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Tunnel Master® Jr. User Manual

Chapter 2: Hardware Installation

24 Outputs

The Tunnel Master® Jr. relay box is the control center for firing the various outputs or services in the wash
tunnel like the soap foamer, reclaim motor, and more. The Tunnel Master® Jr. Controller relay box provides
automatic, computer controlled, or manual firing of the outputs. The relay box can control up to 24
outputs. Each toggle switch controls the operation of one output or service.
The switches have three positions:

UP = Manual Override. Manually turn on output. (This feature can be turned off if desired.)

MIDDLE = Output Off. The output is off and will not fire.

DOWN = Computer controlled on position (normal).

Figure 2-4. Front Panel of the Tunnel Master Jr.

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Summary of Contents for Tunnel Master Jr

Page 1: ...Tunnel Master Jr User Manual Version 5 0...

Page 2: ...ctitious 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 I...

Page 3: ...Switch Electric Eye Wiring 11 Tire Switch Wiring 12 Entrance Management System Wiring 13 Roller Locator Wiring 14 Panic Stop Circuit Wiring 14 Anti Collision Wiring 16 Input Wiring Designations 17 Pu...

Page 4: ...Stacking 52 Entrance Keypad to Process Vehicles Stack 53 Change Service and or Add Retract 54 Add a Car to Stack 54 Remove a Car from Stack 54 View Service Counts for the Current Shift 55 Bump Shift...

Page 5: ...s technical support for customers and installers 1 800 246 3469 Many of the TMJ system features were integrated at the request of current car wash operators We welcome your feedback and want to assure...

Page 6: ...ble fused outputs upgradeable to 72 each with two independent circuits 24 VAC and 120 VAC Programmable flashing relay Exclusive patented anti theft feature to prevent unauthorized processing of car wa...

Page 7: ...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 Jr and any p...

Page 8: ...bjects up to 1mm diameter and not protected against liquid Table 2 1 Tunnel Master Jr Controller Dimensions Measurements and Ratings Entry Keypad Dimensions Dimension Amount Notes Width 9 3 8 Height 7...

Page 9: ...o each relay This power is to fire the solenoids and equipment A separation of 120 VAC and 24 VAC shall be maintained for all field wiring circuits All 24 VAC circuits must be supplied by a class 2 tr...

Page 10: ...time use ICS recommends a complete initialization and clear the factory settings The Tunnel Master Jr is delivered with preloaded settings You can erase these settings before configuring your own set...

Page 11: ...hat keeps the battery in place against the board for at least a minute to drain all the settings from memory 12 Re insert the ribbon cable on the right side of the switchboard 13 After the factory res...

Page 12: ...troller relay box provides automatic computer controlled or manual firing of the outputs The relay box can control up to 24 outputs Each toggle switch controls the operation of one output or service T...

Page 13: ...her device from this transformer NOTE PC and Printer connections are located in the base of the box Power in Power Conditioner Board Comm Cable Terminal Blocks for 16 button Entry Keypad and other TMJ...

Page 14: ...at 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 defined as a Sourcing PN...

Page 15: ...icle is starting through the tunnel All equipment turn on points are measured from this switch to the particular piece of equipment See the wash equipment provider for the location of this relay The f...

Page 16: ...the vehicle s tires pass that piece of equipment In order for this to work properly the tire switch should be located in line with the gate switch The following diagram shows how to wire the Tire Swi...

Page 17: ...ithin 15 seconds of each other from the tire treadle that is wired into Input 10 The first signal represents the front tire and the second signal represents the rear After it sees the second signal th...

Page 18: ...p two things need to be done A roller locator switch needs to be wired into Input 9 and installed on the conveyor This switch should be positioned so that as soon as a roller passes the switch it will...

Page 19: ...Circuit The Panic Stop Circuit allows for certain software programming that could not be programmed without this circuit in place The diagram shows how to wire the Panic Stop Circuit into the Controll...

Page 20: ...collision start time in the wash settings on the Tunnel Master Jr When a car is in the sensing device and a second car reaches the Anti collision Start Time the system will go into a panic until the...

Page 21: ...IN 10 IN 11 IN 11 IN 12 IN 12 External Roller Anti Collision Entrance Mgt Treadle Roller locator switch Panic input Tire detect input Gate input Prox switch power Clock source Clock sink TMJ Input Des...

