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TUNNEL MASTER JR MANUAL

System Hardware

Panic Stop Circuit Wiring

Panic Stop
Circuit Diagram

The following diagram shows how to wire the Panic Stop circuit into
the Controller.

Important!

This drawing shows the basic wiring of the panic circuit. The Panic
circuit allows for certain software programming that could not be
programmed without this circuit in place.

See Diagram on Next Page

Summary of Contents for Tunnel Master Jr

Page 1: ...startup Optional report and or receipt printers ICS developed this manual in order to Provide a comprehensive easy to use system reference guide Enable operators and their employees to obtain the maxi...

Page 2: ...r Settings Relay Box Dip Switch Settings Entrance Keypad Mounting and Installation Entrance Keypad Jumper Settings Entrance Keypad Dip Switch Settings Report Receipt Printer Mounting and Installation...

Page 3: ...Reports 62 4 Troubleshooting 66 Appendix A Equipment Layout Addressing Drawings 1 Relay Box 1 Entry Keypad Report Receipt Printer 2 Relay Boxes 1 Entry Keypad Report Receipt Printer 2 Relay Boxes 2 En...

Page 4: ...er Jr hardware is designed to withstand the harsh environments and hard use of a busy car wash Both the Relay Box and the Input Station Keypad come with a 3 year conditional warranty against defects i...

Page 5: ...ovides for automatic computer controlled or manual firing of the outputs The relay box can control up to 24 outputs Exterior picture 24 toggle switches Each switch controls the operation of one output...

Page 6: ...ester at the center bottom of the box Each relay can be programmed to Flash thus eliminating the need for field installed flashing relays for signs Plug in relays for ease of serviceability Each relay...

Page 7: ...t to power the Relay Box Run a 14 3 cable to the 110vac terminal block It is labeled with H and N for Hot and Neutral respectfully There is a mechanical ground lug located on the back of the box adjac...

Page 8: ...ch functions When using a normally open 2 wire pulse switch use terminals marked CLK SINK and PROX GND See Pulse switch wiring diagrams When using a normally open 3 wire pulse switch use terminals mar...

Page 9: ...s There are two types that are most commonly used either a two wire or three wire Sinking NPN switch The drawing below indicates the wiring for these two types of switches The other type of switch is...

Page 10: ...the first piece of wash equipment This switch signals the OEM Controller that a vehicle is starting through the tunnel All equipment turn on points are measured from this switch to the particular piec...

Page 11: ...customer has purchased a tire position switch from the equipment vendor The switch enables the Controller software to turn equipment on and off as each of the vehicle s tires pass that piece of equip...

Page 12: ...d automatically upon seeing a second 24Volt input on Input 10 At the same time an output can be set to fire and the roller can be delayed When a car enters the tunnel the TMJ will wait to see two sign...

Page 13: ...the TMJ will wait to fire a roller until the trailing edge of the signal is detected from a roller locator There are various devices available to detect the roller and because the TMJ reads the trail...

Page 14: ...m The following diagram shows how to wire the Panic Stop circuit into the Controller Important This drawing shows the basic wiring of the panic circuit The Panic circuit allows for certain software pr...

Page 15: ...TUNNEL MASTER JR MANUAL System Hardware 15...

Page 16: ...where you could have a potential collision The process consists of two variables in order for the Tunnel Master Jr to go into an anti collision panic The first variable is for the Jr to see a car thr...

Page 17: ...TUNNEL MASTER JR MANUAL System Hardware 17 Tunnel Master Junior Input Wiring Summary Input Wiring Summary The following diagram shows where all of the TMJ inputs get wired into...

Page 18: ...ttings Jumper Setting Function J1 N A Does not exist J2 ON BIAS High set ON for the Main Relay box only J3 485 3 position jumper should be on 2 pins to select 485 Communication UP J4 485 3 position ju...

Page 19: ...ins to select 485 Communication Left J7 OFF Receive terminating resister J8 ON Network Interface Chassis Ground Jumper J9 ON Network Interface Signal Ground Jumper J10 ON BIAS Low set ON for the Main...

