Page 1
Wireless Intercom Systems Technical Bulletin 11/23/05 Additional C1060 Headset Parts Available Three additional C1060 headset replacement parts are now available. Please refer to the “Replacement Parts and Service” procedures attached to this letter for detailed information. C1060 Outer Case Assembly...
Model C1060 Headset Intercom System Replacement Parts and Service Replacement Parts List Ordering Replacement Parts Technical Service The following pages show replacement parts for the model C1060 Headset Intercom. For technical assistance, call: Order parts by the model number, part number, 1-800-328-0033 part name and quantity required.
Page 4
Model C1060 Headset Intercom System Replacement Parts and Service Item No. Part Number Description Qty. 0 .......78-9236-6826-9 ....BASE STATION ASSEMBLY, Model C922 (w/o Power Supply)...1 1 .......78-8095-0500-7 ....CABINET, Base Station ..............1 1A.....78-8095-0965-2 ....HINGE, Assembly, (Replacement) ............1 2 .......78-6911-4430-3 ....POWER SUPPLY, 13.5 VDC, 20 VA ..........1 3 .......78-6911-3777-8 ....INTERCONNECT MODULE............1...
Page 6
0 .......78-6911-4723-1 ....Headset Model C1060 .............1 1 .......78-6911-4727-2 ....Headband Pad, for Model C1060 (pkg of 10)......1 2 .......78-6911-4728-0 ....Ear Pad, for Model C1060 (pkg of 10) ........1 3 .......78-6911-4729-8 ....Ear Cup, for Model C1060 (pkg of 5) ........1 4 .......78-8117-4110-3 ....Safety Strap................1 5 .......N/A separately ....Screw, 2-56 X .4375 Pan Hd.
Model C1060 Headset Intercom System Replacement Parts and Service Service Procedures Replacing the Ear Cup, the Ear Pad, or the Headband Pad Headband Pad Replacement: Tools Required: 1. Peel the Headband Pad away from the Battery None Holder Cover. Clean off any adhesive residue.
Page 10
Model C1060 Headset Intercom System Replacement Parts and Service Service Procedures (continued) Replacing Inner Case Assembly or Removing Outer Case: Outer Case Assembly 1. Disconnect the power connector located at the Tools Required: top of the Main PWA. 2. Carefully pull the power wires out of the top...
Page 11
Model C1060 Headset Intercom System Replacement Parts and Service Service Procedures (continued) 2. Remove the Spring Washer, Nylon Washer, Mic Boom Assembly: and Mic Boom. 1. Locate and remove the retaining ring using the 3. Reinstall the Mic Boom by performing steps 1 retaining ring pliers.
Page 12
Model C1060 Headset Intercom System Replacement Parts and Service Service Procedures (continued) Reassembly procedure 12. Reinstall the battery, power up and checkout 1. Replace Mic Boom assembly as described. operation of the headset, including Headband (see previous section Mic Boom Assembly:) slide.
Page 13
Model C1060 Headset Intercom System Replacement Parts and Service Headband Clip. Be sure to press the wires completely down into the wire groove. Service Procedures (continued) Replacing the Headband Assembly 13. Plug the power cable into the connector Tools Required: located at the top of the PWA.
Page 14
Model C1060 Headset Intercom System Replacement Parts and Service Service Procedures (continued) Replacing Battery Holder Parts 5. Press the Battery Latch Spring onto the top Tools Required: peg of the Battery Latch. Insert the Latch with Spring down through the top of the Base as 1 –...
Page 15
Replacement Parts and Service Service Procedures (continued) Checking out Headset Operation Tools Required: Functioning Wireless Intercom System with at least one additional model C1060 Headset. Procedure: NOTE Check headset operation before replacing the case screws. It is a good idea to...
Page 17
3M Commercial Care Division contracted with Orfield Laboratories, Inc.¹, a sound testing company, to independently compare the audio of the 3M™ Wireless Intercom, C1060 analog intercom system to a competitive digital intercom system. Testing focused on inbound intercom intelligibility performance, specifically in the presence of a uniform background noise field at the menu post.
