ICS Tunnel Master Jr User manual

Innovative Control Systems is an industry leading provider of innovative business solutions in
the car wash industry. It is our mission to help car wash operators build successful businesses
through advanced control products and management solutions.
Corporate Oce: 1349 Jacobsburg Road, Wind Gap, PA 18091 | Production Facility: 3370 Fox Hill Road, Easton, PA 18045
Sales: 800.642.9396 | Email: [email protected] | icscarwashsystems.com
Copyright © 2016 Innovative Control Systems, Inc. Portions of this document may contain information that is ICS proprietary.
Tunnel Master®Jr.
User Manual - Version 3.0

2 January 21, 2016
Information in this manual is subject to change without notice. Companies,
names and data used in examples within the manual are fictitious unless
otherwise noted. Nopart 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 © 2016Innovative Control Systems, Inc.
Innovative Control Systems, Inc.
1349 Jacobsburg Road
Wind Gap, PA 18091
610-881-8000

User Manual—Version 3.0 Tunnel MasterJr. TABLE OF CONTENTS
Tunnel Master is a trademark registered in the US Patent and Trademark Office. 3
TABLE OF CONTENTS
Chapter 1:
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Version Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Chapter 2:
System Hardware and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Audience. .........................................................13
Purpose . ..........................................................13
Resetting Default Configuration Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Rules for Installation . ..............................................14
Warning Marking . .................................................15
Output overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
24 Outputs . .......................................................15
Relay Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Relay Box Mounting ...............................................16
Relay Box Wiring ..................................................16
Relay Box Interior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Pulse/Proximity Switch Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Pulse/Proximity Switch Wiring .....................................21
Gate Switch (Electric Eye) Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Gate Eye Switch Wiring ............................................23
Tire Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Tire Switch Wiring .................................................24
Entrance Management System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Entrance Management System Wiring. .............................26
Roller Locator Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Conveyor Roller Locator Cross Section Diagram ....................27
Roller Locator Wiring ..............................................28
Panic Stop Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Panic Stop Wiring .................................................30
Anti-Collision Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Anti-Collision Wiring. ..............................................32
Input Wiring Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

TABLE OF CONTENTS Tunnel MasterJr. User Manual—Version 3.0
4 January 21, 2016
Push Button Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Push Button Wiring 1 Row 8Columns ..............................35
Push Button Wiring First 8Buttons .................................36
Push Button Wiring for Second 8Buttons. ..........................37
Relay Box Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Chapter 3:
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Main Wash Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Wet Down Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Chapter 4:
Wash Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Relay Box Display Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Set Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Access aPassword Protected Menu ................................47
Configure Wash Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Wash Setting Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Set Date Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Configure Wash Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
About Countdown Times ..........................................55
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Assign Outputs to Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Chapter 5:
Entrance Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Entrance Keypad ..................................................65
Entrance Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Entrance Keypad to Process Vehicles (Non-Stacking) . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Entrance Keypad to Process Vehicles (Stack). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Change Service and/or Add Retract ................................69
Add aCar to Stack .................................................70
Remove aCar from Stack ..........................................70
View Service Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Shift Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Bump aShift or ManuallyClose Current Shift .......................73
Chapter 6:

User Manual—Version 3.0 Tunnel MasterJr. TABLE OF CONTENTS
Tunnel Master is a trademark registered in the US Patent and Trademark Office. 5
Communication and Keypad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Entrance Keypad Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Entrance Keypad Mounting . .......................................75
Entrance Keypad Wiring ...........................................75
Second Entrance Keypad Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Second Entrance Keypad Mounting . ...............................80
Second Entrance Keypad Wiring ...................................80
Entrance Keypad Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Entrance Keypad DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Chapter 7:
Optional Report/Receipt Printer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Mounting and Installation of Report/Receipt Printer . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Report Printer Mounting. ..........................................86
Report Printer Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Chapter 8:
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
System Diagnosis. .................................................89
Entrance Keypad ..................................................89
Wash Controller Response .........................................89
Wash Controller Input Check.......................................90
Entrance Keypad Diagnostics ......................................91
Change History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

