ICS Tunnel Master wbc User manual

Tunnel Master® wbc
Installation Guide
Version 11.0

Tunnel Master® wbc Installation Guide Page i
Information in this manual is subject to change without notice. The example companies, organizations,
products, domain names, email addresses logos, people, places and events depicted herein are
ctitious. No association with any real company, organization, product, domain name, email address,
logo, person, place, or event is intended or should be inferred unless otherwise noted. No part of this
manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, for
any purpose without the express written permission of Innovative Control Systems, Inc.
Innovative Control Systems and its product trademarks in this manual are trademarks of Innovative
Control Systems, Inc. All other marks are property of their respective owners.
© 2020 Innovative Control Systems, Inc. | All rights reserved.
Innovative Control Systems, Inc.
81 Highland Avenue, Suite 300
Bethlehem, PA 18017
610-881-8000

Tunnel Master® wbc Installation Guide Page ii
Tunnel Master® wbc Installation Guide
Page ii
Contents
Installation Overview..........................................................................................................................................2
Hardware Specs............................................................................................................................................. 2
Site Planning.......................................................................................................................................................... 3
Determine the Location..............................................................................................................................3
Planning for Installation .............................................................................................................................3
Mounting Template for the Tunnel Master® wbc .............................................................................. 4
Equipment Dimensions ..............................................................................................................................5
Conduit Run Guidelines.............................................................................................................................. 5
Site Grounding Considerations................................................................................................................ 6
Wire Gauge and Conduit Size...................................................................................................................6
Electrical Installation........................................................................................................................................... 7
Locating Boards and Terminal Blocks ....................................................................................................7
Main CPU Board Overview......................................................................................................................... 7
WBC Main CPU Board .................................................................................................................................. 7
Main CPU Board ..........................................................................................................................................10
Input Board Terminal Blocks....................................................................................................................11
Delayed Panic Input ...................................................................................................................................12
Input Board Components ........................................................................................................................12
Manual Bypass Operation........................................................................................................................14
Transformer Selection ...............................................................................................................................15
Auxiliary Input Internal Voltage Wiring- Dry Contact ....................................................................15
Auxiliary Input External Power Wiring.................................................................................................15
Relay Boards Components.......................................................................................................................17
Relay Board Wiring Guidelines...............................................................................................................17
Jumpers ..........................................................................................................................................................18
Start/Stop Inputs Wiring...........................................................................................................................18
Manual Bypass, Conveyor, and Horn Wiring......................................................................................19
Conveyor Relay Wiring ..............................................................................................................................20
Conveyor Relay DIP Switch Settings ....................................................................................................20
Conveyor Relay Wiring on Input and Relay Boards.........................................................................21
Pulse Switch Wiring....................................................................................................................................22
Main Inputs Wiring .....................................................................................................................................23
Common Relay Output Wiring...............................................................................................................24
Common Relay Output Channels .........................................................................................................26
De-Selecting a Selective Relay Wiring.................................................................................................27

Tunnel Master® wbc Installation Guide Page iii
Adding a Second Relay .............................................................................................................................27
Jumper Test Point Locations ...................................................................................................................29
Terminal Block..............................................................................................................................................30
Input Name ...................................................................................................................................................30
Description....................................................................................................................................................30
DIP Switch and Reset Button ..................................................................................................................32
DIP Switch Settings ....................................................................................................................................33
Third Party Kiosk to Tunnel Master® wbc Terminations.................................................................34
Third Party Kiosk to WBC Terminations ...............................................................................................35
Ultrasonic Truck Bed Sensor....................................................................................................................36
Ultrasonic Truck Bed Sensor Mounting Recommendations........................................................37
Exterior of Tunnel Master® wbc..............................................................................................................36
Ultrasonic Truck Bed Sensor Power Supply Wiring .........................................................................38
RS-485 Comm Tiers on Main CPU Board.............................................................................................38
Tunnel Master® wbc AC Power Terminations....................................................................................38
Truck Bed Sensor Power Terminations ................................................................................................39
Connections from WBC to the Ultrasonic Converter Box (Power).............................................39
Ultrasonic Sensor Wiring ..........................................................................................................................39
Ultrasonic Sensor Jumper Settings.......................................................................................................40
Powering the Ultrasonic Sensor ...........................................................................................................41
Communications Wiring..................................................................................................................................43
Installation Requirements........................................................................................................................43
RS-232 COMM Terminal Wiring Diagram............................................................................................43
RS-485 Communication Wiring Layout...............................................................................................44
Install Entrance Keypad....................................................................................................................................45
Equipment Dimensions ............................................................................................................................45
Entrance Keypad Terminal Blocks .........................................................................................................47
Tunnel Master® wbc AC Power Terminations....................................................................................48
Entrance Keypad Comm Cable ..............................................................................................................49
Entrance Keypad Components .............................................................................................................50
Entrance Keypad DIP Switch Settings .................................................................................................51
Second Entrance Keypad Mounting ....................................................................................................51
Second Entrance Keypad Wiring ...........................................................................................................52
Second Entrance Comm Cable...............................................................................................................52
Troubleshooting .................................................................................................................................................53
Preventative Maintenance and Inspection........................................................................................53
Central Log Server ......................................................................................................................................53

