installation guide - version 11 · tunnel master® wbc page 1 installation guide installation...

Tunnel Master® wbcInstallation Guide - Version 11

Information in this manual is subject to change without notice. The example companies, organizations, products, domain names, email addresses logos, people, places and events depicted herein are fictitious. No association with any real company, organization, product, domain name, email address, logo, person, place or event is intended or should be inferred unless otherwise noted. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose without the express written permission of Innovative Control Systems, Inc.

Innovative Control Systems and its product trademarks in this manual are trademarks of Innovative Control Systems, Inc. All other marks are property of their respective owners.

© 2020 Innovative Control Systems, Inc. | All rights reserved.

Innovative Control Systems, Inc.

81 Highland Avenue, Suite 300

Bethlehem, PA 18017

(610) 881-8100

Installation GuidePage iTunnel Master® wbc

ContentsTools Required ....................................................................................................................................................................iii

Installation Overview ........................................................................................................................................................1

Hardware Specs ..................................................................................................................................................................1

Site Planning ........................................................................................................................................................................2

Determine the Location ...................................................................................................................................................2

Planning for Installation ...................................................................................................................................................2

Mounting Template ..........................................................................................................................................................3

Equipment Dimensions ...................................................................................................................................................4

Conduit Run Guidelines ...................................................................................................................................................4

Wire Gauge and Conduit Size ........................................................................................................................................5

Main CPU Board Overview ..............................................................................................................................................7

WBC Main CPU Board........................................................................................................................................................7

Main CPU Board Overview ..............................................................................................................................................9

IInputs Board Terminal Blocks ..................................................................................................................................... 10

Delayed Panic Input ....................................................................................................................................................... 11

Input Board ........................................................................................................................................................................ 12

Manual Bypass Operation ............................................................................................................................................ 13

Transformer Selection .................................................................................................................................................... 14

Relay Board Components ............................................................................................................................................. 16

Relay Board Wiring Guidelines ................................................................................................................................... 16

Start/Stop Inputs Wiring ............................................................................................................................................... 17

Manual Bypass, Conveyor, and Horn Wiring .......................................................................................................... 18

Conveyor Relay Wiring .................................................................................................................................................. 19

Conveyor Relay DIP Switch Settings ......................................................................................................................... 19

Conveyor Relay Wiring on Input and Relay Boards ............................................................................................. 20

Pulse Switch Wiring ........................................................................................................................................................ 21

Main Inputs Wiring .......................................................................................................................................................... 22

Common Relay Output Wiring ................................................................................................................................... 23

Common Relay Output Channels .............................................................................................................................. 23

De-Selecting a Selective Relay Wiring .................................................................................................................... 25

Adding a Second Relay ................................................................................................................................................ 25

Horizontal View of Two Relay Setup ......................................................................................................................... 26

Tunnel Master WBC Install Guide 11.pdf - Revised

Installation GuidePage iiTunnel Master® wbc

Tunnel Master® wbc Relay Board Terminal Blocks .............................................................................................. 26

Jumper Test Point Locations ........................................................................................................................................ 28

DIP Switch Settings ......................................................................................................................................................... 31

Third Party Kiosk to Tunnel Master® wbc Terminations ..................................................................................... 33

Third Party Kiosk to WBC Terminations ................................................................................................................... 34

Exterior of Tunnel Master® wbc .................................................................................................................................. 35

Ultrasonic Truck Bed Sensor ........................................................................................................................................ 35

Ultrasonic Truck Bed Sensor Mounting Recommendations ............................................................................ 35

Ultrasonic Sensor Mounting Dimensions .............................................................................................................. 36

RS-485 Comm Tiers on Main CPU Board ................................................................................................................. 37

Tunnel Master® wbc AC Power Terminations ......................................................................................................... 37

Truck Bed Sensor Power Terminations ..................................................................................................................... 38

Power from the Tunnel Master wbc to the Truck Bed Sensor Converter Box ........................................... 38

Ultrasonic Sensor Wiring .............................................................................................................................................. 38

Truck Bed Sensor (Ultrasonic) Jumper Settings ................................................................................................... 39

Powering the Truck Bed Sensor (Ultrasonic) ........................................................................................................ 40

Ultrasonic Sensor Box .................................................................................................................................................... 39

Communications Wiring ............................................................................................................................................... 42

Installation Requirements ............................................................................................................................................ 42

RS-232 COMM Terminal Wiring Diagram ................................................................................................................ 42

RS-485 Wiring Layout ..................................................................................................................................................... 43

RS-485 Communication Cable Layout ..................................................................................................................... 43

DIP Switch Settings ......................................................................................................................................................... 44

Install Entrance Keypad ................................................................................................................................................. 45

Entrance Keypad Wiring................................................................................................................................................ 46

AC Power Terminations ................................................................................................................................................. 47

Second Entrance Keypad Mouting ........................................................................................................................... 51

Second Entrance Keypad Wiring ............................................................................................................................... 51

Second Entrance Comm Cable ................................................................................................................................... 51

Second Entrance Keypad Wiring ............................................................................................................................... 51

First Entrance Keypad .................................................................................................................................................... 51

Second Entrance Keypad .............................................................................................................................................. 51

Troubleshooting .............................................................................................................................................................. 52

Preventative Maintenance and Inspection ............................................................................................................ 52

Central Log Server ........................................................................................................................................................... 52

Serial Debug Port ............................................................................................................................................................ 52

Installation GuidePage iiiTunnel Master® wbc

Tools Required Tools Required � Small Flat Blade Screwdriver � #2 Phillips Screw Driver

� Wire Cutter � Wire Ties

Part Description Photo of Part4 – 6.3A fuses (FUSE63)

2 – 0.5A fuses (FUSE.5)

1 – 5A fuse (FUSE5)

5 – ¼” x 20 nuts, flat washers, lock washers

8 – #10 x 32 nuts

2 – ICS screwdrivers

1 – set of 2 keys for the Tunnel Master® wbc door

20 - Jumpers (WBCJUMP214)

1 – Breaker (AS2TERMBRK6)

5 - 6 x 8 index cards (WBCIND6X10)

1 - 8 x 10 index card (WBCIND8X10)

Table 1. Part Descriptions

Installation GuidePage 1Tunnel Master® wbc

Installation OverviewThis document was written for the installation of the Tunnel Master® wbc to assist technicians and electricians. A thorough understanding of electrical wiring, installation, codes, and safety protocols is required. Additionally, some familiarity with car wash tunnel equipment and installation is recommended. No prior experience with the Tunnel Master® wbc (Web Based Controller) is required. The Tunnel Master® wbc is also known as the WBC. This guide should be supplied to the electrician prior to the installation of conduit and wiring to ensure the WBC system is installed properly. Faulty installations are the major cause of system malfunctions. The Tunnel Master® wbc system must be installed exactly as described in this manual to ensure its reliability and proper operation.

WARNING: Failure to properly install the WBC system will void the warranty.

Innovative Control Systems provides technical support for customers and installers:

1-800-246-3469

Many of the WBC system features were integrated at the request of current car wash operators. We welcome your feedback and want to assure you that ICS will always remain the industry leader in car wash controller and management systems.

By reading the information and performing the procedures in this manual, you should be able to perform the following:

� Install the WBC system-level wiring

� Install the WBC communications wiring

� Troubleshoot problems if they occur

Related Documents � Tunnel Master® wbc User Manual

Version ConsiderationsThis document is Version 11 released June 17, 2020. Version 11 of this document includes content based on the following ICS software versions:

� Controller software version 1.5 B3 (if compatible)

Completion Time

ICS estimates that it will take 30 minutes to perform this procedure. Keep all hardware organized as you work.

Hardware Specs � Unit weighs 130 lbs

� Hinged panel design measures 32’’ W × 40’’ H × 12’’ D

� IP-based tunnel controller capable of handling:

• 192 outputs

• 48 inputs

� Graphics display shows the status of all inputs and other tunnel status indicators


� Web interface for easy configuration

� Firmware update over network

� Main CPU board

� Directly connect up to four relay boards

� Input board

� All boards powered by 24 V DC from power supply:

• Isolated 12 V DC for display back light

• 12 V AC RS-485 isolation and 16 main inputs

� All isolated inputs powered from separate external AC supply

� Dedicated universal power supplies (UPS) 1500VA/865 Watts output capacity

Site PlanningCareful planning for the layout of the site will help eliminate possible problems with the start-up of your system and will ensure continued, reliable system operation.

� Determine the site layout.