Page 22: ...llers If the Tunnel Master Jr is going to utilize a Push Button Station as a means of remotely selecting the features of each car wash refer to one of the following schematic diagrams of how it must b...

Page 23: ...n Input 5 Input 6 Input 7 Input 8 24VAC Service 1 Service 2 Service 3 Service 4 Service 5 Service 6 Service 7 Service 8 Input 1 Input 2 Inputs 1 8 Common TM Junior Push Button Wiring First 8 buttons 4...

Page 24: ...t 5 Input 6 Input 7 Input 8 24VAC Service 9 Service 10 Service 11 Service 12 Service 13 Service 14 Service 15 ALL CLEAR Input 3 Input 4 Inputs 1 8 Common TM Junior Push Button Wiring Second 8 Buttons...

Page 25: ...location and purpose of the various jumpers switches and controls on the Relay Box circuit board This board is located on the inside of the Relay Box door Relay Box Circuit Contrast Control for front...

Page 26: ...sistor Only ON if first or last device in network If you have a 24 output system this should be ON If you have a 48 output system the main relay box should be OFF and the second relay box should be ON...

Page 27: ...be addressed as ADDR9 Tunnel Master Jr AC Power Terminations Figure 2 19 DIP Switch Settings located on the inside of the Relay Switch Default Setting Function 1 OFF Address Setting 1 2 3 4 OFF 1 ON...

Page 28: ...cian through the 3 4 conduit from the Tunnel Master Jr to the Entrance Keypad The following picture shows the connection points for the various components Optional Pole Display screen termination or t...

Page 29: ...OFF J8 Gnd ON J9 Gnd ON J10 Bias L ON J11 S Lock ON J2 BIAS H OFF J3 485 422 485 J4 485 422 485 J5 T Term ON J6 485 422 485 J7 R Term OFF J8 Gnd ON J9 Gnd ON J10 Bias L OFF J11 S Lock ON J2 BIAS H ON...

Page 30: ...om 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 Line ACN neutral and GND Ground Terminations fo...

Page 31: ...isplayed 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 the second is set to address 6 Jumper Setting Des...

Page 32: ...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 away from the word Config on the circuit...

Page 33: ...topics will be covered in this chapter Tunnel Master Jr Display and Keypad Configure Wash Settings Set or Change Password Configure Wash Menu Configure Wash Settings Outputs Service Settings Tunnel M...

Page 34: ...advance to the next screen F3 CLEAR allows user to clear existing entries F4 SAVE allows user to save new settings entered Menu The Menu button is used when accessing various menu options in your car...

Page 35: ...4 2 Set or Change Password Instructions Access a Password Protected Menu After a password has been set in the system any access to the menu options will require that the user enter that password NOTE...

Page 36: ...from the Main Menu to select Configure Wash 1 Services 4 Wash Settings 2 Outputs 5 Set Date Time 3 Output List 6 Set Password 3 Press the numeric key 5 to select Set Date Time Set Date Time Date _ _...

Page 37: ...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 available to sell 4 Wash Se...

Page 38: ...e 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 is part of the anti theft f...

Page 39: ...recognize a car no outputs would be turned on in the tunnel When set to N the system will allow a roller to be fired for a vehicle that is not assigned to a valid service This will allow that vehicle...

Page 40: ...N if you are using the Tunnel Master Jr Interface Header 1 Enter information desired to display on the first line on the top of reports and receipts This is usually company information Header 2 Enter...

Page 41: ...0 If the report printer is hooked up to the keypad set this option to 5 This is the printer where all of the reports will print out Receipt Address This is the address in which the receipt printer is...

Page 42: ...wn time e g 100 This is the amount of time you want the actual wet down relays to fire and apply water to the equipment For example the Wet Down Period is set to 100 the equipment may only get 90 seco...

Page 43: ...eriod in the Wash Settings O This output is used to start the conveyor once you have a base service selected H This output will fire your Horn The start time for this output is how long in seconds tha...

Page 44: ...Y for yes or N for no if the relay should activate during the Wet Down process in the morning which provides a quick and easy way to prepare the wash tunnel for opening Select Wet Down option 2 on th...

Page 45: ...or the output NOTE Review 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 keypad to advance to the next setting Outpu...

Page 46: ...for no Output 01 Name Roller Start 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...

Page 47: ...vice i e Polish Waxes Rate From the numeric buttons press the 0 button to advance through the available options Setting the desired tax rate will determine how much and which taxes will be applied to...

