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Installing the Cordless Miracle
Note: The Cordless Miracle can be installed by your regular telephone repair person or, for an additional fee, by one of our experienced installers. If your installer has any questions, he can call us on our toll-free number and we will walk him through the installation.
The Cordless Phones
When the customer provides the phones from a local vendor such as Office Depot, Wal-Mart, etc., and if a problem arises, managers can usually get same-day or next-day replacement at their local vendor. This limits downtime and gets them back up-and-running as soon as the batteries charge. Waiting for a replacement from corporate may take who knows how long.
Here's the stuff you'll need for installing The Cordless Miracle.
Preparing the cordless phones
Preparing the cordless phones is pretty simple.
Use an alcohol swab (included) to wipe the dirt and manufacturing residue off of the back of the cordless phone, just outside the edges of the 6 and 7 buttons, and the flat side of The Clip button.
Peel the back off of a Green dot and stick the dot just to the right of the 6 button. Peel the back off of a Red dot and stick the dot just to the left of the 7 button. Press both of the dots down firmly.
Peel off one side of the double-stick tape that came with The Clip. Stick the tape onto the flat side of The Clip button, doing your best to center it. Peel the other backing off the tape and place The Clip button on the back side of the cordless phone about two inches from the top of the cordless phone. Squeeze The Clip in place for about 10 seconds.
Peel the back off of the instruction sheet and stick it onto the back of the cordless phone, just below The Clip button. Smooth it out good.
Most cordless phones change frequencies every time that they are placed back in their chargers, or if they get dropped and the battery pops out. A lot of cordless phones have the tendency to pop their battery covers off when the phone is dropped on concrete (imagine that!) Once your battery has become disconnected, even for just a moment, this will usually make your phone inoperable until you walk all the way back to the cordless phoneís base and set the handset back into the base unit for a couple of seconds. To help remedy this problem, simply tear off a piece of black electrical tape about five inches long and stick it to the bottom edge of the battery cover. Wrap the tape around the bottom of the phone and up the sides along both sides of the seams. Make certain that you do not put the tape over the silver charging contacts on the bottom of the phone. This will help your phone withstand those "occasional" drops.
Placing your handset on someone elseís base will likewise make their phone inoperable until they walk all the way back to the base and switch both phones onto their proper bases.
You may want to color-code or number each phone and handset so that the right handset always gets placed back on the right base.
Go ahead and plug the cordless phones into an electrical outlet and set the handsets on their bases so that they can be charging while you are running wires and installing The Cordless Miracle.
OK, now getting down to the nitty-gritty of installing The Cordless Miracle. You need to find out from the manager WHERE they want to install the cordless phones. Some stores place the cordless phones in the manager's office, while most of the larger stores, such as Albertson's, install the cordless phones in the customer service booth. Wherever they want it, make certain that there is an AC electric outlet nearby.
Next, ask the store manager if they know where the store's telephone control box is. If they don't know, you get to do some exploring around the store until you find it. Usually, it's on a wall in the back of the store, in the mechanical room, or locked up in a closet. Wherever you find it, this is where you will be installing The Cordless Miracle.
Wall mounting The Cordless Miracle is a breeze. If there is wall space available, position The Cordless Miracle flat against the wall with the modular plug holes facing up and the label on the bottom of the box facing you. Draw or scratch a line on the wall along the full length of the bottom edge of the box. Set The Cordless Miracle down. Screw in two of the sheet rock screws along this line, about five inches apart, leaving the heads of the screws extended about a quarter of an inch. Place The Cordless Miracle back into position and screw the third sheet rock screw against the top edge of the box in the center of the box. Tilting the screw back a few degrees will allow easier access. Tighten the bottom two screws and the box is now securely mounted to the wall.
If wall space is not available, I have been known to just lay the box on top of their existing telephone equipment, or to hang it with tie-wraps.
Types of intercom systems
There are two main types intercom systems used in grocery stores throughout the United States. They are the Stor-Com and AiPhone intercom systems.
The Stor-Com system has two types of telephone handsets--wall mount and desk phones. They are cream colored and have toggle switch to determine Red Line or Green Line and are indicated by red and green LEDs. The last intercom path selected remains connected until the rocker switch is moved. The red push-to-talk paging button is on the outside of the handset.
