ICS Tunnel Master Jr User manual

Tunnel Master® Jr.
User Manual - Version 5.0

Tunnel Master® Jr. User Manual Page i
Information in this manual is subject to change without notice. Companies, names and data used
in examples within the manual are ctitious 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.
Copyright © 2020 Innovative Control Systems, Inc.
Innovative Control Systems, Inc.
81 Highland Road, Suite 300
Bethlehem, PA 18017
610-881-8000

Tunnel Master® Jr. User ManualPage ii Copyright © Innovative Control Systems, Inc.
Contents
Version Considerations ............................................................................................................................ 1
Hardware Features..................................................................................................................................... 2
Planning for Installation .......................................................................................................................... 3
Controller Box Dimensions..................................................................................................................... 4
Entry Keypad Dimensions....................................................................................................................... 4
Relay Box Mounting.................................................................................................................................. 5
Relay Box Wiring......................................................................................................................................... 5
Low Voltage Layout................................................................................................................................... 6
Initialize and Clear Settings.................................................................................................................... 6
24 Outputs.................................................................................................................................................... 8
Tunnel Master Jr. Relay Box Interior..................................................................................................... 9
Pulse/Proximity Switch Wiring ............................................................................................................10
Gate Switch (Electric Eye) Wiring........................................................................................................11
Tire Switch Wiring ....................................................................................................................................12
Entrance Management System Wiring.............................................................................................13
Roller Locator Wiring ..............................................................................................................................14
Panic Stop Circuit Wiring.......................................................................................................................14
Anti-Collision Wiring...............................................................................................................................16
Input Wiring Designations....................................................................................................................17
Push Button Wiring..................................................................................................................................18
Relay Box Jumper Settings ...................................................................................................................21
DIP Switch Settings .................................................................................................................................23
Tunnel Master® Jr. AC Power Terminations .....................................................................................23
Communication Cable Terminations ................................................................................................25
Entrance Keypad Jumper Settings.....................................................................................................27
Jumper - J3 .................................................................................................................................................28
Entrance Keypad DIP Switch Settings ..............................................................................................28
Tunnel Master Jr. Display and Keypad..............................................................................................29
Set or Change Password........................................................................................................................31
Access a Password Protected Menu ..................................................................................................31
Set Date Time.............................................................................................................................................32
Congure Wash Menu............................................................................................................................33
Wash Settings............................................................................................................................................34

Tunnel Master® Jr. User Manual Page iii
Congure Wash Settings .......................................................................................................................37
About Countdown Times ......................................................................................................................38
Outputs........................................................................................................................................................38
Output Settings ........................................................................................................................................41
Service Settings ........................................................................................................................................43
Change or Set Services ..........................................................................................................................44
Assign Outputs to Services...................................................................................................................45
Operating Procedures ............................................................................................................................47
Main Wash Menu......................................................................................................................................47
Wet Down Wash........................................................................................................................................48
Processing Cars.........................................................................................................................................49
Entrance Keypad Functions..................................................................................................................50
Entrance Keypad Buttons......................................................................................................................51
Entrance Keypad to Process Vehicles (Non-Stacking).................................................................52
Entrance Keypad to Process Vehicles (Stack) .................................................................................53
Change Service and/or Add Retract..................................................................................................54
Add a Car to Stack....................................................................................................................................54
Remove a Car from Stack ......................................................................................................................54
View Service Counts for the Current Shift.......................................................................................55
Bump Shift..................................................................................................................................................55
Bump a Shift or Manually Close Current Shift ...............................................................................56
Mounting and Installation of the Printer.........................................................................................57
Report Printer Wiring..............................................................................................................................58
System Diagnosis.....................................................................................................................................59
Entrance Keypad ......................................................................................................................................59
Wash Controller Response....................................................................................................................59
Wash Controller Input Check...............................................................................................................59
Entrance Keypad Diagnostics..............................................................................................................60
1 Relay box, 1 Keypad, and 1 Printer .................................................................................................63
2 Relay boxes, 1 Keypad, and 1 Printer.............................................................................................64
2 Relay Boxes, 2 Keypads, and 2 Printers .........................................................................................65

