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Summary of Contents for Innovative Control Systems Tunnel Master wbc
- Page 1 Tunnel Master® wbc Installation Guide - Version 10...
- Page 2 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.
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Page 3: Table Of Contents
Contents Chapter 1: Installation Overview ............9 Related Documents . - Page 4 Main Inputs Wiring ............36 Common Relay Output Wiring .
- Page 5 List of Figures Figure 1. WBC Mounting Box Footprint ........... 13 Figure 2.
- Page 6 Figure 32. Pickup Bed Sensor Mounting ..........56 Figure 33.
- Page 7 List of Tables Table 1. Dimensions, Measurements, and Ratings ....... . . 12 Table 2.
- Page 8 Tunnel Master® wbc - Installation Guide List of Tables...
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Page 9: Chapter 1: Installation Overview
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. -
Page 10: Hardware Specs
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 ... -
Page 11: Chapter 2: Site Planning
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: ... -
Page 12: Equipment Dimensions
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. 32° F to 122° F Interior, non-corrosive surface. -
Page 13: Mounting The Tunnel Master® Wbc
Mounting the Tunnel Master® wbc Figure 1. WBC Mounting Box Footprint Tunnel Master® wbc - Installation Guide Site Planning... -
Page 14: Power Requirements
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. -
Page 15: Site Grounding Considerations
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. -
Page 16: Wire Gauge And Conduit Size
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... -
Page 17: Chapter 3: Electrical Installation
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). -
Page 18: Tunnel Master® Wbc Ac Power Terminations
Tunnel Master® wbc AC Power Terminations WBC AC POWER TERMINATIONS 120 VAC LINE FUSED TERMINAL ICS ONLY SIDE OF 120 VAC NEUTRAL TERMINAL BLOCKS TERMINALS GROUND +24v -24v Controller Ultrasonic Truck GROUND Keypad Bed Sensor Box POWER NEUTRAL LINE (MUST BE TERMINATED AT FUSED TERMINAL) 120 VAC FROM POWER DISTRIBUTION BOX 14/3 SHIELDED WIRE E... -
Page 19: Main Cpu Board Overview
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. -
Page 20: Wbc Main Cpu Board
WBC Main CPU Board Figure 5. Main CPU Board Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 21: Main Cpu Board Descriptions
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,”. Description Description RJ-45 Terminal for Network Connection Display Connection Point Flash Module* Keyboard Connect Point Eight-Port DIP Switch... -
Page 22: Figure 6. Input Board Inputs
Main CPU Board Wiring Guidelines Figure 6. Input Board Inputs Terminal Block Input Name Description Pulse Switch PULSE SINK When using a normally open, two-wire pulse switch, use ter- minals marked PULSE SINK and PROX GND. Input PROX GND See “Pulse Switch Wiring” on page 35. PROX POWER When using a normally open three-wire pulse switch, use terminals marked PROX POWER, PULSE SINK, and PROX... - Page 23 Terminal Block Input Name Description Assigned GATE (SIGNAL) General note: ICS highly recommends using shielded cable Function for all input wiring. Terminate the shield drain as close to the TIRE (SWITCH) Inputs 24 V AC power supply as possible. ROLLER LOCA- See “Main Inputs Wiring”...