� Prepare to have all the necessary tools and parts.

� All permanent wiring connections must be installed by a licensed electrician that must comply with local and national codes.

Determine the LocationThe following are a few primary concerns to consider when determining the site layout:

� The Tunnel Master® wbc must be securely mounted on a dry, non-corrosive interior wall or surface in the equipment room of the car wash.

� The unit has been designed to operate in an environment of 32° F to 122° F (0°C to 50°C).

� The unit is 130 lbs., 32’’ W × 40’’ H × 12’’ D with a hinged-panel door. Hinges are on the right. The door swings open from left to right.

� A minimum of 48 inches of clearance is recommended. This clearance should be available both in front of the door and on the wall to the right of the unit. This minimum will give enough clearance for the door to swing out and be fully opened without interfering with entrances and exits from the equipment room.

� The WBC box must be located so that conduit connections can be easily made and the relays can be readily accessed.

� Recommended minimum mounting height of 32’’ off ground to the bottom of the WBC box. Installer shall first follow any local codes which supersede this recommendation.

Planning for Installation � Wiring can be contained in rigid PVC conduit or metal conduit.

� High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction box, or wire trough.

� Power for the Tunnel Master® wbc and any peripherals must come from the dedicated UPS, as supplied by ICS.

� The Tunnel Master® wbc and peripheral equipment must be properly grounded.


Mounting Template for the Tunnel Master® wbc

Figure 1. Tunnel Master® wbc Mounting Template

4"

2"

9/16"Diameter

Detail5/8"Notch

24"Center to Center

36"Center to Center

9/16"Diameter

Detail

4"

2"

9/16"Dia.

9/16"Dia.

½” Bolts Recommended

Tunnel Master WBCMounting Template

(For reference Only, this is not the actual template.)


Equipment DimensionsWhen mounting the unit, minimum clearances must meet local codes.

Dimension Amount NotesWidth 32'' —

Height 40'' —

Depth 12'' Includes the plastic face.

Weight 130 lbs.Inclusive of the box, board, and door.

Operating Temp. Range 32° F to 122° F

Frequency 60 Hz. —

Supply Voltage 110-120 VAC —

Max Amps 6.0 Amps. —

Power Supply 15 Amps.Power must come from a dedicated, 15-Amp. breaker.

IPX0 Rating Ordinary rating.The Tunnel Master® wbc is not rated for protection against dust and liquid ingress.

Power Requirements � Electrician must provide a dedicated 15 Amp, 120 V AC circuit to the UPS (Uninterrupted Power

Supply), and the UPS will supply power to the Tunnel Master® wbc box.

� A separation of 120 V AC and 24 V DC shall be maintained for all field-wiring circuits. All 24 V DC circuits must be supplied by a class-2 transformer, which is to be provided by the electrician. Electrician must determine proper size of transformer, depending on total required power consumption.

� The Tunnel Master® wbc unit must be properly grounded.

Conduit Run GuidelinesWhen running wires to and from the Tunnel Master® wbc unit, follow these guidelines:

� Punch conduit holes through bottom of WBC box whenever possible.

� Use wiring channels inside WBC box (left and right sides) to contain wires.

� Run a 14/3 cable, from a UPS output, to the 120 V AC terminal block inside the Tunnel Master wbc box. The terminal block is labeled with L and N for Line and Neutral. There is a mechanical ground lug located in the lower-right corner near the AC terminal block within the box. It is labeled with the universal ground symbol.

� All conduit runs should meet local and national codes. Conduit shall be properly connected and securely fastened to the boxes with listed conduit hubs, and should be tightened to the torque specs of the manufacturer.

� Over-torquing may cause enclosure breakage.

Table 2. Equipment Dimensions


� Tighten all wires on the circuit board terminal blocks to 15 inch-pounds. Over-torquing may cause breakage.

� All conduit must be rigid PVC or metal.

� High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction box, or wire trough.

� Power cables and comm cables must not be combined in a common conduit, junction box, or wire trough.

Site Grounding ConsiderationsThe Tunnel Master® wbc and peripheral equipment must be properly grounded.

Recommended and Accepted Grounding Methods

Proper system grounding is an extremely important part of the system installation. Grounds for all system devices should be wired to the breaker panel ground bus bar which, in turn, should be grounded to a ground rod. A conduit ground does not provide a sufficient ground. It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited by local codes.

The universal ground symbol identifies the grounding lug connector located inside the lower-right

corner of the Tunnel Master® wbc box.

WARNING: Improper grounding will void equipment warranty. Ground wire must be connected to the ground lug. Failure to properly ground the unit could result in unit failure and/or bodily injury.

Wire Gauge and Conduit SizeWhen planning the orientation of the wiring runs, follow the applicable ICS wiring diagrams and consider the layout of the components at the site.

To determine conduit size needed, see the table below for more information.

½ ¾ 1 1 ¼ 1 ½ 2 2 ½ 3AWG 14 13 24 39 69 94 154 — —

AWG 12 10 18 29 51 70 114 164 —

AWG 10 6 11 18 32 44 73 104 160

AWG 8 3 5 9 16 22 36 51 79

AWG 6 1 2 6 11 15 26 37 57

AWG 4 1 1 4 7 9 16 22 35

AWG 3 1 1 3 6 8 13 19 29

AWG 2 1 1 3 5 7 11 16 25

AWG 1 1 1 1 3 5 8 12 18

Table 3. Wire Gauge and Conduit Size


Electrical InstallationThe Tunnel Master® wbc is the control center for “firing” the various outputs or services in the wash tunnel: soap foamer, reclaim motor, and more. The Tunnel Master® wbc provides for automatic, computer controlled or manual firing of the outputs. The system can control up to 192 outputs and 64 inputs (48 of which are user-programmable).

Locating Boards and Terminal BlocksThis section provides details on boards, component locations, and terminal block identification:

� Main CPU board

� Input board

� Up to four directly connected Relay boards

� 24 V DC power supply

� 12 V AC transformer used for supplying the following:

• Isolated 5 V DC RS485

• 5 V DC for 16 main CPU board inputs

• 48 auxiliary inputs on the input board

• All start/stop inputs


Tunnel Master® wbc Internal Components Configuration

ID Description1 Relay Board 1 Relays 1-24

2 Relay Board 2 Relays 25-48



5 Input Board

6 Main CPU Board

7 20V DC Power Supply

8 12V AC for all Isolated Inputs

Figure 2. Internal Components

Table 4. Internal Components Descriptions


Tunnel Master® wbc Main CPU Board

Figure 3. Main CPU Board


Main CPU Board OverviewThe following table lists inputs available on the main CPU board. All inputs require 24 V max. line, neutral, and ground.

WARNING: *Removing the Flash Module for any reason will Void the Warranty.

ID Description ID Description

1RJ-45 Terminal for Network Connection

15 Display Connection Point

2 Flash Module* 16 Keyboard Connect Point

3 Eight-Port DIP Switch 17 Pulse Switch Connections

4 Status LEDs 18 Assigned Function Inputs

5 Input Board RJ-45 Terminal Connector 19 Expansion Inputs

6 Relay Board RJ-45 Terminal Connector 20 RS-232 Comm Terminal

Relays 1-24

7 Status LEDs 21 Fuse 500mA

8 Relay Board RJ-45 Terminal Connector 22 RS-485 Comm Terminal

Relays 25-48

9 Status LEDs 23 12V AC Input from Transformer

10 Relay Board RJ-45 Terminal Connector

Relays 49-72

11 Fuse 500mA

12 Relay Board RJ-45 Terminal Connector

Relays 73-96

13 Fuse 500mA

14Input Power from 24V DC Power Supply

� The main CPU board includes a microprocessor module and 16 main inputs. It drives up to four in-box relay boards and one in-box input board.

� A data flash module is included for storage of configuration settings. One eight-port DIP switch is included.

� One RS232 port is available for debug. The main CPU board drives the included PS2 keyboard and 640 × 480 color display monitor.

� One RS485 port with two connectors is included. It is available for connecting a wash selection keypad.

� Optional: Truck Bed Ultra Sonic Sensor

Table 5. Main CPU Board Overview


Inputs Board Terminal Blocks

ID Terminal Block Input Name Description

1 Pulse Switch PULSE SINKWhen using a normally open, two-wire pulse switch, use terminals marked PULSE SINK and PROX GND.

PROX GND See “Pulse Switch Wiring” on page 21.

PROX POWER

SINK

When using a normally open three-wire pulse switch, use terminals marked PROX POWER, PULSE SINK, and PROX GND. System provides 18 V DC power.