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Tunnel Master® wbc Installation Guide
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List of Figures
Figure 1. Tunnel Master® wbc Mounting Template........................................................................... 4
Figure 2. Internal Components ................................................................................................................ 8
Figure 3. Main CPU Board........................................................................................................................... 9
Figure 4. CPU Board Terminal Blocks....................................................................................................11
Figure 5. Delayed Panic Input.................................................................................................................12
Figure 6. Input Board Components......................................................................................................13
Figure 7. Normal and Bypass Operation Settings on the Input Board.....................................14
Figure 8. Transformer Selector on the Input Board.........................................................................15
Figure 9. Auxiliary Input Relay Terminal Strip ...................................................................................15
Figure 10. Auxiliary Input External Power Wiring............................................................................16
Figure 11. Relay Board Components....................................................................................................17
Figure 12. Jumpers for Relay Board Terminal Blocks ......................................................................18
Figure 13. Wiring for Start/Stop Stations and Emergency Stop ................................................18
Figure 14. Manual Bypass, Conveyor, and Horn Wiring.................................................................19
Figure 15. Wiring of On-Board Relays for Conveyor Start Circuit...............................................21
Figure 16. Pulse Switch Wiring ...............................................................................................................22
Figure 17. Main Inputs Wiring.................................................................................................................23
Figure 18. Common Relay Output Wiring ..........................................................................................24
Figure 19. Common Relay Output Channels.....................................................................................26
Figure 20. Normal Wiring for a Relay....................................................................................................27
Figure 21. Adding a Second Relay in Series ......................................................................................27
Figure 22. Horizontal View of Two Relay Setup ................................................................................28
Figure 23. WBC Relay Board Terminations Common Relay Output .........................................28
Figure 24. Jumper Test Point Locations...............................................................................................29
Figure 25. DIP Switch and Reset Button..............................................................................................32
Figure 26. DIP Switch (Input Board)......................................................................................................33
Figure 27. Non-ICS Kiosk (not an Auto Sentry) to Tunnel Master® wbc Terminations........35
Figure 28. Exterior Panel...........................................................................................................................36
Figure 29. Ultrasonic Truck Bed Sensor Mounted............................................................................36
Figure 30. Ultrasonic Sensor Mounting Dimensions......................................................................38
Figure 31. (2) RS-485 Comm Tiers on Main CPU Board..................................................................38
Figure 32. Tunnel Master® wbc Power Terminations ......................................................................38
Figure 33. Warning label located below the Tunnel Master® wbc Power Terminations ....39
Figure 34. Ultrasonic Sensor Power Terminations...........................................................................41

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Figure 35. Ultrasonic Sensor Comm Connections...........................................................................42
Figure 36. Power for the Sensor (Black, brown, and blue wires) ................................................43
Figure 37. Ultrasonic Sensor detecting a pickup truck..................................................................44
Figure 38. RS-232 Comm Terminal Wiring Diagram (Main CPU Board) ...................................46
Figure 39. RS-485 Communication Wiring Layout ..........................................................................48
Figure 40. Keypad Connectors (Keypad Board)................................................................................49
Figure 41. Tunnel Master® wbc Keypad Power Terminal Blocks.................................................50
Figure 42. AC Power Terminations ........................................................................................................42
Figure 43. Main CPU Board RS-485 Comm Terminal Wiring ........................................................42
Figure 44. Keypad Circuit Board Jumper Settings...........................................................................42
Figure 45. Keypad Reset and DIP Switch ............................................................................................42