The Stor-Com control box is dark brown in color and is four inches high, six inches wide and six inches deep. One side has the volume controls and the adjacent side has the screw terminals for attaching the wiring.
For years, the AiPhone system has had telephone handsets that are wall phones only. They are cream colored and have two separate and color-coded push-buttons to determine Red Line or Green Line. The push-to-talk paging button is on the inside of the handset. The newer AiPhone telephones may be either wall mounted or desk sets. They are white in color and have four color-coded push-buttons: Red Line, Green Line, Yellow Line and Orange Line. With a standard Cordless Miracle, you are only going to be able to hook up the Red Line and Green Lines to The Cordless Miracle. When both Red Line and Green Line are in use at the same time, there is usually serious bleed over onto both intercom paths. Adding more intercom paths only makes a bad problem worse. If you still have need of the additional intercom lines, give us a call on our toll-free telephone number 1-888-749-7448.
The AiPhone system has a small silver control box about two inches high three inches wide and five inches long. The volume controls are on one end of the box and screw terminals for the wiring are on the other end.
Both of these types of control boxes are usually installed in the manager's office, the customer service booth, and sometimes with the telephone equipment in a large steel box, almost a three-foot cube. Your assignment, Jim, is to find the box.
Before you even dream of touching ANY wire in the store, ask the store manager if both the store's telephone system AND the store's paging system are working properly, and that there are no intermittent or once-in-a-while problems. Then verify that with the person in the customer service booth, and then with a checker. I failed to do that once and it cost me four days trying to locate a pre-existing problem! The manager told me "It was working when you got here, so you fix it!" Three days later, one of the checkers happened to mention that the intercom on register 8 sometimes doesn't work, and the one in the pharmacy has problems, too. I spent four days tracking down every wire in the store and found six major problems throughout the store, any of which could have easily messed up the control box. I ended up buying the store a replacement Stor-Com control box and eating four days' worth of labor costs because the manager insisted that "It was working when you got here."
Connecting the cordless phones
Since you have already found out where the manager wants the cordless phones installed, it's up to you to find a way to get a single pair of wires from there to the phone room. Sometimes you've got to be real creative to find a way to connect the dots. Ideally, there will be a regular business telephone right there next to where the cordless phones will be installed, and there will be a spare pair of wires that go all the way back to the phone room. Connect the audio toner to this apparently spare pair of wires and turn the toner on. Hopefully, back in the phone room, you can find the audio signal from the toner with the tone tracer. If you hear that wonderful tone, smile, because you've probably just saved yourself a couple of hours.
Connect a jumper to this wire that is long enough to be connected to The Cordless Miracle. If the apparently available pair of wires do not go all the way to the phone room, you've either got to start tracking down the wires and start running jumpers to get the wires to the phone room, or you've got to run your own new wire all the way to the phone room. Ask the store manager if there is any other place where the phone guys go when they are there working on the telephones. Perhaps he can save you an hour or so by pointing out the cross-connects. Once you get the wire run, you can connect an RJ-11 phone jack to the end of the wire where the cordless phones will be installed. Attach the wires to the Red and Green terminals of the RJ-11 jack.
Locating the intercom
Last but not least, you need to locate the store's intercom control box. If the intercom control box is not near the telephone equipment where you will be installing The Cordless Miracle, you get to go exploring again for some way to tap into the intercom system. Locate the intercom phone nearest to where The Cordless Miracle will be installed and follow the wiring going to it. This sometimes gets pretty dirty and you'll probably be cleaning away lots of spider's webs. Once you have located the closest intercom phone, open it up and write down the wiring diagram. The wire colors are NOT the same in all stores. Now, it's up to you to determine whether it will be easier for you to run a four-pair wire from the control box, this intercom phone, or to tap into the wire feeding it. Another option, if there are at least three spare pairs of wires running from a cross-connect location to the phone room, is to tap into the intercom control box or an intercom phone near the cross-connect. Then, run new jumper wires from the other end of the cross-connect to The Cordless Miracle. Run the wire, but don't make any connections on either end yet.
Identifying the telephone lines
The interface for the storeís telephone lines should be there in the phone room. If not, you get to improvise with what you have.