GND See “Pulse Switch Wiring” on page 21.

POWERWhen using a normally closed three-wire pulse switch, use terminals marked PROX POWER, PULSE SRCE, and PROX GND.

PULSE SRCE See “Pulse Switch Wiring” on page 21.

GND

Figure 4. Input Board Terminal Blocks

� LEDs are available for all the I/Os including the RS-232/485 connections.

� LED indicators display the status of inputs. The main status LEDs include the following:

• LED1–Logic

• LED2–Auto pulse

• LED3–6 Reserved

• LED7–Chain travel

• LED8–Conveyor Status


ID Terminal Block Input Name Description

2 Assigned Function Inputs GATE (SIGNAL) General note: ICS highly recommends

Using shielded cable for all input wiring.

Terminate the shield drain as close to the

24 V AC power supply as possible.

TIRE (SWITCH)

ROLLER LOCATOR

REMOTE ROLLER

EM TIRE2

(ENTRANCE MGMT)

ANTI-COLLISION

INPUT 1 (DELAYED PANIC)

3 Expansion INPUT2–9 Reserved for future ICS use.

Delayed Panic InputThe Delayed Panic Input, if active, will pause the conveyor for the programmed amount of time before entering a full Panic Stop Node.

Recommended: purchase either a yellow or orange push/pull stop button.

The Delayed Panic Input is located on the Main CPU board as Input 1.

Delayed Panic Input

Figure 5. Delayed Panic Input

Table 6. Input Descriptions on the Input Board


Input BoardThe input board provides monitoring and error reporting of all 48 inputs wired to the inputs terminal block. Auxiliary inputs help report the state of the tunnel. If an error condition or event occurs, you can use the inputs as monitors to receive alerts or set the tunnel into a panic stop mode. The input board works independently of the main CPU board.

� The input board includes eight stop inputs. One stop input is controlled by the computer. Seven stop inputs are directly controlled by push-button stops. All stop input circuits must be closed for the conveyor to work.

� The input board includes eight start inputs. One start input is controlled by computer. Seven start inputs are directly controlled by push-button starts.

The input board includes 48 undesignated, optically isolated inputs. The board also features on-board relays to control the horn and the conveyor. A DIP switch bank controls the delay time between the horn and the conveyor start.

Figure 6. Input Board



1 Transformer Selector 12 Programmable Input Terminals

2 Fuse 500mA 13 Start/Stop Input Terminals

3 Fuse 500mA 14 Inputs LED Indicators

4 Internal 12V AC Power Input Terminal 15 Manual Bypass

5 Input Board RJ-45 Terminal 16 Additional Output Terminal

6 DIP Switch 1 17 Fuse 6.3A

7 Remote 24V DC Power (If Remote Mount) 18 Conveyor Output Terminal

8 24V DC Power from ICS Provided Power Supply 19 Fuse 6.3A

9 Fuse 6.3A 20 Horn Output Terminal

10 Fuse 500mA 21 Fuse 6.3A

11 Fuse 6.3A

Manual Bypass OperationThe Manual Bypass jumper is used for an emergency and enables the wash to operate even if there is an issue at the wash that would normally prevent the operation of the tunnel.

Plug the connector into JP30 to enable bypass operation

Figure 7. Normal and Bypass Operation Settings on the Input Board

When this jumper is moved from the Normal Operation mode JP29 to the Manual Bypass mode JP30, the WBC Input board will ignore any of the inputs that would be wired up to the Input board and that the WBC could be set up to monitor. This way if there was an issue with several inputs that the WBC would be monitoring, the inputs could be ignored and the user could still start the conveyor and run washes.

WARNING: When in Manual Bypass mode, the conveyor will start immediately when the start button is pressed. The WBC will not wait until the horn relay is fired and the delay is reached before starting the conveyor.

Table 7. Input Board Descriptions


The connector in JP29 enables normal operation on the input board and is the default configuration.

This jumper is used to select the input voltage for the 48 inputs. Customers can choose a separate external voltage for the inputs.

� When configured to use external (E): The voltage must be supplied to the common, and then switched out -- Recommended.

� When configured to use internal (I): The voltage supplied on the INTERNAL 12 V AC POWER INPUT TERMINAL connector will be used for dry contact operation -- Not Recommended.

Transformer Selection

Figure 8. Transformer Selector on the Input Board

Auxiliary Input Internal Voltage Wiring- Dry Contact

ICS does not recommend internal voltage for Auxiliary Inputs. ICS recommends external voltage.

L

N

COMMON NORMALLYOPEN

Alternate symbol for N.O. Switch

Examples:

Low Air PressureLow HydraulicHigh Wateror other Sensing DeviceContacts

CO

M

1 - 48

Auxiliary Input Relay Terminal Strip

Figure 9. Auxiliary Input Relay Terminal Strip


L N

24 Vdc or 24VacExternal Power Supply

COMMON NORMALLYOPEN

Alternate symbol for N.O. Switch

Examples:

Low Air PressureLow HydraulicHigh Wateror other Sensing DeviceContacts

COM

1 - 48

Auxiliary Input Relay Terminal Strip

Auxiliary Input External Power WiringICS does not recommend internal voltage for Auxiliary Inputs. ICS recommends external voltage.

Figure 10. Auxiliary Input External Power Wiring


Figure 11. Relay Board

Relay Board ComponentsThe Tunnel Master® wbc ships with one relay board (standard). Up to three additional boards can be mounted inside the box. The extra relay boards are optional and additional fees apply. Separate data and power cables are used for each board. Each board supports 24 relays for a total of 96 [24 × 4 = 96] directly controlled relays. A manual override switch is included for each relay. Test connections in the manual override position prior to system start-up. Each board includes a 24 V DC power terminal for remote relay board installations of up to 200 feet. A single relay can be configured in ten ways as outputs.


1 Output Relay Terminals 4 Relay 1

2Fuses 6.3 Amp (Fuse testers with spare fuses)

5 Input Power from 24V DC Power Terminal

3

Switch

Up = On

Middle = Off

Down = Computer Controlled

6 24V DC Power Terminal (If Remote Mount)

7 RJ-45 Network Terminal

Relay Board Wiring Guidelines

� Relays on the relay boards are single-pole.

� A 6.3 Amp, 250 V fuse protects each relay. Spare fuses along with LED fuse test indicators are located at the bottom-left of the relay board.

NOTE: � Fuses should not be replaced with any device other than those supplied and specified by Innovative Control Systems.

Table 8. Relay Board Descriptions


� Spare relay board fuses are contained in the Tunnel Master® wbc packaging.

� Relay circuits should be supplied with no greater than 120 V AC, 15 amp. This 120 V AC must be a separate circuit from the dedicated 120 V AC circuit used to supply power to the WBC.

� Electrician can supply a separate 24 V AC and/or 120 V AC circuit to the common (C) terminal block. Then, the commons can be tied together via the supplied six-pole jumpers or daisy-chained individually with the appropriate gauge wire. This power is to “fire” the solenoids and equipment.

Figure 12. Jumpers for Relay Board Terminal Blocks

Start/Stop Inputs WiringWiring is to be done on the input board.

Figure 13. Wiring for Start/Stop Stations and Emergency Stop

SP7

SP1

SP1

SP2

SP2

SP3

SP3

SP4

SP4

SP5

SP5

SP6

SP6

SP7

WH

ITE

BLAC

K

RED

GRE

EN

GRE

EN WH

ITE

BLAC

K RED

BLAC

K

RED

BLAC

K

RED

ST7

ST1

ST1

ST2

ST2

ST3

ST3

ST4

ST4

ST5

ST5

ST6

ST6

ST7BL

ACK

RED

BLAC

K

RED

BLAC

K

RED

GRE

ENW

HIT

E

WH

ITE

BLAC

K

RED

GRE

EN

GRE

ENW

HIT

EBL

ACK R

ED

JU

MPE

R I

FN

OT

USE

D

JU

MPE

R I

FN

OT

USE

D

JU

MPE

R I

FN

OT

USE

D

MOMENTARY START/STOP STATION

(SEE NOTE #1)

PUSH/PULL EMERGENCY STOP N/C

(SEE NOTE#2)

PUSH/PULL EMERGENCY STOP N/C

(SEE NOTE#2)

MOMENTARY START BUTTON N/O

MOMENTARY START/STOP STATION

(SEE NOTE #1)

Note - IF STOPCIRCUITS ARE NOT USEDTHEY MUST BE JUMPEDOUT

START CIRCUITTERMINALS

STOPCIRCUIT

TERMINALS

START/STOP TERMINALS ON INPUT BOARD

SITE

PRO

VIDE

D18

/4 S

HIEL

DED

SITE

PRO

VIDE

D18

/4 S

HIEL

DED

SITE

PRO

VIDE

D18

/2 S

HIEL

DED

SITE

PRO

VIDE

D18

/2 S

HIEL

DED

SITE

PRO

VIDE

D18

/2 S

HIEL

DED

Jumpers � ICS supplied six-pole jumpers for relay board terminal

block wiring. Phoenix Contact®, order number 1733 208, Part EBP 6-5


NOTES:

1. Each momentary start/stop station must be home-run with 18/4 shielded cable back to the input-conveyor interlock board inside the controller cabinet. The station may be with or without a lockout on the stop circuit. If a mechanical interlock exists between the start and stop circuits within this station, it must be removed prior to testing the conveyor.