Page 20: ...ressed as ADDR9 The following picture shows the Relay Box door Dip switch Relay Box Dip Switch Switch Normal Setting Function These are the dipswitch settings for normal operations Switch Setting Func...

Page 21: ...Keypad it is very important that the electrician adhere to the wiring instructions provided with the Relay Box Alpha buttons are all programmable and used for entering services Data indicator light w...

Page 22: ...system prior to processing vehicle Roller button when pressed will activate the roller relay AC All Clear button when pressed will clear all previously entered services To clear a button pushed in er...

Page 23: ...m the OEM Relay Box See wiring in the Relay Box section of this manual The conduit shall be secured with a Listed watertight conduit hub and should be tightened to the torque specs of the manufacturer...

Page 24: ...is only one transformer terminate power from it OEM Relay Box Entrance Keypad 24ACH 24H 24ACL 24L Gnd Trm GND Note The Gnd Trm refers to the grounding lug connector fastened to the lower right hand co...

Page 25: ...ed 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 th...

Page 26: ...ypad circuit boards labeled with DT DT and GND for Data Data and Ground respectfully Terminations for the single twisted pair COM wires should be torqued to 20 pound inches 2 3 n m Overtorquing may ca...

Page 27: ...e jumper functions and their normal settings By default the keypad comes address as 5 There is no reason to change this unless advised by ICS If you have two keypads you should address the second as a...

Page 28: ...e previous Entrance Keypad picture on page 23 The OFF position is toward the word Config on the circuit board The following picture shows the Keypad lid Dipswitch Entrance Keypad Dip Switch Switch Nor...

Page 29: ...o the system after initial installation Helpful Tip Please refer to the Operator s Manual supplied with the printer for proper care and maintenance of your printer If you are using the Epson Dot Matri...

Page 30: ...Box Drill and provide access into the Relay Box using a Listed water tight compression connector for a cable The connector should be tightened to the torque specs of the manufacturer Overtorquing may...

Page 31: ...as the Relay Box if possible Drill and provide access into the Entrance Keypad using a Listed water tight compression connector for a cable The connector should be tightened to the torque specs of th...

Page 32: ...que features usually found only in the high end full service wash controller systems Things such as the copyrighted anti theft software integration with a Panic Stop circuit and for quick morning wash...

Page 33: ...ad Note In order to utilize the full functionality of the Tunnel Master Jr Controller it is very important that the electrician adhere to the wiring instructions provided with the Relay Box 5 Volt ind...

Page 34: ...sh to enter the letter C press the number 1 key three times Numeric 0 The 0 button has multiple functionality depending on what is being programmed In most menu options the 0 button when pressed will...

Page 35: ..._ _ _ _ ADDR 1 CARS 0000 2 Using the numeric keypad type in the first letter of the password Example For the letter L press the 4 key three times ICS OEM Tunnel Controller 10 25 35 PM VER 1 REV 5 11...

Page 36: ...hat each output is operating and the various settings for that output 3 Outputs List This option allows the user to assign what selective outputs will be activated for which services that are availabl...

Page 37: ...ash 1 Shift Break 4 View Counts 2 Wet Down Wash 5 Print Reports 3 Configure Wash 2 Press the numeric key 5 to select Set Date Time 1 Services 4 Wash Settings 2 Outputs 5 Set Date Time 3 Output List 6...

Page 38: ...key 3 from the Main Menu to select Configure Wash 1 Shift Break 4 View Counts 2 Wet Down Wash 5 Print Reports 3 Configure Wash 2 Press the numeric key 6 to select Set Password 1 Services 4 Wash Settin...

Page 39: ...the number of pulses of the minimum size vehicle that may enter the car wash This can be as little as 24 but must be greater than the minimum pulse length and greater than the anti bounce value This...

Page 40: ...the Gate input If the Gate input goes down you can turn this feature on This will simulate the measuring of the car It will set every car length to the value set for Max Car Length Roller Control Ent...

Page 41: ...stem is currently on You cannot change this setting Auto Shift Enter Y for yes N for no If you set this option to Y the system will automatically close the shift at midnight This option should be set...

Page 42: ...er Footer 4 Enter information desired to display on the fourth line on the bottom of receipts This is usually a message to the customer Display Cars Enter Y for yes N for no When this option is set to...