Tunnel Master® Jr. User Manual - Page 1
Chapter 1: Introduction
Chapter 1: Introduction
This document was written for the installation of the Tunnel Master® Jr. (also known as the
TMJ) to assist technicians, electricians, and operators. 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® Jr. This guide should be supplied to the electrician prior to the installation of
conduit and wiring to ensure the TMJ is installed properly. Faulty installations are the major
cause of system malfunctions. The Tunnel Master® Jr. system must be installed exactly as
described in this manual to ensure its reliability and proper operation.
WARNING: Failure to properly install the Tunnel Master Jr. system will void the warranty.
Innovative Control Systems provides technical support for customers and installers:
1-800-246-3469
Many of the TMJ 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 committed to
being the industry leader in car wash controller and management systems.
By following the procedures in this manual, you should be able to perform the following:
Install the Tunnel Master® Jr. system-level wiring
Install the Tunnel Master® Jr. communications wiring
Congure your wash settings and features
Process vehicles through your wash
View car counts
View historical information
Track sales
Print reports
Troubleshoot problems if they occur
Provide a comprehensive, easy-to-use system reference guide
Enable operators and their employees to obtain the maximum value from the system
Furnish operators with a tool for training their employees on the Car Wash Controller
Version Considerations
This document is 5.0 released September 16, 2020, and includes content based on the
following ICS® software versions:
Tunnel Master® Jr. software Version 7.49 released April 28, 2020

Page 2 - Tunnel Master® Jr. User Manual Chapter 1: Introduction
Hardware Features
The Tunnel Master® Jr. hardware is designed to withstand the harsh environments and hard
use of a busy car wash. As an ICS customer, you benet from a thoroughly researched and
developed car wash controller. This manual will enable the operator to have an active part in
the control and operation of your car wash facility with the many Tunnel Master® Jr. features:
24 programmable, fused outputs, upgradeable to 72, each with two independent circuits.
24 VAC and 120 VAC.
Programmable ashing relay.
Exclusive, patented anti-theft feature to prevent unauthorized processing of car washes.
Input for Pulse, Gate, Tire, Roller Locater, Entrance Management, and Panic circuits.
Auto Pulse feature allows pulse simulation in the event of pulse switch failure.
Auto Gate feature allows gate switch simulation in the event of gate switch failure.
Exterior indicators for easy troubleshooting.
16 programmable service buttons on the entry keypad, upgradeable to 32.
Automated wet down feature for easy startup.
Optional report and/or receipt printers.

Tunnel Master® Jr. User Manual - Page 3
Chapter 2: Hardware Installation
Chapter 2: Hardware Installation
This chapter provides a brief description of the hardware components and their function and
the tunnel settings wiring diagrams for a new Tunnel Master® Jr. installation. The following
instructions will provide detailed information on proper relay box mounting and installation
of the Entrance Keypad.
Planning for Installation
Before you begin, please read this entire manual.
Permanent connections must be installed by a licensed electrician and must comply in
accordance with all local and national codes.
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® Jr. and any peripherals must come from the dedicated UPS
as supplied by ICS.
The Tunnel Master® Jr. and peripheral equipment must be properly grounded.
Test connections in the manual override position prior to system start-up.
Before disposing boxes and cartons, look through to make certain all manuals, cables,
connectors, and more have been removed.
WARNING: Failure to properly install the Tunnel Master® Jr. system will void the warranty
and could result in serious injury or death.
Innovative Control Systems provides a toll-free number for customers and installers who have
questions pertaining to the installation:
800-246-3469