User Manual—Version 3.0 Tunnel Master Jr. List of Figures
January 21, 2016 7
List of Figures
Figure 1.Front Panel ..............................................................15
Figure 2. Low Voltage Layout Wiring Diagram. .....................................18
Figure 3. Relay Box Interior Components. ..........................................19
Figure 4. Pulse/Proximity Switch Wiring. ...........................................21
Figure 5. Gate Eye (Switch) Wiring .................................................23
Figure 6. Tire Switch Wiring. .......................................................24
Figure 7.Entrance Management Overview and Wiring Diagram ....................26
Figure 8. Roller Locator Cross Section Diagram . ....................................27
Figure 9. Roller Locator Wiring. ....................................................28
Figure 10. Panic Stop Circuit Wiring. ...............................................30
Figure 11.Anti-Collision Wiring . ...................................................32
Figure 12. Inputs . .................................................................33
Figure 13. Push Button Wiring 1 Row 8Columns ...................................35
Figure 14. Push Button Wiring First 8Buttons ......................................36
Figure 15. Push Button Wiring for Second 8Buttons. ...............................37
Figure 16. Relay Jumper Box Settings ..............................................38
Figure 17.DIP Switch located on inside of Relay Box Door ..........................40
Figure 18. Main Screen Display and Keypad . .......................................44
Figure 19. Entrance Keypad .......................................................66
Figure 20. Keypad Connectors (Keypad Board) .....................................76
Figure 21.AC Power Terminations . ................................................77
Figure 22. Communication CableTermination Diagram ............................79
Figure 23. Keypad Circuit Board Jumper Settings . ..................................82
Figure 24. DIP Switch. .............................................................83
Figure 25. Epson Dot Matrix Report/Receipt Printer ................................86
Figure 26. Appendix A- 1 Relay Box/1 Entrance Keypad/1 Receipt Printer ...........97
Figure 27.Appendix B - 2Relay Boxes/1 Entrance Keypad/1 Receipt Report Printer . .99
Figure 28. Appendix C- 2Relay Boxes/2Entrance Keypads/Report Receipt Printer. .101

User Manual—Version 3.0 Tunnel Master Jr. List of Tables
January 21, 2016 9
List of Tables
Table1.Relay Box Circuit Descriptions . ...............................................39
Table2. DIP Switch Normal Settings/Functions. .......................................40
Table3. Main Wash Menu ............................................................41
Table4. Wet Down Wash Instructions. ................................................42
Table5. Relay Box Display and Keypad Indicator Light Descriptions. ...................45
Table6. Change the System Password Instructions . ...................................46
Table7.Add Password Instructions . ..................................................47
Table8. Configure Wash Menu .......................................................48
Table9. Wash Settings Menu .........................................................49
Table10. Set Date and Time Instructions. .............................................53
Table11.Configure Wash Settings. ...................................................54
Table12. Outputs Descriptions .......................................................56
Table13. Output Settings ............................................................58
Table14. Services Menu Item Descriptions . ...........................................60
Table15. Change or Set Services Instructions .........................................61
Table16. Assign Outputs to Services Instructions. .....................................63
Table17.Entrance Keypad Buttons ...................................................67
Table18. Process Vehicles (Non-Stacking).............................................68
Table19. Process Vehicles Stack Instructions . .........................................69
Table20. View Service Counts Instructions . ...........................................71
Table21.ManuallyClose or Bump the Current Shift Instructions . ......................73
Table22. 120 VAC Terminations ......................................................80
Table23. Comm CableTerminations. .................................................82
Table24. DefaultJumper Settings ....................................................83
Table25. DIP Switch Settings . ........................................................84
Table26. Relay Box Troubleshooting. .................................................91
Table27.Entrance Keypad Troubleshooting ..........................................92
Table28. Miscellaneous Troubleshooting . ............................................93

User Manual—Version 3.0 Tunnel MasterJr. Introduction
January 2016 11
CHAPTER 1:
INTRODUCTION
Welcome, and thank you for purchasing your new Tunnel MasterJr.
car wash controller (also known as the TMJ) from
Innovative Control Systems, Inc.
As an ICS customer, you benefit from athoroughlyresearched and
developed car wash controller system. This manual will enablethe
operator to have an active part in the control and operation of your car
wash facility with the many Tunnel MasterJr. features.
VERSION CONSIDERATIONS
This document is Version 3.0 released January 2016. Version 3.0 of this
document includes content based on the following ICS software versions:
Tunnel Master® software version 5.30 B2.
ICS API 4.2.12.7.
WashConnect®software version 1.3.2.
Tunnel MasterJr. software version 7.47.
RELATED DOCUMENTS
The following documents are availablefor further reference:
WashConnect® User Manual.
AUDIENCE
This document is intended for end-user audiences. Noprior experience
with the Tunnel MasterJr. is required. Some familiarity with
WashConnect®management software and Auto Sentry® operations is
assumed. ICS developed this manual in order to:
Provide acomprehensive, easy-to-use system reference guide.