2. Each push/pull e-stop mushroom button must be home-run with 18/2 shielded cable back to the input-conveyor interlock board inside the controller cabinet. The e-stop button may be with or without a lockout.

3. Ground shield drains on controller cabinet ground.

Manual Bypass, Conveyor, and Horn WiringWiring is to be done on the input board.

NC

NOCOM

NC

NOCOM

NC

NOCOM HORN

RELAY

AUXILIARY RELAY

CONVEYOR RELAY

SITE SUPPLIEDELECTRICAL INPUT

LINENEUTRAL

DEVICE THAT FOLLOWS THECONVEYOR RELAY (SEE NOTE #1)

CONVEYOR MOTOR STARTER LOCATED IN MOTOR CONTROLPANEL (SEE NOTE #2)

CONVEYOR HORN (SEE NOTE #3)

WBCInput Board

N LN L

Figure 14. Manual Bypass, Conveyor and Horn Wiring


NOTES:

1. The manual bypass relay will activate and deactivate as the conveyor relay does. Any piece of tunnel equipment that is meant to be on and off with the conveyor, should be terminated to this relay.

2. The conveyor relay will activate upon the start circuit being momentarily closed or a wash having been loaded into the controller, dependent upon how the controller is programmed. This relay will remain fired until after the last car in the tunnel has passed the last piece of equipment in the tunnel, plus that piece of equipment’s extend time, plus the value programmed for the auto stop delay.

3. The horn relay will activate if the conveyor is stationary and a wash has been loaded into the controller. The horn will activate for the time programmed through the settings of DIP switches one and two on the input board. The extend time represents the pause in seconds between the horn relay deactivating and the conveyor relay activating. It is programmed through the settings of DIP switch three and four.

Conveyor Relay WiringWiring for the conveyor control circuit is energized via a separately configured conveyor relay. Conveyor wiring summary is as follows:

� The conveyor relay on the input board is wired to a designated conveyor relay on a dedicated relay board, and then it is wired to the conveyor equipment.

� Input supply voltage, for example 120 V AC or 24 V AC, for all equipment is switched through Relay 1 or Relay 2 on the input board.

� Normally Open (NO) terminal block for Relay 1 or Relay 2 on the input board is wired to the Common (C) terminal position of the Relay board for the designated Conveyor Relay.

� Normally Open (NO) terminal block on the designated Conveyor Relay is wired to the conveyor equipment.

Details include the following: � During a panic stop, the circuit is guaranteed to break power to the relays and thus not depend

on a computer to stop.

� During a staggered restart, the computer initiates a wash start which energizes the relays. Only at the end of the wash start is the conveyor relay turned on.

� Wetdown process turns on the conveyor relay.

Conveyor Relay DIP Switch SettingsThe conveyor horn and delay control is handled via the DIP switch settings on the input board.

The DIP switches on the input board follow the silk-screen reference on the board (0 and 1) to determine the desired switch positions.


Conveyor Relay Wiring on Input and Relay Boards

Figure 15. Wiring of On-Board Relays for Conveyor Start Circuit


Pulse Switch WiringWiring is to be done on the main CPU board.

2-WIREPULSE

SWITCH

3-WIRESINKING

PULSE SWITCH

3-WIRESOURCING

PULSE SWITCH

NO

COM

0VSIGNAL+VOLT

0VSIGNAL+VOLT

SOURCE

0V

+V

SINK

SOURCE

SOURCE

SINK

SINK

+V

+V

0V

0V

SINKING JUMPERCONFIGURATION

SOURCING JUMPERCONFIGURATION

ICS HIGHLY RECOMMENDSUSING 18 / 2 SHIELDED CABLE

ICS HIGHLY RECOMMENDS USING 18 / 3 SHIELDED CABLE

ICS HIGHLY RECOMMENDS USING 18 / 3 SHIELDED CABLE

BLUE WIRE

BLACK WIRE

BROWN WIRE

BLUE WIRE

BLACK WIRE

BROWN WIRE

WIRING FOR THE CONVEYORPROXIMITY SWITCH IS DONE

ON THE CPU BOARD

ENSURE THAT THEJUMPER IS SET FOR"SINKING"

ENSURE THAT THEJUMPER IS SET FOR"SINKING"

ENSURE THAT THEJUMPER IS SET FOR"SOURCING"

BELOW ARE EXAMPLES OF PROXIMITY SWITCH WIRING. PLEASECONFIRM THE TYPE OF WIRING REQUIRED PRIOR TO ANY WIRE

TERMINATION

Figure 16. Pulse Switch Wiring


Main Inputs WiringWiring is to be done on the main CPU board.

GATE SWITCH/PHOTO-EYEEXTERNAL VOLTAGE-24VAC

TIRE SWITCHEXTERNAL VOLTAGE-24VAC

ROLLER LOCATOR SWITCH

EXTERNAL VOLTAGE-24VAC

REMOTE ROLLER/ROLLER CALL SWITCHEXTERNAL VOLTAGE-24VAC

ENTRANCE MANAGEMENT/FLOOR SWITCH


ANTI-COLLISION PAD AMPLIFIER


COM

COM

COM

COM

COM

COM

N/O

N/O

N/C

N/O

N/O

N/O

EXTERNAL VOLTAGEJUMPER POSITION

DRY CONTACT JUMPER POSITION

PRE-ASSIGNEDFUNCTION INPUTS

ICS RECOMMENDS 18 / 2 SHIELDED CABLEPROVIDED BY SITE

GATE

TIRE SWITCH

ROLLER LOCATOR

REMOTE ROLLER

ENTRANCE MANAGEMENT

ANTI-COLLISION

JUMPERS SET TOEXTERNAL VOLTAGE

DEVICES LOCATED IN THE CARWASH TUNNEL

Figure 17. Main Inputs Wiring

GENERAL NOTE: ICS highly recommends using shielded cable for all input wiring. Terminate the shield drain on the ground lug provided in the controller. Jumpers for each input must be set to external voltage 24 V AC.

NOTE 1: Optimally, the roller locator switch should be wired normally closed to the ICS controller. Wiring the roller locator switch normally open is acceptable but will mean waiting longer for the roller to fire.


Common Relay Output WiringCommon relay output wiring is to be done on the relay board.

Figure 18. Common Relay Output Wiring

CH1

CH2

CH3

CH4

CH5

CH6

CH7

CH8D24VAC SOLENOID

SITE SUPPLIED 24VACTRANSFORMER

+-

24VAC SUPPLY

NORMALLY CLOSED

VOLTAGE SUPPLY TERMINALS

NORMALLY OPEN

VOLTAGE SUPPLY TERMINALS

AB

C

+

-

COMMON RELAYOUTPUT WIRING

FOUR PRONGTERMINAL JUMPER

TWO PRONGTERMINAL JUMPER

On the Relay Board, each relay is referred to as a channel (channels 1 through 24 on each relay board). Each relay is a single pole - double throw (SPDT). On the terminal strip, each channel has two common terminals that are shorted to each other (the upper tier common and the lower tier common), a normally open terminal and normally closed terminal. No voltage is supplied by the relay. A set of dry-contacts is provided at each channel. External power is required to be run through the dry-contacts of each relay, ending at the motor starter, solenoid, or device that the relay will be controlling.

If the device to be controlled operates on a 24 V AC, run a wire from the neutral side of the transformer to the neutral side of the device as shown above (A). Run another wire (B) from the load side of the transformer to the upper tier common of the relay that is to control the device (channel/relay #1 shown). Run a third wire (C) from the normally open terminal on channel 1 to the load side of the device controlled by the relay.


