Innovative Control Systems Tunnel Master wbc Installation Manual

Tunnel Master® wbc
Installation Guide - Version 10
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.
© 2018 Innovative Control Systems, Inc.
Innovative Control Systems, Inc.
1349 Jacobsburg Road
Wind Gap, PA 18091
(610) 881-8100
Contents
Chapter 1: Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Version Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hardware Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Planning for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Chapter 2: Site Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Determine the Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Equipment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Mounting the Tunnel Master® wbc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Conduit Run Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Site Grounding Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Recommended and Accepted Grounding Methods . . . . . . . . . . . . . . . . . 15
Wire Gauge and Conduit Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chapter 3: Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Locating Boards and Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Tunnel Master® wbc AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Main CPU Board Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
WBC Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main CPU Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Delayed Panic Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Input Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Bypass Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relay Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Relay Board Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Jumpers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Start/Stop Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Manual Bypass, Conveyor, and Horn Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Conveyor Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Conveyor Relay DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pulse Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
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Contents
Main Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Common Relay Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Common Relay Output Wiring (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Jumper Test Point Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Third Party Kiosk to Tunnel Master® wbc Terminations . . . . . . . . . . . . . . . . . . . . . . . . .45
Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Ultrasonic Truck Bed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Ultrasonic Truck Bed Sensor Mounting Recommendations . . . . . . . . . . 49
Ultrasonic Sensor Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ultrasonic Sensor Power Supply Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Ultrasonic Truck Bed Sensor Wiring Components . . . . . . . . . . . . . . . . . . . 51
WBC AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ultrasonic Sensor Power Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Connections from WBC to the Ultrasonic Converter Box (Power) . . . . 52
Ultrasonic Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ultrasonic Sensor Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Powering the Ultrasonic Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Chapter 4: Communications Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
RS-232 COMM Terminal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
RS-485 Wiring Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Chapter 5: Install Entrance Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Second Entrance Keypad Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Second Entrance Keypad Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Second Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Second Entrance Keypad Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Entrance Keypad DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Preventative Maintenance and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Central Log Server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Serial Debug Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
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Contents
List of Figures
Figure 1. WBC Mounting Box Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 2. Universal Ground Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3. WBC Internal Components Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 4. AC Power Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 5. Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 6. Input Board Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 7. Delayed Panic Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 8. Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 9. Normal and Bypass Operation Settings on the Input Board. . . . . . . . . . . . . . . . . . . . . . . 27
Figure 10. Transformer Selector on the Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 11. Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 12. Jumpers for Relay Board Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 13. Wiring for Start/Stop Stations and Emergency Stop Stations . . . . . . . . . . . . . . . . . . . . 31
Figure 14. Wiring of On-Board Relays for Conveyor Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 15. Conveyor Relay Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 16. Pulse Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 17. Main Inputs Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 18. WBC Relay Board Terminations Common Relay Output Wiring . . . . . . . . . . . . . . . . . . 37
Figure 19. Common Relay Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20. Jumper Test Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 21. Main Figure 21: CPU Board DIP Switches and Reset button Location . . . . . . . . . . . . 43
Figure 22. Non-ICS Kiosk (not an Auto Sentry) to Tunnel Master® wbc Terminations . . . . . . . . 46
Figure 23. Exterior Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 24. Ultrasonic Sensor Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 25. Ultrasonic Sensor Dimensions (dimensions are in mm) . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 26. Two RS-485 Comm Tiers on Main CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 27. WBC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 28. WARNING Label located below Tunnel Master® wbc Power Terminations. . . . . . . . 51
Figure 29. Ultrasonic Sensor Power Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 30. Ultrasonic Sensor Comm Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 31. Power the Sensor (Black, Brown, and Blue wires). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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List of Figures
Figure 32. Pickup Bed Sensor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 33. RS-232 COMM Terminal Wiring Diagram (Main CPU Board) . . . . . . . . . . . . . . . . . . . . . 57
Figure 34. RS-485 Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 35. Keypad Connectors (Keypad Board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 36. Tunnel Master® wbc Power Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 37. AC Power Terminations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Figure 38. Main CPU Board RS-485 Comm Terminal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 39. Keypad Circuit Board Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 40. Keypad Reset and DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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List of Figures
List of Tables
Table 1. Dimensions, Measurements, and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 2. Max. Number of Wires (THHN) in a Given Conduit Size . . . . . . . . . . . . . . . . . . . . . 16
Table 3. WBC Internal Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 4. Main CPU Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 5. Input Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 6. Input Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 7. Relay Board Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 8. Jumper Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 9. Main CPU Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 10. Input Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 11. Exterior Description for the. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 12. Ultrasonic Truck Bed Sensor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 13. Ultrasonic Sensor Communications Wiring Connections. . . . . . . . . . . . . . . . . . 53
Table 14. Key to Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 15. Keypad Connector Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 16. 12VAC Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 17. Comm Cable Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 18. Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 19. DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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List of Tables
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List of Tables
CHAPTER 1: Installation Overview
This 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 Considerations
This document is Version 10.0 released June 28, 2018. Version 10.0 of this document includes
content based on the following ICS software versions:
 Controller software version 1.2 B51
 Controller software version 1.3B10 (only available if hardware is compatible)
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Installation Overview
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
 Up to four directly connected 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
Planning for Installation
 Before you begin, please read this entire manual.
