ICS Tunnel Master wbc, Installation Manual

Page 1: ...Tunnel Master wbc Installation Guide Version 11 0...

Page 2: ...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 p...

Page 3: ...n CPU Board 7 Main CPU Board 10 Input Board Terminal Blocks 11 Delayed Panic Input 12 Input Board Components 12 Manual Bypass Operation 14 Transformer Selection 15 Auxiliary Input Internal Voltage Wir...

Page 4: ...ns 38 Truck Bed Sensor Power Terminations 39 Connections from WBC to the Ultrasonic Converter Box Power 39 Ultrasonic Sensor Wiring 39 Ultrasonic Sensor Jumper Settings 40 Powering the Ultrasonic Sens...

Page 5: ...ing of On Board Relays for Conveyor Start Circuit 21 Figure 16 Pulse Switch Wiring 22 Figure 17 Main Inputs Wiring 23 Figure 18 Common Relay Output Wiring 24 Figure 19 Common Relay Output Channels 26...

Page 6: ...ck 44 Figure 38 RS 232 Comm Terminal Wiring Diagram Main CPU Board 46 Figure 39 RS 485 Communication Wiring Layout 48 Figure 40 Keypad Connectors Keypad Board 49 Figure 41 Tunnel Master wbc Keypad Pow...

Page 7: ...Relay Board Components 17 Table 9 Jumper Functions and Settings 31 Table 10 DIP Switch and Reset Button 32 Table 11 DIP Switch Input Board Functions and Settings 33 Table 12 Exterior Descriptions of...

Page 8: ...on Photo of Part Included 4 6 3A fuses FUSE63 2 0 5A fuses FUSE 5 1 5A fuse FUSE5 5 x 20 nuts flat washers lock washers 8 10 x 32 nuts 2 ICS screwdrivers 1 set of 2 keys for the Tunnel Master wbc door...

Page 9: ...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 alwa...

Page 10: ...e 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 righ...

Page 11: ...nting Template for the Tunnel Master wbc Figure 1 Tunnel Master wbc Mounting Template 4 2 9 16 Diameter Detail 5 8 Notch 24 Center to Center 36 Center to Center 9 16 Diameter Detail 4 2 9 16 Dia 9 16...

Page 12: ...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...

Page 13: ...sufficient ground It is recommended that the neutral and ground bus bars be bonded together when it is not prohibited by local codes The universal ground symbol identifies the grounding lug connector...

Page 14: ...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...

Page 15: ...rnal Components 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 24V DC Power Supply 8...

Page 16: ...Tunnel Master wbc Installation Guide Page 9 Tunnel Master wbc Main CPU Board Figure 3 Main CPU Board...

Page 17: ...inal Relays 1 24 7 Status LEDs 21 Fuse 500mA 8 Relay Board RJ 45 Terminal Connector 22 RS 485 Comm Terminal Relays 25 48 9 Status LEDs 23 12V AC Input from Transformer 10 Relay Board RJ 45 Terminal Co...

Page 18: ...ls marked PROX POWER PULSE SINK and PROX GND System provides 18 V DC power GND See Pulse Switch Wiring on page 22 POWER When using a normally closed three wire pulse switch use terminals marked PROX P...

Page 19: ...H ROLLER LOCATOR REMOTE ROLLER EM TIRE2 ENTRANCE MGMT ANTI COLLISION INPUT 1 DELAYED PANIC 3 Expansion INPUT2 9 Reserved for future ICS use Delayed Panic Input The Delayed Panic Input if active will p...

Page 20: ...t 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 boar...

Page 21: ...o operate even if there is an issue at the wash that would normally prevent the operation of the tunnel Plug the connector into JP30 to enable bypass operation Figure 7 Normal and Bypass Operation Set...

Page 22: ...d 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 8 Transformer Select...

Page 23: ...OPEN Alternate symbol for N O Switch Examples Low Air Pressure Low Hydraulic High Water or other Sensing Device Contacts COM 1 48 Auxiliary Input Relay Terminal Strip Auxiliary Input External Power W...

Page 24: ...the manual override position prior to system start up 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...

Page 25: ...g Wiring is to be done on the input board Figure 13 Wiring for Start Stop Stations and Emergency Stop SP7 SP1 SP1 SP2 SP2 SP3 SP3 SP4 SP4 SP5 SP5 SP6 SP6 SP7 WHITE BLACK RED GREEN GREEN WHITE BLACK RE...

Page 26: ...om 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 o...

Page 27: ...elay 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 de...

Page 28: ...Tunnel Master wbc Installation Guide Page 21 Conveyor Relay Wiring on Input and Relay Boards Figure 15 Wiring of On Board Relays for Conveyor Start Circuit...

Page 29: ...CONFIGURATION ICS HIGHLY RECOMMENDS USING 18 2 SHIELDED CABLE ICS HIGHLY RECOMMENDS USING 18 3 SHIELDED CABLE ICS HIGHLY RECOMMENDS USING 18 3 SHIELDED CABLE BLUE WIRE BLACK WIRE BROWN WIRE BLUE WIRE...

Page 30: ...R POSITION PRE ASSIGNED FUNCTION INPUTS ICS RECOMMENDS 18 2 SHIELDED CABLE PROVIDED BY SITE GATE TIRE SWITCH ROLLER LOCATOR REMOTE ROLLER ENTRANCE MANAGEMENT ANTI COLLISION JUMPERS SET TO EXTERNAL VOL...

Page 31: ...pplied 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 th...

Page 32: ...ns 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 o...

Page 33: ...Tunnel Master wbc Installation Guide Page 26 Tunnel Master wbc Installation Guide Page 26 Common Relay Output Channels Figure 19 Common Relay Output Channels...