In this example, when the controller fires the relay at the programmed time, the circuit between the common and the normally open terminals will close, thus allowing the electricity to flow through the relay and activating the load side of the device controlled. Since the neutral is already directly wired to the neutral side of the device, the device now has both the load and neutral and will turn on until the load circuit is again broken when the relay stops firing.

If sequential relays will be controlling devices that require the same voltage, jump the required voltage through the commons using the prefabricated shorting bars provided by ICS. Each terminal jumper is long enough to connect the commons for six consecutive channels. If a lesser number of channel commons are to be connected, simply cut off those not needed with pliers.

NOTE: the two pin shorting bar connecting the commons for channels 7 & 8. If the number of sequential relays using the same voltage is greater than six, then use two or more shorting bars and over-lap them. Use a wire jumper (D) to connect the voltage from one block of shorted channels to another block of shorted channels as shown above.

In Figure 19, “Common Relay Output Wiring,” channels 1, 2, 3, 4, 7, & 8 all have 24 V AC connected to their commons and will provide 24 V AC to the piece of equipment that is wired into the normally/open terminal of each relay. Channels 5 & 6 have been left open for another voltage to be connected to them.


De-Selecting a Selective Relay Wiring The reason for turning off a selective function on a wash is if a customer requests this. A customer requesting to disable the tire shine for their wash is an example. Typically, the tire shine is a selective option.

To de-select the selective relay, the selective function or relay needs to turn off. This is accomplished by adding another relay.

These instructions explain how to wire and set up a second relay in series with the original selective relay to disable a selective function in the Tunnel Master® wbc.

Adding a Second Relay Adding a second relay in the series with the first relay. Relays are typically wired with two wires going to the equipment, one wire being run from the equipment to Normally Open (NO) and the second from the equipment going to Common (C). These are terminated in the terminal strip on the left side of each relay board. See Figure 18.

See the Tunnel Master® wbc User Manual to learn how to program the relay to function correctly, and create a service to use the new retract.

Figure 19. Normal Wiring for a Relay

In the new configuration, move the wire going to the Common (C) to the second relay. After the wire is moved, add a separate wire between the original relay and the new one that was added and terminate at Normally Closed (NC) on the new relay. The new wire runs and terminates in the original relay on Common (C). See Figure 21.

Figure 20. Adding a Second Relay in Series


Figure 21. Horizontal View of Two Relay Setup

Tunnel Master® wbc Relay Board Terminal Blocks

WBC RELAY BOARD

123456789

101112131415161718192021222324

123456789

101112131415161718192021222324

123456789

101112131415161718192021222324

123456789

101112131415161718192021222324

WBC Relay Board Terminal Blocks

COMCOM

N.O. N.C.

COM N.O. B

A

A C

BC

COM N.C.R1 R3

Example Diagram of Relay Connections for RetractsPower In

Power Out

Example Diagram explanation : Using R1, asNormally Open, in this example as the maincontact that powers the output when "ON" to thedevice and using R3, as the Normally Closedwhen "OFF". This allows the programming of aretract through the R3 contact meanwhile the R1will remain in it's original state. R3 acts simply asa pass through until the program activates it and itinterrupts or retracts the service on R1.

REV.REV.

Date5.12.15

NameDDCDrawn

Chk'dApp'd

This drawing contains proprietary andconfidential information of INNOVATIVE

CONTROL SYSTEMS. Neither the drawingnor the information contained in it may becopied or used for any purpose other than

that for which it is being provided. It may notbe disclosed in whole or in part to any partyother than the authorized recipient and must

be returned upon request.

Figure 22. Tunnel Master wbc Relay Board Terminal Blocks

Horizontal View of Two Relay Setup


The prefabricated terminal jumpers should be terminated into the lower common tier and all wire feeds to the commons and wire jumpers should be made on the upper common tier. This will prevent the terminal jumpers from covering up any screw terminals.

Figure 23. Jumper Test Point Locations


Jumper Test Point Locations

TP5TP4

This section explains the location and purpose of the jumpers on the Tunnel Master® wbc circuit boards.

Figure 24. DIP Switch Settings


The following table describes jumper functions and settings:

Jumper Jumped Not Jumped

TP4Transformer Selection. Both jumpers must be in either the E or I position, depending on the application. This is for the voltage required for the user-configurable inputs.

TP5

Position I will use the voltage from JP25 to supply power to the individual inputs. (Dry Contact). (Default).

Position E will need to have voltage supplied between the COM and the individual inputs. (External Voltage).

TP6 Delayed reset when S2 is pressed (default). Immediate reset when S2 is pressed.

TP7 RS-485 select (default). RS-422 select.

TP8 RS-485 select (default). RS-422 select.

TP9Keyboard processor diagnostics (internal use).

Standard operation (default).

TP10 GND test point.

TP11 GND test point.

TP12 Isolated GND test point.

TP13 Powers 5 V DC in battery back-up mode.Powers 3.3 V DC only in battery back-up mode (default).

TP21Both TP 21 and TP 22 must be in either SINK or SOURCE position, depending on the application:

TP22SOURCE jumps pins 1 and 2.

SINK jumps pins 3 and 2.

TP23Connects 120R termination resistor across TX+ and TX– on JP10.

No termination resistor across TX+ and TX– on JP10.

TP24Connects 120R termination resistor across RX+ and RX– on JP10.

No termination resistor across TX+ and TX– on JP10.

TP25 Connects 1.5 K pull-up to RX+ on JP20. No pull-up on RX+ on JP20.

TP26 Connects 1.5 K pull-down to RX– on JP20. No pull-down on RX– on JP20.

TP27

RS-422, RS-485 selection:

RS-485 jumps pins 1 and 2 (default).

RS-422 jumps pins 3 and 2.

TP28 — —

TP29 INPUT2 input selection.



Jumper Jumped Not JumpedTP31 INPUT4 input selection.






TP37 —

TP38 GATE input selection.

TP39 TIRE input selection.

TP40 ROLLER LOCATOR input selection.

TP41 REMOTE ROLLER input selection.

TP42 EM TIRE2 input selection.

TP43 ANTI COLLISION input selection.


TP45 — —

TP46 — —

TP47 Pulls PD15 low on the Coldfire® module.Pulls PD15 high on the Coldfire module (default).

TP48 — —

TP49

Selects the voltage source for the LCD I/O:

+LCD jumps pins 1 and 2.

+3 V jumps pins 3 and 2 (default).DRY CONTACT: Jumps 1 to 2 and 3 to 4.

Example: To wire ANTI COLLISION as dry contact, connect 1 to 2 & 3 to 4 on TP 43.

Table 27. DIP Switch


DIP Switch SettingsDIP Switch and reset buttons are located on the Main CPU Board.

Dip switch default settings are OFF. After setting DIP Switch to ON, press Reset button on Main CPU board to activate.

DIP Switch

Reset Button

ID Description ID DescriptionSW1 Clears configuration data. SW5 SW5–SW8 not used.

SW2 Clears daily shift data. SW6

SW3Clears monthly and yearly shift data.

SW7

SW4 Clears data flash completely. SW8

Table 28. Exterior of Tunnel Master wbc Descriptions

Figure 25. DIP Switch Settings


DIP Switch

DIP Switch

DIP Switch Function SettingsSW1 & SW2 Horn-on time SW1 SW2 Sec. (On)

0 0 0

0 1 1

1 0 4

1 1 6

SW3 & SW4 Delay after horn, before SW3 SW4 Sec. (Delay)

conveyor starts 0 0 0

0 1 1

1 0 4

1 1 6

Switch Settings:

0 = off (opened)

1 = on (closed)

Table 29. DIP Switch Settings

Figure 26. DIP Switch and Reset Button


Third Party Kiosk to Tunnel Master® wbc TerminationsAuto Sentry payment terminals are recommended for optimal use, but other manufacturer’s kiosks can be wired to communicate with the Tunnel Master® wbc.

NOTE: � Push button is optional and additional fees apply. � Wire services from the kiosk to auxiliary inputs 33–48 on the input board.

� Use 18 gauge cable.

� Third party devices using relays will make all output connections to their normally open relay contacts.

� All relay output connections will be using dry contacts. Therefore, the transformer selector on the input board should be configured for internal.

� Service 1 on the kiosk is wired to auxiliary input 33 on the input board. Service 2 is wired to auxiliary input 34, and so on.