Page 18
Excellent 0.85 0.75 Good 0.65 0.55 Competitive Digital System, Model C1060 without Noise Reduction, Competitive Digital System with Noise Reduction, per 3M is a trademark of 3M out-of-box configurations. Company. Based upon test performed by independent laboratory with limited sample.
Page 19
(70dBA) Excellent 0.75 Good 0.65 0.55 Competitive Digital System, Model C1060 with Noise Reduction, 3M is a trademark of 3M Competitive Digital System with Noise Reduction. Company. Based upon test performed by independent laboratory with limited sample. High Background Noise (80dBA) 0.54...
Page 20
Objective measurements do not necessarily reflect perceived intercom sound quality; therefore, 3M conducted an initial survey of QSR employees familiar with using intercom equipment, rating their sound preference of the 3M™ Wireless Intercom System, C1060 as compared against the competitive digital intercom system. The audio recordings prepared by Orfield Laboratories, Inc.
Page 21
If you have any of these units in your inventory/stock, please return them to 3M for upgrade or replacement. Please use the 3M CCD Repair Center Repair/Return Form and indicate “Short Range per Tech Bulletin”...
Page 22
AUDIO IN AUDIO OUT AUDIO IN AUDIO OUT ALERT ALT ALERT ALT ALERT ALERT ALT ALERT VEH DET COMMON COMMON ALERT OUT LOOP DET. BASE STATION Outside Order Taking using 3M Cross-Lane Module to Disable Menu Post Components 2 of 2...
Page 23
Reminder - In addition to Technical Service telephone support, faxed copies of our Installation Instructions, Selling Sheets, Spec Sheets, Operating Guides and Trouble-Shooting Guides are available by calling our Fax-on-Demand @ 1-800-240-4799. You may find these documents on the 3M FST web site: www.3M.com/foodservice, click on “Customer & Technical support”.
Page 24
Service Procedures – 3M C1060 Headset Replacing the Headband Assembly C1060 Headband Assembly - Part Number 78-8117-4123-6 (includes Headband and Clip) C1060 Clip, Headband Slide - Part Number 78-8117-4088-1 (Clip available separately) Tools Required: 1 - Small size Phillips Screwdriver 1 –...
Page 25
Talk Lock. It is labeled "HIGH - NRML". HIGH – Set this jumper to HIGH when using a C1060 headset, and ONLY if you experience reduced volume from the menu microphone during use with Talk Lock. With the left 2 pins jumpered, the menu microphone dynamic gain circuit will operate at a higher threshold, which is compatible with the C1060 headset.
Page 26
C1060 Headset Parts Available The Battery Terminal Kit for the C1060 headset is now available. Part number 78-6911-4882-5 contains the parts listed below. When replacing the wires on the circuit board (part #8), please note the polarity marked on the board.
Page 27
C1060 Battery Charger Power Supply Plug May Fall Out The power supply plug may fall out of some C1060 Battery Chargers. The plastic portion of the power supply plug can easily be trimmed with a razor knife to allow a snug fit. See illustration:...
Page 28
Technical Bulletin 12/7/01 Revision B C1060 Batteries Early versions of the C1060 batteries had 4 contacts. The contacts were labeled “-, ID, TM, +”. Recent versions of the batteries do not have the ID contact. The ID contact has no function. The batteries will perform identically.
Page 30
FIX: Unplug the charger for a short time; then plug it back in. The problem will go away. If the problem comes back, send it into 3M Repair Center. In normal operation, the red LED blinks 5 or 6 times then stays red until charging is complete.
The Cross-Lane System can be used with C760, C860, C960, 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.
Page 32
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.
Page 33
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;...
Page 34
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. 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.
Page 36
Tips and Tricks • When troubleshooting inbound noise or interference problems on the C960 Intercom System try removing the outside microphone by disconnecting the top 4-position connector from the Base Station momentarily, during the interference. If the all the noise disappears, the problem may be solved by improving the wire shielding or the acoustic isolation of the microphone.
Page 37
3M Loop Detectors, Models A200 and A201 on Hold The 3M Loop Detectors, Models A200 and A201 are on hold until further notice. A problem with the sensitivity has been discovered that causes some units to fail to detect cars that are very close together in the drive-thru lane.