Page 48: ...Type Rate F1 PREV F2 NEXT F3 ERASE F4 SAVE 6 Using the numeric buttons enter in the name of the service Service 01 Name GOLD WASH Price Type Rate F1 PREV F2 NEXT F3 ERASE F4 SAVE 7 Press the ENT butt...

Page 49: ...service and only selective or deselective outputs should be added to the list Also you can only add up to 16 outputs to the Output List and these are typically used for higher end washes Step Action...

Page 50: ...s 6 7 until all desired outputs have been programmed Service 03 Outputs 05 06 9 Press the F4 button to save the Output List assigned to this service NOTE The input will be saved and the display will b...

Page 51: ...onnel in the proper selection of these menu options to ensure accurate shift reporting and to review operations The following is a list of menu options in the Main Wash menu and a brief explanation of...

Page 52: ...at the Tunnel Master Jr display Item Menu Option Function 1 Bump Shift When selected this menu option will print a report if a report printer is attached and ask if the operator wishes to close Bump...

Page 53: ...hicles are processed at the front of the wash with Entrance Keypad Stack N Control can be managed at the Entrance Keypad Some equipment diagnostics occur at the Entrance Keypad Processing Cars After t...

Page 54: ...bump the current shift moving the car counts back to 0 Also if a printer is set up this will print off the reports This works when the input device is set to either K or C The Car button is the Rolle...

Page 55: ...through the gate switch and reached minimum car length To clear a button selected in error simply press the button again and the LED light will go out Button Function 1 After all desired services hav...

Page 56: ...attached to the Entrance Keypad Customer receipt will print out 4 After all the desired services are loaded and the vehicle is staged and ready to be washed press the Roller button the button with the...

Page 57: ...ess 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 will start through th...

Page 58: ...lash again displaying the cars on stack NOTE Setup for Retracts is on the Tunnel Master Jr services page Add a Car to Stack To add a new car to the end of the stack follow these steps 1 On the keypad...

Page 59: ...cessed 1 Bump Shift 4 View Counts 2 Wet Down Wash 5 Print Reports 3 Configure Wash 2 Press the numeric 3 key to select View Counts Unloaded Vehicles washed without a service being programmed Cars of c...

Page 60: ...button on the display pad NOTE If a password has been set it will be necessary to enter the password before the main menu can be accessed 1 Bump Shift 4 View Counts 2 Wet Down Wash 5 Print Reports 3 C...

Page 61: ...atrix printer please be sure to check the DIP switch settings of the printer DSW1 DIP switch 3 should be the only DIP switch set to ON all of the others should be off The DIP switches are located on t...

Page 62: ...e 25 pin RS 232 connector attached supplied by ICS into the Tunnel Master Jr Relay Box Allow excess cable outside the Tunnel Mster Jr Relay Box for easy access to the backside of the printer so that t...

Page 63: ...cating that the system processor is functioning Check the Data light in the upper right hand corner of the keypad This light should be blinking indicating that the keypad is communicating with the ICS...

Page 64: ...t corner of the Relay Box NOTE In some cases a low oil level switch for the hydraulic power pack may be wired into the panic circuit As a precaution always check the oil level in the power pack to be...

Page 65: ...fire Mandatory outputs This is known as an unloaded car Table 8 1 Tunnel Master Jr Relay Box Troubleshooting Symptom Cause Remedy Keypad not responding Keypad address not correct In most circumstances...

Page 66: ...oked up to the keypad it should be address 5 If the report printer is hooked up to the relay box then the address should be 0 All of my equipment is shutting off half way through the tunnel Faulty Gat...

Page 67: ...s as Keypad if it is attached to a Keypad Entry Keypad Wash Entrance 1 Keypad power supplied by 24 VAC from Relay Box 2 Communication cable from Relay Box 3 Keypad Address set to 5 or greater Receipt...

Page 68: ...dedicated 120 VAC circuit as Relay Box 2 Communication from Keypad 3 Report Address set to same address as Keypad it is attached to in this example 5 4 Receipt Address set to same address as Keypad it...

Page 69: ...d Address set to 5 2nd Entry Keypad Wash Entrance 1 Keypad power supplied by 24 VAC from Relay Box 2 Communication cable from Relay Box 3 Keypad Address set to 6 Receipt Printer Wash Entrance 1 Receip...

Page 70: ......

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