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