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Page 24: Delayed Panic Input
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. -
Page 25: Input Board
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. -
Page 26: Figure 8. Input Board
Input Board Figure 8. Input Board Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 27: Input Board Descriptions
Input Board Descriptions Description Description Transformer Selector Programmable Input Terminals Fuse 500mA Start/Stop Input Terminals Fuse 500mA Inputs LED Indicators Internal 12V AC Power Input Terminal Manual Bypass Input Board RJ-45 Terminal Additional Output Terminal DIP Switch 1 Fuse 6.3A Remote 24V DC Power (If Remote Mount) Conveyor Output Terminal 24V DC Power from ICS Provided Power Supply... -
Page 28: Transformer Selection
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. -
Page 29: Relay Boards
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. -
Page 30: Relay Board Wiring Guidelines
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. -
Page 31: Start/Stop Inputs Wiring
Start/Stop Inputs Wiring Wiring is to be done on the input board. START/STOP TERMINALS ON INPUT BOARD START CIRCUIT Note - IF STOP STOP CIRCUITS ARE NOT USED CIRCUIT THEY MUST BE JUMPED TERMINALS PUSH/PULL MOMENTARY START/STOP MOMENTARY START/STOP PUSH/PULL MOMENTARY START STATION STATION... -
Page 32: Manual Bypass, Conveyor, And Horn Wiring
Manual Bypass, Conveyor, and Horn Wiring Wiring is to be done on the input board. DEVICE THAT CONVEYOR MOTOR CONVEYOR HORN FOLLOWS THE STARTER LOCATED (SEE NOTE #3) CONVEYOR RELAY IN MOTOR CONTROL (SEE NOTE #1) PANEL (SEE NOTE #2) SITE SUPPLIED ELECTRICAL INPUT NEUTRAL... -
Page 33: Conveyor Relay Wiring
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. -
Page 34: Figure 15. Conveyor Relay Wiring
Conveyor Relay Wiring Figure 15. Conveyor Relay Wiring Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 35: Pulse Switch Wiring
Pulse Switch Wiring Wiring is to be done on the main CPU board. BELOW ARE EXAMPLES OF PROXIMITY SWITCH WIRING. PLEASE CONFIRM THE TYPE OF WIRING REQUIRED PRIOR TO ANY WIRE SINKING JUMPER CONFIGURATION TERMINATION SOURCING JUMPER CONFIGURATION ICS HIGHLY RECOMMENDS USING 18 / 2 SHIELDED CABLE SINK 2-WIRE... -
Page 36: Main Inputs Wiring
Main Inputs Wiring Wiring is to be done on the main CPU board. ICS RECOMMENDS 18 / 2 SHIELDED CABLE PROVIDED BY SITE GATE SWITCH/PHOTO-EYE PRE-ASSIGNED EXTERNAL VOLTAGE-24VAC FUNCTION INPUTS TIRE SWITCH EXTERNAL VOLTAGE-24VAC GATE ROLLER LOCATOR SWITCH TIRE SWITCH EXTERNAL VOLTAGE-24VAC ROLLER LOCATOR REMOTE ROLLER/ROLLER CALL... -
Page 37: Common Relay Output Wiring
Common Relay Output Wiring Common relay output wiring is to be done on the relay board. SITE SUPPLIED 24VAC TRANSFORMER 24VAC SUPPLY FOUR PRONG TERMINAL JUMPER 24VAC SOLENOID TWO PRONG TERMINAL JUMPER 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). - Page 38 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.
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Page 39: Common Relay Output Wiring (Cont.)
Common Relay Output Wiring (cont.) Figure 19. Common Relay Output Wiring Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 40: Jumper Test Point Locations
Jumper Test Point Locations Figure 20. Jumper Test Point Locations This section explains the location and purpose of the jumpers on the Tunnel Master® wbc circuit boards. Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 41: Table 8. Jumper Settings
The following table describes jumper functions and settings. Jumper 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). - Page 42 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.