 Permanent connections must be installed by a licensed electrician and must comply in
accordance with all local and national codes.
 Wiring can be contained in rigid PVC conduit or metal conduit.
 High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit, junction
box, or wire trough.
 Power for the Tunnel Master® 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.
 Test connections in the manual override position prior to system start-up.
 Before disposing boxes and cartons, look through to make certain all manuals, cables,
connectors, and more have been removed.
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10
Installation Overview
CHAPTER 2: Site Planning
Careful 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. In the site planning stage,
keep the following objectives in mind:
 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 Location
The 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.
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Site Planning
Equipment Dimensions
When mounting the unit, minimum clearances must meet local codes.
Dimension
Amount
Notes
Width.
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
Interior, non-corrosive surface.
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.
0° C to 50° C
Table 1: Dimensions, Measurements, and Ratings
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12
Site Planning
Mounting the Tunnel Master® wbc
Figure 1. WBC Mounting Box Footprint
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13
Site Planning
Power Requirements
 Electrician must provide a dedicated 15 Amp, 120 V AC circuit to power the Tunnel Master®
wbc box. This dedicated circuit must supply the UPS. The UPS will supply power to the WBC.
 A separation of 120 V AC and 24 V AC shall be maintained for all field-wiring circuits. All 24 V AC
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.

See “Site Grounding Considerations” on page 15.
Conduit Run Guidelines
When 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. 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.
 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.
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Site Planning
Site Grounding Considerations
The 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.
Figure 2. Universal Ground Symbol
The universal ground symbol identifies the grounding lug connector located inside the lowerright hand 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.
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15
Site Planning
Wire Gauge and Conduit Size
When 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
1¼
1½
2
2½
3
AWG 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 2: Max. Number of Wires (THHN) in a Given Conduit Size
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Site Planning
CHAPTER 3: Electrical Installation
The Tunnel Master® wbc is the control center for “firing” the various outputs or services in the
wash tunnel; for example, 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 Blocks
This 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
ID
Description
1
Relay Board 1 Relays 1-24
2
Relay Board 2 Relays 25-48
3
Relay Board 3 Relays 49-72
4
Relay Board 4 Relays 73-96
5
Input Board
6
Main CPU Board
7
20V DC Power Supply
8
12V AC for all Isolated inputs
Power Terminations and Transformer
Table 3: WBC Internal Component Descriptions
Figure 3. WBC Internal Components Configuration
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Electrical Installation
Tunnel Master® wbc AC Power Terminations
WBC AC POWER TERMINATIONS
120 VAC LINE FUSED
TERMINAL
ICS ONLY SIDE OF
TERMINAL BLOCKS
120 VAC NEUTRAL
TERMINALS
GROUND
LUG
6.0
A
Controller
Keypad
BLUE
G
N
D
GREEN
BLACK
WHITE
POWER
A
C
N
BROWN
+24v -24v
A
C
L
Ultrasonic Truck
Bed Sensor Box
A A G
C C N
L N D
GROUND
NEUTRAL
WHITE
BLACK
GREEN
LINE
(MUST BE TERMINATED AT FUSED TERMINAL)
SHIELD DRAIN NOT
TERMINATED
120 VAC FROM POWER
DISTRIBUTION BOX 14/3
SHIELDED WIRE E
ELECTRICIAN
SUPPLIED 24/4
SHIELDED
ELECTRICIAN
SUPPLIED 18/4
SHIELDED
Figure 4. AC Power Terminations
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Electrical Installation
Main CPU Board Overview
 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.
 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
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Electrical Installation
WBC Main CPU Board
Figure 5. Main CPU Board
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20
Electrical Installation
Main CPU Board Descriptions
The following table lists inputs available on the main CPU board. All inputs require 24 V max. line,
neutral, and ground.The following table describes Figure 5, “Main CPU Board,”.
ID
Description
ID
Description
1
RJ-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
23
12V AC Input from Transformer
Relays 25-48
9
Status LEDs
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
14
Input Power from 24V DC Power Supply
Table 4: Main CPU Board
*Removing the Flash Module for any reason will Void the Warranty.
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Electrical Installation
Main CPU Board Wiring Guidelines
Figure 6. Input Board Inputs
ID
1
Terminal Block
Input Name
Pulse Switch
PULSE SINK
Input
PROX GND
PROX POWER
SINK
GND
POWER
PULSE SRCE
GND
Description
When using a normally open, two-wire pulse switch, use terminals marked PULSE SINK and PROX GND.
See “Pulse Switch Wiring” on page 35.
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.
See “Pulse Switch Wiring” on page 35.
When using a normally closed three-wire pulse switch, use
terminals marked PROX POWER, PULSE SRCE, and
PROX GND.
See “Pulse Switch Wiring” on page 35.
Table 5: Input Descriptions
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Electrical Installation
ID
2
Terminal Block
Assigned
Function
Inputs
Input Name
Description
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
See “Main Inputs Wiring” on page 36.