� Service common on the kiosk is wired to any one of the common inputs located on the first eight positions of the terminal block

� An ICS Entrance Keypad is optional but recommended. An Entrance Keypad provides an alternate way to wash cars should the kiosk fail. There is a terminal block (POWER), located on the keypad circuit board labeled with ACH, ACN, and GND, for Line, Neutral, and Ground respectively. Terminations for the 3 AWG wires should be torqued to 20 pound-inches (2.3 n-m.) Over torquing may cause enclosure breakage. Electrician must run a single-twisted pair, 24AWG shielded com cable (can be purchased from ICS) through 3/4” conduit from the relay box to the Entrance Keypad.

� The General Settings dialog box in the Tunnel Master® wbc web interface contains two fields you can adjust for a third-party kiosk: Stacking and Wash Input Device.

� Set Stacking to Yes.

• If a keypad is available, then set Wash Input Device to Push Button and Keypad.

• If a keypad is not available, then set Wash Input Device to Push Button.


Figure 39. Non-ICS Kiosk (not an Auto Sentry) to Tunnel Master® wbc Terminations

Third Party Kiosk to WBC Terminations


Exterior of Tunnel Master® wbc

Figure 40. Exterior Panel

� The display shows the status of all the inputs, along with other tunnel status indicators.

ID Description

1 The display is a 640 × 480 color monitor

2 Built-in light above the keyboard

3 On-board Keyboard

Ultrasonic Truck Bed SensorThe ultrasonic sensor can detect the bed of a pickup truck.

NOTE: � This feature is optional and additional fees apply.

Figure 41. Ultrasonic Truck Bed Sensor Mounted

Specification Description Specification Description

Range 1–9 feet IP Code IP65

Housing ABS or PVC Sensor Adjust RS-485 interface

Outputs RS-485 and NPN Operating temp. –13° F to 158° F (-25° C to 70° C)

Supply Voltage 24 V DC ResolutionEvaluation range [mm]/4000, but ≥ 0.35 mm

Power Consumption ≤ 900 mW Repeat Accuracy ≤ 0.1% of full-scale value

Transducer Type Ceramic Temp. Comp.≤ 2% from full-scale value (with temperature compensation)

Ratings NEMA 4xCommon Mode Operation

≤ 13 Hz

Beam Pattern24 degrees off axis (when operating with high sensitivity)

CableCable is hard wired to sensor and cut to 18” to fit into NEMA enclosure on terminal blocks.

Table 30. Exterior of Tunnel Master wbc

Table 31. Ultrasonic Truck Bed Sensor Descriptions

1

2

3


Ultrasonic Truck Bed Sensor Mounting RecommendationsWhen mounting the ultrasonic sensor, alignment is critical. Ensure the face of the transducer is clear of obstructions and parallel to the target. A misalignment of a few degrees can affect the accuracy and reliability of the sensor.

NOTE: � If any of the Ultrasonic Mounting Recommendations cannot be met, a custom mounting solution can be fabricated for your location. Contact your ICS sales representative for more information. Additional charges may apply.

� Mounting height must be at 9 feet.

� Mount the sensor directly on a stable solid arch that will not move.

WARNING: Consideration should be taken if the arch is a “lava” or similar arch as sometimes the product from the arch can significantly over-spray and interfere with the sonar’s accuracy.

� Position the sensor at the mid-point between the walls of the tunnel on center line of equipment.

� Position the sensor so it is mounted directly over the photo eye system directly in line with the eye beam.

� In the case of an inductive loop, position the sensor in line with the area of the loop that first starts sensing the car.

� There needs to be solid ground directly below where the sensor is mounted. Do not install over a car wash pit grating with openings in it. If there is a pit directly below, place a 2’ to 3’ solid piece of metal plate or plastic matting directly under the sensor so there is a consistent floor that the sensor can use as a baseline.

� Use ½” conduit for the communications wiring.

� A green LED light appears inside the converter box to indicate the power is on.

Ultrasonic Sensor Mounting Dimensions

Figure 42. Ultrasonic Sensor Mounting Dimensions


Ultrasonic Truck Bed Sensor Power Supply WiringWire the Ultrasonic Sensor to the power supply within Tunnel Master® wbc. Terminal blocks are located in the bottom right of the Tunnel Master® wbc. There is only 35’ of cable that runs from the sensor to the converter box. This cable cannot be spliced to add additional cable.

� Orange 24 V DC (+)

� Black 0 V DC (–)NOTE: � High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit,

junction box, or wire trough.

RS-485 Comm Tiers on Main CPU Board

RS-485 Comm Tiers

Figure 43. (2) RS-485 Comm Tiers on Main CPU Board

Tunnel Master® wbc AC Power Terminations

Figure 44. Tunnel Master® wbc Power Terminations


Truck Bed Sensor Power Terminations

TUNNEL MASTER WBC 24 VDCAC POWER TERMINATIONS

ULTRA SONIC ORANGE BLACK

+ -

TRUCK BEDULTRASONIC

CONVERTER BOXORANGE BLACK

24+ 24-

18/4 with Shielded Cable

Figure 46. Truck Bed Sensor Power Terminations

Power from the Tunnel Master wbc to the Truck Bed Sensor Converter Box Use +24 V DC from the Tunnel Master wbc to power the Truck Bed Sensor.

1. Connect the orange terminal block inside the WBC on the bottom right side to the orange terminal block in the Truck Bed Sensor (Ultrasonic Converter) box.

2. Connect the black terminal block inside the WBC on the bottom right side to the black terminal block in the Truck Bed Sensor (Ultrasonic Converter) box.

Ultrasonic Sensor WiringSensor communication connections are RS-485. ICS recommends wiring the ultrasonic sensor on a dedicated line. Avoid wiring additional devices: a keypad or smart relay box on the same line as the truck bed sensor.

Two RS-485 communications ports are available on the Tunnel Master® wbc. Use one port for the truck bed sensor, and the other for additional devices.

Communication wiring runs from the Tunnel Master® wbc directly to the terminations blocks on the Converter inside the Truck Bed Sensor box (Ultrasonic Converter).

Figure 45. Warning label located below the Tunnel Master® wbc Power Terminations


Connections to the Tunnel Master® wbc are shown in Table 33 and Figure 47.

Tunnel Master® wbc Ultrasonic Sensor Box

TX– (G) DATA-

TX+ (Y) DATA+

Ground Signal Ground Drain Wire.

NOT USED.

— White NPN (200 ma max).

NOT USED.

— Green Clock Sync.

NOT USED.

Vin

6-Vi

n 7+

Vin

7-(Y

)DAT

A+(G

)DAT

A-(R

)+Vs

(B)G

ND 1

0

ADAM CONVERTER BOXLOCATED INSIDE THE SENSOR BOX

TX-

TX+

RX-

RX+

GND

MAIN CPU BOARD

TWO 485 COMM TIERSLOCATED ON THE

WBC CONTROLLERSMAIN CPU BOARD

BLACK WIRE

WHITE WIRE

ICS SUPPLIED 24/4 COMM CABLE

Ultrasonic SensorCommunication Wiring

Figure 47. Truck Bed Sensor (Ultrasonic) Comm Connections

Truck Bed Sensor (Ultrasonic) Jumper SettingsICS recommends leaving RS-485 jumpers unterminated on the Tunnel Master® wbc main CPU board. If the ultrasonic sensor is tested and returns communication errors, then you can terminate one or both RS-485 jumpers. The jumpers are labeled TP23 and 24.

Table 32. Ultrasonic Sensor Jumper Settings


Powering the Truck Bed Sensor (Ultrasonic) Locate the gray power cable coming from the Truck Bed Sensor (Ultrasonic). In this gray cable, connect three of the five wires as follows: (See Figure 48)

1. The brown wire connects to the orange terminal block (+24 V DC).

2. The blue wire connects to the black terminal block (-24 V DC).

3. The black wire connects to the converter box (Vin 0+)

Figure 48. Power for the Truck Bed Sensor (Black, Brown, and Blue wires)


The truck bed sensor operation for detecting a pickup truck bed is shown in Figure 49.

Sensor Settings for letters A and B shown in the figure above are described in the table below.

Letter Field Name Recommended Setting* Description

A Bed Drop Distance 16 InchesSensed first. From top of truck to inside floor of bed.

B Bed Minimum Length 18 Inches

Sensed second. After Bed Drop Distance is sensed. If both thresholds (A and B) are met, then system recognizes a pickup truck bed.

Figure 49. Truck Bed Sensor (Ultrasonic) detecting the bed of a pickup truck

Table 33. Truck Bed Sensor Settngs


Communications WiringThis chapter describes wiring for RS-232, RS-422 and RS-485 communications.