Page 39
Based on 100 headsets, we recommend purchasing the following: Pricing can be found in your 3M Communication Products Service Parts Price Pages.
Page 40
Do not use alcohol to clean the switch traces on the C960 circuit board! Use only a soft dry cloth. Technicians in the 3M Repair Center have the best success with a 3M brand “Scotch-Brite High Performance Cloth”. These cloths can be found in the FST Related Products Price Pages “CFM-...
Page 41
continue to use alcohol to clean the silicone switches, but use only a dry cloth to clean the circuit board. • Symptoms of hearing constant programming tones in C860 Belt Packs can be caused by dirty switches or poor solder connections to the switch circuit board. Clean the silicone switches with alcohol or replace them.
Cross-Lane System Installation Description The Cross-Lane system is designed for facilities that have two menu signs. It consists of two 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.
Programming the Headsets for Cross-Lane Operation Follow the steps below to program the C960 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 always communicate with the lane 1 base station;...
Page 45
If you are aware that this problem exists at a location, you can choose to fix it yourself by performing one of the two fixes listed above, or return the Base Station to 3M for an exchange. Please indicate why you are returning it.
Page 46
Use this detector if a backup wired intercom is used to support the primary intercom. The Model A201 Loop Detector comes with a special ribbon cable and is designed specifically as an optional accessory for the 3M C921BA or later Base Station. Power and switch closure signals are supplied through a ribbon cable.
Page 47
ü Turn on its power switch. If the phone is “smart”, it will see that the talk and listen frequencies of the C960 are busy and go to some other channel. 3M Food Services Trade Department 3M Center, Building 551-1E-02 Printed in U.S.A.
Page 48
This is an addendum to the C960AA Headset Intercom System Installation Instructions. The only change in the System is the C921BA Base Station. Description The 3M C921BA Base Station is improved over the C921AA Base Station in several ways: • Improved Duplex Operation •...
Page 49
HEADBAND ASSEMBLY, Main 26-1014-3439-2 SCREW, Pan Head, 6-32 x 7/16” 78-6911-4510-2 SIDE PAD ASSEMBLY (Package of 10) 78-6911-4507-8 TOP PAD ASSEMBLY (Package of 5) 78-6911-4491-5 BATTERY ASSEMBLY 78-8095-0591-6 CAP/VISOR CLIP (Package of 5) 13B-1 78-8095-0607-0 CAP, HEADBAND WIDTH ADJUSTMENT ã3M 1999 October...
Page 50
Model C960 Headset Intercom System Replacement Parts and Service Section 3 - 3-Slot Battery Charger Assembly Item No. Part Number Description Qty. 78-8095-0580-9 3-SLOT BATTERY CHARGER ASSEMBLY, Model C923AA 78-8028-9283-2 TRANSFORMER ASSEMBLY, 14 VAC, 20 VA ã3M 1999 October...
Page 51
C-Series Intercom Systems Model C960 Technical Bulletin 7/14/99 C960 Headband Width Adjustment Tab Cover A new plastic cover (78-8095-0607-0) is now available to repair C960 main headband assemblies with broken width adjustment tabs. Clean the old tab halves with alcohol, apply "super glue", and slip on new cover. Tips and Tricks •...
Page 53
C-Series Intercom Systems Model C960 Technical Bulletin 3/28/99 No Talk LED or Delayed Talk LED Some C960/760 base Stations may experience symptoms where the Talk LED won't light at all or lights after a delay when the Talk button is pressed on any headset. This can also happen to the Page LED when the Page button is pressed.
Page 54
Instructions for replacing the C960 Inner Case The C960 Inner Case Assembly is now available as a spare part (78-8095-0559-3). Be sure to transfer the serial number sticker to the new case to continue the warranty, and it is a good idea to write the serial number on the case with an indelible marker.
Page 56
Figure 3-3. Figure 3-4. Replacement Hinge for C760/C960 Base Station Cover A replacement metal hinge (78-8095-0965-2) is now available to repair C760/C960 half-covers with broken hinge teeth. It is supplied with double-stick tape and requires removal of the original teeth and struts. It is listed in the May 1, 1999 Service Parts pages.