REMOTE
ROLLER
EM TIRE2
(ENTRANCE
MGMT)
ANTI-COLLISION
3
Expansion
INPUT 1
(DELAYED
PANIC)
If this input is active, the conveyor will pause for the programmed amount of time before entering a full Panic Stop.
INPUT2–9
Reserved for future ICS use.
Table 5: Input Descriptions
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Electrical Installation
Delayed Panic Input
The 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 7. Delayed Panic Input
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Electrical Installation
Input Board
The 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.
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Electrical Installation
Input Board
Figure 8. Input Board
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26
Electrical Installation
Input Board Descriptions
ID
Description
ID
Description
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
Table 6: Input Board Descriptions
Manual Bypass Operation
The 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.
INSTALLFORNORMALOPERATION
JP29
JP30
PLUGTHECONNECTORINTOJP30
TOENABLEBYPASSOPERATION
INSTALLFORBYPASSOPERATION
Figure 9. Normal and Bypass Operation Settings on the Input Board
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Electrical Installation
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.
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 10. Transformer Selector on the Input Board
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Electrical Installation
Relay Boards
The Tunnel Master® wbc ships with one relay board (standard). Up to an optional three additional
boards can be mounted inside the box (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. 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.
Figure 11. Relay Board
ID
Description
ID
Description
1
Output Relay Terminals
4
Relay 1
2
Fuses 500mA
5
Input Power from 24V DC Power Terminal
3
Switch
6
24V DC Power Terminal (If Remote Mount)
7
RJ-45 Network Terminal
Up = ON
Middle = Off
Down = Computer Controlled
Table 7: Relay Board Descriptions
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29
Electrical Installation
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.
 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
box.
 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 daisychained individually with the appropriate gauge wire. This power is to “fire” the solenoids and
equipment.
Jumpers
ICS supplied six-pole jumpers for relay board terminal block wiring.
Phoenix Contact®, order number 1733 208, Part EBP 6-5
Figure 12. Jumpers for Relay Board Terminal Blocks
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Electrical Installation
Start/Stop Inputs Wiring
Wiring is to be done on the input board.
START/STOP TERMINALS ON INPUT BOARD
SP1
RED
STOP
CIRCUIT
TERMINALS
GREEN
RED
PUSH/PULL MOMENTARY START
EMERGENCY
BUTTON N/O
STOP N/C
(SEE NOTE#2)
RED
SITE PROVIDED
18/4 SHIELDED
BLACK
SP1
GREEN
WHITE
WHITE
RED
GREEN
RED
SITE PROVIDED
18/2 SHIELDED
RED
BLACK
SITE PROVIDED
18/2 SHIELDED
PUSH/PULL
EMERGENCY
STOP N/C
(SEE NOTE#2)
BLACK
RED
BLACK
RED
GREEN
SITE PROVIDED
18/2 SHIELDED
SITE PROVIDED
18/4 SHIELDED
WHITE
BLACK
MOMENTARY START/STOP
STATION
(SEE NOTE #1)
START
CIRCUIT
7(50,1$/6
ST1
SP2
SP3
SP4
JUMPER
IF
NOT USED
SP5
SP6
JUMPER
IF
NOT USED
JUMPER
IF
NOT USED
SP7
ST1
SP2
BLACK
CIRCUITS ARE NOT USED
THEY MUST BE JUMPED
OUT
GREEN
WHITE
BLACK
RED
Note - IF STOP
SP3
SP4
SP5
ST2
ST3
ST4
WHITE
SP6
SP7
ST5
ST2
BLACK
ST6
ST7
ST3
ST4
ST5
BLACK
ST6
ST7
MOMENTARY START/STOP
STATION
(SEE NOTE #1)
Figure 13. Wiring for Start/Stop Stations and Emergency Stop Stations
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.
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Electrical Installation
Manual Bypass, Conveyor, and Horn Wiring
Wiring is to be done on the input board.
DEVICE THAT
FOLLOWS THE
CONVEYOR RELAY
(SEE NOTE #1)
SITE SUPPLIED
ELECTRICAL INPUT
N L
CONVEYOR MOTOR
STARTER LOCATED
IN MOTOR CONTROL
PANEL (SEE NOTE #2)
N
CONVEYOR HORN
(SEE NOTE #3)
L
NEUTRAL
LINE
AUXILIARY
RELAY
CONVEYOR
RELAY
HORN
RELAY
NO
COM
NC
NO
COM
NC
NO
COM
NC
WBC
Input Board
Figure 14. Wiring of On-Board Relays for Conveyor Start Circuit
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 switch
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.
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Electrical Installation
Conveyor Relay Wiring
Wiring 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 from there, wired to the conveyor equipment.
 Input supply voltage, for example 120 VAC or 24 VAC, 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 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 Settings
The 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.
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Electrical Installation
Conveyor Relay Wiring
Figure 15. Conveyor Relay Wiring
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34
Electrical Installation
Pulse Switch Wiring
Wiring is to be done on the main CPU board.