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Tunnel Master® wbc Installation Guide
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List of Tables
Table 1. Tools Required and Parts Included.........................................................................................1
Table 2. Equipment Dimensions..............................................................................................................5
Table 3. Wire Gauge and Conduit Size................................................................................................... 6
Table 4. Internal Components of Tunnel Master® wbc .................................................................... 8
Table 5. Main CPU Board Inputs.............................................................................................................10
Table 6. CPU Board Terminal Blocks......................................................................................................12
Table 7. Input Board Components........................................................................................................14
Table 8. Relay Board Components ........................................................................................................17
Table 9. Jumper Functions and Settings.............................................................................................31
Table 10. DIP Switch and Reset Button................................................................................................32
Table 11. DIP Switch (Input Board) Functions and Settings.........................................................33
Table 12. Exterior Descriptions of the Tunnel Master® wbc.........................................................36
Table 13. Ultrasonic Sensor Specications.........................................................................................36
Table 14. Ultrasonic Sensor Jumper Settings....................................................................................40
Table 15. Ultrasonic Sensor Settings....................................................................................................42
Table 16. Keypad Dimensions and Ratings........................................................................................45
Table 17. Keypad Connector Descriptions.........................................................................................46
Table 18. Entrance Keypad.......................................................................................................................50
Table 19. Entrance Keypad DIP Switch Settings...............................................................................51
Table 20. Second Entrance Keypad Wiring.........................................................................................52
Table 21. Network 485...............................................................................................................................52

Tunnel Master® wbc Installation Guide Page 1
Tools Required
Small Flat Blade Screwdriver #2 Phillips Screw Driver
Wire Cutter Wire Ties
Part Description Photo of Part Included
4 – 6.3A fuses (FUSE63)
2 – 0.5A fuses (FUSE.5)
1 – 5A fuse (FUSE5)
5 – ¼” x 20 nuts, at washers, lock washers
8 – #10 x 32 nuts
2 – ICS screwdrivers
1 – set of 2 keys for the Tunnel Master® wbc door
20 – jumpers (WBCJUMP214)
1 – Breaker (AS2TERMBRK6)
5 – 6 x 8 index cards (WBCIND6X10)
1– 8 x 10 index card (WBCIND8X10)
Table 1. Tools Required and Parts Included

Tunnel Master® wbc Installation Guide Page 2
Tunnel Master® wbc Installation Guide
Page 2
Installation Overview
This document was written for the installation of the Tunnel Master® wbc to assist technicians and
electricians. A thorough understanding of electrical wiring, installation, codes, and safety protocols
is required. Additionally, some familiarity with car wash tunnel equipment and installation is
recommended. No prior experience with the Tunnel Master® wbc (Web Based Controller) is required.
The Tunnel Master® wbc is also known as the WBC. This guide should be supplied to the electrician
prior to the installation of conduit and wiring to ensure the WBC system is installed properly. Faulty
installations are the major cause of system malfunctions. The Tunnel Master® wbc system must be
installed exactly as described in this manual to ensure its reliability and proper operation.
WARNING: Failure to properly install the WBC system will void the warranty.
Innovative Control Systems provides technical support for customers and installers:
1-800-246-3469
Many of the WBC system features were integrated at the request of current car wash operators. We
welcome your feedback and want to assure you that ICS will always remain the industry leader in car
wash controller and management systems.
By reading the information and performing the procedures in this manual, you should be able to
perform the following:
Install the WBC system-level wiring
Install the WBC communications wiring
Troubleshoot problems if they occur
Related Documents
Tunnel Master® wbc User Manual
Version Considerations
This document is Version 11 released February 5, 2020. Version 11 of this document includes content
based on the following ICS software versions:
Controller software version 1.2 B51
Controller software version 1.3 B10 (only available if hardware is compatible)
Completion Time
We estimate that it will take 30 minutes to perform this procedure. Keep all hardware organized.
Hardware Specs
Unit weighs 130 lbs
Hinged panel design measures 32’’W × 40’’ H × 12’’ D
IP-based tunnel controller capable of handling:
• 192 outputs
• 48 inputs
Graphics display shows the status of all inputs and other tunnel status indicators
Web interface for easy conguration