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Page 43: Dip Switch Settings
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. 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... -
Page 44: Table 10. Input Board Dip Switch Settings
DIP Switch Switch DIP Switch Function Settings SW1 & SW2 Horn-on time Sec. (On) SW3 & SW4 Delay after horn, before Sec. (Delay) conveyor starts Table 10: Input Board DIP Switch Settings Switch settings: 0 = off (opened) 1 = on (closed) Tunnel Master®... -
Page 45: Third Party Kiosk To Tunnel Master® Wbc Terminations
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. ... -
Page 46: Figure 22. Non-Ics Kiosk (Not An Auto Sentry) To Tunnel Master® Wbc Terminations
THIRD-PARTY KIOSK SERVICE RELAYS DRY CONTACTS WIRING CONNECTIONS ARE MADE TO THE RELAYS "NORMALLY OPEN" OUTPUT SITE SUPPLIED 18 GAUGE CABLE 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. -
Page 47: Exterior
Exterior Figure 23. Exterior Panel The display shows the status of all the inputs, along with other tunnel status indicators. Description The display is a 640 × 480 color monitor. On-board Keyboard Table 11: Exterior Description for the Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 48: Ultrasonic Truck Bed Sensor
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 ≤... -
Page 49: Ultrasonic Truck Bed Sensor Mounting Recommendations
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. -
Page 50: Ultrasonic Sensor Mounting Dimensions
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. -
Page 51: Ultrasonic Truck Bed Sensor Wiring Components
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 Tunnel Master® wbc - Installation Guide Electrical Installation... -
Page 52: Ultrasonic Sensor Power Terminations
Ultrasonic Sensor Power Terminations ULTRASONIC CONVERTER BOX TUNNEL MASTER WBC 24 VDC ORANGE BLACK ORANGE BLACK 24+ 24- 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. -
Page 53: Ultrasonic Sensor Wiring
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. -
Page 54: Ultrasonic Sensor Jumper Settings
Ultrasonic Sensor Communication Wiring ADAM CONVERTER BOX LOCATED INSIDE THE SENSOR BOX TWO 485 COMM TIERS LOCATED ON THE WBC CONTROLLERS MAIN CPU BOARD BLACK WIRE WHITE WIRE ICS COMM CABLE MAIN CPU BOARD Figure 30. Ultrasonic Sensor Comm Connections Ultrasonic Sensor Jumper Settings ICS recommends leaving RS-485 jumpers unterminated on the Tunnel Master®... -
Page 55: Powering The Ultrasonic Sensor
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). -
Page 56: Figure 32. Pickup Bed Sensor Mounting
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. Recommended Letter Field Name Description Setting* Bed Drop Distance 16 Inches... -
Page 57: Chapter 4: Communications Wiring
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. -
Page 58: 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. -
Page 59: Chapter 5: Install Entrance Keypad
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. -
Page 60: Entrance Keypad Wiring
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. -
Page 61: Figure 37. Ac Power Terminations
AC Power Terminations are shown in Figure 37. WBC AC POWER TERMINATIONS 120 VAC LINE FUSED TERMINAL ICS ONLY SIDE OF 120 VAC NEUTRAL TERMINAL BLOCKS TERMINALS GROUND +24v -24v Controller Ultrasonic Truck GROUND Keypad POWER Bed Sensor Box NEUTRAL LINE (MUST BE TERMINATED AT FUSED TERMINAL) 120 VAC FROM POWER DISTRIBUTION BOX –... -
Page 62: Second Entrance Keypad Mounting And Installation
Entrance Keypad Communication cable terminations must be made as shown in Figure 38. 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. -
Page 63: Second Entrance Keypad Wiring
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. -
Page 64: Figure 39. Keypad Circuit Board Jumper Settings
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 Tunnel Master® wbc - Installation Guide Install Entrance Keypad... -
Page 65: Table 18. Jumper Settings
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. Jumper Setting Description... -
Page 66: Entrance Keypad Dip Switch Settings
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. -
Page 67: Chapter 6: Troubleshooting
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: ... - Page 68 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. Tunnel Master®...
- Page 69 Index Amperage Hardware description ANTI COLLISION Horn, conveyor and manual bypass Auto Sentry Flex wiring system wiring for two lanes Input and conveyor interlock board Battery INPUT1-9 back-up Inputs Bypass main wiring IPX0 rating Codes Communications wiring Jumper Conduit Jumpers sizing TP4 through TP49 Configuration...
- Page 70 Site layout Start and stop inputs wiring Supply voltage TIRE Torque specifications Transformer Transformer selector Truck bed sensor. See Ultrasonic sensor Ultrasonic Ultrasonic sensor dimensions jumper settings mounting recommendations operations specifications wiring Versions Warranty voiding Wire gauge Wiring communications cpu board input and conveyor interlock board system Tunnel Master®...
- Page 71 Version History Document Contributor Dates Description Version Initials 03/18/2008 JL-S First release. 04/07/2008 BB, JL-S, KK, Full review. RH, SD, TR 04/09/2008 S.D. Updated two drawings on pages 26 and 36 that reversed PULSE SRCE and PROX PWR. 05/28/2009 — S.D., R.H., J.M., -Pickup bed sensor specs and diagrams.
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