SINKING JUMPER
CONFIGURATION
BELOW ARE EXAMPLES OF PROXIMITY SWITCH WIRING. PLEASE
CONFIRM THE TYPE OF WIRING REQUIRED PRIOR TO ANY WIRE
TERMINATION
SOURCING JUMPER
CONFIGURATION
ICS HIGHLY RECOMMENDS
USING 18 / 2 SHIELDED CABLE
0V
SINK
2-WIRE
PULSE
SWITCH
NO
COM
SOURCE
+V
ICS HIGHLY RECOMMENDS
USING 18 / 4 SHIELDED CABLE
ENSURE THAT THE
JUMPER IS SET FOR
"SINKING"
0V
SINK
BLUE WIRE
3-WIRE
SINKING
PULSE SWITCH
0V
BLACK WIRE
SIGNAL
+VOLT
SOURCE
+V
BROWN WIRE
ICS HIGHLY RECOMMENDS
USING 18 / 4 SHIELDED CABLE
ENSURE THAT THE
JUMPER IS SET FOR
"SINKING"
0V
SINK
BLUE WIRE
0V
SIGNAL
BLACK WIRE
+VOLT
3-WIRE
SOURCING
PULSE SWITCH
SOURCE
+V
BROWN WIRE
ENSURE THAT THE
JUMPER IS SET FOR
"SOURCING"
Figure 16. Pulse Switch Wiring
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Electrical Installation
Main Inputs Wiring
Wiring is to be done on the main CPU board.
ICS RECOMMENDS 18 / 2 SHIELDED CABLE
PROVIDED BY SITE
COM
PRE-ASSIGNED
FUNCTION INPUTS
N/O
COM
N/O
GATE
COM
GATE SWITCH/PHOTO-EYE
EXTERNAL VOLTAGE-24VAC
TIRE SWITCH
EXTERNAL VOLTAGE-24VAC
ROLLER LOCATOR
SWITCH
TIRE SWITCH
N/C
EXTERNAL VOLTAGE-24VAC
ROLLER LOCATOR
COM
REMOTE ROLLER/ROLLER CALL
SWITCH
EXTERNAL VOLTAGE-24VAC
N/O
REMOTE ROLLER
COM
ENTRANCE MANAGEMENT
N/O
ANTI-COLLISION
COM
JUMPERS SET TO
EXTERNAL VOLTAGE
DRY CONTACT JUMPER
POSITION
N/O
EXTERNAL VOLTAGE
JUMPER POSITION
ENTRANCE MANAGEMENT/FLOOR
SWITCH
EXTERNAL VOLTAGE-24VAC
ANTI-COLLISION PAD
AMPLIFIER
EXTERNAL VOLTAGE-24VAC
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 VAC.
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.
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Electrical Installation
Common Relay Output Wiring
Common relay output wiring is to be done on the relay board.
SITE SUPPLIED 24VAC
TRANSFORMER
-
+
CH1
CH2
24VAC SUPPLY
B
A
CH3
CH4
FOUR PRONG
TERMINAL JUMPER
CH5
CH6
-
CH7
D
24VAC SOLENOID
VOLTAGE SUPPLY TERMINALS
VOLTAGE SUPPLY TERMINALS
C
NORMALLY CLOSED
TWO PRONG
TERMINAL JUMPER
NORMALLY OPEN
+
CH8
Figure 18. WBC Relay Board Terminations Common Relay Output Wiring
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 VAC, 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
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37
Electrical Installation
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 VAC connected
to their commons and will provide 24 VAC 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.
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.
Tunnel Master® wbc - Installation Guide
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Electrical Installation
Common Relay Output Wiring (cont.)
Figure 19. Common Relay Output Wiring
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39
Electrical Installation
Jumper Test Point Locations
TP4
TP5
Figure 20. Jumper Test Point Locations
This section explains the location and purpose of the jumpers on the Tunnel Master® wbc
circuit boards.
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Electrical Installation
The following table describes jumper functions and settings.
Jumper
TP4
TP5
Jumped
Not Jumped
Transformer 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.
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.
TP9
Keyboard 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.
TP21
Both TP 21 and TP 22 must be in either SINK or SOURCE position, depending on the application:
TP22
Powers 3.3 V DC only in battery back-up
mode (default).
SOURCE jumps pins 1 and 2.
SINK jumps pins 3 and 2.
TP23
Connects 120R termination resistor across
TX+ and TX– on JP10.
No termination resistor across TX+ and TX–
on JP10.
TP24
Connects 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.
TP30
INPUT3 input selection.
—
Table 8: Jumper Settings
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Electrical Installation
Jumper
Jumped
Not Jumped
TP31
INPUT4 input selection.
TP32
INPUT5 input selection.
TP33
INPUT6 input selection.
TP34
INPUT7 input selection.
TP35
INPUT8 input selection.
TP36
INPUT9 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.
TP44
INPUT1 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.
EXTERNAL VOLTAGE: Jumps 2 to 3.
Example: To wire ANTI COLLISION as external voltage, connect 2 to 3 on TP 43.
Table 8: Jumper Settings (Continued)
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Electrical Installation
DIP Switch Settings
Main CPU Board
Figure 21 shows DIP the switch and reset button locations on the main CPU board.
DIP Switch
Reset Button
Figure 21.
M
a
i
n
Figure 21: CPU Board DIP Switches and Reset button Location
The following table describes the main CPU board DIP switch settings and functions.