Page 4 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Controller Box Dimensions
Dimension Amount Notes
Width 27 3/8” —
Length 15 3/8” —
Depth 6 3/8” Includes the plastic face.
Weight 48 lbs. Inclusive of the box, board, and door.
Operating Temp. Range 32 °F to 122 °F
0 °C to 50 °C
—
Frequency 50/60 Hz. —
Supply Voltage 120 VAC —
Max. Amps 6.0 Amps. —
Power Supply 6.0 Amps. Power must come from a dedicated 6-Amp. breaker
IP Rating IP40 The Tunnel Master® Jr. is rated for protection against
solid objects up to 1mm diameter and not protected
against liquid.
Table 2-1. Tunnel Master Jr. Controller Dimensions, Measurements, and Ratings
Entry Keypad Dimensions
Dimension Amount Notes
Width 9 3/8” —
Height 7” —
Depth 2 5/8” Includes the plastic face.
Weight 3 lbs. Inclusive of the box, board, and door.
Operating Temp. Range 32 °F to 122 °F
0 °C to 50 °C
—
Frequency 50/60 Hz. —
Supply Voltage 12 VAC —
Max. Amps .02 Amps —
Power Supply .02 Amps Power must come from a dedicated ICS transformer.
IP Rating IP65 The Tunnel Master® Jr. is rated for total protection
against dust and strong jets of water from all directions,
limited ingress permitted.
Table 2-2. Tunnel Master Jr. Keypad Dimensions, Measurements, and Ratings

Tunnel Master® Jr. User Manual - Page 5
Chapter 2: Hardware Installation
Relay Box Mounting
The relay box must be securely mounted to the wall in the equipment room of the car
wash. The relay box is designed to be located in a dry, non-corrosive environment.
The relay box must be located so that conduit connections can be easily made, and the
relays can be readily accessed.
Relay Box Wiring
Install one approved 3/4”conduit from the relay box to the entrance keypad box located
near the front of the wash tunnel. All conduit runs should meet all local and national
codes. Conduits 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.
Electrician must provide a dedicated 120 VAC circuit to power the relay box.
Run a 14-3 cable to the 120 VAC terminal block. It is labeled with L and N for Load and
Neutral, respectively. There is a mechanical ground lug located on the back of the
box adjacent to the terminal block. It is labeled with the universal ground symbol.
Terminations for the shielded cable should be torqued to 35 pound-inches.
Electrician must supply a separate 24 VAC and 120 VAC circuit to the common (C) side of
the upper and lower termination points of each relay respectively, then loop the commons
together to each relay. This power is to re the solenoids and equipment.
A separation of 120 VAC and 24 VAC shall be maintained for all eld-wiring circuits. All 24
VAC circuits must be supplied by a class 2 transformer.
Tighten all wires on the circuit board in the relay box to 20 pound-inches (2.3 n-m.) Over
torquing may cause enclosure breakage.
Relays in the relay box are double pole with independent commons so that each relay
can have two circuits running through it. Commons are independent to provide a power
source to switch two devices through either the normally open or normally closed circuits.
Relays circuits should be supplied with no greater than 120 VAC 15 Amp.
NOTE:This 120 VAC MUST BE A SEPARATE CIRCUIT from the dedicated 120 VAC circuit terminated
in the lower-left corner of the Relay Box.
A 6.3 Amp 250V fuse protects each relay. Four spare fuses along with LED fuse test
indicators are located at the center of the relay board. (Fuses should not be replaced with
any other device.)
Another approved ¾” conduit needs to be run to your motor control center to the relay
box, and will contain the low voltage wires for clock (Pulse), gate (Entrance switch), and
Tire switch functions.
When using a normally open 2-wire pulse switch, use terminals marked CLK SINK and
PROX GND.
When using a normally open 3-wire pulse switch, use terminals marked PROX PWR, CLK
SINK, and PROX GND.
Gate and Tire inputs require a constant 24 VAC neutral supplied from a class 2 transformer.
The load signal would be terminated to the normally open pole of the electric eye (Gate)
switch.