Page 58
Instructions for replacing the C960 Inner Case The C960 Inner Case Assembly is now available as a spare part (78-8095-0559-3). Be sure to transfer the serial number sticker to the new case to continue the warranty, and it is a good idea to write the serial number on the case with an indelible marker.
Page 60
Figure 3-3. Figure 3-4. Replacement Hinge for C760/C960 Base Station Cover A replacement metal hinge (78-8095-0965-2) is now available to repair C760/C960 half-covers with broken hinge teeth. It is supplied with double-stick tape and requires removal of the original teeth and struts. It is listed in the May 1, 1999 Service Parts pages.
Page 62
C-Series Intercom Systems Model C960 Technical Bulletin 11/3/98 In this Technical Bulletin, we will discuss three issues followed by a series of Tips and Tricks. 1. C960 Cross Lane Operation 2. C960 Radio Interference C960 – 900MHz vs. Licensed frequencies C960 Tips and Tricks 1.
Page 63
• In cases where a cellular phone tower is nearby, certain combinations of cell frequencies may cause interference. In some cases, changing channels may have no effect. Please call 3M FST Communications Products Technical Service (800-328-0033 press 2, 4) in these cases.
Page 64
475 MHz These licensed units must compete with other radios of local businesses that may have up to 5 watts of power. However, to maximize battery life, power is restricted to less than 5% of this figure. This makes them susceptible to interference from these high-powered radios operating nearby. In addition, there are mobile radios within this frequency range on service trucks, ambulances, and inventory systems.
Page 65
These compress with age resulting in discomfort and a loose fit. • If a C760 system has been upgraded with C960 headsets, a symptom of delayed or no TALK LED has been reported. Please call 3M FST Communications Products Technical Service (800-328-0033) for a solution to this problem.
Page 66
See drawing below: Note 2 raised stops here Headband, Adjustable Headband, Main 78-8095-0583-3 78-8095-0582-5 (not changed) 0.375" smaller InTouch Products Food Services Trade Department 3M Commercial Care Division 3M Center, Building 551-1E-02 St. Paul, MN 55144-1000 19980615...
Page 67
Headbands are being redesigned to be 0.375” smaller. They will be in production and spare parts soon. Place foam tape here InTouch Products Food Service Business 3M Commercial Care Division 3M Center, Building 551-1E-02 St. Paul, MN 55144-1000 19980427...
Page 68
This will force the plug up from the receptacle. Remove the speaker plug the same way. Slide tweezers in here to raise plug InTouch Products Food Service Business 3M Commercial Care Division 3M Center, Building 551-1E-02 St. Paul, MN 55144-1000 19980427...
(4897 would indicate the 48th week of 1997). 3M does not accept warranty claims for short life, broken batteries, damaged contacts, or claims traceable to damage Reminder: To troubleshoot batteries effectively you should use the optional analyzer.
Page 70
(model 2475) Station Selector or with the original 8-button (model 5108) or 16-button (model 5116) Station Selector. The 3M Repair Center will repair or replace the original POS Translator (78-9236-6387-2) as needed. Recommending Wire Gauges for 3M™ Intercom Systems Audio and Call Station Wiring: The goal is to achieve less than 10 Ohms for the total distance of the longest wire run.
Page 71
Separate Power Supply for C5000 and Performance Series Station Selectors When installing a Station Selector for the C5000 and Performance Series Intercoms we recommend adding a separate power supply to the Station Selector if it is located more than 100 feet from the Communications Controller.
Page 72
Power Supply Failures for Performance Series (2470) and C5000 Systems Another cause of the 9 VAC Power Supply failing on the Performance Series model 2470 and the C5000 systems is incorrect RS-485 cable wiring. Pins 1,2,3,4 from J3 on the Controller must be routed to Pins 1,2,3,4 on the 4-pin connector on the Selector.