Introduction Tunnel Master Jr.User Manual—Version 3.0
12 January 2016
Enableoperators and their employees to obtain the maximum value
from the system.
Furnish operators with atool for training their employees on the
Car Wash Controller.
After reading this manual,you shouldbe ableto:
Install your Tunnel MasterJr. Controller
Configure your wash settings and features
Process vehicles through your wash
View car counts
View historical information
Track sales
Print reports
Troubleshoot issues, if they occur
Many of the features you will find in the ICS Controller system were
integrated at the request of car wash operators. We welcome your
feedback and want to assure you that ICS is committed to being the
leader in the industry in car wash controller and management systems.
CONTROLLER FEATURES
24 programmable, fused outputs, upgradeableto 48, each with two
independent circuits for 24 VAC and 120 VAC.
Programmableflashing 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.
16programmableservice buttons on the entry keypad,
upgradeableto 32.
Automated wet down feature for easy startup.
Optional report and/or receipt printers.

User Manual—Version 3.0 TunnelMaster Jr. System Hardware and Installation
January 2016 13
CHAPTER 2:
SYSTEM HARDWARE AND INSTALLATION
This chapter includes preliminary steps to takefor anew Tunnel Master Jr.
installation. This chapter provides abrief description of the hardware
components and their function and the tunnel settings wiring diagrams.
The Tunnel Master
Jr. hardware is designed to withstand the harsh
environments and hard use of abusy car wash.
Audience
This chapter is intended for installation technicians and electricians. A
thorough understanding of electrical wiring, installation, codes and safety
protocolsis required. Additionally, some familiarity with car wash tunnel
equipment and installation is recommended. Noprior experience with the
Tunnel Master
Jr. is required.
Purpose
This installation guide is provided to assist you in installing the Tunnel
Master
Jr. controller relay box. This guide shouldbe supplied to the
electrician prior to the installation of conduit and wiring to ensure the Tunnel
Master Jr. system is installed properly.
Faulty installations are the major cause of system malfunctions. The Tunnel
Master Jr. system must be installed exactlyas described in this manual to
ensure its reliability and proper operation.
NOTE: Innovative Control Systems provides atoll-free number for
customers and installers who have questions pertaining to the
installation:
800-246-3469
!
WARNING: Failure to properlyinstall the Tunnel MasterJr.
system will void the warranty and couldresultin serious
injury or death.

System Hardware and Installation TunnelMaster Jr. User Manual—Version 3.0
14 January 2016
RESETTING DEFAULT CONFIGURATION SETTINGS
The Tunnel Master Jr. is delivered with pre-loaded settings. You can erase
these settings before configuring your own settings. The following procedure
shows how to erase the current settings.
NOTE: ICS recommends acomplete, first-time erase using DIP switch 6, as
described below.
Toerase all configuration settings, follow these steps:
1Remove the battery from the Main CPU PCB.
2On the main CPU board, set DIP switch 6to the ON position.
3On the main CPU board, press and holdthe reset switch (SW1) for about
30 seconds, and then release the reset button.
Wait for the display to come back up. All settings are erased.
4Put the battery back into its socket.
5On the main CPU board, return or set the DIP switch 6to the OFF position.
The Tunnel Master
Jr.is ready to begin your configuration process.
 See “DIPSwitch Settings” on page 40.
Rules for Installation
Before you begin, please read this entire manual.
Install permanent connections in accordance with local building/fire
codes, all Federal,State, and Local codes.
All wiring must meet the National Electrical Code ANSI/NFPA 70.
Canadian users must also complywith the Canadian Electrical Code CEC,
CAN/CSA C22.1 Pt. 1.
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 peripheralsmust 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.
Check through packing materialsfor manuals, cables, connectors, etc.
before disposing of cartons.

User Manual—Version 3.0 TunnelMaster Jr. System Hardware and Installation
January 2016 15
Warning Marking
OUTPUT OVERVIEW
24 Outputs
The Tunnel Master
Jr. Relay Box is the control center for firing the various
outputs or services in the wash tunnel:Soap foamer, Reclaim motor, etc.
The Tunnel Master Jr. Controller relay box provides for automatic, computer
controlled, or manual firing of the outputs. The relay box can control
up to 24 outputs.
Figure 1. Front Panel
!
WARNING: This warning on equipment or hardware
indicates the need to consult accompanying
documentation before proceeding.