Page 43: ...ter is hooked up to If the report printer is hooked up to the main relay box then set this to 0 If the report printer is hooked up to the keypad set this option to 5 This is the printer where all of t...

Page 44: ...F1 PREV F2 NEXT F3 RESET F4 SAVE 4 Using the numeric key pad enter the desired setting for Pulse Length Note Review button functions on page 31 PulseLength 7 75_ _ _ _ _ _ F1 PREV F2 NEXT F3 RESET F4...

Page 45: ...a total maximum of 48 Menu Items Function The following is a list of menu items within the Outputs menu and a brief explanation of their function Menu Item Function Output Enter the relay number corr...

Page 46: ...ler up cylinder is activated If you enter an extend time the system will fire the roller up relay for the start time then pause for the extend time and then fire for the start time a second time This...

Page 47: ...tory service EM Entrance Management relay will activate after second tire hits the entrance management treadle which is wired into Input 10 This relay will stay activated until Min Car Length is reach...

Page 48: ...during the Wet Down process in the morning The Wet Down process provides a quick and easy way to prepare the wash tunnel for opening Select Wet Down option 2 on the main menu and any outputs that wer...

Page 49: ...irst use the 0 button to select the desired option Y Turn On the relay if there is a Panic condition N Turn Off the relay if there is a Panic condition X Leave the relay in whatever status it was when...

Page 50: ...t _ Panic _ _ _ F1 PREV F2 NEXT F3 ERASE F4 SAVE 5 Press the ENT button on the display pad to advance to the next setting Output 01 Name Start _ _ Type _ Part _ _ Flash _ Extend _ _ _ _ Look _ _ _ Wet...

Page 51: ...t 0084 Type R Part AC Flash N Extend 000 Look 000 Wet N Panic N 0 F1 PREV F2 NEXT F3 ERASE F4 SAVE 13 Press the ENT button on the display pad to advance to the second setting in the Panic option Outpu...

Page 52: ...f menu items within the Services menu and a brief explanation of their function Menu Item Function Service Enter a numeric value of 01 up to 16 These numbers represent the wash services options that w...

Page 53: ...termine how much and which taxes will be applied to the service when it is sold 0 Non Taxable There will not be any taxes applied to the sale of the service 1 Tax Rate 1 The tax rate set in Tax Rate 1...

Page 54: ...button functions on page 31 Service 01 Name Price Type Rate F1 PREV F2 NEXT F3 ERASE F4 SAVE 5 Press the ENT button on the display pad to advance to the next setting Service 01 Name _ _ _ _ _ _ _ _ _...

Page 55: ...the ENT button on the display pad to advance to the next setting Service 01 Name GOLD WASH Price 9 99 Type B Rate _ F1 PREV F2 NEXT F3 ERASE F4 SAVE 12 Using the numeric buttons enter the desired tax...

Page 56: ...NDATORY OUTPUTS IN THE OUTPUT LIST Never assign those Outputs that have been programmed as Conveyor Roller or Auto Stop to a service in the Output Lists Menu Items Function The following is a list of...

Page 57: ...s 6 Set Password 3 Press the numeric key 3 to select the Output Lists menu option Service _ _ Outputs 4 Using the numeric keypad enter the PLU of the service to be programmed Service 03 Outputs 5 Pres...

Page 58: ...ist assigned to this service Note The input will be saved and the display will be ready to start new input Service _ _ Outputs 10 Repeat steps 4 9 until all Services which need outputs assigned in the...

Page 59: ...ugh the reports available As in the previous chapters the instructions will follow a logical trail through a days operations beginning with the opening process Proper operation will assure the operato...

Page 60: ...Function 1 Shift Break When selected this menu option will print a report if a report printer is attached and ask if the operator wishes to close Bump the current shift 2 Wet Down Wash This option all...

Page 61: ...sh to the customer Procedures Follow these procedures to Wet Down the wash Step Action Screen Displays 1 Access the Main Menu by pressing the Menu button on the display pad Note If a password has been...

Page 62: ...ss is simple and easy to follow Diagram This is a picture of the Entrance Keypad Indicator lights on each number and the roller button will light after the button has been pressed This indicates that...