Page 73
D-20V Gooseneck VOX Microphone Change The D-20V, 6-station, (model 445) intercom, original dynamic, gooseneck, VOX, mic (78-8050-8485-7) will be replaced with a 16” electret , gooseneck, VOX, mic (78-8095-0839-9). This electret mic is the same one used on C5000 and Performance Series intercoms. This mic change will begin approximately May 2003.
Page 74
Best Wiring Practices for Terminal Strips Strip and fold the wire when connecting to a screw-clamp terminal block, such as those found on most 3M™ intercoms and accessories. Use this method for wires less than 18 AWG. See Figure A. Figure A Use this strip-only method for wires 18 AWG and larger.
Page 75
C5000 Installation Examples The following two examples are intended to show an overview of typical C5000 Installations. DISPENSERS CAR WASH C1060 CONTROLLER Critical Programming Steps: WIRELESS A 01: Selector ID = 1 03: Audio Channel = A 04: # Business = 1...
Page 77
C5000 8 Station Communications Controllers starting with serial number 5108001690 and C5000 16 Station Communications Controllers starting with serial number 5116001308 contain software version 2.10. It is possible to upgrade existing Controllers to “Version 2.10”. Please contact 3M Technical Service (800-328- 0033) for update instructions.
Page 78
C5000 Remote Microphone The 3M C5000 Three-Button Remote Microphone (78-8095-0893-6) functions as a remote workstation for a Station Selector in the C5000 System. It can be used to answer incoming calls in the order they were received or broadcast to all Call Stations simultaneously.
Page 79
Programming Program the Station Selectors and the Communications Controller to conform to your planned configuration and desired operation. Programming the Communications Controller Before adjusting the Communications Controller, you must place it in the programming mode: 1. Turn the Communications Controller off. 2.
Page 80
Software Program the Communications Controller for the settings shown in Table 2: Table 2. Communications Controller Programming Options Parameter Parameter Display Value Value Display l l l l l l l l ¡¡¡ ¡¡¡ 1. Number of 1=One Business (Food OR Businesses Fuel) ¡¡...
Page 81
Controller to the Selectors be 18 gauge. Another solution is to use an additional 9 VDC power supply on the offending Station Selector. Food Service Trade Department 3M Commercial Care Division 3M Center, Building 551-1E-02 St. Paul, MN 55144-1000...
Page 84
Handset External Speaker Intercom To Intercom (if used) Audio Call Sw Common W HT W HT A 10 B B 1 A A 9 B B 2 A 1k Ohms GRAY/RED A 8 B B 3 A A 7 B B 4 A 10 uF A 6 B...
Page 85
Technical Bulletin 11/20/00 3M Loop Detectors, Models A200 and A201 The 3M Loop Detectors, Models A200 and A201 are now available. Sensitivity settings have been modified for performance with various vehicle sizes. The new units have “Version 1.5” or greater printed on a label on the processor chip.
Page 86
We have revised the contents of the saw-in magnetic loop kit (78-8016-9813-1). The quart-sized cartridges, applied with a standard caulking gun are no longer available. 3M has repackaged the Detector Loop Sealant. The sealant is the same, however it is now only available in 1-liter Ply pack cartridges. The new Ply packs require a special applicator gun, which you will need to purchase.
Page 87
Parts needed: 1 each, 3M Sonic Detector (78-6911-4432-9) 1 each, 1000 microFarad, 25 Volt capacitor (optional) 2 each, 1 inch lengths of shrink tubing or wire insulation to insulate the capacitor leads.
Page 88
D-15 (black/white wire) Sonic Detector Circuit Board Schematic Diagram SHIELD MENU SPKR MENU SPKR Pin 5 Pin 3 Pin 2 Pin 1 TB1 Sonic Detector C960/760 Base Station Food Service Trades Department 3M Center, Building 551-1E-02 St. Paul, MN 55144-1000 19981203...
Page 89
D-Series Intercoms Technical Bulletin 1/22/98 1-98 Heavy Duty Security Handset Reliability Improvement This modification reduces potential problems caused by the cradle switch contacts. It can be used when the handset is used alone or with a separate speaker/mic and switch assembly. All handsets shipped from our stock after July, 1998 have these updates.