Tunnel Master® wbc Installation Guide Page 3
Firmware update over network
Main CPU board
Directly connect up to four relay boards
Input board
All boards powered by 24 V DC from power supply:
• Isolated 12 V DC for display back light
• 12 V AC RS-485 isolation and 16 main inputs
All isolated inputs powered from separate external AC supply
Dedicated universal power supplies (UPS) 1500VA/865 Watts output capacity
Site Planning
Careful planning for the layout of the site will help eliminate possible problems with the start-up of
your system and will ensure continued, reliable system operation.
Determine the site layout.
Prepare to have all the necessary tools and parts.
All permanent wiring connections must be installed by a licensed electrician that must comply
with local and national codes.
Determine the Location
The following are a few primary concerns to consider when determining the site layout:
The Tunnel Master® wbc must be securely mounted on a dry, non-corrosive interior wall or
surface in the equipment room of the car wash.
The unit has been designed to operate in an environment of 32° F to 122° F (0°C to 50°C).
The unit is 130 lbs., 32’’W × 40’’ H × 12’’ D with a hinged-panel door. Hinges are on the right. The
door swings open from left to right.
A minimum of 48 inches of clearance is recommended. This clearance should be available both
in front of the door and on the wall to the right of the unit. This minimum will give enough
clearance for the door to swing out and be fully opened without interfering with entrances and
exits from the equipment room.
The WBC box must be located so that conduit connections can be easily made and the relays
can be readily accessed.
Recommended minimum mounting height of 32’’ o ground to the bottom of the WBC box.
Installer shall rst follow any local codes which supersede this recommendation.
Planning for Installation
Wiring can be contained in rigid PVC conduit or metal conduit.
High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction
box, or wire trough.
Power for the Tunnel Master® wbc and any peripherals must come from the dedicated UPS, as
supplied by ICS.
The Tunnel Master® wbc and peripheral equipment must be properly grounded.

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Tunnel Master® wbc Installation Guide
Page 4
Mounting Template for the Tunnel Master® wbc
Figure 1. Tunnel Master® wbc Mounting Template
4"
2"
9/16"
Diameter
Detail
5/8"
Notch
24"
CentertoCenter
36"
CentertoCenter
9/16"
Diameter
Detail
4"
2"
9/16"
Dia.
9/16"
Dia.
½”Bolts
Recommended
Tunnel Master WBC
Mounting Template
(ForreferenceOnly,thisisnottheactualtemplate.)

Tunnel Master® wbc Installation Guide Page 5
Equipment Dimensions
When mounting the Tunnel Master® wbc unit, minimum clearances must meet local codes.
Dimension Amount Notes
Width 32'' —
Height 40'' —
Depth 12'' Includes the plastic face.
Weight 130 lbs Inclusive of the box, board, and door.
Operating Temp. Range 32° F to 122° F
0° C to 50° C —
Frequency 60 Hz —
Supply Voltage 110-120 VAC —
Max Amps 6.0 Amps —
Power Supply 15 Amps Power must come from a dedicated, 15-Amp.
breaker.
IPX Rating Ordinary rating The Tunnel Master® wbc is not rated for
protection against dust and liquid ingress.
Power Requirements
Electrician must provide a dedicated 15 Amp, 120 V AC circuit to the Uninterrupted Power
Supply (UPS), and the UPS will supply power to the Tunnel Master® wbc box.
A separation of 120 V AC and 24 V DC shall be maintained for all eld-wiring circuits. All 24 V DC
circuits must be supplied by a class-2 transformer, which is to be provided by the electrician.
Electrician must determine proper size of transformer, depending on total required power
consumption.
The Tunnel Master® wbc unit must be properly grounded.
Conduit Run Guidelines
When running wires to and from the Tunnel Master® wbc unit, follow these guidelines:
Punch conduit holes through bottom of WBC box whenever possible.
Use wiring channels inside WBC box (left and right sides) to contain wires.
Run a 14/3 cable, from a UPS output, to the 120 V AC terminal block. Inside the WBC box, the
terminal block is labeled with L and N for Line and Neutral. In the lower-right corner near the
AC terminal block, there is a mechanical ground lug, labeled with the universal ground symbol.
All conduit runs should meet local and national codes. Conduit shall be properly connected
and securely fastened to the boxes with listed conduit hubs, and should be tightened to the
torque specs of the manufacturer.
Over-torquing may cause enclosure breakage.
All conduit must be rigid PVC or metal.
Table 2. Equipment Dimensions