You absolutely cannot go by the labels inside of the interface. Donít make the automatic assumption that the lines are in proper order. Of the first 40 grocery stores that I installed, only ONE was marked correctly and in the proper order. The easiest way to verify is to have a buddy stand near a phone and have him shout when he hears you short each of the lines out with a screwdriver, and then write down which number line it is. The best way is to connect one of the storeís phones there in the phone room and verify it for yourself by selecting a phone line, and shorting out the wires until you hear the clicking in your ear. Again, write down which number line it is.
Connecting the telephone lines
Whew...the hard part is over. Now itís time to start making connections. Go ahead and cut all of your connector wires from the telephone line interface to The Cordless Miracle pretty much to length, leaving room for neatening up and stapling.
Each Cordless Miracle comes with a bag of 25 modular plug connectors. Since you are just using single pair wire going into the modular plug, youíll need to add a bit of strain-relief to keep the wire from pulling out or shifting. Taking a few seconds now to add the strain-relief sure beats having to drive back to the store later and fix it.
Cut off about five inches of outside insulation from the four-pair wire. Separate the four-pair wire into single pairs (blue, orange, green, and brown) and make a strain-relief for each pair of wires. Simply tear off a piece of electrical tape about an inch long and then wrap it tightly in an overlapping manner around the wires about a quarter of an inch from the end. This will give the modular plug something to hold on to when crimped rather than just the wires being held in place by the gold pins.
Since some of the older telephone systems are polarity sensitive on the telephone lines, take your time and observe the way that you connect the modular plugs. The easiest way is to be consistent with how you insert the wires into the modular plugs. Trim the end of the wires so that they are even, and that only about an eighth of an inch of wire extends beyond the electrical tape. Hold the modular plug so that the opening is to your left.
The first set of modular plug connections that you make will be for the CO phone lines. Insert the wires with the white wire on the top. Make certain that the wires go all the way to the end of the plug and that they are in the center two positions of the four-pin plug. Insert the modular plug and wire into the modular plug crimp tool. Look again and verify that the wires are centered above the gold pins. (Sometimes they have a tendency to wander.) Crimp. Do the same for the rest of the CO input wires.
The KSU output wires are done the same, except that the white wires are on the bottom this time. (This insures proper polarity.)
The three modular plugs for the intercom system should have the white wires on top. (If you donít, youíll probably end up buying the store a new intercom control box.)
The single modular plug going to the cordless phone should have the white wire on top.
Plug the modular plugs for the telephone lines into the top row of The Cordless Miracle.
The Blue wires go into the socket marked Line 1.
Make a written or mental note of which set of wires are going to the CO phone lines, which to the KSU, and which to the intercom. Run the phone line wires to the storeís CO interface. The storeís CO phone line interface should either be RJ-11ís or a 66 punch-down block.
Installations with RJ-11 jacks:
Connect a modular plug to the end of the wire coming from the CO line side of The Cordless Miracle in the method described above with the white wire on the bottom. Using a telephone test set, or by using the store telephone that you have installed there with you, verify that CO line one is not in use. Unplug the existing modular plug from the RJ-11 jack and, if it will reach, plug it into the Line one of the bottom row of The Cordless Miracle. (Yes, you must unplug the other wire first.) If the wire is not long enough to reach The Cordless Miracle, splice it with the new wire you just made. Cut the end off of the old modular plug, separate the wires, and strip off about an inch of insulation from each of the wires. Strip off about an inch of insulation from the end of the wires coming from the KSU output side of The Cordless Miracle. Twist one wire from the KSU and one wire from The Cordless Miracle together. Repeat with the other set of wires and insulate both splices with electrical tape. Plug the new modular plug from the CO input side of The Cordless Miracle into the RJ-11 jack. This should reroute CO line one to The Cordless Miracle and then back to the KSU. Verify with your test set or the store phone that line one is working on the storeís telephone system.
Repeat the same for each of the other CO phone lines that you will be connecting.
For the 66 punch-down block:
Using a telephone test set, or by using the store telephone that you have installed there with you, verify that CO line one is not in use. Remove the bridging clips from line one of the punch-down block. Determine which side of the punch-down block goes to the phone lines and which side goes to the KSU. Punch-down the wires coming from The Cordless Miracle where the clips were removed. If there is already a wire in that place, strip off about two inches of insulation from the new wires and wrap the wire around the proper terminal. Make at least two good tight wraps. This should reroute CO line one to The Cordless Miracle and then back to the KSU. Verify with your test set or the store phone that line one is working on the storeís telephone system. Repeat the same for each of the other CO phone lines that you will be connecting.
