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User Manual—Version 3.0 Tunnel Master



Jr. System Hardware and Installation

January 2016 21

Pulse/Proximity Switch Wiring

Figure 4. Pulse/Proximity Switch Wiring

PROX PWR

CLK SRCE

CLK SINK

PROX GND

GATE +

GATE -

TIRE +

TIRE -

PANIC +

PANIC -

Terminals not used in this diagram

"Used when connecting a standard

"Push Button" entry box.

2-Wire pulse

switch with

N.O. contact

3-Wire (NPN)

Proximity

switch - Sinking

Terminal strip on top of relay board

SINK

SOURCE

JP2

JP1

SINK

SOURCE

Refer to Jumper settings

Default Chapter3
- Table of Contents3
Chapter 1 Introduction11
Version Considerations11
Related Documents11
Audience11
Controller Features12
Chapter 2 System Hardware and Installation13
- Audience13
- Purpose13
Resetting Default Configuration Settings14
- Rules for Installation14
- Warning Marking15
Output Overview15
- 24 Outputs15
- Figure 1. Front Panel15
Relay Box Installation16
- Relay Box Mounting16
- Relay Box Wiring16
Relay Box Interior18
- Figure 2. Low Voltage Layout Wiring Diagram18
- Figure 3. Relay Box Interior Components19
Pulse/Proximity Switch Wiring20
- Pulse/Proximity Switch Wiring21
- Figure 4. Pulse/Proximity Switch Wiring21
Gate Switch (Electric Eye) Wiring22
- Gate Eye Switch Wiring23
- Figure 5. Gate Eye (Switch) Wiring23
Tire Switch Wiring24
- Figure 6. Tire Switch Wiring24
Entrance Management System Wiring25
- Entrance Management System Wiring26
Roller Locator Wiring26
- Figure 7. Entrance Management Overview and Wiring Diagram26
- Conveyor Roller Locator Cross Section Diagram27
- Figure 8. Roller Locator Cross Section Diagram27
- Figure 9. Roller Locator Wiring28
- Roller Locator Wiring28
Panic Stop Circuit Wiring29
- Panic Stop Wiring30
- Figure 10. Panic Stop Circuit Wiring30
Anti-Collision Wiring31
- Anti-Collision Wiring32
- Figure 11. Anti-Collision Wiring32
Input Wiring Summary33
- Figure 12. Inputs33
Push Button Wiring34
- Push Button Wiring 1 Row 8 Columns35
- Figure 13. Push Button Wiring 1 Row 8 Columns35
- Push Button Wiring First 8 Buttons36
- Figure 14. Push Button Wiring First 8 Buttons36
- Push Button Wiring for Second 8 Buttons37
- Figure 15. Push Button Wiring for Second 8 Buttons37
Relay Box Jumper Settings38
- Figure 16. Relay Jumper Box Settings38
- Table 1. Relay Box Circuit Descriptions39
DIP Switch Settings40
- Figure 17. DIP Switch Located on Inside of Relay Box Door40
- Table 2. DIP Switch Normal Settings/Functions40
Chapter 3 Operating Procedures41
Main Wash Menu41
- Table 3. Main Wash Menu41
Wet down Wash42
- Table 4. Wet down Wash Instructions42
Chapter 4 Wash Configuration43
Relay Box Display Keypad44
- Figure 18. Main Screen Display and Keypad44
Set Password45
- Table 5. Relay Box Display and Keypad Indicator Light Descriptions45
- Table 6. Change the System Password Instructions46
- Access a Password Protected Menu47
- Table 7. Add Password Instructions47
Configure Wash Menu48
Wash Setting Descriptions48
- Table 8. Configure Wash Menu48
- Table 9. Wash Settings Menu49
Set Date Time52
- Table 10. Set Date and Time Instructions53
Configure Wash Settings54
- Table 11. Configure Wash Settings54
- About Countdown Times55
Outputs56
- Table 12. Outputs Descriptions56
Output Settings58
- Table 13. Output Settings58
- Table 14. Services Menu Item Descriptions60
- Table 15. Change or Set Services Instructions61
Assign Outputs to Services63
- Table 16. Assign Outputs to Services Instructions63
Chapter 5 Entrance Keypad65
Entrance Keypad Functions66
- Figure 19. Entrance Keypad66
- Table 17. Entrance Keypad Buttons67
Entrance Keypad to Process Vehicles (Non-Stacking)68
- Table 18. Process Vehicles (Non-Stacking)68
Entrance Keypad to Process Vehicles (Stack)69
- Change Service And/Or Add Retract69
- Table 19. Process Vehicles Stack Instructions69
- Add a Car to Stack70
- Remove a Car from Stack70
View Service Counts71
- Table 20. View Service Counts Instructions71
Shift Break72
- Bump a Shift or Manually Close Current Shift73
- Table 21. Manually Close or Bump the Current Shift Instructions73
- User Manual-Version75
Communication and Keypad Installation75
- Tunnel Master Jr75
Entrance Keypad Mounting and Installation75
- Entrance Keypad Mounting75
- Entrance Keypad Wiring75
- Figure 20. Keypad Connectors (Keypad Board)76
- Figure 21. AC Power Terminations77
- Figure 22. Communication Cable Termination Diagram79
Second Entrance Keypad Mounting and Installation80
- Second Entrance Keypad Mounting80
- Second Entrance Keypad Wiring80
- Table 22. 120 VAC Terminations80
Entrance Keypad Jumper Settings82
- Figure 23. Keypad Circuit Board Jumper Settings82
- Table 23. Comm Cable Terminations82
Entrance Keypad DIP Switch Settings83
- Figure 24. DIP Switch83
- Table 24. Default Jumper Settings83
- Table 25. DIP Switch Settings84
Chapter 7 Optional Report/Receipt Printer Installation85
Mounting and Installation of Report/Receipt Printer86
- Report Printer Mounting86
Report Printer Wiring86
- Figure 25. Epson Dot Matrix Report/Receipt Printer86
Chapter 8 Trouble Shooting89
- System Diagnosis89
- Entrance Keypad89
- Wash Controller Response89
- Wash Controller Input Check90
- Entrance Keypad Diagnostics91
- Table 26. Relay Box Troubleshooting91
- Table 27. Entrance Keypad Troubleshooting92
- Table 28. Miscellaneous Troubleshooting93
- Figure 26. Appendix A - 1 Relay Box/1 Entrance Keypad/1 Receipt Printer97
- Figure 27. Appendix B - 2 Relay Boxes/1 Entrance Keypad/1 Receipt Report Printer99
- Figure 28. Appendix C - 2 Relay Boxes/2 Entrance Keypads/Report Receipt Printer101
Change History107

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General

Brand	ICS
Model	Tunnel Master Jr
Category	Controller
Language	English

ICS Tunnel Master Jr User Manual

Table of Contents

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ICS Tunnel Master Jr Specifications