Installation Requirements � All equipment connected to the RS-232 ports must be Listed, have an Electronics Industrial

Association (EIA) standard RS-232 communications protocol, and not be installed over a hazardous location.

� RS-232 communication must not exceed 100 feet. RS-232 communication wires must be in a separate PVC conduit away from any AC wire.

� Communications equipment signal wires must also be run in separate rigid PVC or metal conduit, separate from any power conduit.

� 24/4 Comm Cable (can be purchased from ICS)

RS-232 COMM Terminal Wiring DiagramWiring to be done on the main CPU board.

9

123

45

67

8

PIN 1PIN 6PIN 2PIN 7PIN 3PIN 8PIN 4

PIN 5PIN 9

DB-9 CONNECTOR FOR A LAPTOP OR PC

COMPUTER CONNECTION

ICS 24/4 COMM CABLE

TWO RS-232 COMMTIERS LOCATED ON THE MAIN

CPU BOARD

Wiring to be done onthe Main CPU Board

GND

5V

TX

RX

Figure 50. RS-232 Comm Terminal Wiring Diagram (Main CPU Board)


RS-485 Wiring LayoutYou can wire up to a maximum of four smart relay boards. Connectors are interchangeable on all boards even though there are two separate ports, either one can be used. In Figure 51, you can see the sample layout for a Tunnel Master® wbc System with a double Tunnel Master Jr. configuration with 72 outputs.

(G)D

ata

-(Y

)Dat

a +

GND

RX+

RX-

TX+

TX-

GND

RX+

RX-

TX+

TX-

GND

RX+

RX-

TX+

TX-

GND

RX+

RX-

TX+

TX-

GND

RX+

RX-

TX+

TX-

GND

RX+

RX-

TX+

TX-

DT+

DT-

GND

DT+

DT-

GND

WHT BLK

BLK/

WHT

WHT BLK

BLK/

WHT

WHT BLK

BLK/

WHT

WHT BLK

BLK/

WHT BLK

BLK/

WHT

WHT

BLK

BLK

WHT

SHIELDDRAIN

SHIELDDRAIN

SHIELDDRAIN

SHIELDDRAIN

SHIELDDRAIN

SHIELDDRAIN

SHIELDDRAIN

485 LOWER TIERCOMM PORT

485 UPPER TIERCOMM PORT








Installation NoteAttach the drain shield ateach end of the COMM cableto the ground lug of eachenclosure. Shield groundneeds to be tied to the earthground at one end only.

WARNING: Do not connect both ends ofthe shield ground to different ground points.

Ultrasonic Sensor Box

Tunnel Master wbc Tunnel Master Jr. 1st Relay Box48 Outputs

Tunnel Master Jr.2nd Relay Box

48 Outputs Tunnel Master wbcController Keypad


Figure 51. RS-485 Layout

RS-485 Communication Cable Layout for a Tunnel Master® wbc System

with a Double Junior Configuration 96 + 24 + 24 =144 Outputs


Tunnel Master®

Jr.

Jumper

Setting

JP2 Off

JP3 On

JP4 On

JP5 Off

JP6 485 (on the left two terminals)

JP7 Off

JP8 On

JP9 On

JP10 Off

DIP Switch SettingsThe DIP Switch is located on the inside of the Tunnel Master Jr. relay box door.

For the first Tunnel Master Jr. relay box, set to Address 9 using dispswitches as shown in Figure 52.NOTE: � If adding a second Tunnel Master Jr. relay box, set to Address10.

Keypad

JumperSetting

JP1 On

JP2 On

JP3 Pins 1 & 2

JP4 On

JP5 Off

JP6 Off

JP7 On

Figure 52. DIP Switch Setting for Address equal to 9

Figure 53. Jumpers inside Tunnel Master Jr. Relay BoxTable 34. Tunnel Master, Jr. Jumper Settings

Table 35. Keypad Jumper Settings


Install Entrance KeypadThe following instructions will provide detailed information on the proper mounting and installation of the entrance keypad.

� The Entrance Keypad should be mounted securely to the wall of the car wash, in the entrance to the tunnel, at approximately chest height.

� The keypad is a Type 3 enclosure, which means it is a watertight enclosure, but should not be mounted where it is constantly inundated with water.

� The keypad should be mounted away from corrosive chemicals.

� Locate the conduit that was previously run from the Tunnel Master® wbc.

� The conduit should be secured with a Listed watertight conduit hub, and should be tightened to the torque specs of the manufacturer.

NOTE: � Over torquing may cause enclosure breakage. � The conduit will contain the 12V AC and Communications Cable and enters the opening in the

bottom of the keypad enclosure.

� Electrician must run 4 - 18 AWG wires, or cable (supplied by customer) through the 3/4” conduit from the Tunnel Master® wbc to the entrance keypad.

The following picture shows the connection points for the various components of the keypad and the table below provides descriptions of the numbered items in the image.

Figure 54. Keypad Jumpers

ID Description

1 Optional Pole Display screen termination point.

2Communications wire termination points. You can use either contact block. In a second keypad, you would use serial.

3 12V AC termination block.

Table 36. Truck Bed Sensor Descriptions


Entrance Keypad Wiring � There is a terminal block (POWER) located on the keypad circuit board labeled with ACH (Line),

ACN (Neutral), and then to the Ground Lug (Ground). Terminations for the “4 – 18 AWG wires should be torqued to 5.31 in. lbs to 7 in. lbs (.6 -.8 Nm).

NOTE: � Over torquing may cause enclosure breakage. The Tunnel Master® wbc has terminal blocks specified for keypad power.

Figure 55. Keypad Connectors (Keypad Board)


Tunnel Master® wbc AC Power Terminations

6.0A

6.0A

120 VAC LINE FUSED TERMINAL

120 VAC NEUTRAL TERMINALS

WARNING: DO NOT USE FOR ICS USE ONLY

GROUND

Tunnel Master® wbc Ground Lug

NEUTRALLINE

(MUST BE TERMINATED AT FUSED TERMINAL)

120 VAC FROM ICS POWER DISTRIBUTION BOX

14/3 SHIELDED WIRE

ACL

ACN

GND

POWER

ControllerKeypad

This side is the ICS side of the terminal blocks for the

Tunnel Master® wbc

Ultrasonic Truck Bed Sensor Box

ELECTRICIAN SUPPLIED 18/4 WITH SHIELD

ACL

ACN

Controller Keypad Power 12vACWBC ACL yellow terminal block (L) terminates on the ACH terminal block inside the Controller Keypad box.

WBC ACN black terminal block (N) terminates on the ACN terminal block inside the Controller Keypad box. WBC ground lug terminates on the GND terminal block inside the Controller Keypad box.

Ultrasonic Truck Bed Sensor Box 24vDCWBC orange terminal block (24+) terminates on theorange terminal block inside the Ultrasonic Truck Bed Sensor box.

WBC black terminal block (24-) terminates on the black terminal block inside the Ultrasonic Truck Bed Sensor box.

GND

Shield Drain

Keypad Ground

Lug

Shield Drain

Controller Keypad Terminal Blocks

Tunnel Master® wbc

Ground Lug

+24v -24v

EMI FILTER

INTERNAL USE ONLY

Figure 56. Tunnel Master® wbc Keypad Power Terminal Blocks

AC Power Terminations


Entrance Keypad Comm Cable � Electrician must run a single-twisted pair, 24 AWG shielded comm cable (can be purchased from

ICS) through 3/4” conduit from the Tunnel Master® wbc 485 terminal to the entrance keypad.

� There is a terminal block (NETWORK 485), located on the keypad circuit board labeled with DT+, DT-, for Data+, Data-, respectfully. Terminations for the single-twisted pair Comm wires torqued to 4.42 in. lbs to 5.31 in. lbs (.5 -.6 Nm).

� Also, the Drain Shield terminates on the Ground Lug.

CAUTION: Over torquing may cause enclosure breakage.

� Entrance Keypad Communication cable terminations must be made as shown in Figure 58.