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Tunnel Master® wbc Installation Guide
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Tighten all wires on the circuit board terminal blocks to 15 inch-pounds. Over-torquing may
cause breakage.
High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit,
junction box, or wire trough.
Power cables and comm cables must not be combined in a common conduit, junction box,
or wire trough.
Site Grounding Considerations
The Tunnel Master® wbc and peripheral equipment must be properly grounded.
Recommended and Accepted Grounding Methods
Proper system grounding is an extremely important part of the system installation. Grounds for
all system devices should be wired to the breaker panel ground bus bar which, in turn, should
be grounded to a ground rod. A conduit ground does not provide a sucient ground. It is
recommended that the neutral and ground bus bars be bonded together when it is not prohibited
by local codes.
The universal ground symbol identies the grounding lug connector located inside the lower-right
corner of the Tunnel Master® wbc box.
WARNING: Improper grounding will void equipment warranty.
Ground wire must be connected to the ground lug. Failure to
properly ground the unit could result in unit failure and/or bodily
injury.
Wire Gauge and Conduit Size
When planning the orientation of the wiring runs, follow the applicable ICS wiring diagrams and
consider the layout of the components at the site.
To determine conduit size needed, see the table below for more information.
½ ¾ 1 1 ¼ 1 ½ 2 2 ½ 3
AWG 14 13 24 39 69 94 154 — —
AWG 12 10 18 29 51 70 114 164 —
AWG 10 6 11 18 32 44 73 104 160
AWG 8 3 5 9 16 22 36 51 79
AWG 6 1 2 6 11 15 26 37 57
AWG 4 1 1 4 7 9 16 22 35
AWG 3 1 1 3 6 8 13 19 29
AWG 2 1 1 3 5 7 11 16 25
AWG 1 1113581218
Table 3. Wire Gauge and Conduit Size

Tunnel Master® wbc Installation Guide Page 7
Electrical Installation
The Tunnel Master® wbc is the control center for“ring”the various outputs or services in the wash
tunnel: soap foamer, reclaim motor, and more. The Tunnel Master® wbc provides for automatic,
computer controlled, or manual ring of the outputs. The system can control up to 192 outputs and
64 inputs (48 of which are user-programmable).
Locating Boards and Terminal Blocks
This section provides details on boards, component locations, and terminal block identication:
Main CPU board
Input board
Up to four directly connected Relay boards
24 V DC power supply
12 V AC transformer used for supplying the following:
• Isolated 5 V DC RS485
• 5 V DC for 16 main CPU board inputs
• 48 auxiliary inputs on the input board
• All start/stop inputs

Tunnel Master® wbc Installation Guide Page 8
Tunnel Master® wbc Installation Guide
Page 8
Tunnel Master® wbc Internal Components
ID Description
1 Relay Board 1 Relays 1-24
2 Relay Board 2 Relays 25-48
3 Relay Board 3 Relays 49-72
4 Relay Board 4 Relays 73-96
5 Input Board
6 Main CPU Board
7 24V DC Power Supply
8 12V AC for all Isolated Inputs
Figure 2. Internal Components
Table 4. Internal Components of Tunnel Master® wbc

Tunnel Master® wbc Installation Guide Page 9
Tunnel Master® wbc Main CPU Board
Figure 3. Main CPU Board