DIP Switch
Function
DIP Switch
SW1
Clears configuration data.
SW5
SW2
Clears daily shift data.
SW6
SW3
Clears monthly and yearly shift data.
SW7
SW4
Clears data flash completely.
SW8
Function
SW5–SW8 not used.
Table 9: Main CPU Board DIP Switch Settings1
1. DIP switch default settings are OFF. After setting DIP switch to ON, press Reset button on Main CPU
board to activate.
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Electrical Installation
1.
DIP Switch
DIP
Switch
DIP Switch
SW1 & SW2
SW3 & SW4
Settings1
Function
Horn-on time
SW1
SW2
Sec. (On)
0
0
0
0
1
1
1
0
4
1
1
6
Delay after horn, before
SW3
SW4
Sec. (Delay)
conveyor starts
0
0
0
0
1
1
1
0
4
1
1
6
Table 10: Input Board DIP Switch Settings
1.
Switch settings:
0 = off (opened)
1 = on (closed)
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Electrical Installation
Third Party Kiosk to Tunnel Master® wbc Terminations
Auto 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.

For more information on the transformer selector, see “Transformer Selection”
on page 28.
 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. A 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 nm.) 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.
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Electrical Installation
THIRD-PARTY KIOSK
SERVICE RELAYS
DRY CONTACTS
WIRING CONNECTIONS ARE MADE
TO THE RELAYS "NORMALLY OPEN"
OUTPUT
SITE SUPPLIED 18
36
35
34
33
SERVICE 1
SERVICE 2
SERVICE 3
SERVICE 4
SERVICE COM
GAUGE CABLE
COM
AUXILIARY INPUTS
WBC SETUP FOR THIRD PARTY KIOSK
STACKING-ON
INPUT DEVICE= PUSH BUTTON (NO KEY PAD)
INPUT DEVICE= PUSH BUTTON AND KEY PAD (IF KEYPAD)
Figure 22. Non-ICS Kiosk (not an Auto Sentry) to Tunnel Master® wbc Terminations
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Electrical Installation
Exterior
Figure 23. 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
On-board Keyboard
Table 11: Exterior Description for the
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47
Electrical Installation
Ultrasonic Truck Bed Sensor
The ultrasonic sensor can detect a pickup truck bed.
Figure 24. Ultrasonic Sensor Mounted
Ultrasonic Truck Bed Sensor Specifications Table
Specification
Description
Range
1–9 feet
Housing
ABS or PVC
Outputs
RS-485 and NPN
Supply Voltage
24 VDC
Power Consumption
≤ 900 mW
Transducer Type
Ceramic
Ratings
NEMA 4x
IP Code
IP65
Sensor Adjust
RS-485 interface
Operating temp.
–13° F to 158° F (-25° C to 70° C)
Resolution
Evaluation range [mm]/4000, but ≥ 0.35 mm
Repeat Accuracy
≤ 0.1% of full-scale value
Temp. Comp.
≤ 2% from full-scale value (with temperature compensation)
Common Mode Operation
≤ 13 Hz
Beam Pattern
24 degrees off axis (when operating with high sensitivity)
Cable
This is hard wired to sensor. It is cut to 18” to fit into NEMA enclosure on terminal blocks.
Table 12: Ultrasonic Truck Bed Sensor Specifications
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Electrical Installation
Ultrasonic Truck Bed Sensor Mounting Recommendations
When 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.
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Electrical Installation
Ultrasonic Sensor Mounting Dimensions
Figure 25. Ultrasonic Sensor Dimensions (dimensions are in mm)
Ultrasonic Sensor Power Supply Wiring
Wire the UC4000-30GM-IUR2-V15 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 VDC (+)
 Black 0 VDC (–)
NOTE: High-voltage (AC) and low-voltage (DC) must not be combined in a common conduit,
junction box, or wire trough.
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Electrical Installation
Ultrasonic Truck Bed Sensor Wiring Components
RS-485 Comm Tiers
Figure 26. Two RS-485 Comm Tiers on Main CPU Board
WBC AC Power Terminations
Figure 27. WBC Power Terminations
Figure 28. WARNING Label located below Tunnel Master® wbc Power Terminations
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Electrical Installation
Ultrasonic Sensor Power Terminations
ULTRASONIC
CONVERTER BOX
TUNNEL MASTER WBC
24 VDC
ORANGE BLACK
ORANGE
24+ 24-
+
BLACK
-
18/4 Shielded Cable
Figure 29. Ultrasonic Sensor Power Terminations
Connections from WBC to the Ultrasonic Converter Box (Power)
Use +24 V DC from WBC to power the Ultrasonic Sensor.
1 Connect the orange terminal block inside the WBC on the bottom right side to the orange
terminal block in the Ultrasonic Converter box.
2 Connect the black terminal block inside the WBC on the bottom right side to the black
terminal block in the Ultrasonic Converter box.
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Electrical Installation
Ultrasonic Sensor Wiring
Sensor communication connections are RS-485. ICS recommends wiring the ultrasonic sensor on a
dedicated line. Avoid wiring additional devices, for example, a keypad, or smart relay box, on the
same line as the ultrasonic sensor.