ICS SUPPLIED24/4 COMM CABLE

Tunnel Master® wbc Main CPU Terminations485 COMM Terminal

TX +

RX -

GND

Two 485 COMM Tiers Located on the

Tunnel Master® wbc Main CPU Board

TX -

RX +

JUMPER SETTINGSJ1 – Ext ProgJ2 – A15 ONJ3 – EPCE 1&2J4 – Gnd ONJ5 – Rec+ OFFJ6 – Rec- OFFJ7 – Term ON

Entrance Controller Keypad

DT-

GN

D

DT+

DT-

GN

D

DT+

WHITE

WHITE / BLACK

WH

ITE

WH

ITE

/ BLA

CK

SHIELD DRAIN

Tunnel Master® wbc Ground Lug

Entrance Controller Keypad Ground Lug

SHIE

LD

DRA

IN

Figure 57. AC Power Terminations


Entrance Keypad The following figure shows the entrance keypad circuit board and location of the various jumpers on the entrance keypad circuit board.

In Figure 59, the jumper functions are displayed with their normal settings. By default, the keypad is address 5. There is no reason to change this unless advised by ICS. If you have two keypads, you should address the second keypad as address 6.

ID Jumper Setting Description

1 J1 ON Reserved Jumper; ALWAYS ON

2 J2 ON Reserved Jumper; ALWAYS ON

3 SW1 Circuit board reset

4DIP

Switch

5 J5 OFF Biasing Resister High (+)

6 J6 OFF Biasing Resister Low (-)

7 J7 ONTerminating Resister. Set to ON if it is the first or last device in the network.

8 J3 1 and 2 E-Prom Chip Enable; Jumper Down next to “CE”

9 J4 ON Ground Jumper

Figure 58. Main CPU Board RS-485 Comm Terminal

Table 37. Entrance Keypad Ummper Settings


Entrance Keypad DIP Switch SettingsThe following picture and table shows the Entrance Keypad DIP switch and the various settings that may be used.

NOTE: The OFF position is toward the word OPEN or CONFIG on the circuit board.

The following picture shows the DIP Switch on the Keypad cover.

Switch Setting Function

1 OFF Address setting 1, 2 OFF = Address 5

1 OFF, 2 ON = Address 6

2 OFF Address setting 1 ON, 2 OFF = Address 7

1, 2 ON = Address 8

3 OFF Baud Rate OFF = 9600 ON = 38,400

4 OFF Test Mode

Wiring

Table 38. Entrance Keypad DIP Switch Settings


Second Entrance Keypad MoutingThe following instructions provide proper installation of the optional second entrance keypad.

The second entrance keypad should be mounted securely to the wall of the car wash, directly next to the first entrance keypad in the entrance to the tunnel.

� The keypad is a Type 3 enclosure, which means it is a watertight enclosure, but should not be mounted where it is constantly inundated with water.

� The keypad should be mounted away from corrosive chemicals.

Second Entrance Keypad Wiring � Second keypad allows for an additional 16 services to be selected for a total of 32 selectable

services.

� Approved 3/4” conduit must be run between the first and second keypads. Conduit should originate from the bottom of the first keypad enclosure to the bottom of the second keypad enclosure. All conduits should properly be connected and securely fastened to the boxes with Listed conduit hubs and be tightened to the torque specs of the manufacturer.

� The conduit shall be secured with a Listed watertight conduit hub.

� The conduit contains the 12VAC and Communications cable entering from the opening in the bottom of the keypad enclosure.

� Electrician must run 4 - 18 AWG wires, or cable (supplied by customer) through the 3/4” conduit above from the first entrance keypad to the second Entrance Keypad.

� There are terminal blocks (POWER), located on each of the keypad circuit boards labeled with ACH, ACN and then a Ground Lug, for Line, Neutral and Ground, respectfully. Terminations for the 4 – 18AWG wires should be torqued to 4.42 in. lbs to 5.31 in. lbs (.5 -.6 Nm).

NOTE: � Over torquing may cause enclosure breakage.

Second Entrance Comm CableElectrician must run a single-twisted pair, 24 AWG shielded COM cable (can be purchased from ICS) through the 3/4” conduit from the first entrance keypad to the second entrance keypad.

Second Entrance Keypad WiringThere is a terminal block (NETWORK 485), located on each of the keypad circuit boards labeled with DT+, DT-, for Data+, Data- , respectfully. The Shield Drain terminates on the Ground Lug. Terminations for the single-twisted pair 24/4 COMM wires should be torqued to 20 pound inches (2.3 n-m.)

NOTE: � Over torquing may cause enclosure breakage.

First Entrance Keypad Second Entrance Keypad

ACH ACH

ACN ACN

Ground Lug Ground Lug

First Entrance Keypad (Either Connector) Second Entrance Keypad (Second Entrance Keypad)

DT+ DT+

DT- DT-

Ground Lug Ground Lug


TroubleshootingPreventative Maintenance and Inspection

� Visually inspect unit daily for loose connections or damage.

� Wipe exterior of unit with damp cloth to clean. Do not use chemicals or cleaning agents.

Central Log ServerFor troubleshooting, you can view Tunnel Master® wbc operations data via the CLS (Central Log Server) application:

� CentralLogServer.exe

The application file is located on the site server. It can be started with a desktop shortcut. The executable is in \\ICS\CLS\. A network connection to the Tunnel Master® wbc is required. Plug the network cable into the RJ-45 terminal on the WBC main CPU board.

Serial Debug PortIf the network connection fails, you can use the RS-232 terminals to transmit debug and diagnostic data from the Tunnel Master® wbc to a laptop computer. The RS-232 terminals are located on the main CPU board. You can wire a female DB9 COM cable to the terminal.

1. Prepare a COM cable with a female DB9 connector on one end. Strip the other end to expose the wires. Tone out the wires to the pins:

• 2 is receive data. Connect wire to TX on WBC.

• 3 is transmit data. Connect wire to RX on WBC.

• 5 is ground. Connect wire to GND on WBC.

2. Connect the female end of the COM cable to a serial port on a laptop computer. If the laptop does not include a serial port, then use a serial (male) to USB converter.

3. The laptop must also include software to communicate with the Tunnel Master® wbc over a COM port. ICS recommends the multi-threaded TTY (MTTTY) application, which is installed along with the WBC software on the site’s network server. Locate the MTTTY.exe file in the WBC directory, you can simply copy it to the laptop.

4. Start MTTTY.exe, and then verify the following settings:

• Select the Port.

• Set Baud to 115200.

• Set Parity to None.

• Set Data Bits to 8.

• Set Stop Bits to 1.

5. Click Connect.

Data from the Tunnel Master® wbc appears in the MTTTY window.


IndexA

Auxiliary Input External Power Wiring 19

Auxiliary Input Internal Voltage Wiring- Dry Contact 18

C

Central Log Server 53

Common Relay Output Wiring 27, 29

Communications Wiring 44

Conduit Run Guidelines 8

Connections from WBC to the Ultrasonic Converter Box (Power) 40

Conveyor Relay DIP Switch Settings 23

Conveyor Relay Wiring 23, 24

D

Delayed Panic Input 15

Determine the Location 6

DIP Switch 34

DIP Switch Settings 33

E

Electrical Installation 10

Entrance Keypad 50

Entrance Keypad Comm Cable 49

Entrance Keypad DIP Switch Settings 51

Entrance Keypad Wiring 47

Equipment Dimensions 8

H

Hardware Specs 5

I

Input Board 16

Terminal Blocks on Input Board 14

Install Entrance Keypad 46

Internal Components 11


J

Jumpers 21

Jumper Test Point Locations 30

M

Main CPU Board 12

Main CPU Board Overview 13

Main Inputs Wiring 26

Manual Bypass Operation 17

Mounting Template 7

P

Planning for Installation 6

Powering the Ultrasonic Sensor 42

Power Requirements 8

Preventative Maintenance and Inspection 53

Pulse Switch Wiring 25

R

Relay Boards 20

Relay Board Wiring Guidelines 20

RS-485 Comm Tiers on Main CPU Board 39

RS-485 Wiring Layout 45

S

Second Entrance Comm Cable 52

Second Entrance Keypad Installation 52

Second Entrance Keypad Mounting 52

Second Entrance Keypad Wiring 52

Serial Debug Port 53

Site Grounding Considerations 9

Site Planning 6

Start/Stop Inputs Wiring 21

T

Third Party Kiosk 35

Transformer Selection 18

Troubleshooting 53

Tunnel Master® wbc AC Power Terminations 39


U

Ultrasonic Sensor Jumper Settings 41

Ultrasonic Sensor Power Terminations 40

Ultrasonic Sensor Wiring 40

Ultrasonic Truck Bed Sensor 37

Ultrasonic Truck Bed Sensor Mounting Recommendations 38

Ultrasonic Truck Bed Sensor Power Supply Wiring 39

W

Wire Gauge and Conduit Size 9