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Tunnel Master® wbc Installation Guide
Page 10
Main CPU Board
The following table lists inputs available on the main CPU board. All inputs require 24 V max. line,
neutral, and ground.
WARNING: *Removing the Flash Module for any reason will Void the Warranty.
ID Description ID Description
1 RJ-45 Terminal for Network Connection 15 Display Connection Point
2 Flash Module* 16 Keyboard Connect Point
3 Eight-Port DIP Switch 17 Pulse Switch Connections
4 Status LEDs 18 Assigned Function Inputs
5 Input Board RJ-45 Terminal Connector 19 Expansion Inputs
6 Relay Board RJ-45 Terminal Connector 20 RS-232 Comm Terminal
Relays 1-24
7 Status LEDs 21 Fuse 500mA
8 Relay Board RJ-45 Terminal Connector 22 RS-485 Comm Terminal
Relays 25-48
9 Status LEDs 23 12V AC Input from Transformer
10 Relay Board RJ-45 Terminal Connector
Relays 49-72
11 Fuse 500mA
12 Relay Board RJ-45 Terminal Connector
Relays 73-96
13 Fuse 500mA
14 Input Power from 24V DC Power Supply
The main CPU board includes a microprocessor module and 16 main inputs. It drives up to
four in-box relay boards and one in-box input board.
A data ash module is included for storage of conguration settings. One eight-port DIP
switch is included.
One RS232 port is available for debug. The main CPU board drives the included PS2
keyboard and 640 × 480 color display monitor.
One RS485 port with two connectors is included. It is available for connecting a wash
selection keypad.
Table 5. Main CPU Board Inputs

Tunnel Master® wbc Installation Guide Page 11
Input Board Terminal Blocks
ID Terminal Block Input Name Description
1 Pulse Switch PULSE SINK
When using a normally open, two-wire pulse
switch, use terminals marked PULSE SINK and
PROX GND.
PROX GND See "Pulse Switch Wiring" on page 22.
PROX POWER
SINK
When using a normally open three-wire pulse
switch, use terminals marked PROX POWER,
PULSE SINK, and PROX GND. System provides
18 V DC power.
GND See "Pulse Switch Wiring" on page 22.
POWER
When using a normally closed three-wire pulse
switch, use terminals marked PROX POWER,
PULSE SRCE, and PROX GND.
PULSE SRCE See "Pulse Switch Wiring" on page 22.
GND
Figure 4. CPU Board Terminal Blocks
LEDs are available for all the I/Os including the RS-232/485 connections.
LED indicators display the status of inputs. The main status LEDs include the following:
• LED1–Logic
• LED2–Auto pulse
• LED3–6 Reserved
• LED7–Chain travel
• LED8–Conveyor Status

Tunnel Master® wbc Installation Guide Page 12
Tunnel Master® wbc Installation Guide
Page 12
ID Terminal Block Input Name Description
2 Assigned Function Inputs GATE (SIGNAL) General note: ICS highly recommends
Using shielded cable for all input wiring.
Terminate the shield drain as close to the
24 V AC power supply as possible.
TIRE (SWITCH)
ROLLER LOCATOR
REMOTE ROLLER
EM TIRE2
(ENTRANCE MGMT)
ANTI-COLLISION
INPUT 1 (DELAYED
PANIC)
3 Expansion INPUT2–9 Reserved for future ICS use.
Delayed Panic Input
The Delayed Panic Input, if active, will pause the conveyor for the programmed amount of time before
entering a full Panic Stop Node.
Recommended: purchase either a yellow or orange push/pull stop button.
The Delayed Panic Input is located on the Main CPU board as Input 1.
Input Board Components
Delayed Panic Input
Figure 5. Delayed Panic Input
Table 6. CPU Board Terminal Blocks

Tunnel Master® wbc Installation Guide Page 13
The input board provides monitoring and error reporting of all 48 inputs wired to the inputs terminal
block. Auxiliary inputs help report the state of the tunnel. If an error condition or event occurs, you can
use the inputs as monitors to receive alerts or set the tunnel into a panic stop mode. The input board
works independently of the main CPU board.
The input board includes eight stop inputs. One stop input is controlled by the computer.
Seven stop inputs are directly controlled by push-button stops. All stop input circuits must be
closed for the conveyor to work.
The input board includes eight start inputs. One start input is controlled by computer. Seven
start inputs are directly controlled by push-button starts.
The input board includes 48 undesignated, optically isolated inputs. The board also features on-board
relays to control the horn and the conveyor. A DIP switch bank controls the delay time between the
horn and the conveyor start.
ID Description ID Description
Figure 6. Input Board Components