Page 6 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Low Voltage Layout
LOW VOLTAGE LAYOUT
*** THIS DRAWING IS NOT TO SCALE. THIS DRAWING IS MEANT ONLY TO
SHOW THE TYPES OF WIRING THAT MUST BE RUN BETWEEN PIECES OF ICS
EQUIPMENT. THE INDIVIDUAL RUNNING THE WIRING MUST ENSURE THAT
AMPLE WIRE IS AVAILABLE AT EITHER END TO FACILITATE TERMINATION.
THE TERMINATION POINTS OF THE CABLES ARE NOT SHOWN ON THIS
DOCUMENT.***
CONTROLLER
KEYPAD
ICS SUPP LIE D 24/4
SHIELDED COMM
CABLE ONLY
TUNNEL MASTER JR.
RELAY BOX
SERVER
COMPUTER
NETWORK CABL E
Initialize and Clear Settings
Reset the default conguration of the Tunnel Master® Jr.
NOTE:For rst time use, ICS recommends a complete initialization and clear
the factory settings.
The Tunnel Master® Jr. is delivered with preloaded settings. You can erase these settings before
conguring your own settings. This is also known as performing an initialize and clear. The
following procedure shows how to erase the current settings:
1. Open the Tunnel Master Jr. door.
2. On the inside of the Tunnel Master Jr. door, remove the motherboard cover, if necessary.
3. Locate DIP switch 6, and then slide the switch up to the On position.
4. Press the Reset button located above the battery.
5. On the Tunnel Master Jr. (TMJ) display, press the Menu button.
6. On the display keypad, press #1.
The TMJ display quickly ashes the “Initialize Files”message.
7. On the display keypad, press #2.
The TMJ display quickly ashes the “Clear Memory” message.
Figure 2-1. Low Voltage Layout

Tunnel Master® Jr. User Manual - Page 7
Chapter 2: Hardware Installation
8. On the display keypad, press #4 which is the factory reset.
Figure 2-2. DIP Switch 6 On Position
9. To remove power from the switchboard, remove the ribbon cable on the right-side
of the board.
10. Remove the battery from the switchboard.
11. Press in and hold the clip that keeps the battery in place against the board for at
least a minute to drain all the settings from memory.
12. Re-insert the ribbon cable on the right-side of the switchboard.
13. After the factory reset, move DIP switch 6 back to the O position.
14. Press the Reset button.
The TMJ display shows the“System Shut Down” message.
15. After completing these instructions, contact ICS Technical Support at 800-246-3469
to clear the“System Shut Down” message.
Figure 2-3. Reset Button and Battery on Switchboard
DIP Switch 6
ON
OFF
Reset
Battery

Page 8 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
24 Outputs
The Tunnel Master® Jr. relay box is the control center for ring the various outputs or services in the wash
tunnel like the soap foamer, reclaim motor, and more. The Tunnel Master® Jr. Controller relay box provides
automatic, computer controlled, or manual ring of the outputs. The relay box can control up to 24
outputs. Each toggle switch controls the operation of one output or service.
The switches have three positions:
UP = Manual Override. Manually turn on output. (This feature can be turned o if desired.)
MIDDLE = Output O. The output is o and will not re.
DOWN = Computer controlled on position (normal).
Figure 2-4. Front Panel of the Tunnel Master Jr.

Tunnel Master® Jr. User Manual - Page 9
Chapter 2: Hardware Installation
Termination points
for Pulse, Gate, Tire,
and Panic Circuits.
Plug in relays for ease of
serviceability. Each relay
has 2 fuses
(24 V AC and 120 V AC).
Built in spare fuses and
fuse tester (located near
the center of the box).
12 V AC transformer
powers the Keypad Power
Board only. WARNING:
Do NOT power any
other device from this
transformer!
NOTE: PC and Printer
connections are located in the
base of the box.
Power in.
Power
Conditioner
Board
Comm Cable Terminal Blocks
for 16 button Entry Keypad
and other TMJ relay box.
Figure 2-5. Tunnel Master Jr. Interior Components
Tunnel Master Jr. Relay Box Interior
Each relay has circuits to control both 24 V AC and 120 V AC simultaneously so that a service sign as
well as the service solenoid can be operated from the same relay.
Each relay can be programmed to ash, eliminating the need for eld installed ashing
relays for signs.

