do not mount programming station too
close above the countertop or other wall-mounted object.
2. Mount the programming station module using the included screws and anchors. (See Figure 4.)
Figure 4. Programming Station Mounting Holes
3. Connect the 18 inch long programming cable provided between the base station programming jack and the
programming station jack.
4. If needed, connect the programming cable for use with C860 and C960 headsets and allow it to hang from
the programming station
4
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
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