Tapping into the intercom
Now that youíve located where you are going to tap into the intercom system, and you have your jumper wires in place, itís time to do it. The screw terminals on both the intercom boxes and the handsets should be the same. Wiring colors may vary from store to store, but the screw terminals will always be the same.
If there are very short leads to the intercom control box, you may want to kill power to the box so that you wonít blow a fuse. Itís amazing how dependent the stores are on their intercom systems, so try to have the power restored as quickly as possible. If the existing connector leads are really short, you may want to extend them a few inches so that it will be easier to work on.
Strip off about ĺ of an inch of insulation from each of the wires coming from The Cordless Miracle. You will only be wiring in the Orange, Green and Brown pair of wires. The blue pair will not be used.
Wiring to the Stor-Com intercom
Terminals 1 and 2 will not be connected to The Cordless Miracle.
Twist all three of the white wires together and connect them to Terminal 3, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Brown/White wire to Terminal 4, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Green/White wire to Terminal 5, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Orange/White wire to Terminal 6, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Wiring to the Ai-Phone intercom
Connect the White/Brown wire to Terminal 1, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Brown/White wire to Terminal 2, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Green/White wire to Terminal 3, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Connect the Orange/White wire to Terminal 4, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
Twist the White/Orange and the White/Green wires together and connect them to Terminal 5, or to whichever color wire is connected to that terminal. If you are splicing in on a wire, insulate the splice with electrical tape.
NOTE: On wiring to AiPhone's Four-Line Intercom, switch the Orange/White and Green/White wires.
Once youíve tapped into the storeís intercom system, please attach the appropriate label (included) to that point identifying the wires. If you don't, the next trip by the intercom service company, they will wonder what these new wires are for, scratch their heads, and then yank your wires off. Then, you will have to make a repeat service call to reconnect them.
NOTE: These instructions work the same whether you are tapping in at the intercom control box, at a handset, or at the nearest intercom wire.
Now youíre ready to program The Cordless Miracle. This is real simple. You will need either a single line telephone, a telephone test set with a modular plug end, or you will need to go get one of the cordless phones that you will be using for the store. Plug the phone into the Cordless Phone jack on The Cordless Miracle. (The reason that you plug the phone straight into The Cordless Miracle instead of using the cordless phone plugged into its regular location is that sometimes the telephone room is so far away from the base of the cordless phone that it cannot receive the signals from the cordless phone. If it is a small store and the cordless phone is in range, use the cordless phone. Do whichever is easiest for you.) Plug The Cordless Miracleís power supply into the unit and the wall transformer into a standard AC outlet. All that you do to program The Cordless Miracle is turn the cordless phone ON, listen for The Cordless Miracleís system dial tone, and dial #92. If you are standing next to The Cordless Miracle, you will hear a series of clicks coming from the box for about five seconds. From the earpiece of the cordless phone, you will hear a series of clicks for about five seconds, followed by a steady tone. When you hear the tone, turn the cordless phone OFF.
Thatís it! What you just did was tell The Cordless Miracle to look and see how many telephone lines were connected to it so that when you dial a 9 for an outside telephone line, it knows what lines are available.
Test the storeís regular telephones to verify that all of the phone lines are still working on those phones. Test each phone line with the cordless phone. If any line is in use by the storeís telephone system, you will get a busy signal from the cordless phone when you try to access that line.
Since The Cordless Miracle is installed in front of the KSU, the cordless phone has priority over all phone lines. Pressing the * button is an override that will allow you to take a call from HOLD, or to interrupt a call in progress. Once you press the * button, the next line number that you press is yours. You cannot put it back on HOLD or transfer it to another phone. It is now your phone call. Test this feature with lines that you have seized, not someone else.
Test the cordless phone
Dial 1-5 to test each telephone line.
If there are any problems, go back and check your work.
Make certain that youíve got everything plugged in and secured so that some clown wonít be unplugging cords and/or power supplies. Make certain that youíve got the cordless phones secured to the wall and that the cords are neatened up. Use black electrical tape to keep the wires of the cordless phones together. Be neat!
Test the cordless phone and all of its features again!
You are now ready to show off The Cordless Miracle to the store manager. And, you are about to make a friend for life!
If you have any questions, please call us at 757-694-1045.
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