Page 10 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Pulse/Proximity Switch Wiring
IMPORTANT: The pulse switch is a critical input for the Controller. It signals the system that
the conveyor is moving and is the measuring device from which the system knows when to
turn equipment devices on and o.
See wash equipment vendor for location of the switch.
The Controller is designed to accept all commonly used pulse/proximity switches. There are two types
that are most commonly used, either a two wire or three wire Sinking (NPN) switch. The drawing below
indicates the wiring for these two types of switches.
The other type of switch is dened as a Sourcing (PNP). If it is determined that this type of proximity
switch is being used, there are two jumpers located just below the CLK SINK and CLK SRCE terminal
blocks (JP1) and (JP2). These jumpers must be moved to the SOURCE jumper position. Some pulse
switches vary in the wire color. You should check the pulse/proximity switch manual for proper color
codes. The following diagram shows how to wire the pulse/proximity switch into the Relay Box.
Figure 2-6. Pulse/Proximity Switch Wiring

Tunnel Master® Jr. User Manual - Page 11
Chapter 2: Hardware Installation
Figure 2-7. Gate Eye (Switch) Wiring
Gate Switch (Electric Eye) Wiring
IMPORTANT: The Gate switch is the second critical input device to the Relay Box. It is
usually an electric eye system or some type of vehicle position detector located just
before the rst piece of wash equipment. This switch signals the Controller that a vehicle is
starting through the tunnel. All equipment turn on points are measured from this switch
to the particular piece of equipment.
See the wash equipment provider for the location of this relay. The following diagram to the Smart
Relay Box starts at the control relay for the sensing device being used. The diagram shows how to wire
the Gate (electric eye) switch into the Relay Box.
24 VAC SUPPLY
(BY OTHERS)
COMMON NORMALLY
OPEN
ELECTRIC PHOTO EYE
OR OTHER SENSING
DEVICE CONTACTS
GATE (ELECTRIC EYE) DETECTION CIRCUIT
L N
TMJ RELAY BOX TERMINAL STRIP (TOP)
Gate - Gate +
Alternate symbol for N.O. Switch

Page 12 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Tire Switch Wiring
IMPORTANT: This circuit is used if the customer has purchased a tire position switch from
the equipment vendor. The switch enables the Controller software to turn equipment on
and o as each of the vehicle’s tires pass that piece of equipment. In order for this to work
properly, the tire switch should be located in line with the gate switch.
The following diagram shows how to wire the Tire Switch (tire position detection) into the Relay Box.
24 VAC SUPPLY
(BY OTHERS)
TMJ RELAY BOX TERMINAL STRIP (TOP)
COMMON NORMALLY
OPEN
ELECTRIC TIRE
POSITION SENSING
DEVICE CONTACTS
TIRE POSITION DETECTION CIRCUIT
L N
TIRE - TIRE +
Alternate symbol for N.O. Switch
Figure 2-8. Tire Switch Wiring

Tunnel Master® Jr. User Manual - Page 13
Chapter 2: Hardware Installation
Entrance Management System Wiring
IMPORTANT: This circuit is used if the customer has purchased a treadle switch from the
equipment vendor. The Entrance Management System in the Tunnel Master® Jr. allows a
roller to be red automatically upon seeing a second 24V input on Input 10. At the same
time, an output can be set to re and the roller can be delayed.
When a car enters the tunnel, the Tunnel Master® Jr. will wait to see two signals within 15 seconds
of each other from the tire treadle that is wired into Input 10. The rst signal represents the front
tire, and the second signal represents the rear. After it sees the second signal, the Tunnel Master® Jr.
will re an optional sign relay followed by a roller relay. The amount of time between the sign ring
and the roller is called the Entrance Management Delay in the Wash Settings. The following diagram
shows how to wire the treadle switch for the EMS into the Relay Box.
24 VAC SUPPLY
(BY OTHERS)
COMMON NORMALLY
OPEN
TREADLE SWITCH
N.O. CONTACTS
TIRE TREADLE CIRCUIT WIRING
L N
TMJ RELAY BOX TERMINAL STRIP (TOP)
Input 10 - Input 10 +
Figure 2-9. Entrance Management Overview and Wiring Diagram

