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