Two RS-485 communications ports are available on the Tunnel Master® wbc. Use one port for the
ultrasonic sensor, and the other for additional devices.
Communication wiring runs from the Tunnel Master® wbc directly to the terminations blocks on
the Adam Converter inside the Ultrasonic Sensor box (truck bed sensor).
Connections to the Tunnel Master® wbc are shown in Table 13 and Figure 30.
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.
Table 13: Ultrasonic Sensor Communications Wiring Connections
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53
Electrical Installation
Ultrasonic Sensor
Communication Wiring
Vin 6Vin 7+
Vin 7(Y) DATA+
(G) DATA(R) +Vs
(B) GND 10
ADAM CONVERTER BOX
LOCATED INSIDE THE SENSOR BOX
TWO 485 COMM TIERS
LOCATED ON THE
WBC CONTROLLERS
MAIN CPU BOARD
TXTX+
BLACK WIRE
WHITE WIRE
RXRX+
ICS COMM CABLE
GND
MAIN CPU BOARD
Figure 30. Ultrasonic Sensor Comm Connections
Ultrasonic Sensor Jumper Settings
ICS 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.
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Electrical Installation
Powering the Ultrasonic Sensor
Locate the gray power cable coming from the Ultrasonic Sensor. In this gray cable, connect three
of the five wires as follows: (See Figure 31)
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 Adam box (Vin 0+).
Figure 31. Power the Sensor (Black, Brown, and Blue wires)
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Electrical Installation
The ultrasonic sensor operation for detecting a pickup truck bed is shown in Figure 32.
Figure 32. Pickup Bed Sensor Mounting
Settings for letters A and B shown in the figure above are described in Table 14.
Letter
Field Name
Recommended
Setting*
Description
A
Bed Drop Distance
16 Inches
Sensed 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.
Table 14: Key to Sensor Settings
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Electrical Installation
CHAPTER 4: Communications Wiring
This chapter describes wiring for 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.
RS-232 COMM Terminal Wiring Diagram
Wiring to be done on the main CPU board.
DB-9 CONNECTOR FOR A
LAP-TOP OR TOWER
COMPUTER CONNECTION
PIN 1
PIN 6
PIN 2
PIN 7
PIN 3
PIN 8
PIN 4
PIN 9
PIN 5
TWO RS-232 COMM
TIERS LOCATED ON THE MAIN
CPU BOARD
1
2
3
4
5
6
7
8
9
5V
ICS COMM CABLE
TX
RX
GND
Figure 33. RS-232 COMM Terminal Wiring Diagram (Main CPU Board)
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57
Communications Wiring
RS-485 Wiring Layout
You 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 34, you can
see the sample layout for a Tunnel Master wbc System with a double Tunnel Master Jr.
configuration with 72 outputs.
GND
GND
TX-
SHIELD
DRAIN
BLK/WHT
BLK
TX+
RX-
RX+
WHT
TXBLK/WHT
TX+
RX-
RX+
BLK
BLK
WHT
TX-
TX+
RX-
WHT
RX+
DT+
(Y) Data +
WHT
(G) Data BLK
SHIELD
DRAIN
GND
485 UPPER TIER
COMM PORT
DT-
485 UPPER TIER
COMM PORT
DT+
485 UPPER TIER
COMM PORT
7XQQHO0DVWHUZEF
&RQWUROOHU.H\SDG
GND
7XQQHO0DVWHU-U
QG5HOD\%R[
2XWSXWV
7XQQHO0DVWHUZEF
DT-
7XQQHO0DVWHU-U
VW5HOD\%R[
2XWSXWV
GND
8OWUDVRQLF
6HQVRU%R[
SHIELD
DRAIN
SHIELD
DRAIN
ICS SUPPLIED CABLE
ICS SUPPLIED CABLE
SHIELD
DRAIN
SHIELD
DRAIN
BLK/WHT
TX-
TX+
BLK
RX-
RX+
GND
TX-
485 LOWER TIER
COMM PORT
BLK/WHT
TX+
BLK
RX-
RX+
GND
485 LOWER TIER
COMM PORT
WHT
TXBLK/WHT
RX-
RX+
TX+
BLK
WHT
GND
485 LOWER TIER
COMM PORT
SHIELD
DRAIN
ICS SUPPLIED CABLE
ICS SUPPLIED CABLE
Installation Note
Attach the drain shield at
each end of the COMM cable
to the ground lug of each
enclosure. Shield ground
needs to be tied to the earth
ground at one end only.
WARNING: Do not connect both ends of
the shield ground to different ground points.
Figure 34. RS-485 Layout
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58
Communications Wiring
CHAPTER 5: Install Entrance Keypad
The 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 12VAC and Communications cable and should enter the opening
in the bottom of the keypad enclosure.
 Electrician must run 3 - 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:
Figure 35. Keypad Connectors (Keypad Board)
ID
Description
1
Optional Pole Display screen termination points
2
Communications wire termination points. You can use either contact block. In a
second keypad, you would use serial.