Page 14 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Roller Locator Wiring
IMPORTANT: You can add a roller locator to the Tunnel Master® Jr. to keep your rollers
from jamming your conveyor. In order to do this, a roller locator switch must be installed
on your conveyor to signal the presence of a roller.
When a roller locator is used, the Tunnel Master® Jr. will wait to re a roller until the trailing edge of
the signal is detected from a roller locator. There are various devices available to detect the roller and
because the Tunnel Master® Jr. reads the trailing edge of the signal either a normally open or normally
closed switch can be used.
To set this up two things need to be done:
A roller locator switch needs to be wired into Input 9, and installed on the conveyor. This
switch should be positioned so that as soon as a roller passes the switch it will be in a
position where it is safe for the roller forks to come up.
Turn the roller locator function on in Wash Settings.
The following diagram shows how to wire the roller locator into the Relay Box.
Panic Stop Circuit Wiring
Roller Locator Device
Conveyor Surface
Roller forks in the UP position
Conveyor direction
Roller
Roller forks in the DOWN position
Conveyor roller locator cross section diagram
Figure 2-10. Roller Locator Cross Section Diagram
24 VAC SUPPLY
(BY OTHERS)
COMMON NORMALLY
OPEN
ROLLER LOCATOR
DEVICE CONTACTS
ROLLER LOCATOR CIRCUIT
L N
TMJ RELAY BOX TERMINAL STRIP (TOP)
Input 9 - Input 9 +
Alternate symbol for N.O. Switch
Figure 2-11. Roller Locator Wiring

Tunnel Master® Jr. User Manual - Page 15
Chapter 2: Hardware Installation
IMPORTANT: This drawing shows the basic wiring of the Panic Stop Circuit. The Panic Stop
Circuit allows for certain software programming that could not be programmed without
this circuit in place.
The diagram shows how to wire the Panic Stop Circuit into the Controller.
NOTE: ICS sells a conveyor enable box which makes wiring the Panic Stop Circuit a lot easier.
Figure 2-12. Panic Stop Circuit Wiring

Page 16 - Tunnel Master® Jr. User Manual Chapter 2: Hardware Installation
Anti-Collision Wiring
IMPORTANT: The anti-collision on the Tunnel Master® Jr. is a function to help prevent cars from
running into each other at the exit end of the tunnel. In order for this to work you need an anti-
collision device mounted in the tunnel at the spot where you could have a potential collision.
The process consists of two variables in order for the Tunnel Master® Jr. to go into an anti-collision
panic. The rst variable is for the Tunnel Master® Jr. to validate a car through some sort of sensing
device. The second variable is the anti-collision start time in the wash settings on the Tunnel Master®
Jr. When a car is in the sensing device and a second car reaches the Anti-collision Start Time, the
system will go into a panic until the sensing device is cleared. The system must also have a panic
circuit wired for this function to be able to restart the conveyor.
The magnetic loop and the photo eye are two examples of anti-collision devices that operate the
open contacts that interact with the Tunnel Master® Jr. wash controller.
The following diagram shows how to wire an anti-collision system into the Tunnel Master® Jr.
24 VAC SUPPLY
(BY OTHERS)
COMMON NORMALLY
OPEN
ANTI- COLLISION
DEVICE CONTACTS
ANTI - COLLISION DETECTION CIRCUIT
L N
TMJ RELAY BOX TERMINAL STRIP (TOP)
Input 11 - Input 11 +
Alternate symbol for N.O. Switch
Figure 2-13. Anti-Collision Wiring