Page 34: ...in the series with the first relay Relays are typically wired with two wires going to the equipment one wire being run from the equipment to Normally Open NO and the second from the equipment going t...

Page 35: ...output when ON to the device and using R3 as the Normally Closed when OFF This allows the programming of a retract through the R3 contact meanwhile the R1 will remain in it s original state R3 acts si...

Page 36: ...ter wbc Installation Guide Page 29 Jumper Test Point Locations TP5 TP4 This section explains the location and purpose of the jumpers on the Tunnel Master wbc circuit boards Figure 24 Jumper Test Point...

Page 37: ...elect 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 Powers...

Page 38: ...tion 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 T...

Page 39: ...ault settings are OFF After setting DIP Switch to ON press Reset button on Main CPU board to activate Figure 25 DIP Switch and Reset Button DIP Switch Reset Button ID Description ID Description SW1 Cl...

Page 40: ...Setting Defaults SW1 SW2 Horn on time SW1 SW2 Sec On 0 0 0 0 1 1 1 0 4 1 1 6 SW3 SW4 Delay after horn before SW3 SW4 Sec Delay conveyor starts 0 0 0 0 1 1 1 0 4 1 1 6 Figure 26 DIP Switch Input Board...

Page 41: ...ny one of the common inputs located on the first eight positions of the terminal block An ICS Entrance Keypad is optional but recommended An Entrance Keypad provides an alternate way to wash cars shou...

Page 42: ...MADE TO THE RELAY S NORMALLY OPEN OUTPUTS COM COM SITE SUPPLIED 18 GAUGE CABLING 36 33 34 35 SPECIAL PROGRAMMING FOR WBC GENERAL SETTINGS STACKING ON INPUT DEVICE PUSH BUTTON IF NO KEYPAD INPUT DEVICE...

Page 43: ...9 feet IP Code IP65 Housing ABS or PVC Sensor Adjust RS 485 interface Outputs RS 485 and NPN Operating temp 13 F to 158 F 25 C to 70 C Supply Voltage 24 V DC Resolution Evaluation range mm 4000 but 0...

Page 44: ...s 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 equipm...

Page 45: ...e that runs from the sensor to the converter box This cable cannot be spliced to add additional cable Orange 24 V DC Black 0 V DC NOTE High voltage AC and low voltage DC must not be combined in a comm...

Page 46: ...ock inside the WBC on the bottom right side to the black terminal block in the Ultrasonic Converter box Ultrasonic Sensor Wiring Sensor communication connections are RS 485 ICS recommends wiring the u...

Page 47: ...UNNEL MASTER WBC CONTROLLER S MAIN CPU BOARD TX RX GND TX RX TX RX GND TX RX Y DATA G DATA B GND 10 Vin 7 R Vs CONVERTER BOX INSIDE THE ULTRASONIC SENSOR BOX Vin 7 Vin 6 Black Wire White Wire ICS Supp...

Page 48: ...ltrasonic Sensor Connect three of the five wires from the gray power cable as follows 1 The brown wire connects to the orange terminal block 24 V DC 2 The blue wire connects to the black terminal bloc...

Page 49: ...the figure above are described in the table below 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 Le...

Page 50: ...ion 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 24 4 Com...

Page 51: ...th ends of the shield ground to different ground points BLK Y Data RS 485 Communication Cable Layout for a Tunnel Master wbc System with a Double Junior Configuration 96 24 24 144 Outputs TX TX RX RX...

Page 52: ...torquing may cause enclosure breakage The conduit will contain the 12V AC and Communications Cable and enters the opening in the bottom of the keypad enclosure Electrician must run 4 18 AWG wires or...

Page 53: ...wire termination points You can use either contact block In a second keypad you would use serial 3 12V AC termination block The following picture shows the connection points for the various components...

Page 54: ...t board labeled with ACH Line ACN Neutral and then to the Ground Lug Ground Terminations for the 4 18 AWG wires should be torqued to 5 31 in lbs to 7 in lbs 6 8 Nm NOTE Over torquing may cause enclosu...

Page 55: ...ypad Power 12vAC WBC ACL yellow terminal block L terminates on the ACH terminal block inside the Controller Keypad box WBC ACN black terminal block N terminates on the ACN terminalblock inside the Con...

Page 56: ...the Drain Shield terminates on the Ground Lug CAUTION Over torquing may cause enclosure breakage Entrance Keypad Communication cable terminations must be made as shown in Figure 42 ICS SUPPLIED 24 4 C...

Page 57: ...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 Default Description 1 J1 ON Reserved Jumper ALWAYS ON 2 J2...

Page 58: ...2 OFF Address 7 1 2 ON Address 8 3 OFF Baud Rate OFF 9600 ON 38 400 4 OFF Test Mode Second Entrance Keypad Mounting The following instructions provide proper installation of the optional second entra...

Page 59: ...trance Keypad There are terminal blocks POWER located on each of the keypad circuit boards labeled with ACH ACN and then a Ground Lug for Line Neutral and Ground respectfully Terminations for the 4 18...

Page 60: ...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 wire...

Page 61: ...t Locations 30 M Main CPU Board 12 Main CPU Board Overview 13 Main Inputs Wiring 26 Manual Bypass Operation 17 Mounting Template 7 P Planning for Installation 6 Powering the Ultrasonic Sensor 42 Power...

Page 62: ...ce 81 Highland Avenue Suite 300 Bethlehem PA 18017 Sales 800 642 9396 Email sales icscarwashsystems com icscarwashsystems com If you have any questions or concerns please contact ICS Technical Support...