3
12VAC termination block
Table 15: Keypad Connector Descriptions
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59
Install Entrance Keypad
Entrance Keypad Wiring
 There is a terminal block (POWER) located on the keypad circuit board labeled with ACH (Line),
ACN (Neutral), and GND (Ground). Terminations for the 3 – 18AWG wires should be torqued to
20 pound-inches (2.3 n-m.)
NOTE: Over torquing may cause enclosure breakage.
 The Tunnel Master® wbc has terminal blocks specified for keypad power.
Figure 36. Tunnel Master® wbc Power Terminal Block
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60
Install Entrance Keypad
AC Power Terminations are shown in Figure 37.
WBC AC POWER TERMINATIONS
120 VAC LINE FUSED
TERMINAL
ICS ONLY SIDE OF
TERMINAL BLOCKS
120 VAC NEUTRAL
TERMINALS
GROUND
LUG
6.0
A
POWER
Controller
Keypad
BLUE
G
N
D
BROWN
A
C
N
GREEN
BLACK
WHITE
+24v -24v
A
C
L
Ultrasonic Truck
Bed Sensor Box
A A G
C C N
H N D
GROUND
NEUTRAL
WHITE
BLACK
GREEN
LINE
(MUST BE TERMINATED AT FUSED TERMINAL)
SHIELD DRAIN NOT
TERMINATED
120 VAC FROM POWER
DISTRIBUTION BOX – 14/3
SHIELDED WIRE “E”
ELECTRICIAN
SUPPLIED 24/4
SHIELDED
ELECTRICIAN
SUPPLIED 18/4
SHIELDED
Figure 37. AC Power Terminations
 Electrician must run a single-twisted pair, 24AWG shielded com 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-, and GND, for Data+, Data-, and Ground, respectfully. Terminations for the singletwisted pair Comm wires should be torqued to 20 pound-inches (2.3 n-m.)
NOTE: Over torquing may cause enclosure breakage.
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61
Install Entrance Keypad
 Entrance Keypad Communication cable terminations must be made as shown in Figure 38.
*1'
'7
'7
*1'
%/$&.
'7
'7
:+,7(
:+,7(%/$&.
-803(56(77,1*6
-±([W3URJ
-±$
21
-±(3&(
-±*QG
21
-±5HF
2))
-±5HF
2))
-±7HUP
21
7:2&200
7,(56/2&$7('21
&21752//(5¶6
0$,1&38%2$5'
7;
:+,7(%/$&.
7;
:+,7(
,&6&200
&$%/(21/<
5;
5;
*1'
%/$&.
Figure 38. Main CPU Board RS-485 Comm Terminal Wiring
Second Entrance Keypad Mounting and Installation
The following instructions will provide detailed information on proper mounting and installation
of the optional second entrance keypad.
Second Entrance Keypad Mounting
 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.
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Install Entrance Keypad
Second Entrance Keypad Wiring
 One 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 should be tightened to the torque specs of the
manufacturer.
 The conduit shall be secured with a Listed watertight conduit hub, and should be tightened to
the torque specs of the manufacturer. Over torquing may cause enclosure breakage.
 The conduit will contain the 12VAC and Communications cable and should enter the opening
in the bottom of the keypad enclosure.
 Electrician must run 3 - 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 GND, for Line, Neutral and Ground, respectfully. Terminations for the 3 – 16AWG
wires should be torqued to 20 inch pounds (in-lb) (2.3 n-m.)
NOTE: Over torquing may cause enclosure breakage.
First Entrance Keypad
Second Entrance Keypad
ACH
ACH
ACN
ACN
GND
GND
Table 16: 12VAC Terminations
 Electrician must run a single-twisted pair, 24 AWG shielded COM cable (can be purchased
from ICS) through the above 3/4” conduit from the first entrance keypad to the second
entrance keypad.
Second Entrance Keypad Wiring
There is a terminal block (NETWORK 485), located on each of the keypad circuit boards labeled
with DT+, DT-, and GND, for Data+, Data- and Ground, respectfully. Terminations for the singletwisted pair COMM wires should be torqued to 20 pound inches (2.3 n-m.) Over torquing may
cause enclosure breakage. See Table 17.
First Entrance Keypad
(Either Connector)
Second Entrance Keypad
(Either Connector)
DT+
DT+
DT-
DT-
GND
GND
Table 17: Comm Cable Terminations
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Install Entrance Keypad
Entrance Keypad
The following figure shows the entrance keypad circuit board and location of the various jumpers
on the entrance keypad circuit board.
Figure 39. Keypad Circuit Board Jumper Settings
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Install Entrance Keypad
In Figure 39, “Keypad Circuit Board Jumper Settings,” 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
4
DIP Switch
5
J5
OFF
Biasing Resister High (+)
6
J6
OFF
Biasing Resister Low (-)
7
J7
ON
Terminating 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
Circuit board reset
Table 18: Jumper Settings
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Install Entrance Keypad
Entrance Keypad DIP Switch Settings
The following picture and table will show 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.