Page 63: ...ss the Receipt button to print a customer receipt if there is a receipt printer attached to the Entrance Keypad Customer receipt will print out 4 Once all desired services are loaded press the Roller...

Page 64: ...on a second time 4 Press the Roller Button to process the next car on the stack The Roller light will turn on and the roller will fire If you have auto roller set to Y this is not necessary 5 Vehicle...

Page 65: ...back to zero to start the new shift For this reason if the user wishes to verify a register report to the controller counts these numbers must be written down at the end of each shift before the shif...

Page 66: ...dvance to additional services 01 EXTERIOR W 0052 05 POLISH WAX 0023 02 SILVER WAS 0023 06 CLEAR COAT 0015 03 GOLD WASH 0015 07 EMPTY 0000 04 PLATNUM W 0009 08 EMPTY 0000 4 Repeat Step 3 to review up t...

Page 67: ...shift You may also you re your shift by pressing the up arrow on the entrance keypad DOING THIS WILL RESET YOUR CURRENT CAR COUNT Procedures Follow these procedures to manually break close the current...

Page 68: ...nation of their function Item Menu Option Function 1 Shift History Allows user to scroll through shifts and select which shift to printout This option is especially useful if the original shift report...

Page 69: ...setup as having tax rates 1 or 2 applied to them Sales Combined Tax Rate Total sales of all services setup as having both tax rates applied Taxes Rate 1 2 The actual taxes in paid for the services so...

Page 70: ...ry 4 Wash Settings 2 Monthly Summary 3 Yearly Summary 3 Press the numeric key 1 to select Shift History Shift 1006 04 15 2002 06 57 57pm Shift 1007 04 16 2002 06 45 25pm Shift 1008 04 17 2002 06 35 52...

Page 71: ...s 3 Configure Wash 2 Press the numeric key 5 to select Print Reports 1 Shift History 4 Wash Settings 2 Monthly Reports 3 Yearly Reports 3 Press the numeric key 2 or 3 to select the desired option of e...

Page 72: ...he service button is pressed Check the Power light in the upper right hand corner of the keypad to verify that it is lit If the light is not lit then the keypad is not receiving power from the OEM Rel...

Page 73: ...ith this option set to Y the controller will simulate the gate sensor This will tell the system that every car that goes through the tunnel is the Max Car Length value that is set in the wash settings...

Page 74: ...the number LED s will be flashing If you press a number once it will go solid if you hit it again it will shut off if you hit it again it will flash again Do this for each one of the numbers The rolle...

Page 75: ...lugged in incorrectly Re attach Ribbon cable Check position of relay toggle switch Move switch to down position No power to Relay Box Check 110VAC power to relay box Relay not firing Pulse Gate not op...

Page 76: ...ure Contact your distributor for a replacement Misc Troubleshooting Rollers keep coming up Check the pulse switch Please refer to Wash Controller Input Check on page 67 Equipment timing is off Check t...

Page 77: ...e loop and see if the gate light on the relay box comes on If the gate does not function properly set Auto Gate to Y See Wash Controller Input Check on page 68 All of my equipment is shutting off half...

Page 78: ...TUNNEL MASTER JR MANUAL Appendix 78 Appendix A...

Page 79: ...TUNNEL MASTER JR MANUAL Appendix 79...

Page 80: ...TUNNEL MASTER JR MANUAL Appendix 80...

Page 81: ...on functions 18 19 jumper locations 24 jumper settings 24 keypad connectors 20 mounting 20 picture 18 second keypad wiring 22 23 wire terminations 21 wiring 20 21 Entry keypad introduction 30 Entry Ke...

Page 82: ...th or Year summary report 66 procedures 65 Processing Vehicles entrance keypad 58 59 Proximity Switch wiring 9 Pulse Switch wiring 9 PulseLength 36 PushButtonCols 38 PushButtonRows 38 R Rate service m...

Page 83: ...enu item function 55 Viewing Service Counts procedures 60 61 Violation Count report entry 64 ViolationCount 39 W Wash Configuration introduction 29 Wash Settings Configure Wash Menu 33 menu options fu...

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