System Hardware and Installation TunnelMaster Jr. User Manual—Version 3.0
16 January 2016
Each toggleswitch controlsthe operation of one output or service.
The switch has three positions:
UP= Manual Override. Manuallyturn on output. (This feature can be
turned off if desired.)
MIDDLE= Output Off. The output is off and will not fire.
DOWN = Computer controlled on position (normal).
The following instructions will provide detailed information on proper relay
box mounting and installation of the Entrance Keypad.
RELAY BOX INSTALLATION
 For Entrance Keypad Installation, See “Entrance Keypad” on page 65.
Relay Box Mounting
All site wiring must be performed by alicensed electrician that must
complywith all local and national codes.
The relay box must be securelymounted to the wall in the equipment
room of the car wash. The relay box is designed to be located in adry,
non-corrosive environment.
The relay box must be located so that conduit connections can be easily
made, and the relays can be readilyaccessed.
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
shouldmeet all local and national codes. Conduits shall be properly
connected and securelyfastened to the boxes with Listed conduit hubs,
and shouldbe tightened to the torque specs of the manufacturer. Over
torquing may cause enclosure breakage.
Electrician must provide adedicated 120 VAC circuit to power the relay
box.
Run a14-3cableto the 120 VAC terminal block.It is labeled with L and N
for Load and Neutral,respectively. There is amechanical 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
shouldbe torqued to 35 pound-inches.
Electrician must supplyaseparate 24 VAC and 120 VAC circuit to the
common (C) side of the upper and lower termination points of each relay

User Manual—Version 3.0 TunnelMaster Jr. System Hardware and Installation
January 2016 17
respectively, then loop the commons together to each relay. This power is
to fire the solenoids and equipment.
Aseparation of 120 VAC and 24 VAC shall be maintained for all field-wiring
circuits. All 24 VAC circuits must be supplied by aclass 2transformer.
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 doublepolewith independent commons so
that each relay can have two circuits running through it. Commons are
independent to provide apower source to switch two devices through
either the normallyopen or normallyclosed circuits.
Relays circuits shouldbe supplied with no greater than 120 VAC 15amp.
NOTE: This 120 VAC MUST BE A SEPARATE circuit from the dedicated
120 VAC circuit terminated in the lower right corner of the Relay
Box.
A6.3 amp. 250 fuse protects each relay. Four spare fuses along with LED
fuse test indicators are located at the center of the relay board. (Fuses
shouldnot 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 anormallyopen 2-wire pulse switch, use terminalsmarked
CLK SINK and PROX GND.
 See Figure4,“Pulse/Proximity Switch Wiring.”
When using anormallyopen 3-wire pulse switch, use terminalsmarked
PROX PWR, CLK SINK,and PROX GND.
 See Figure4,“Pulse/Proximity Switch Wiring.”
Gate and Tire inputs require aconstant 24 VAC neutral supplied from a
class 2transformer. The load signal wouldbe terminated to the normally
open poleof the electric eye (Gate) switch.
 See Figure5,“Gate Eye (Switch) Wiring.”
 See Figure6,“Tire Switch Wiring.”

System Hardware and Installation TunnelMaster Jr. User Manual—Version 3.0
18 January 2016
.
Figure 2. Low Voltage Layout Wiring Diagram
RELAY BOX INTERIOR
Each relay has circuits to control both 24 VAC and/or 120 VAC simultaneously
so that aservice sign as well as the service solenoid can be operated from
the same relay.
Plug in relays for ease of serviceability.
Each relay has 2fuses.
Builtin spare fuses and fuse tester near the center of the box.
Each relay can be programmed to flash, eliminating the need for field
installed flashing relays for signs.

User Manual—Version 3.0 TunnelMaster Jr. System Hardware and Installation
January 2016 19
Figure 3. Relay Box Interior Components
T
ermination points for Pulse,
Gate, Tire, and Panic Circuits.
Plug in relays for ease of
serviceability. Each relay has
two fuses (24 VAC and 120
VAC).
Builtin spare fuses
and fuse tester.
Power In
12VAC transformer
powers the Relay
circuit board only.
WARNING:
DO NOT Power any
other devices from this
transformer!
Power Conditioner
Board
Comm CableTerminal Blocksfor 16button
Entrance Keypad and other TMJrelay box.

System Hardware and Installation TunnelMaster Jr. User Manual—Version 3.0
20 January 2016
PULSE/PROXIMITY SWITCH WIRING
See wash equipment vendor for location of the switch.
The Controller is designed to accept all commonlyused pulse/proximity
switches. There are two types that are most commonlyused, either atwo
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 defined as aSourcing (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 shouldcheck the pulse/proximity switch
manual for proper color codes. The following diagram shows how to wire the
pulse/proximity switch into the Relay Box.
!
IMPORTANT: The pulse switch is acritical input for the
Controller. It signalsthe system that the conveyor is
moving and is the measuring device from which the
system knows when to turn equipment
devices on and off.