Figure 40. Keypad Reset and DIP Switch
Switch
Setting
1
OFF
2
OFF
Function
Address setting
Address setting
3
OFF
Baud Rate
4
OFF
Test Mode
1, 2 OFF
= Address 5
1 OFF, 2 ON
= Address 6
1 ON, 2 OFF
= Address 7
1, 2 ON
= Address 8
OFF = 9600
ON = 38,400
Table 19: DIP Switch Settings
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Install Entrance Keypad
CHAPTER 6: Troubleshooting
Preventative 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 Server
For 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 Port
If 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.
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Troubleshooting
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.
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Troubleshooting
Index
A
H
Amperage, 12
ANTI COLLISION, 23
Auto Sentry Flex
system wiring for two lanes, 45
Hardware description, 10
Horn, conveyor and manual bypass
wiring, 31
B
I
Input and conveyor interlock board, 24
INPUT1-9, 23
Inputs
main wiring, 36
IPX0 rating, 12
Battery, 68
back-up, 41
Bypass, 27
C
J
Codes, 10
Communications wiring, 57, 59
Conduit
sizing, 16
Configuration
WBC user manual, 9
Contact, 9
Conveyor
dip switch settings, 33
updated wiring, 33
CPU board
overview, 17, 19
wiring, 22
Jumper, 40
Jumpers
TP4 through TP49, 41
M
Main CPU board overview, 19
Mounting
height, 11
O
Operating temperature, 11, 12
P
D
Delayed, 24
Dimensions, 15
DIP switch
conveyor relay, 33
SW1 to SW8, 43
Display, 47
DRY CONTACT, 42
Power
requirements, 14
supply, 12
PROX GND, 22
PROX POWER, 22
PULSE SINK, 22
PULSE SRCE, 22
Pulse switch, 35
E
R
Electronics industrial association, 57
EM TIRE 2, 23
EXTERNAL VOLTAGE, 42
Related documents, 9
Relay, 29
Relay boards, 29
jumpers, 30
output wiring, 37, 39
wiring guidelines, 30
REMOTE ROLLER, 23
ROLLER LOCATOR, 23
RS-232 COM terminal wiring diagram, 57, 59
RS-485
COM terminal wiring diagrams, 62
wiring layout, 58
F
Frequency, 12
Fuses, 30
G
GATE, 23
Ground
lug, 14
Grounding, 15
S
Serial debug port, 67
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Index
Site layout, 11
Start and stop inputs wiring, 31
Supply voltage, 12
T
TIRE, 23
Torque specifications, 14
Transformer, 28
Transformer selector, 28
Truck bed sensor. See Ultrasonic sensor
U
Ultrasonic, 48
Ultrasonic sensor
dimensions, 50
jumper settings, 54
mounting recommendations, 49
operations, 63
specifications, 54
wiring, 53, 62
V
Versions, 9
W
Warranty
voiding, 15
Wire gauge, 16
Wiring
communications, 57, 59
cpu board, 22
input and conveyor interlock board, 24
system, 17
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Index
Version History
Document
Version
Dates
Contributor
Initials
Description
1.0
03/18/2008
JL-S
First release.
1.1
04/07/2008
BB, JL-S, KK,
RH, SD, TR
Full review.
1.2
04/09/2008
S.D.
Updated two drawings on pages 26 and 36 that reversed PULSE SRCE and
PROX PWR.
2.0
05/28/2009 —
10/12/2009
S.D., R.H., J.M.,
J.L-S.
-Pickup bed sensor specs and diagrams.
-Smart relay board wiring diagram.
-Entrance management sensor diagram
-Tire sensor diagram.
-Added double Wash Valet system section.
-Updated Conveyor Wiring section in System Wiring chapter.
-Added Network Debug Log and Serial Debug Port sections to
Troubleshooting chapter.
3.0
09/17/2010—
10/21/2010
S.D., J.L-S.
-More detailed ultrasonic sensor installation instructions.
-Changed references from Double Wash Valet® to Double Auto Sentry® flex
in text and drawings.
-Third Party Kiosk Wiring Terminations.
4.0
10/10/2012-8/
20/2013
J.M., S.D., B.M.,
J.L., K.K., A.D.,
W.S.
-Detailed ultrasonic sensor installation instructions (pages 57-59).
-Wetdown turns on conveyor relay.
-Recommend use external voltage and supply 24 VAC for the inputs.
5.0
9/10/2014
B.M., W.S.
6.0
10/22/2015
A.C., B.M., C.B.,
W.S
Ultra-sonic Sensor update pg. 62-63. Updated drawing on page 69. Input
board (prior ICIB) page 27.
7.0
4/1/2016
B.M., W.S., S.B.,
S.S.
New look. Added Delayed Panic drawing.
8.0
3/13/2017
W.S., T.R
Included 7.0 Addendum, New Ultrasonic Sensor
9.0
8/15/2017
W.S., R.R., N.R.,
T.R.
Updated Figures 16 and 19, and Ultrasonic Converter Box.
9.1
1/30/2018
W.S., N.R., T.R.
Added wiring for Truck Bed Ultrasonic Sensor
9.2
4/20/2018
WS, TR
Updated photo for Ultrasonic Terminal Blocks
10
6/28/2018
WS
Updated auxiliary, de-select selective relays, updated images, ICS Book
Graphics
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